Ring composite spinning method based on film filamentization
10577727 ยท 2020-03-03
Assignee
Inventors
Cpc classification
D02G3/06
TEXTILES; PAPER
International classification
D01D5/42
TEXTILES; PAPER
D02G3/06
TEXTILES; PAPER
Abstract
A ring composite spinning method based on film filamentization is provided, which belongs to a textile technical field. According to the method, a film cutting drafting device is arranged above each drafting system on a ring spinning machine for cutting film material into ribbon-shaped multi-filaments to achieve the film filamentization, which changes a conventional formation of filament through linear spraying by spinneret orifices; then the multi-filaments formed pass through first and second filament drafting zones in sequence for drawing, so as to enhance and attenuate the multi-filaments. After in drawing, the multi-filaments are twisted with conventional staple fibers to form a composite yarn with high quality and functions, achieving one-step production of composite yarns of nano-micro fibers without online combination of nanofibers spinning and ring staple spinning, thereby breaking restriction of low bulk and low-speed production of nano-spun fibers and integrating film industry with textile industry.
Claims
1. A ring composite spinning method based on film filamentization, comprising steps of: feeding staple fiber roving unwound from a roving package (1) corresponding to each drafting system on a ring spinning machine into a drafting zone successively through a guide bar (4) and a feed guider (18), wherein the drafting zone consists of a rear roller (11), a rear rubber roller (10), a middle-bottom roller (14), a middle-bottom apron (20), a middle-top roller (13), a middle-top apron (19), a front roller (16) and a front rubber roller (15); drawing the staple fiber roving into flat ribbon-shaped staple fiber strands; outputting the staple fiber strands through a front roller nip which is formed by the front rubber roller (15) engaging with the front roller (16), then entering a ring yarn formation twisting zone to be twisted to form ring staple yarn; respectively passing through a yarn pigtail guider (17), a ring (22) and a traveler (23) by the ring staple yarn, and finally winding the ring staple yarn on a bobbin (24); wherein: a film cutting drafting device is arranged above each drafting system on the ring spinning machine; the film cutting drafting device consists of a bearing roller (21), an unwinding roller (6), a cutting roller (7), a filament drafting roller (9), a filament drafting rubber-covered roller (8) and a heater (12); a cut-resistant apron (5) is wrapped onto the unwinding roller (6); circular cutters are arranged on a circumference of the cutting roller (7) in parallel; the cut-resistant apron (5) corresponds to cutting edges of the circular cutters on the cutting roller (7); a cutting zone is formed between the cut-resistant apron (5) and the cutting roller (7); the filament drafting roller (9) is located below the filament drafting rubber-covered roller (8); the filament drafting roller (9) engages with the filament drafting rubber-covered roller (8) to form a filament drafting roller nip; a middle vertical plane of a filament drafting roller nip line overlaps with a middle vertical plane of the cutting zone and a middle vertical plane of a front roller nip line; a first filament drafting zone is formed between the filament drafting roller nip and the cutting zone; a second filament drafting zone is formed between the filament drafting roller nip and the front roller nip; the heater (12) is arranged in the second filament drafting zone; and, a heating groove of the heater (12) is parallel with the filament drafting roller nip line and the front roller nip line; during composite-spinning, by a film material unwound from a film material package (2) arranged between the bearing roller (21) and the unwinding roller (6), entering the cutting zone formed between the cut-resistant apron (5) and the cutting roller (7) through the unwinding roller (6); cutting and fiberizing the film material by the circular cutters to form uniformly-spread ribbon-shaped multi-filaments; after being outputted from the cutting zone, the ribbon-shaped multi-filaments entering the first filament drafting zone to get a primary drawing; after the primary drawing, the ribbon-shaped multi-filaments outputted from the filament drafting roller nip entering the second filament drafting zone, wherein the ribbon-shaped multi-filaments heated in the heating groove of the heater (12) get a secondary drawing; after the secondary drawing, the ribbon-shaped multi-filaments outputted from the front roller nip entering the ring yarn formation twisting zone to converge together with the flat ribbon-shaped staple fiber strands outputted from the drafting zone of the ring spinning machine, wherein the ribbon-shaped multi-filaments have a spread width larger than the staple fiber strands; combining and twisting filaments at a middle position of the ribbon-shaped multi-filaments with the staple fiber strands to form a composite yarn body, and wrapping filaments at two sides of the ribbon-shaped multi-filaments onto a surface layer of the composite yarn body to protect and capture the staple fiber strands, in such a manner that a composite yarn is formed; subsequently passing through the yarn pigtail guider (17), the ring (22) and the traveler (23) successively by the composite yarn, and finally winding the composite yarn onto the yarn bobbin (24).
2. The ring composite spinning method based on the film filamentization, as recited in claim 1, wherein the cut-resistant apron (5) is made of polyethylene sufficient to interact with the circular cutters, aramid, or rubber sufficient to interact with the circular cutters.
3. The ring composite spinning method based on the film filamentization, as recited in claim 1, wherein a distance between cutting edges of adjacent circular cutters is ranged from 0.1 mm to 3 mm.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
(3) A ring composite spinning method based on film filamentization provided by the preferred embodiments of the present invention is further described in detail with accompanying drawings as follows.
(4) Referring to
(5) During composite-spinning, the film material package 2 is arranged between the bearing roller 21 and the unwinding roller 6 and between one pair of the isolation bars 3, that is to say one isolation bar 3 is arranged at each of two sides of the film material package 2. The film material is organic polymer film material, inorganic film material or organic-inorganic mixed film material, and the film material has a width smaller than a width of the cutting zone and a thickness less than or equal to 1 mm. The thinner the film material, the finer each filament in the ribbon-shaped multi-filaments formed through cutting fiberization. The heater 12 is externally connected with the safety source through the wires, so as to heat an inner wall surface of the heating groove of the heater 12 to 60-240 C. When the film material is the inorganic or the organic-inorganic mixed film material, the heater 12 is not heated, or the internal walls of the heating grooves of the heater 12 are only heated to 60 C., merely for facilitating each filament in the ribbon-shaped multi-filaments after the film filamentization being fully stretched. When the film material is an organic polymer film material with an obvious glass-transition temperature, the thicker the film material and the higher the glass-transition temperature of the film material, the higher the heating temperature; the thinner the film material and the lower the glass-transition temperature, the lower the heating temperature. The film material unwound from the film material package 2 between the bearing roller 21 and the unwinding roller 6 enters the cutting zone formed between the wear-resistant apron 5 and the cutting roller 7 through the unwinding roller 6; in the cutting zone, the circular cutters cut and fiberize the film material to form uniformly-spread ribbon-shaped filaments, which effectively achieves the filamentization of the film material. After being outputted through the cutting zone, the ribbon-shaped filaments enter the first filament drafting zone to get a primary drawing therein, so that the multi-filaments are primarily drafted and stretched, which prepares for high drafting of the multi-filaments; after the primary drawing, the ribbon-shaped multi-filaments are outputted from the filament drafting roller nip, then enter the second filament drafting zone wherein the ribbon-shaped multi-filaments heated in the heating groove of the heater 12 get a secondary drawing, wherein the inner consolidation structure of the polymer filaments with the obvious glass transition temperature is loosened, so that each filament of the multi-filaments is completely in the high-elastic state, as a result that the filaments become further attenuated and get inner molecular orientation and crystallization further improved, increasing the strength of the filaments and quickly achieving uniform and consistent high-yield output of the nano-filaments, so as to avoid the conventional nano-spinning route such as electro-spinning and centrifugal spinning. Therefore, a problem that insufficient drafting of filaments during the conventional nano-spinning incurs poor orientation of the macromolecules in the nano-fibers, unsatisfactory fineness of the nano-fibers, low strength of the nano-fibers, poor adhesion and durability of the nano-fibers; therefore, nano-fibers overlaying onto the fabric surface are very easy to be worn off, and nano-fiber strands fail to be spun into a composite yarn by conventional ring spinning is solved; after the secondary drawing, the ribbon-shaped multi-filaments outputting from the front roller nip enter the ring yarn formation twisting zone to converge together with the flat ribbon-shaped staple fiber strands outputted from the drafting zone of the ring spinning machine, being combined and twisted to form a composite yarn. The specific combination and yarn forming during the above process is described as follows. The ribbon-shaped multi-filaments after the secondary drawing are fed into the front roller nip, wherein the ribbon-shaped multi-filaments have a spread width larger than the staple fiber strands. The filaments at the middle position of the ribbon-shaped multi-filaments overlap with the flat ribbon-shaped staple fiber strands at the front roller nip and are uniformly combined to form the composite strands. The filaments at the two sides of the ribbon-shaped multi-filaments are outputted together with the composite strands through the front roller nip and then enter the ring yarn formation twisting zone. In the ring yarn formation twisting zone, the filaments at the middle position of the ribbon-shaped multi-filaments are combined and twisted with staple fibers in the composite strands to form the composite yarn body in which filaments and staple fibers perform sufficient migrations and even blending so as to form the high-functionality high-quality composite yarn with the inner structure having the uniform mixture and full coherence between the nano-micro filaments and the conventional staple fiber; meanwhile, the mono-filaments at the two sides of the ribbon-shaped multi-filaments effectively protect and capture the staple fibers of the composite strands during the twisting process to max the usage of staple fibers. Thereafter, the fiber ends exposed at the surface of the composite yarn are effectively wrapped at the composite yarn surface with tightly fastening by filaments, so as to from the surface structure having the compact wrapping and full exposure of nano-micro filaments. Therefore, a yarn layered structure is realized that: the yarn body is formed through twisting the nano-micro filaments and the conventional staple fibers after uniformly mixing and fully cohering; and the nano-micro filaments fully wrap the outer layer of the yarn body for capturing the conventional fibers and showing the function of the nano-micro filaments. The yarn layered structure effectively solves the technical problems that: for composite spinning with filaments formed through spraying by the spinneret orifice and conventional staple fibers, and composite spinning with the nanofibers formed through spinning spraying and the conventional staple fibers, it is difficult to uniformly mix and fully cohere and twist; and when twisting the various film materials or composite-twisting the film material with the conventional staple fibers, it is difficult to get sufficient fiber migrations and coherence. The composite yarn passes through the yarn pigtail guider 17, the ring 22 and the traveler 23, and is finally wound onto the yarn bobbin 24. According to the method provided by the present invention, one-step production of filament/staple-fiber composite yarn using the film material and conventional staple fibers is rapidly realized through the film filamentization, attenuation and blended twisting. The direct feeding of functional films can complete the highly-efficient composite spinning with the conventional staple fibers, so as to obtain the high-functionality high-quality yarn for textile, which effectively integrates the film industry and the textile and garment industry. Therefore, the present invention takes in film materials as the expanded textile raw materials, and breaks limits of conventional nano-spinning producing nano-fibers in low bulk and low-speed unable to meet the textile industrial application requirements, which provides an effective method for functional films to be used in the production and processing of composite yarn and apparel fabrics. The method of the present invention is convenient to operate and is easy to be popularized and applied widely.
(6) The specific application of the present invention is further illustrated in detail with the following ring composite spinning process based on the filamentization of various film materials.
(7) First Preferred Embodiment
(8) To form a yarn by composite twisting of cotton fibers and polyamide (nylon) porous film after filamentization
(9) The film material used is the polyamide porous film, having a width of 15 mm and a thickness of 0.1 mm. The cut-resistant apron 5 is made of high-strength polyethylene cut-resistant material. The distance between the cutting edges of the neighboring circular cutters on the circumference of the cutting roller 7 is 0.1 mm. The heater 12 is externally connected with the safety source of 24 V through the wire, and the inner wall surface of the heating groove of the heater 12 is heated to 150 C. The formed film material package 2 of the polyamide porous film is arranged between the bearing roller 21 and the unwinding roller 6. The film material unwound from the film material package 2 enters the cutting zone formed between the cut-resistant apron 5 and the cutting roller 7 through the unwinding roller 6, and is cut and fiberized into uniformly-spread ribbon-shaped multi-filaments. After being outputted through the cutting zone, the ribbon-shaped multi-filaments successively enter the first filament drafting zone and the second filament drafting zone. In the first filament drafting zone, the multi-filaments are processed with the primary drawing with a drafting ratio of 1.03. In the second filament drafting zone, the multi-filaments are heated with a temperature of 150 C. in the heating groove in the second filament drafting zone, so that the internal macromolecules of each filament in the ribbon-shaped multi-filaments are at a high-elastic state and the inner molecular reinforcement structure of the polyamide filaments becomes loosened; and then the filaments are processed with a high-ratio drafting, namely the secondary drawing, with a drafting ratio of 35. The ribbon-shaped multi-filaments after the secondary drawing are fed into the front roller nip. The roving adopts 385Tex cotton roving. The cotton roving unwound from the roving package 1 is drafted with a drafting ratio of 55 through the drafting system of the spinning machine and forms the flat ribbon-shaped staple fiber strands. The staple fiber strands enter the front roller nip. The width of the ribbon-shaped multi-filaments is larger than that of the staple fiber strands. The filaments at the middle position of the ribbon-shaped filaments overlap with the flat ribbon-shaped staple fiber strands at the front roller nip, and then are uniformly mixed and combined to form the composite strands. The filaments at the two sides of the ribbon-shaped multi-filaments are distributed at the two sides of the composite strands and are outputted together with the composite strands through the front roller nip, and then enter the ring yarn formation twisting zone. In the ring yarn formation twisting zone, the filaments at the two sides of the ribbon-shaped multi-filaments combine with the composite strands and are twisted together to form a composite yarn. The spun composite yarn passes through the yarn pigtail guider 17, the ring 22 and the traveler 23, and is finally wound on the bobbin 24. The original nylon porous film has the strength of 20.0 cN; and the yarn obtained merely through spinning the cotton roving without feeding the nylon porous film has the strength of 148.7 cN, the elongation at break of 5.0%, the yarn levelness CVm % of 14.9 and the USTER yarn hairiness H value of 5.8. According to the present invention, the yarn obtained through the composite spinning with cotton fibers and the nylon porous film after the filamentization has the strength of 228.1 cN, the elongation at break of 7.2%, the yarn levelness CVm % of 12.2 and the USTER yarn hairiness H value of 2.3. It can be seen that the composite yarn has a high quality. A polyamide filament is unwound from the inner of the composite yarn body, and the size thereof is observed with the optical microscope. The results show that: the filament is in a branched continuous long and thin shape and has a fineness of 926 nm, which realizes the composite yarn forming with the nano-micro superfine polyamide muti-filaments and the conventional staple fibers. Because part of the nano-micro superfine polyamide filaments are exposed and wrapped on the surface of the composite yarn body, compared with the surface of the conventional cotton textile fabrics, the surface of the fabric made by the composite yarn provided by the present invention has functions of water repellency and abrasive resistance.
(10) Second Preferred Embodiment
(11) To form a yarn by composite twisting of wool fibers and polysulfone (PSF) nanofiber film after filamentization
(12) The film material used is the PSF nanofiber film with a nanofiber fineness of 400-600 nm, belonging to the thermoplastic nanofiber film material. The film material has a width of 20 mm and a thickness of 0.1 mm. The cut-resistant apron 5 is made of aramid material. The distance between the cutting edges of the neighboring circular cutters on the circumference of the cutting roller 7 is 3 mm. The heater 12 is externally connected with the safety source of 36 V through the wire, and the inner wall surface of the heating groove of the heater 12 is heated to 240 C. The formed film material package 2 of the PSF nanofiber film is arranged between the bearing roller 21 and the unwinding roller 6. The film material unwound from the film material package 2 enters the cutting zone formed between the cut-resistant apron 5 and the cutting roller 7 through the unwinding roller 6, and is cut and fiberized into uniformly-spread ribbon-shaped multi-filaments. After being outputted through the cutting zone, the ribbon-shaped multi-filaments successively enter the first filament drafting zone and the second filament drafting zone. In the first filament drafting zone, the filaments are processed with the primary drawing with a drafting ratio of 1.05. In the second filament drafting zone, the filaments are heated with a temperature of 240 C. in the heating groove in the second filament drafting zone, so that the internal macromolecules of each mono-filament in the ribbon-shaped multi-filaments are at a high-elastic state and the inner molecular reinforcement structure of the PSF nanofibers becomes loosened; and then the filaments are processed with a high-ratio drafting, namely the secondary drawing, with a drafting ratio of 6. The ribbon-shaped filaments after the secondary drawing are fed into the front roller nip. The roving adopts 305Tex wool roving. The wool roving unwound from the roving package 1 is drafted with a drafting ratio of 35 through the drafting system of the spinning machine and forms the flat ribbon-shaped staple fiber strands. The staple fiber strands enter the front roller nip. The width of the ribbon-shaped multi-filaments is larger than that of the staple fiber strands. The filaments at the middle position of the ribbon-shaped multi-filaments overlap with the flat ribbon-shaped staple fiber strands at the front roller nip, and then are uniformly mixed and combined to form the composite strands. The filaments at the two sides of the ribbon-shaped multi-filaments are distributed at the two sides of the composite strands and are outputted together with the composite strands through the front roller nip, and then enter the ring yarn formation twisting zone. In the ring yarn formation twisting zone, the filaments at the two sides of the ribbon-shaped multi-filaments combine with the composite strands and are twisted together to form a composite yarn. The spun composite yarn passes through the yarn pigtail guider 17, the ring 22 and the traveler 23, and is finally wound on the bobbin 24. The original PSF nanofiber film has the strength of 12.0 cN; and the yarn obtained merely through spinning the wool roving without feeding the PSF nanofiber film has the strength of 157.2 cN, the elongation at break of 7.9%, the yarn levelness CVm % of 15.1 and the USTER yarn hairiness H value of 6.2. According to the present invention, the yarn obtained through the composite spinning with wool fibers and the PSF nanofiber film after the filamentization has the strength of 224.3 cN, the elongation at break of 8.7%, the yarn levelness CVm % of 13.6 and the USTER yarn hairiness H value of 2.2. It can be seen that the composite yarn has a high quality. A PSF filament is unwound from the inner of the composite yarn body, and the size thereof is observed with the optical microscope. The results show that: the single PSF filament is in a meshed continuous long and thin shape, and has a width of about 1.0 mm and a width of 0.04 mm; and moreover, the nanofibers in the filament have a fineness distributed in a range of 97-178 nm, which realizes the composite yarn forming with the nanofibers and the conventional fibers. Because part of the PSF filaments are exposed and wrapped on the surface layer of the composite yarn body, compared with the surface of the corresponding conventional wool textile fabrics, the surface of the fabric made by the composite yarn provided by the present invention has functions of softness, water repellence and self-cleaning.
(13) Third Preferred Embodiment
(14) To form a yarn by composite twisting of ramie fibers and inorganic copper film after filamentization
(15) The film material is the copper film, having a width of 10 mm and a thickness of 0.06 mm. The cut-resistant apron 5 is made of ultrahigh strength rubber. The distance between the cutting edges of the neighboring circular cutters on the circumference of the cutting roller 7 is 1 mm. The heater 12 is externally connected with the safety source of 36 V through the wire, and the inner wall surface of the heating groove of the heater 12 is heated to 60 C. The formed film material package 2 of the copper film is arranged between the bearing roller 21 and the unwinding roller 6. The film material unwound from the film material package 2 enters the cutting zone formed between the cut-resistant apron 5 and the cutting roller 7 through the unwinding roller 6, and is cut and fiberized into uniformly-spread ribbon-shaped multi-filaments. After being outputted through the cutting zone, the ribbon-shaped multi-filaments successively enter the first filament drafting zone and the second filament drafting zone. In the first filament drafting zone, the multi-filaments are processed with the primary drawing with a drafting ratio of 1.05. In the second filament drafting zone, the multi-filaments are heated with a temperature of 60 C. in the heating groove at the second filament drafting zone. Although the inner structure of the copper material does not become loosened, stretching and drawing of each filament in the ribbon-shaped multi-filaments are facilitated. Thereafter, the multi-filaments are processed with the secondary drawing, with a drafting ratio of 1.05. The ribbon-shaped filaments after the secondary drawing are fed into the front roller nip. The roving adopts 470Tex ramie fiber roving. The ramie fiber roving unwound from the roving package 1 is drafted with a drafting ratio of 24.85 through the drafting system of the spinning machine and forms the flat ribbon-shaped ramie fiber strands. The staple fiber strands enter the front roller nip. The width of the ribbon-shaped multi-filaments is larger than that of the ramie fiber strands. The filaments at the middle position of the ribbon-shaped multi-filaments overlap with the flat ribbon-shaped ramie fiber strands at the front roller nip, and then are uniformly mixed and combined to form the composite strands. The filaments at the two sides of the ribbon-shaped multi-filaments are distributed at the two sides of the composite strands and are outputted together with the composite strands through the front roller nip, and then enter the ring yarn formation twisting zone. In the ring yarn formation twisting zone, the filaments at the two sides of the ribbon-shaped multi-filaments combine with the composite strands and are twisted together to form a composite yarn. The spun composite yarn passes through the yarn pigtail guider 17, the ring 22 and the traveler 23, and is finally wound on the bobbin 24. The original copper film has the strength of 127.3 cN; and the yarn obtained merely through spinning the ramie roving without feeding the copper film has the strength of 257.2 cN, the elongation at break of 5.4%, the yarn levelness CVm % of 19.7 and the USTER yarn hairiness H value of 11.6. According to the present invention, the yarn obtained through composite-spinning with the copper film after filamentization and the ramie roving has the strength of 467.2 cN, the elongation at break of 6.8%, the yarn levelness CVm % of 17.1 and the USTER yarn hairiness H value of 4.2. Thus, it can be seen that the composite yarn has a high quality. A copper filament is unwound from the inner of the composite yarn body, and then the size and morphology thereof are observed with the optical microscope. The results show that: the single copper filament is in a ribbon-shaped continuous long and thin shape, and has a width of about 0.75 mm and a thickness of about 0.05 mm. Because part of the copper filaments are exposed and wrapped on the surface layer of the composite yarn body, compared with the surface of the conventional ramie textile fabrics, the surface of the fabric made by the composite yarn provided by the present invention has functions of electric conduction and electromagnetic wave shielding.