CALCULUS SPINNING DEVICE AND METHOD FOR PRODUCING WRAPPED-CORE YARNS

Abstract

Provided are a calculus spinning device and method for producing wrapped-core yarns. The calculus spinning device includes a feeding unit, an auxiliary core-wrapping unit and a yarn winding unit. The feeding unit includes: a staple fiber feeding unit, configured to stretch a roving into a staple fiber strand and feed the staple fiber strand into the auxiliary core-wrapping unit, and a core yarn feeding unit, configured to feed a core yarn into the auxiliary core-wrapping unit. The auxiliary core-wrapping unit includes: an auxiliary core-wrapping assembly; a pressurizing/conveying assembly, configured to provide pressure or power to the auxiliary core-wrapping assembly; a yarn guiding assembly, disposed between the auxiliary core-wrapping assembly and the yarn winding unit; and a wrapping area for wrapping and converging.

Claims

1. A calculus spinning device, the calculus spinning device comprising a feeding unit, an auxiliary core-wrapping unit and a yarn winding unit; wherein the feeding unit comprises: a staple fiber feeding unit, configured to stretch a roving into differential dispersed staple fiber strands and feed the staple fiber strands into the auxiliary core-wrapping unit, and a core yarn feeding unit, configured to feed a core yarn into the auxiliary core-wrapping unit; wherein the auxiliary core-wrapping unit comprises: an auxiliary core-wrapping assembly; a pressurizing/conveying assembly, configured to provide pressure or power to the auxiliary core-wrapping assembly; a yarn guiding assembly, disposed between the auxiliary core-wrapping assembly and the yarn winding unit; and a wrapping area for wrapping and converging; and wherein the auxiliary core-wrapping unit is configured to make the staple fiber strands intersect and converge with the core yarn at the wrapping area and make the staple fiber strands integrally wrap the core yarn to form a wrapped-core yarn; and is configured to convey the wrapped-core yarn to the yarn winding unit for twisting and winding.

2. The calculus spinning device as claimed in claim 1, wherein the feeding unit further comprises a front roller disposed at an input end of the auxiliary core-wrapping unit; wherein the auxiliary core-wrapping assembly is internally provided with a staple fiber channel and a filament channel, the filament channel is separated from the staple fiber channel by a target spacing, a width of the staple fiber channel is 5-10 mm, the target spacing between the staple fiber channel and the filament channel is 2-5 mm, a width of the filament channel is 3-5 mm, the staple fiber channel is a channel with a same width along a conveying direction of the staple fiber strands, or a channel with a shape of gradually widening along the conveying direction of the staple fiber strands; and when the staple fiber channel is the channel with the shape of gradually widening, a width of a narrower channel portion of the staple fiber channel is 5-7 mm; wherein the auxiliary core-wrapping assembly is internally provided with a negative pressure air suction assembly, a surface facing towards the negative pressure air suction assembly of the staple fiber channel is provided with uniform grid holes, and the negative pressure air suction assembly is configured to absorb the staple fiber strands in the staple fiber channel through the uniform grid holes; and wherein the pressurizing/conveying assembly comprises a front top roller and a bridge component connecting the front top roller and the auxiliary core-wrapping assembly, the front top roller and the front roller are oppositely arranged, a nip is defined between the front top roller and the front roller and is configured to output the staple fiber strands and the core yarn to the auxiliary core-wrapping assembly, and the bridge component is configured to exert pressure on the auxiliary core-wrapping assembly to make an inner side of the auxiliary core-wrapping assembly attach to a surface of the front roller.

3. The calculus spinning device as claimed in claim 1, wherein the auxiliary core-wrapping assembly is a fiber spreading roller, the fiber spreading roller comprises a central shaft, a roller body and a negative pressure adsorption assembly disposed inside the roller body, the negative pressure adsorption assembly is fixedly disposed on the central shaft of the fiber spreading roller, a surface of the roller body is provided with evenly distributed grid holes configured for only allowing airflow to pass therethrough, and the negative pressure adsorption assembly is configured to adsorb that staple fiber strands to surfaces of the grid holes under negative pressure to form a negative pressure fiber expansion area; wherein the negative pressure adsorption assembly comprises a negative pressure suction port, the negative pressure suction port is disposed to face towards the grid holes, the negative pressure air suction port is an air outlet with a same width along a conveying direction of the staple fiber strands, or an air outlet with a shape of gradually widening along a conveying direction of the staple fiber strands, and a width of the negative pressure suction port is 5-10 mm; and wherein the pressurizing/conveying assembly is a front top roller disposed opposite to the fiber spreading roller.

4. The calculus spinning device as claimed in claim 1, wherein the feeding unit further comprises a front roller disposed at an input end of the auxiliary core-wrapping unit; wherein the auxiliary core-wrapping assembly comprises a special shaped pipe and a grid circle covered on a surface of the special shaped pipe, the grid circle is configured to only allow airflow to pass therethrough, and is configured to widen and spread the staple fiber strands to form a differential dispersed widened strand; wherein the auxiliary core-wrapping assembly further comprises negative pressure suction ports disposed on the special shaped pipe, the negative pressure suction ports are covered by the grid circle arranged on the surface of the special shaped pipe, the negative pressure suction ports are configured to adsorb that staple fiber strands on a surface of the grid circle under negative pressure, the negative pressure suction ports are one of the following three types: air ports uniformly distributed on the special shaped pipe, equal-width air ports formed along a curved surface of the special shaped pipe, or air ports disposed on the special shaped pipe and gradually widened along a conveying direction of the widened strands on the grid circle; wherein the pressurizing/conveying assembly comprises a front top roller, a drive top roller and a bridge component connecting the front top roller and the drive top roller, the front top roller is configured to drive the bridge component to synchronously rotate the drive top roller, the drive top roller is configured to be in contact with the grid circle to drive the grid circle to rotate and transport forward, a middle of the drive top roller is provided with a roller groove with a width, and the width of the roller groove is one third of a width of the drive top roller; and wherein the yarn guiding assembly is a yarn guiding rod, the yarn guiding rod is provided with a heating groove, a temperature of the heating groove is 100-200 C., the heating groove is configured to change a transmission path of a yarn output from the auxiliary core-wrapping unit, and the yarn guiding rod is configured to convey the yarn to the yarn winding unit.

5. The calculus spinning device as claimed in claim 1, wherein the core yarn feeding unit is provided with an electrostatic fiber opening assembly and a threaded guide rod, the electrostatic fiber opening assembly is configured to electrostatically open the core yarn to form a ribbon-like fiber, the threaded guide rod is configured to input the ribbon-like fiber into the auxiliary core-wrapping unit, and the ribbon-like fiber is partially or completely overlapped with the staple fiber strands in the auxiliary core-wrapping unit; wherein the auxiliary core-wrapping assembly is a negative pressure adsorption assembly, the negative pressure adsorption assembly comprises a special shaped air suction plate, a drive roller, a grid circle sleeved on outer surfaces of the special shaped air suction plate and the drive roller, and an air suction assembly disposed in the special shaped air suction plate, and the air suction assembly is configured to absorb the staple fiber strands and the ribbon-like fiber on a surface of the grid circle under negative pressure; wherein the negative pressure adsorption assembly further comprises a negative pressure suction port disposed on a surface of the special shaped air suction plate, the negative pressure suction port is covered by the grid circle, a narrowest width of the negative pressure suction port is not less than a width of each of the staple fiber channel and the ribbon-like fiber, the negative pressure adsorption assembly is configured to adsorb the staple fiber strands and the ribbon-like fiber on the surface of the grid circle through the negative pressure suction port, to open the staple fiber strands and further expand the ribbon-like fiber, the negative pressure air suction port is an air outlet with a same width along a conveying direction of the staple fiber strands and the ribbon-like fiber, or an air outlet with a shape of gradually widening along a conveying direction of the staple fiber strands and the ribbon-like fiber, and a narrowest width of the negative pressure air suction port is 5-10 mm; and wherein the pressurizing/conveying assembly comprises a transmission gear and an auxiliary conveying component disposed opposite to the grid circle, the auxiliary conveying component comprises a front top roller, a drive top roller and a bridge component connecting the front top roller and the drive top roller, the front top roller is configured to drive the bridge component to synchronously rotate the drive top roller; and the drive top roller is configured to be in contact with the grid circle to drive the grid circle to rotate and transport forward.

6. The calculus spinning device as claimed in claim 1, wherein feeding unit further comprises a front roller disposed at an input end of the auxiliary core-wrapping unit, and a spacing between the core yarn and the staple fiber strands on the front roller is 2-5 mm; wherein auxiliary core-wrapping assembly is a negative pressure absorption assembly, the negative pressure adsorption assembly comprises a special shaped air suction plate, a drive roller and a grid circle sleeved on outer surfaces of the special shaped air suction plate and the drive roller; the special shaped air suction plate is provided with a negative pressure suction port with a width greater than or equal to a width of the staple fiber strand, and an air suction assembly is disposed at the negative pressure suction port; wherein the auxiliary core-wrapping unit also comprises a negative pressure air flow guide assembly, the negative pressure air flow guide assembly is disposed above the special shaped air suction plate and is configured to provide diffused air flow to the staple fiber strands, the negative pressure air flow guide assembly comprises a diversion housing and rows of diffusion guide holes obliquely disposed on the diversion housing, the negative pressure suction port on the special shaped air suction plate corresponds to the diffusion guide hole, to make air flow through the diffusion guide hole and enter the negative pressure suction port, the negative pressure air flow guide assembly also comprises an airflow stabilizing hole vertically disposed on the diversion housing, the diffusion guide hole and the airflow stabilizing hole are sequentially arranged along an advancing direction of the core yarn and the staple fiber stands, and the airflow stabilizing hole is a hole with a same diameter up and down, or a hole with a tail end being bell-shaped along an airflow direction; wherein the pressurizing/conveying assembly comprises a transmission gear and an auxiliary conveying component, the auxiliary conveying component comprises a front top roller, a drive top roller and a bridge component disposed between the front top roller and the drive top roller, an axle core of the front top roller, the bridge component and an axle core of the drive top roller are connected, the front top roller and the front roller are disposed up and down correspondingly, the drive top roller and the drive roller are disposed up and down correspondingly, the front roller, the transmission gear and the drive roller are meshed and connected; and the drive top roller is in contact with the grid circle; and wherein the diversion housing is embedded below the bridge component and connected with the axle core of the front top roller.

7. The calculus spinning device as claimed in claim 1, wherein the feeding unit further comprises a front roller disposed at an input end of the auxiliary core-wrapping unit, the core yarn feeding unit is configured to simultaneously feed at least one core yarn and at least one wrapping yarn arranged at intervals, the staple fiber feeding unit is configured to feed at least one staple fiber strand arranged at intervals, the wrapping yarn is overlapped with a staple fiber strand close to the core yarn, and a spacing between the core yarn and a staple fiber strand close to the core yarn on the front roller is 2-5 mm; when one staple fiber strand is fed by the staple fiber feeding unit, the wrapping yarn is disposed within of a width of the one staple fiber strand close to the core yarn; the one staple fiber strand, the wrapping yarn and the core yarn are integrally converged to form a wrapped-core yarn with a part of the staple fiber strand as a core and another part of the staple fiber strand facing away from the core yarn as a sheath, and the part of the staple fiber strand is clamped by the wrapping yarn and the core yarn and is disposed close to the core yarn; wherein when a staple fiber strand and a second staple fiber strand facing away from the core yarn in sequence are fed by the staple fiber feeding unit simultaneously, the wrapping yarn is overlapped with the staple fiber strand; the staple fiber strand, the second staple fiber stand, the wrapping yarn and the core yarn are merged to form a wrapped-core yarn with the staple fiber strand clamped by the wrapping yarn and the core yarn as a core and with the second staple fiber as a sheath; wherein the auxiliary core-wrapping assembly is a negative pressure adsorption assembly, the negative pressure adsorption assembly comprises a special shaped air suction plate, a drive roller and a grid circle sleeved on outer surfaces of the special shaped air suction plate and the drive roller; the special shaped air suction plate is provided with a negative pressure suction port with a width greater than or equal to a width of the staple fiber strand, an air suction assembly is disposed at the negative pressure suction port, and the negative pressure air suction port is a structure with equal width at the top and bottom or a structure with a narrower top and wider bottom; and wherein the pressurizing/conveying assembly comprises a transmission gear and an auxiliary conveying component; the auxiliary conveying component comprises a front top roller, a drive top roller and a bridge component disposed between the front top roller and the drive top roller; an axle core of the front top roller, the bridge component and an axle core of the drive top roller are connected; the front top roller and the front roller are arranged up and down correspondingly, the drive top roller and the drive roller are arranged up and down correspondingly; and the front roller, the transmission gear and the drive roller are meshed, and the drive top roller is in contact with the grid circle.

8. The calculus spinning device as claimed in claim 7, wherein the core yarn is a water-soluble fiber with a fine denier flat-shaped structure or a water-insoluble fiber with fine denier flat-shaped structure, and a single filament width of the core yarn is 10-80 m; the wrapping yarn is a fine denier flexible structure, and a monofilament fineness of the wrapping yarn is 0.3-1.0 dtex; and the staple fiber strand and the wrapping yarn intersect and converge with the core yarn at the wrapping area to form a soft and wear-resistant yarn, a softness of the soft and wear-resistant yarn is improved by more than 20% compared with a wrapped-core yarn of a same specification with the soft and wear-resistant yarn, a wear-resistance of the soft and wear-resistant yarn is improved by more than 30% compared with a wrapped-core yarn of a same specification with the soft and wear-resistant yarn, and a minimum linear density of the soft and wear-resistant yarn is 2.1 tex.

9. The calculus spinning device as claimed in claim 1, wherein the staple fiber feeding unit comprises a bell mouth, a rear roller, a rear top roller, a middle roller and a middle top roller, which are sequentially arranged along a feeding and stretching direction of the roving in that order; wherein the core yarn feeding unit comprises a godet, the yarn guiding assembly comprises a yarn guiding rod and a heating groove disposed on the yarn guiding rod, and the yarn winding unit comprises a guide hook, a traveler, a steel ring and a ring bobbin.

10. The calculus spinning device as claimed in claim 1, wherein the staple fiber feeding unit comprises a bell mouth, a rear roller, a rear top roller, a middle roller and a middle top roller, which are sequentially arranged along a feeding and stretching direction of the roving in that order; wherein the core yarn feeding unit comprises a godet, the yarn guiding assembly comprises a connecting component connected with the pressurizing/conveying assembly and a compliant reinforcing component connected with the connecting component, and the compliant reinforcing component comprises a heating compliant block and a reinforcing sequentially arranged along an advancing direction of the wrapped-core yarn; and wherein the yarn winding unit comprises a guide hook, a traveler, a steel ring and a ring bobbin.

11. The calculus spinning device as claimed in claim 1, wherein the staple fiber feeding unit comprises a bell mouth, a rear roller, a rear top roller, a middle roller and a middle top roller, which are sequentially arranged along a feeding and stretching direction of the roving in that order; wherein the core yarn feeding unit comprises a core yarn unwinding unit, a tension adjusting frame and a godet sequentially arranged along an advancing direction of the core yarn; the core yarn unwinding unit comprises a pair of unwinding rollers rotating in a same direction, and the unwinding rollers are meshed with a winding roller for winding the core yarn; and the tension adjusting frame comprises tension adjusting rods arranged in parallel; and wherein the yarn guiding assembly comprises a yarn guiding rod and a heating groove disposed on the yarn guiding rod, and the yarn winding unit comprises a guide hook, a traveler, a steel ring and a ring bobbin.

12. The calculus spinning device as claimed in claim 1, wherein the staple fiber feeding unit comprises a bell mouth, a rear roller, a rear top roller, a middle roller and a middle top roller, which are sequentially arranged along a feeding and stretching direction of the roving in that order; wherein the core yarn feeding unit comprises a core yarn unwinding unit, a tension adjusting frame and a godet sequentially arranged along an advancing direction of the core yarn; the core yarn unwinding unit comprises a pair of unwinding rollers rotating in a same direction, and the unwinding rollers are meshed with a winding roller for winding the core yarn; and the tension adjusting frame comprises tension adjusting rods arranged in parallel; wherein the yarn guiding assembly comprises a connecting component connected with the pressurizing/conveying assembly and a compliant reinforcing component connected with the connecting component, and the compliant reinforcing component comprises a heating compliant block and a reinforcing sequentially arranged along an advancing direction of the wrapped-core yarn; and wherein the yarn winding unit comprises a guide hook, a traveler, a steel ring and a ring bobbin.

13. A calculus spinning device, the calculus spinning device comprising a feeding unit, an auxiliary core-wrapping unit and a yarn winding unit; wherein the feeding unit comprises: a staple fiber feeding unit, configured to stretch a roving into differential dispersed staple fiber strands and feed the staple fiber strands into the auxiliary core-wrapping unit, and a core yarn feeding unit, configured to feed a core yarn into the auxiliary core-wrapping unit; wherein the auxiliary core-wrapping unit comprises: an auxiliary core-wrapping assembly; a pressurizing/conveying assembly, configured to provide pressure or power to the auxiliary core-wrapping assembly; a yarn guiding assembly, disposed between the auxiliary core-wrapping assembly and the yarn winding unit; and a wrapping area for wrapping and converging; and wherein the auxiliary core-wrapping unit is configured to make the staple fiber strands intersect and converge with the core yarn at the wrapping area and make the staple fiber strands integrally wrap the core yarn to form a wrapped-core yarn; and is configured to convey the wrapped-core yarn to the yarn winding unit for twisting and winding; wherein the feeding unit further comprises a front roller disposed at an input end of the auxiliary core-wrapping unit; and wherein the auxiliary core-wrapping assembly comprises: a special shaped pipe, a grid circle covered on a surface of the special shaped pipe, and negative pressure suction ports disposed on the special shaped pipe, the grid circle is configured to only allow airflow to pass therethrough, and is configured to widen and spread the staple fiber strands to form a differential dispersed widened strand, and the negative pressure suction ports are covered by the grid circle arranged on the surface of the special shaped pipe.

14. The calculus spinning device as claimed in claim 13, wherein the pressurizing/conveying assembly comprises a front top roller, a drive top roller and a bridge component connecting the front top roller and the drive top roller, the front top roller is configured to drive the bridge component to synchronously rotate the drive top roller, the drive top roller is configured to be in contact with the grid circle to drive the grid circle to rotate and transport forward, a middle of the drive top roller is provided with a roller groove with a width, and the width of the roller groove is one third of a width of the drive top roller.

15. The calculus spinning device as claimed in claim 14, wherein the negative pressure suction ports are one of the following three types: air ports uniformly distributed on the special shaped pipe, equal-width air ports formed along a curved surface of the special shaped pipe, or air ports disposed on the special shaped pipe and gradually widened along a conveying direction of the widened strands on the grid circle.

16. The calculus spinning device as claimed in claim 15, wherein the yarn guiding assembly comprises a yarn guiding rod and a heating groove disposed on the yarn guiding rod.

17. The calculus spinning device as claimed in claim 16, wherein a temperature of the heating groove is 100-200 C., the heating groove is configured to change a transmission path of a yarn output from the auxiliary core-wrapping unit, and the yarn guiding rod is configured to convey the yarn to the yarn winding unit.

18. The calculus spinning device as claimed in claim 15, wherein the yarn guiding assembly comprises a connecting component connected with the pressurizing/conveying assembly and a compliant reinforcing component connected with the connecting component, and the compliant reinforcing component comprises a heating compliant block and a reinforcing sequentially arranged along an advancing direction of the wrapped-core yarn.

19. The calculus spinning device as claimed in claim 18, wherein the auxiliary core-wrapping assembly is internally provided with a staple fiber channel and a filament channel, the filament channel is separated from the staple fiber channel by a target spacing, a width of the staple fiber channel is 5-10 mm, the target spacing between the staple fiber channel and the filament channel is 2-5 mm, a width of the filament channel is 3-5 mm, the staple fiber channel is a channel with a same width along a conveying direction of the staple fiber strands, or a channel with a shape of gradually widening along the conveying direction of the staple fiber strands; and when the staple fiber channel is the channel with the shape of gradually widening, a width of a narrower channel portion of the staple fiber channel is 5-7 mm.

20. A calculus spinning device, the calculus spinning device comprising a feeding unit, an auxiliary core-wrapping unit and a yarn winding unit; wherein the feeding unit comprises: a staple fiber feeding unit, configured to stretch a roving into differential dispersed staple fiber strands and feed the staple fiber strands into the auxiliary core-wrapping unit, and a core yarn feeding unit, configured to feed a core yarn into the auxiliary core-wrapping unit; wherein the auxiliary core-wrapping unit comprises: an auxiliary core-wrapping assembly; a pressurizing/conveying assembly, configured to provide pressure or power to the auxiliary core-wrapping assembly; a yarn guiding assembly, disposed between the auxiliary core-wrapping assembly and the yarn winding unit; and a wrapping area for wrapping and converging; and wherein the auxiliary core-wrapping unit is configured to make the staple fiber strands intersect and converge with the core yarn at the wrapping area and make the staple fiber strands integrally wrap the core yarn to form a wrapped-core yarn; and is configured to convey the wrapped-core yarn to the yarn winding unit for twisting and winding; wherein the feeding unit further comprises a front roller disposed at an input end of the auxiliary core-wrapping unit; wherein the auxiliary core-wrapping assembly is internally provided with a negative pressure air suction assembly, a surface facing towards the negative pressure air suction assembly of the staple fiber channel is provided with uniform grid holes, and the negative pressure air suction assembly is configured to absorb the staple fiber strands in the staple fiber channel through the uniform grid holes; and wherein the pressurizing/conveying assembly comprises a front top roller and a bridge component connecting the front top roller and the auxiliary core-wrapping assembly, the front top roller and the front roller are oppositely arranged, a nip is defined between the front top roller and the front roller and is configured to output the staple fiber strands and the core yarn to the auxiliary core-wrapping assembly, and the bridge component is configured to exert pressure on the auxiliary core-wrapping assembly to make an inner side of the auxiliary core-wrapping assembly attach to a surface of the front roller.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0022] FIG. 1 illustrates a schematic structural diagram of a calculus spinning device according to an embodiment 1.

[0023] FIG. 2 illustrates a specific schematic structural diagram of an auxiliary core-wrapping unit in the embodiment 1.

[0024] FIG. 3 illustrates an enlarged view of a partial structure of the auxiliary core-wrapping unit in FIG. 1.

[0025] FIG. 4 illustrates a schematic diagram of an internal partial structure of the auxiliary core-wrapping assembly in FIG. 2.

[0026] FIG. 5 illustrates a schematic diagram of a calculus spinning method according to the embodiment 1.

[0027] FIG. 6 illustrates a polyester-cotton wrapped-core yarn spun by the core wrapping device and method in the embodiment 1 under 35 times magnification using a 3D microscope.

[0028] FIG. 7 illustrates a polyester-cotton wrapped-core yarn spun by a conventional ring core spinning method in a comparative example 1 under 35 times magnification using a 3D microscope.

[0029] FIG. 8 illustrates a polyester-cotton wrapped-core yarn in a comparative example 2 under 35 times magnification using a 3D microscope.

[0030] FIG. 9 illustrates a schematic structural diagram of a calculus spinning device according to an embodiment 2.

[0031] FIG. 10 illustrates an enlarged view of a partial structure of an auxiliary core-wrapping unit in FIG. 9.

[0032] FIG. 11 illustrates a specific schematic structural diagram of the auxiliary core-wrapping unit of the calculus spinning device in the embodiment 2.

[0033] FIG. 12 illustrates a schematic diagram of a calculus spinning method according to the embodiment 2.

[0034] FIG. 13 illustrates examples of shapes of grid holes.

[0035] FIG. 14 illustrates micrographs of polyester-cotton wrapped-core yarns spun in the embodiment 2 and a comparative example 3, which are respectively shown in a and b of FIG. 14.

[0036] FIG. 15 illustrates micrographs of basalt/polyester/cotton wrapped-core yarns spun in an embodiment 3 and a comparative example 4, which are respectively shown in a and b of FIG. 15.

[0037] FIG. 16 illustrates a schematic structural diagram of a calculus spinning device according to an embodiment 4.

[0038] FIG. 17 illustrates a schematic view of a partial structure of an auxiliary core-wrapping unit in the embodiment 4.

[0039] FIG. 18 illustrates a schematic diagram of a calculus spinning method according to the embodiment 4.

[0040] FIG. 19 illustrates a micrograph of a basalt wrapped-core yarn spun in the embodiment 4.

[0041] FIG. 20 illustrates a micrograph of a basalt wrapped-core yarn spun in an embodiment 5.

[0042] FIG. 21 illustrates a micrograph of a wrapped-core yarn spun in a comparative example 5.

[0043] FIG. 22 illustrates a schematic structural diagram of a calculus spinning device according to an embodiment 6.

[0044] FIG. 23 illustrates a schematic view of a partial structure of an auxiliary core-wrapping unit in FIG. 22.

[0045] FIG. 24A through FIG. 24C illustrate a preparation process and a schematic structural diagram of a wrapped-core yarn when an axis of a staple fiber strand and an axis of a ribbon-like fiber are coincided and input in a front roller nip.

[0046] FIG. 25A and FIG. 25B illustrate a preparation process and a schematic structural diagram of a wrapped-core yarn when an axis of a staple fiber strand and an axis of a ribbon-like fiber are spaced from each other at a certain spacing and input in a front roller nip.

[0047] FIG. 26 illustrates a schematic structural diagram of a calculus spinning device according to an embodiment 12.

[0048] FIG. 27 illustrates a connection relationship diagram of a negative pressure adsorption assembly, an auxiliary conveying component and a negative pressure airflow guide assembly in FIG. 26.

[0049] FIG. 28 illustrates a schematic structural diagram of the negative pressure air flow guide assembly.

[0050] FIG. 29 illustrates a schematic structural diagram of a compliant reinforcement component.

[0051] FIG. 30 illustrates a path diagram of forming a wrapped-core yarn through staple fiber strand and core yarn.

[0052] FIG. 31 illustrates an image of wrapped-core yarn spun in the embodiment 12 under 35 times magnification using a 3D microscope with a scale of 500 m.

[0053] FIG. 32 illustrates an image of a wrapped-core yarn spun in the embodiment 13 under 35 times magnification using a 3D microscope with a scale of 500 m.

[0054] FIG. 33 illustrates an image of a wrapped-core yarn spun in a comparative example 9 under 35 times magnification using a 3D microscope with a scale of 500 m.

[0055] FIG. 34 illustrates an image of a wrapped-core yarn spun in a comparative example 10 under 35 times magnification using a 3D microscope with a scale of 500 am.

[0056] FIG. 35 illustrates an image of a wrapped-core spun in a comparative example 11 under 35 times magnification using a 3D microscope with a scale of 500 m.

[0057] FIG. 36 illustrates a schematic structural diagram of a calculus spinning device according to an embodiment 8.

[0058] FIG. 37 illustrates a connection relationship diagram between a negative pressure adsorption assembly and an auxiliary conveying component.

[0059] FIG. 38 illustrates a path diagram of forming a wrapped-core yarn by using a staple fiber wide strand, a wrapping yarn and a core yarn in the embodiment 8.

[0060] FIG. 39 illustrates a composition diagram of the staple fiber wide strand in FIG. 36.

[0061] FIG. 40 illustrates a schematic structural diagram of a calculus spinning device according to an embodiment 9.

[0062] FIG. 41 illustrates a path diagram of forming a wrapped-core yarn by using a staple fiber wide strand, a wrapping yarn and a core yarn in the embodiment 9.

[0063] FIG. 42 illustrates an image of a wrapped-core yarn spun in the embodiment 8 under 35 times magnification using a 3D microscope with a scale of 200 m.

[0064] FIG. 43 illustrates an image of a wrapped-core yarn spun in a comparative example 7 under 35 times magnification using a 3D microscope with a scale of 200 m.

[0065] FIG. 44 illustrates an image of a wrapped-core yarn spun in a comparative example 8 under 35 times magnification using a 3D microscope with a scale of 200 m.

REFERENCE NUMERALS

[0066] S0, S1roving; S11staple fiber strand; S12second staple fiber strand; F1core yarn; F2wrapping yarn; F11ribbon-like filaments; S2wrappedcore yarn; S13partial staple fiber strand near the core yarn F1; S14partial staple fiber strand facing away from the core yarn F1; [0067] 10staple fiber feeding unit; 11a, 11b, 11c, 11d, 11e, 11fbell mouth; 12a, 12b, 12c, 12d, 12e, 12frear roller; 13a, 13b, 13c, 13d, 13e, 13fback top roller; 14a, 14b, 14c, 14d, 14e, 14fmiddle roller; 15a, 15b, 15c, 15d, 15e, 15fmiddle top roller; 16a, 16c, 16d, 16e, 16ffront roller; [0068] 20core yarn feeding unit; 21a, 21b, 21c, 21d, 21e, 21fgodet; 22electrostatic fiber opening assembly; 23core yarn unwinding unit; 24tension adjusting frame; [0069] 30auxiliary core-wrapping unit; 31auxiliary core-wrapping assembly; 32pressurizing/conveying assembly; 33yarn guiding assembly; 34wrapping area; 35d, 35e, 35ftransmission gear; 36negative pressure air flow guide assembly; 311staple fiber channel; 312filament channel; 313fiber spreading roller; 314special shaped pipe; 315c, 315d, 315e, 315fgrid circle; 316d, 316e, 316fspecial shaped air suction plate; 317d, 317e, 317fdrive roller; 321a, 321b, 321c, 321d, 321e, 321ffront top roller; 322a, 322c, 322d, 322e, 322fbridge component; 323c, 323c, 323e, 323fdrive top roller; 324c, 324d, 324e, 324froller groove; 331a, 331b, 331c, 331fyarn guiding rod; 332a, 332bheating groove; 333connecting component; 334compliant reinforced component; 361diversion housing; 362diffusion guide hole; 363airflow stabilizing hole; 3131roller body; 3132b, 3132d, 3132e, 3132fnegative pressure adsorption assembly; 3133b, 3133c, 3133d, 3133e, 3133fnegative pressure suction port; 3134grid hole; 3135negative pressure fiber expansion area; 3311fyarn groove; 3341heating compliant block; 3342reinforcing block; 3343arc groove; 33421fixing block; 33422tension adjusting plate; [0070] 40yarn winding unit; 41a, 41b, 41c, 41d, 41e, 41fguide hook; 42a, 42b, 42c, 42d, 42e, 42ftraveler; 43a, 43b, 43c, 43d, 43e, 43fsteel ring; 44a, 44b, 44c, 44d, 44e, 44fring bobbin.

DETAILED DESCRIPTION OF EMBODIMENTS

[0071] In order to make the objectives, technical solutions and advantages of the disclosure clearer, the disclosure will be described in detail with accompanying drawings and specific embodiments.

[0072] Here, it should also be noted that in order to avoid obscuring the disclosure with unnecessary details, only the structures and/or processing steps closely related to the technical solutions of the disclosure are shown in the drawings, while other details that are not related to the disclosure are omitted.

[0073] In addition, it should be noted that the terms including, containing or any other variation thereof are intended to cover non-exclusive inclusion, so that a process, a method, an article or a device including a series of elements includes not only those elements, but also other elements not explicitly listed, or elements inherent to such process, method, article or device.

[0074] As illustrated in FIG. 1 through FIG. 42, the disclosure provides a calculus spinning device, which includes a feeding unit, an auxiliary core-wrapping unit 30 and a yarn winding unit 40.

[0075] The feeding unit includes a staple fiber feeding unit 10 and a core yarn feeding unit 20. The staple fiber feeding unit 10 is configured to stretch a roving S1 into staple fiber strand S11 and feed the staple fiber strand S11 into the auxiliary core-wrapping unit 30. The core yarn feeding unit 20 is configured to feed a core yarn F1 into the auxiliary core-wrapping unit 30.

[0076] The auxiliary core-wrapping unit 30 includes an auxiliary core-wrapping assembly 31, a pressurizing/conveying assembly 32 configured to provide pressure or power to the auxiliary core-wrapping assembly 31, a yarn guiding assembly 33 disposed between the auxiliary core-wrapping assembly 31 and the yarn winding unit 40, and a wrapping area 34 for wrapping and converging the staple fiber strand S11 and the core yarn F1.

[0077] The auxiliary core-wrapping unit 30 is configured to make the staple fiber strand S11 intersect and converge with the core yarn F1 at the wrapping area 34, and make the staple fiber strand S11 wrap the core yarn F1 to form a wrapped-core yarn S2. The auxiliary core-wrapping unit 30 is further configured to convey the wrapped-core yarn S2 to the yarn winding unit 40 for twisting and winding. In a process of yarn formation, the staple fiber strand obtained by stretching the roving S1 through the staple fiber feeding unit 10 is differentially dispersed and expanded into highly stretched and fully dispersed flat ribbon-like single fibers under the action of the auxiliary core-wrapping unit 30, and the ribbon-like single fibers are wrapped around an outer layer of the self-rotating twisted core yarn F1 in an orderly revolution one by one, and finally, the ribbon-like single fibers are wrapped around the core yarn F1 by continuously gathering to form the wrapped-core yarn S2. The whole process of yarn formation adopts the principle of differentiation first and integration second. Moreover, a yarn guiding assembly 33 further makes a structure of the wrapped-core yarn S2 more compact and improves the quality of the wrapped-core yarn S2, which is equivalent to further integration. Based on above, the device of the disclosure is named as a calculus spinning device.

[0078] The disclosure will be described in detail by specific embodiments and comparative examples.

Embodiment 1

[0079] As illustrated in FIG. 1 through FIG. 5, a staple fiber channel 311 and a filament channel 312 are disposed in the auxiliary core-wrapping assembly 31. The filament channel 312 is separated from the staple fiber channel 311 by a spacing, and a width of the staple fiber channel 311 is 5-10 mm.

[0080] The calculus spinning device of this embodiment is provided with the auxiliary core-wrapping assembly 31 with a special structure, so that the staple fiber strands S11 form staple fiber strands each with a certain width and a uniform structure in the staple fiber channel 311. By cooperation operation of the auxiliary core-wrapping assembly 31, the feeding unit, other components of the auxiliary core-wrapping unit 30 and the yarn winding unit 40, the tight integral wrapping of the staple fiber strands on the core yarn F1 is realized, so as to obtain the wrapped-core yarn S2 with a good covering effect and a core yarn ratio of 60%-70%, which maximizes the utilization of the staple fiber strands and reduces the raw material cost of the wrapped-core yarn S2, and solves the problem in the related art that the core yarn is easily exposed from the wrapped-core yarn for a ring spinning machine, and the core yarn ratio is lower. Through the cooperation of various units, the calculus spinning device can be applied to industrial production, realizing industrial high-speed and batch spinning, and the produced wrapped-core yarn has good comprehensive properties and has great market application prospects.

[0081] In particular, as illustrated in FIG. 2 through FIG. 4, the staple fiber channel 311 is a channel with a same width along a conveying direction of the staple fiber strands S11, or a channel with a shape of gradually widening along the conveying direction of the staple fiber strands S11, so as to avoid generating a concentrated force by the staple fiber channel 311 on the staple fiber strands S11 and enable the staple fiber strands S11 to form staple fiber strands each with a certain width in the staple fiber channel 311. When the staple fiber channel 311 is the channel with the shape of gradually widening, a width of a narrower portion of the staple fiber channel 311 is 5-7 mm. In this way, during a high-speed spinning process, the roving S1 is stretched by the staple fiber feeding unit 10 to form staple fiber strands S11, and a diameter of each of the staple fiber strands S11 is 1-3 mm; after the staple fiber strands S11 enter the staple fiber channel 311, the staple fiber strands S11 form the staple fiber strands each with a certain width, high fiber parallelism and uniform fiber distribution in a wider channel by its own force; after the staple fiber strands converge with the core yarn F1 in the wrapping area 34, the staple fiber strands are evenly wrapped on a surface of the core yarn F1 by the rotation of the core yarn F1, thereby achieving a good wrapping effect. In addition, the staple fiber channel 311 with a larger width compared with the filament channel 312 is only used to support and transport the staple fiber strands S11, and no twist is applied to the staple fiber strands S11, thus avoiding the problem that the staple fiber strands S11 are aggregated and are not conducive to the subsequent coating of the core yarn F1.

[0082] Specifically, the spacing between the staple fiber channel 311 and the filament channel 312 is 2-5 mm. A width of the filament channel 312 is 3-5 mm. The yarn guiding assembly 33 includes a yarn guiding rod 331a and a heating groove 332 disposed on the yarn guiding rod 331a. The heating groove 332a is directly opposite to an output port of the staple fiber channel 311, so that the staple fiber strands are output from the staple fiber channel 311 in a straight line (from FIG. 5, it can be seen that a conveying direction of the staple fiber strands S11 in the staple fiber channel 311 is the same as a conveying direction of the staple fiber strands output from the staple fiber channel 311), and the core yarn F1 is output from the filament channel 312 in a broken line (from FIG. 5, a conveying direction of the core yarn F1 in the filament channel 312 is different from a conveying direction of the core yarn F1 output from the filament channel 312) and offset to the staple fiber strands S11, and the core yarn F1 and the staple fiber strands formed by the staple fiber strands S11 enter the wrapping area 34 at a certain angle and converge in the wrapping area 34. In this way, the staple fiber channel 311 is separated from the filament channel 312 by the spacing, and the core yarn F1 after being output from the filament channel 312 is offset to the staple fiber strands under the arrangement of the yarn guiding assembly 33. As such, the core yarn F1 converges with the staple fiber strands formed by the staple fiber strands S11 at the wrapping area 34 at a certain angle, which not only helps the core yarn F1 to rotate and drive the staple fiber strands to wrap around an outer layer of the core yarn F1 to form the wrapped-core yarn with a uniform wrapping structure, but also avoids the problem that a twist of a bottom yarn is transferred to the staple fiber strands S11, which leads to self-twisting of the staple fiber strands S11, which is not conducive to the formation of staple fiber strands. In addition, in this process, it is unnecessary to change an angle of the staple fiber strands S11, so that the staple fiber strands S11 can be transported to the staple fiber channel 311 in a natural state, so as to maintain the integrity of the staple fiber strands formed by the staple fiber strands S11 in the staple fiber channel 311 and avoid aggregation of the staple fiber strands S11.

[0083] It should be noted that a temperature of the heating groove 332a disposed in the yarn guiding rod 331a is 100-200 C., and the higher the modulus, vitrification or softening temperature of the used staple fiber strands, the higher the setting temperature of the heating groove 332a. Besides positioning a yarn forming path, surfaces of the staple fiber strands can be ironed and softened by the heating groove 332a, and a yarn forming smoothness can be improved through the heating groove 332a, and the yarn forming path from a nip formed between a front roller 16a and a front top roller 321a to the yarn guiding rod 331a is adhered to a surface of the front roller 16a. It is also possible to adjust a tension of the wrapped-core yarn S2 on the front roller 16a by adjusting a vertical position of the yarn guiding rod 331a perpendicular to the yarn forming path, and further, a yarn lateral movement caused by airflow is eliminated, and a structure of the wrapped-core yarn S2 is more stable.

[0084] In some other embodiments, a negative pressure air suction assembly is disposed in the auxiliary core-wrapping assembly 31, a surface facing towards the negative pressure air suction assembly of the staple fiber channel 311 is provided with uniform grid holes, and the staple fiber strands S11 in the staple fiber channel 311 are absorbed by the negative pressure air suction assembly through the uniform grid holes, so that the staple fiber strands S11 are laid flat on an inner surface of the staple fiber channel 311 to form staple fiber strands with a uniform structure. Setting the negative pressure air suction assembly not only increases a clamping force of the staple fiber channel 311 on the staple fiber strands S11, but also reduces a hairiness on a surface of the wrapped-core yarn S2, and does not form any twist on the staple fiber strand S11, which is beneficial to the formation of the uniform staple fiber strands in the staple fiber channel 311. According to the disclosure, the staple fiber strands S11 are firstly formed into widened staple fiber strands, and then the core yarn F1 is coated by the widened staple fiber strands, so that the core yarn ratio of the wrapped-core yarn is improved, the consumption of the roving is saved, and the preparation cost of the wrapped-core yarn is reduced.

[0085] Compared with the wrapped-core yarn spinning device in the related art, the calculus spinning device of the disclosure does not form any twist on the staple fiber strands S11, and does not make the staple fiber strands S11 gather, so that the core yarn F1 is wrapped by the staple fiber strands S11 in a natural state only through the support of the staple fiber channel 311 for the staple fiber strands S11. The calculus spinning device of the disclosure is suitable for high-speed spinning of ring spinning in practical factories, and will not exert an excessive force on the staple fiber strands S11 during high-speed spinning, and thus the staple fiber strands with uniform structure are formed, rather than leading to warping or agglomeration, staple fiber accumulation, winding and other problems.

[0086] As illustrated in FIG. 1, the feeding unit further includes a front roller 16a disposed at an input end of the auxiliary core-wrapping unit 30. The staple fiber feeding unit 10 includes a bell mouth 11a, a rear roller 12a, a rear top roller 13a, a middle roller 14a and a middle top roller 15a, which are sequentially arranged along a feeding and stretching direction of the roving S1. The front roller 16a is disposed to be in contact with the auxiliary core-wrapping assembly 31. The pressurizing/conveying assembly 32 includes a front top roller 321a and a bridge component 322a connecting the front top roller 321a and the auxiliary core-wrapping assembly 31. The front top roller 321a and the front roller 16a are disposed opposite to each other, and the nip is defined as a nipping jaw between front top roller 321a and the front roller 16a. Both the staple fiber strand S11 and the core yarn F1 are output from the nip to enter the auxiliary core-wrapping assembly 31. The bridge component 322a is configured to apply pressure to the auxiliary core-wrapping assembly 31, so that an inner side of the auxiliary core-wrapping assembly 31 is attached to a surface of the front roller 16a.

[0087] The core yarn feeding unit 20 includes a godet 21a configured to change an angle of the core yarn F1. The core yarn F1 is guided by the godet 21a, and is input into the filament channel 312 via the nip between the front top roller 321a and the front roller 16a at a certain angle. After being output from the filament channel 312, the core yarn F1 and the staple fiber strands S11 enter the wrapping area 34 at a certain angle (that is to say, the certain angel is formed between the core yarn F1 and the staple fiber strands S11) and converge in the wrapping area 34, and a rotation of the core yarn F1 drives the staple fiber strands S11 to be wrapped around an outer layer of the core yarn F1 to form the wrapped-core yarn S2.

[0088] The calculus spinning device of the disclosure only needs to improve an auxiliary core-wrapping unit on the ordinary ring spinning device to realize the fiber separation of the staple fiber strands S11 to form the staple fiber strands; further, the core yarn feeding unit 20 is disposed to adjust the angle of the core yarn F1 fed to the auxiliary core-wrapping unit 30 and to adjust a spacing between the core yarn and the staple fiber strands S11, so as to realize the effect of tightly wrapping the core yarn F1 by the staple fiber strands S11 to form the wrapped-core yarn. The calculus spinning device of the disclosure has low cost, wide application range and good industrial application prospect and value.

[0089] A calculus spinning method implemented by the calculus spinning device provided in the embodiment 1 is provided, as illustrated in FIG. 5.

[0090] In the calculus spinning method, the staple fiber feeding unit 10 stretches a roving S1 into staple fiber strands S11. Then, the staple fiber strands S11 are conveyed into the staple fiber channel 311 of the auxiliary core-wrapping assembly 31 through the nip between the front top roller 321a and the front roller 16a, and the staple fiber strands S11 form staple fiber strands in the staple fiber channel 311. Then the staple fiber strands are output from the staple fiber channel 311 and are conveyed forward along an operation direction of the front roller 16a.

[0091] Simultaneously, a core yarn F1 is guided by the godet 21a, and is input into the filament channel 312 of the auxiliary core-winding assembly 31 from the nip between the front top roller 321a and the front roller 16a at a certain angle, and after being output, the core yarn F1 and the staple fiber strands on a surface of the front roller 16a enter the winding area 34 at a certain angle (that is to say, the certain angel is formed between the core yarn F1 and the staple fiber strands) and converge in the winding area 34, and the rotation of the core yarn F1 drives the staple fiber strands to be wrapped around an outer layer of the core yarn F1 to form a core-wrapped-core yarn S2.

[0092] The wrapped-core yarn S2 passes through the heating groove 332a on the yarn guiding rod 331a, so as to realize the positioning of a yarn forming path and eliminate a yarn lateral movement caused by airflow. The yarn guiding rod 331a conveys the wrapped-core yarn S2 to a guide hook 41a of the yarn winding unit 40, and the wrapped-core yarn S2 is wound on a ring bobbin 44a by a traveler 42a rotating at higher speed on the steel ring 43a, therefore, the calculus spinning process is completed.

[0093] In particular, a spacing between the wrapping area 34 and the nip is greater than a fiber length of each of the staple fiber strands S11, so that the staple fiber strand S11 can be wrapped on a surface of the core yarn F1 by the rotation of the core yarn F1. An input spacing between the staple fiber strand S11 and the core yarn F1 in the nip is 2-5 mm, and the input spacing indicates a spacing between the staple fiber strand S11 and the core yarn F1 before inputting into the nip. By setting the spacing between the wrapping area 34 and the nip between the front top roller 321a and the front roller 16a to be greater than the fiber length of each of the staple fiber strand S11, the staple fiber strand S11 can be wrapped on the outer layer of the core yarn F1 by better utilizing the rotation of the core yarn F1, and the high-speed rotation of the core yarn F1 can also produce a certain stretching effect on the staple fiber strand S11, thereby further improving the yarn quality of the wrapped-core yarn S2. The purpose of restricting the input spacing between the staple fiber strand S11 and the core yarn F1 in the nip between the front top roller 321a and the front roller 16a (that is to say, before entering the nip, the staple fiber strand S11 are separated from the core yarn F1 by the input spacing) is to match the spacing between the staple fiber channel 311 and the filament channel 312 and the restriction function of the yarn guiding assembly 33, so that the core yarn F1 converges with the staple fiber strands formed by the staple fiber strand S11 at the wrapping area 34 at a certain angle, which is beneficial to the wrapping effect of the staple fiber strands on the core yarn F1.

[0094] In this embodiment, the spacing between the staple fiber channel 311 and the filament channel 312 is 5 mm, a width of the filament channel 312 is 3 mm, the staple fiber channel 311 is a channel with a same width of 10 mm along a conveying direction of the staple fiber strand S11. In the calculus spinning process, the input spacing between the staple fiber strand S11 and core yarn F1 in the nip is 5 mm.

[0095] As illustrated in FIG. 6, FIG. 6 illustrates a polyester-cotton wrapped-core yarn spun by the calculus spinning device and method in the embodiment 1 under 35 times magnification using a 3D microscope. A material of a core yarn of the polyester-cotton wrapped-core yarn is 120 D blue polyester yarn. A material of a staple fiber strand is 735 tex cotton roving. Process parameters are as follows: a spindle speed is 8000 r/min, a twist is 70 T/10 cm, a speed of a front roller is 11.43 m/min, a total drafting multiple is 82.68, a linear density of cortical cotton fiber is 8.89 tex, and a back zone drafting multiple is 1.25. In FIG. 6, a core yarn ratio of the polyester-cotton wrapped-core yarn is 60%.

[0096] As can be seen from FIG. 6, in the polyester-cotton wrapped-core yarn spun by the calculus spinning device and method in the embodiment 1, a polyester core yarn is completely covered by an outer cotton fiber without exposure the polyester core yarn, an overall yarn coating effect is good, and parallelism of the outer cotton fiber is higher.

Comparative Example 1

[0097] The comparative example 1 provides a wrapped-core yarn device and method. Compared with the embodiment 1, the difference is that the device in the comparative example 1 is a conventional ring spinning device, and the method in the comparative example 1 includes: gathering staple fiber strands around a core yarn and twisting the staple fiber strands to obtain a wrapped-core yarn. The rest process is basically the same as that of the embodiment 1, so the details are not repeated herein.

[0098] FIG. 7 illustrates a polyester-cotton wrapped-core yarn spun by an ordinary ring core spinning method under 35 times magnification using a 3D microscope. The ordinary ring core spinning method directly gathers staple fiber strands and twists the staple fiber strands and a core yarn to prepare the polyester-cotton wrapped-core yarn, and the auxiliary core-wrapping unit 30 of the disclosure is not provided therein. As can be seen from FIG. 7, the polyester-cotton wrapped-core yarn spun by the ordinary ring core spinning method can't cover the core yarn well when the core yarn ratio is 60%, and there is an obvious phenomenon that the blue polyester core yarn is exposed, and the yarn quality of the wrapped-core yarn is poorer.

Comparative Example 2

[0099] This comparative example 2 provides another calculus spinning device and method. Compared with the embodiment 1, the difference is that the staple fiber channel 311 and the filament channel 312 are closely disposed (i.e., there is no spacing between the staple fiber channel 311 and the filament channel 312), and the rest are basically the same as those in the embodiment 1, so the details are not repeated herein.

[0100] As illustrated in FIG. 8, FIG. 8 illustrates a polyester-cotton wrapped-core yarn spun by a device with no spacing between the staple fiber channel 311 and the filament channel 312 in a comparative example 2 under 35 times magnification using a 3D microscope, in which a core yarn ratio is 60%. As can be seen from FIG. 8, the polyester-cotton wrapped-core yarn spun by the device with no spacing between the staple fiber channel 311 and the filament channel 312 forms the appearance of a plied yarn, and a blue polyester core yarn is twisted with an outer cotton fiber instead of completely covering the blue polyester core yarn.

[0101] The wrapped-core spun yarns spun in the embodiment 1 and the comparative examples 1-2 are compared in terms of core yarn ratio, breaking strength and elongation at break, and corresponding results are shown in Table 1.

TABLE-US-00001 TABLE 1 Comparative results of performance of wrapped-core yarns in embodiment 1 and comparative examples 1-2 Core Breaking strength Elongation at yarn (centiNewton break (%) ratio (cN)) Standard (%) Standard deviation deviation Embodiment 1 60 930.57 8.07 7.72 0.16 Comparative 60 712.91 28.57 7.42 0.22 example 1 Comparative 60 745.63 10.34 7.56 0.21 example 2

[0102] As can be seen from Table 1, the wrapped-core yarn of the embodiment 1 is closer to an ideal wrapped-core yarn structure in structure, in a stretching process, the core yarn of the wrapped-core yarn mainly bears stress, therefore, a breaking strength of the wrapped-core yarn is higher. However, in the wrapped-core yarn in the comparative example 1, the wrapped-core yarn is exposed from the wrapped-core yarn, and the core yarn is not completely straightened in a yarn body (i.e., wrapped-core yarn), but is constantly transferred from inside to outside. Therefore, during a stretching process of the wrapped-core yarn in the comparative example 1, the core yarn and the staple fiber strands are jointly stressed, and the core yarn is subjected to a shearing force generated by the stretching of the staple fiber strands, so a breaking strength of the wrapped-core yarn is lower, there is a higher likelihood that the core yarn and the staple fiber strands will break at different times, and a standard deviation is higher. The wrapped-core yarn in the comparative example 2 completely presents the appearance of the plied yarn. During a stretching process of the wrapped-core yarn in the comparative example 2, the core yarn and the staple fiber strands are jointly stressed, and the core yarn and the staple fiber strands are twisted together. The breaking strength and the elongation at break of the wrapped-core yarn in the comparative example 1 are lower than those of the wrapped-core yarn in the embodiment 1, and the standard deviation in the comparative example 1 is lower than that in the embodiment 1.

Embodiment 2

[0103] As illustrated in FIG. 9 through FIG. 13, the auxiliary core-wrapping assembly 31 is a fiber spreading roller 313, the pressing/conveying assembly 32 is a front top roller 321b disposed opposite to the fiber spreading roller 313. The fiber spreading roller 313 is configured to perform negative pressure fiber expansion on the staple fiber strands S11 conveyed from the staple fiber feeding unit 10 to form widened fiber strands, the widened fiber strands tightly wrap the core yarn F1 conveyed from the core yarn feeding unit 20 to form a wrapped-core yarn S2, and the formed wrapped-core yarn S2 is conveyed to the yarn winding unit 40 by the yarn guiding assembly 33.

[0104] In this calculus spinning device, the auxiliary core-wrapping unit 30 is set to perform negative pressure fiber expansion on the staple fiber strand S11 to form the widened fiber strands, and the feeding unit and the yarn winding unit 40 are cooperated with the auxiliary core-wrapping unit 30 to realize the tight integral wrapping of the core yarn F1 by the widened fiber strands, so that the wrapped-core yarn S2 with good covering effect and a ratio of the core yarn F1 to the wrapped-core yarn S2 accounting for 60%-80% can be obtained. The calculus spinning device in the embodiment 2 has advantages as the same as those of the calculus spinning device in the embodiment 1, and will not be described herein.

[0105] As illustrated in FIG. 10 through FIG. 11, the fiber spreading roller 313 includes a central shaft, a roller body 3131, and a negative pressure adsorption assembly 3132b disposed in the roller body 3131. The negative pressure adsorption assembly 3132b is fixedly disposed on the central shaft of the fiber spreading roller 313 and does not rotate with the fiber spreading roller 313. A surface of the roller body 3131 is provided with evenly distributed grid holes 3134, which only allow airflow to pass therethrough and have the function of supporting and transporting the staple fiber strand S11. The negative pressure adsorption assembly 3132b is configured to adsorb the staple fiber strand S11 to surfaces of the grid holes 3134 under negative pressure, thereby forming a negative pressure fiber expansion area 3135 (as illustrated in FIG. 12). The negative pressure adsorption assembly 3132b in this embodiment increases a clamping force of the fiber spreading roller 313 to the staple fiber strand S11, which is beneficial to the formation of the uniform fiber belt on the surface of the fiber spreading roller 313. A specific function of the negative pressure adsorption assembly 3132b is the same as that of the negative pressure air suction assembly in the embodiment 1, and will not be described herein.

[0106] In some specific embodiments, the core yarn F1 is an inorganic fiber filament, an organic fiber filament, an organic/inorganic composite filament, or a staple yarn or a filament/staple composite yarn.

[0107] Specifically, the negative pressure adsorption assembly 3132b includes a negative pressure suction port 3133b, which is disposed to face towards the grid holes 3134 (i.e., the negative pressure suction port 3133b is disposed to close to the grid holes 3134). The negative pressure air suction port 3133b has air inlets with a same width along a conveying direction of the staple fiber strand S11, or the negative pressure air suction port 3133b has air outlets gradually widened along the conveying direction of the staple fiber strand S11, so as to realize the fiber spreading of the staple fiber strand S11. In this way, the staple fiber strand S11 are adsorbed on the surface of the fiber spreading roller 313 through the grid holes 3134 by the negative pressure adsorption assembly 3132b, such that the staple fiber strand S11 are supported and transported by the negative pressure adsorption assembly 3132b, and no twist is applied to the staple fiber strand S11. Moreover, through a guiding spreading action of a negative pressure airflow generated by the negative pressure suction port 3133b with the air outlets and a micro-vibration action of the fiber spreading roller 313, the fiber spreading of the staple fiber strand S11 is realized, and the widened fiber strands each with a certain width, high fiber parallelism and uniform fiber distribution are formed. After the widened fiber strands converge with the core yarn F1 in the wrapping area 34, the widened fiber strands are evenly wrapped on the surface of the core yarn F1 by the rotation of the core yarn F1.

[0108] As illustrated in FIG. 13, FIG. 13 illustrates examples of shapes of the grid holes 3134 of the disclosure. It can be seen that the shape of the grid holes 3134 is not unique. For example, a suction area gradually widened along the conveying direction of the staple fiber strand S11 can be formed according to the shape of the negative pressure suction port 3133b, so that the staple fiber strand S11 can be absorbed in the suction area under the guidance of a negative pressure airflow, and the staple fiber strand S11 can be expanded to form the widened fiber strands with uniform structure.

[0109] It should be noted that a diameter of the staple fiber strand S11 output by the staple fiber feeding unit 10 is 1-3 mm, so a width of the negative pressure suction port 3133b is 5-10 mm, and a width of a narrowest portion of the negative pressure suction port 3133b is 5-7 mm. In this way, the staple fiber strand S11 can be better expanded in the negative pressure spreading area 3135 on the surface of the fiber spreading roller 313, and no aggregation occurs, thereby forming the widened fiber strands with uniform structure.

[0110] Specifically, the yarn guiding assembly 33 is disposed on a surface of the fiber spreading roller 313. The yarn guiding assembly 33 is a yarn guiding rod 331a, and the yarn guiding rod 331a is provided with a heating groove 332b thereon. A temperature of the heating groove 332b is 100-200 C., and a setting principle for the temperature is the same as that in the embodiment 1. Through the heating groove 332b, the wrapped-core yarn S2 is formed between the fiber spreading roller 313 and the yarn guiding assembly 33, and the wrapped-core yarn S2 formed by wrapping the spreading fibers onto F1 is then passed into the heating groove 332b of the yarn guiding assembly 33 to the yarn winding unit 40, and the heating groove 332b locates a yarn forming path of the wrapped-core yarn S2, and a surface of the wrapped-core yarn S2 can be ironed and softened to improve the smoothness of the wrapped-core yarn S2. The position of the heating groove 332b on the yarn guiding assembly 33 satisfies a condition that an angle of the staple fiber strand S11 when staple fiber strand S11 are input into the auxiliary core-wrapping unit 30 is the same as an angle of the widened fiber strands when the widened fiber strands are transported in the auxiliary core-wrapping unit 30, so as to maintain the integrity and structural uniformity of the widened fiber strands formed by the staple fiber strand S11 in the auxiliary core-wrapping unit 30 and make the widened fiber strands cover the surface of the core yarn F1 in a natural state. By only adjusting the core yarn F1 to generate an included angle between the core yarn F1 and the widened fiber strands, it is not only beneficial to the covering of the core yarn F1 by the widened fiber strands, but also avoids the problem that a twist of a bottom yarn (i.e., the core yarn F1) is transferred to the staple fiber strand S11, which leads to self-twisting of the staple fiber strand S11, and it is not beneficial the staple fiber strand S11 to expand to form the widened fiber strands. The position of the yarn guiding assembly 33 in a direction perpendicular to the yarn forming path can be adjusted to adjust a tension of the wrapped-core yarn S2 on the fiber spreading roller 313, and to eliminate a yarn lateral movement caused by airflow, so that the structure of the wrapped-core yarn S2 is more stable.

[0111] Specifically, the staple fiber feeding unit 10 includes a bell mouth 11b, a back roller 12b, a back top roller 13b, a middle roller 14b and a middle top roller 15b, which are sequentially arranged along a feeding direction of the roving S1 in that order. After the roving S1 is stretched into the staple fiber strand S11 by the staple fiber feeding unit 10, the staple fiber strand S11 are clamped by the middle roller 14b and the middle top roller 15b, and are conveyed between the fiber spreading roller 313 and the front top roller 321b of the auxiliary core-wrapping unit 30. The core yarn feeding unit 20 includes a godet 21b configured to change an angle of the core yarn F1. The core yarn F1 is guided by the godet 21b, and then is input into the auxiliary core-wrapping unit 30 from the nip between the front top roller 321b and the fiber spreading roller 313 at a certain angle. Then, the core yarn F1 converges with the widened fiber strands on the surface of the negative pressure fiber expansion area 3135 at a certain angle in the wrapping area 34, and the core yarn F1 rotates to drive the widened fiber strands to be wrapped around an outer layer of the core yarn F1 to form a wrapped-core yarn S2.

[0112] The godet 21b of the core yarn feeding unit 20 can change the angle of the core yarn F1 (i.e., an inputting angle of the core yarn F1 into the nip), so as to control the included angle between the core yarn F1 and the widened fiber strands in the wrapping area to be 5-65, so that the widened fiber strands can better rotate and wrap the surface of the core yarn F1. The staple fiber feeding unit 10 is configured to stretch the roving S1 to thereby obtain staple fiber strand S11, and feed the obtained staple fiber strand S11 into the auxiliary core-wrapping unit 30 for negative pressure fiber expansion to form the widened fiber strands. By defining the spacing between the staple fiber strand S11 and the core yarn F1 before entering the auxiliary core-wrapping unit 30 and defining the position of the heating groove 332b in the yarn guiding assembly 33, the following effects are brought out: the widened fiber strands are conveyed in the auxiliary core-wrapping unit 30 in a natural state without changing the conveying angle of the widened fiber strands, and the structural integrity and uniformity of the widened fiber strands are maintained; and an included angle is generated between the core yarn F1 and the widened fiber strands, which is not only beneficial to the covering of the core yarn F1 by the widened fiber strands, but also avoids the problem that a twist of the bottom yarn is transferred to the staple fiber strand S11, which leads to self-twisting of the staple fiber strand S11, and it is not beneficial the staple fiber strand S11 to expand to form the widened fiber strands.

[0113] Compared with the core spinning device in the related art, the calculus spinning device of this embodiment of the disclosure has the same advantages as in the embodiment 1. In addition, when the staple fiber strand S11 encounter breakage or other operational issues, the difficulty for workers to repair is lower, and no additional unnecessary operations on the calculus spinning device are required.

[0114] As illustrated in FIG. 12, FIG. 12 illustrates a schematic diagram of a calculus spinning method according to the embodiment 2. Specifically, the staple fiber strand S11 are subjected to negative pressure expansion by the auxiliary core-wrapping unit 30 to form widened fiber strands each with a certain width and parallelism, and the widened fiber strands tightly wrap the core yarn F1 to obtain the wrapped-core yarn S2. The specific calculus spinning method is as follows.

[0115] The staple fiber feeding unit 10 stretches the roving S1 into the staple fiber strand S11 and conveys the staple fiber strand S11 to the fiber spreading roller 313 of the auxiliary core-wrapping unit 30. The staple fiber strand S11 are absorbed by the negative pressure absorption assembly 3132b through the grid holes 3134 and spread on the surface of the roller body 3131, and a widened fiber strands is formed in the negative pressure spreading area 3135. Then, the widened fiber strands are transported forward along an operation direction of the fiber spreading roller 313.

[0116] Simultaneously, the core yarn F1 is guided by the godet 21b, and its guiding principle and conveying path thereof are as described above.

[0117] The heating groove 332b of the yarn guiding assembly 33 locates a yarn forming path of the wrapped-core yarn S2 and eliminates a yarn lateral movement caused by airflow. The yarn guiding assembly 33 conveys the wrapped-core yarn S2 to the guide hook 41b of the yarn winding unit 10, and the wrapped-core yarn S2 is wound on the ring bobbin 44b by a traveler 42b rotating at a higher speed on the steel ring 43b, thereby completing the wrapped-core yarn process in which the staple fiber strands are spread and tightly wrapped with high-proportion core yarns.

[0118] Particularly, the spacing between the wrapping area 34 and the nip between the front top roller 321b and the fiber spreading roller 313 is greater than a fiber length of each of the staple fiber strand S11, so that the staple fiber strand S11 are wrapped on an outer layer of the core yarn F1 by the rotation of the core yarn F1. The core yarn F1 has a certain spacing from the staple fiber strand S11 at a feeding position of the nip of the fiber spreading roller 313, and the certain spacing between the core yarn F1 and the staple fiber strand S11 is preferably 2-5 mm. The included angle between the core yarn F1 and the widened fiber strands in the wrapping area 34 is in range from 5 to 65.

[0119] In this calculus spinning method, after the core yarn F1 is guided by the godet 21b, the core yarn F1 enters the nip between the front top roller 321b and the fiber spreading roller 313. Before the core yarn F1 enters the nip between the front top roller 321b and the fiber spreading roller 313, the core yarn F1 is separated from the staple fiber strands by with a certain spacing. After the core yarn F1 enters the nip between the front top roller 321b and the fiber spreading roller 313, the core yarn F1 converges with the widened fiber strands conveyed forward by the fiber spreading roller 313 at a certain angle in the wrapping area, and then the widened fiber strands are driven by the rotation of the core yarn F1 to be wrapped around an outer layer of the core yarn F1, thereby forming the wrapped-core yarn S2 with a uniform wrapping structure. In addition, the spacing between the wrapping area 34 and the nip between the front top roller 321b and the fiber spreading roller 313 is greater than the fiber length of each of the staple fiber strand S11, so as to better wrap the staple fiber strand S11 on the outer layer of the core yarn F1 by the rotation of the core yarn F1, and the high-speed rotation of the core yarn F1 can also produce a certain stretching effect on the staple fiber strand S11, further improving the yarn quality of the wrapped-core yarn S2.

[0120] As illustrated in FIG. 14, (a) shows a polyester-cotton wrapped-core yarn spun by using the calculus spinning device and method in the embodiment 2 under 35 times magnification using a 3D microscope. A material of a core yarn of the polyester-cotton wrapped-core yarn is 162 D blue polyester yarn. A material of a staple fiber strand is 653 tex red colored cotton roving. Process parameters are as follows: a spindle speed is 11000 r/min, a twist is 104 T/10 cm, a speed of a front roller is 10.58 m/min, a total drafting multiple is 54.42, a linear density of cortical cotton fiber is 12.00 tex, and a back zone drafting multiple is 1.25. The core yarn ratio of the polyester-cotton wrapped-core yarn is 60%.

[0121] As can be seen from a of FIG. 14, in the polyester-cotton wrapped-core yarn spun in the embodiment 2, a blue polyester core yarn is completely covered by an outer red colored cotton fiber when the core yarn ratio is 60%. An overall yarn coating effect is good, and parallelism of an outer coated fiber is higher.

Comparative Example 3

[0122] Comparative example 3 provides a wrapped-core yarn device and method. The wrapped-core yarn device is a conventional ring spinning device. The method includes: gathering staple fiber strands around a core yarn and twisting the staple fiber strands to obtain a wrapped-core yarn. Used materials and process parameters in the comparative example are the same as those in the embodiment 2.

[0123] As illustrated in FIG. 14, (b) shows a polyester-cotton wrapped-core yarn spun in the comparative example 3 under 35 times magnification using a 3D microscope. As can be seen from (b) of FIG. 14, the structural uniformity of the wrapped-core yarn is poorer, and a blue polyester yarn is exposed seriously.

Embodiment 3

[0124] The embodiment 3 provides a calculus spinning device and method. Compared with the embodiment 2, the difference is that the wrapped-core yarn in the embodiment 3 is a double twist yarn of a basalt filament and a flame-retardant polyester filament, a linear density of the core yarn is 48 tex, and a core yarn ratio of the wrapped-core yarn is 80%. The rest are basically the same as those in the embodiment 1, and will not be described herein.

Comparative Example 4

[0125] The comparative example 4 provides a wrapped-core yarn device and method. The wrapped-core yarn device is a conventional ring spinning device. The method includes: gathering staple fiber strands around a core yarn and twisting the staple fiber strands to obtain a wrapped-core yarn. Used materials and process parameters in the comparative example are the same as those in the embodiment 3.

[0126] As illustrated in FIG. 15, (a) shows a basalt/polyester/cotton wrapped-core yarn spun by using the calculus spinning device and method in the embodiment 2 under 35 times magnification using a 3D microscope; and b shows a basalt/polyester/cotton wrapped-core yarn spun in the comparative example 4 under 35 times magnification using a 3D microscope. As can be seen from FIG. 15, in the comparative example 4, an outer fiber of the conventional ring spinning wrapped-core yarn cannot completely cover the core yarn, and there is a serious exposure phenomenon.

[0127] The yarns spun in the embodiments 2-3 and the comparative examples 3-4 are compared in terms of core yarn ratio, breaking strength and elongation at break, and corresponding results are shown in Table 2.

TABLE-US-00002 TABLE 2 Comparative results of performance of yarns spun in the embodiments 2-3 and the comparative examples 3-4 Breaking Elongation Core strength at break yarn (CN) (%) ratio Standard Standard (%) deviation deviation Embodiment 2 60 659.43 12.69 23.82 1.24 Comparative 60 603.32 23.00 34.42 3.18 example 3 Embodiment 3 80 761.40 21.55 7.95 0.88 Comparative 80 713.03 9.60 12.80 0.98 example 4

[0128] As can be seen from Table 2, compared with the wrapped-core yarns made by conventional ring spinning method, the wrapped-core yarns spun in the embodiments 2-3 can greatly increase the core yarn ratio of the yarn, with the core yarn ratio as high as 80%, on the premise of ensuring the good covering effect of the wrapped-core yarn and no core exposure. In addition, the wrapped-core yarn spun by the spinning device and method of the embodiment 2-3 is closer to the wrapped-core yarn structure in the ideal state in the yarn structure, and the core yarn of the wrapped-core yarn mainly bears stress during a stretching process. However, the wrapped-core yarn spun by the conventional ring spinning core spinning method is similar to a Sirofil yarn in the yarn structure, and the core yarn is seriously exposed. During a stretching process of the wrapped-core yarn spun by the conventional ring core spinning method, the core yarn and the staple fiber strands are jointly stressed, and the core yarn is subjected to a greater shear force, as such, the breaking strength of the wrapped-core yarn in the comparative example 3 is lower than the breaking strength of the wrapped-core yarn in the embodiment 2, the breaking strength of the wrapped-core yarn in the comparative example 4 is lower than the breaking strength of the wrapped-core yarn in the embodiment 3, the elongation at break of the wrapped-core yarn in the comparative example 3 is greater than the elongation at break of the wrapped-core yarn in the embodiment 2, and the elongation at break of the yarn in the comparative example 4 is greater than the elongation at break of the wrapped-core yarn in the embodiment 3.

Embodiment 4

[0129] As illustrated in FIG. 16 through FIG. 18, the auxiliary core-wrapping assembly 31 widens and expands the staple fiber strand S11 to form widened strand, and the widened strand stably cover a core yarn to obtain a wrapped-core yarn S2. The yarn guiding assembly 33 is a yarn guiding rod 331c, and the yarn guiding rod 331c is provided with a heating groove with a temperature of 100-200 C. A temperature setting principle and function of the heating groove are the same as those of the heating groove 332a. The yarn guiding rod 331c changes a transmission path of the wrapped-core yarn S2 output from the auxiliary core-wrapping unit 30 through the heating groove, and conveys the wrapped-core yarn S2 to the yarn winding unit 40.

[0130] In this device, through cooperation operation of the auxiliary core-wrapping unit 30, the staple fiber feeding unit 10 and the core yarn feeding unit 20, by using a grid circle 315c covered on a special shaped pipe 314 of the auxiliary core-wrapping unit 30, the widened strands formed after fiber opening and expansion are uniformly coated on an outer layer of the core yarn F1, and the wrapped-core yarn with good coating effect and a ratio of the core yarn F1 to the wrapped-core yarn S2 accounting for 60%-70% is obtained. Its advantages are the same as those of the embodiment 1, so it will not be described herein.

[0131] As illustrated in FIG. 17, the auxiliary core-wrapping assembly 31 includes the special shaped pipe 314 and the grid circle 315c covered on a surface of the special shaped pipe 314. The grid circle 315c only allows airflow to pass therethrough, which widens and spreads the staple fiber strand S11 to form the widened strands, and plays a role in supporting and transporting the widened strands. The grid circle 315c is driven by the pressurizing/conveying assembly 32 to rotate forward along the special shaped pipe 314, and drives the widened strands attached to the surface of the grid circle 315c to convey forward, so that the core yarn F1 is coated by the widened strands in the wrapping area 34 to form the wrapped-core yarn S2. In this way, the grid circle 315c which rotates along the special shaped pipe 314 is used to expand and spread the staple fiber strand S11 to form the widened strands, and the grid circle 315c only supports and transports the widened strands, and no twist is applied to the widened strands, so that a fiber layer (i.e., the widened strands) with a certain width, high fiber parallelism and uniform fiber distribution is formed on the surface of the grid circle 315c. After the fiber layer converges with the core yarn F1 in the wrapping area 34, the fiber layer is uniformly wrapped around the surface of the core yarn F1 by utilizing the rotation of the core yarn F1.

[0132] Particularly, the auxiliary core-wrapping assembly 31 further includes a negative pressure suction port 3133c disposed on the special shaped pipe 314, and the negative pressure suction port 3133c is covered by the grid circle 315c disposed on the surface of the special shaped pipe 314. The negative pressure suction port 3133c absorbs the widened strand on the surface of the grid circle 315c under negative pressure, so that the widened strand formed on the surface of the grid circle 315c are further widened and spread in a fiber-opening manner, and a fiber layer with a larger width and higher parallelism is formed. In this way, by arranging the negative pressure suction port 3133c on the special shaped pipe 314, a clamping force of the grid circle 315c on the widened strands is increased, and a flatness of the widened strand is increased. Functions of the negative pressure adsorption assembly 3132b and the negative pressure suction port 3133c in this embodiment are basically the same as those of the negative pressure suction assembly in the embodiment 1, which is not repeated herein.

[0133] Specifically, the negative pressure suction port 3133c has one of the following three structures: air inlets uniformly distributed on the special shaped pipe 314, equal-width air inlets formed along a curved surface of the special shaped pipe 314, or air inlets disposed on the special shaped pipe 314 and gradually widened along a conveying direction of the widened strands on the grid circle 315c. After the negative pressure suction port 3133c of the disclosure absorbs the staple fiber strand S11, the staple fiber strand S11 are widened and spread on the grid circle 315c to form the widened strand, which are evenly dispersed, thereby forming a fiber layer with a uniform structure, which is beneficial to the uniform coating of the core yarn F1 by the widened strand.

[0134] More specifically, when the negative pressure suction port 3133c has equal-width air inlets formed along the curved surface of the special shaped pipe 314, a width of the negative pressure suction port 3133c is 5-10 mm; when the negative pressure suction port 3133c has air inlets disposed on the special shaped pipe 314 and gradually widened along the conveying direction of the widened strand on the grid circle 315c, a width of a narrowest portion of the negative pressure suction port 3133c is 5-7 mm, as such, the widening and expanding of the staple fiber strand S11 with a diameter of 1-3 mm is achieved, and widened strand with interactive force are formed. In this way, by limiting the shape and size of the negative pressure suction port 3133c, it is avoided that when the negative pressure suction port 3133c absorbs the widened strand, the widened strands will gather on the grid circle 315c, which will affect the subsequent winding effect of the core yarn F1.

[0135] The pressurizing/conveying assembly 320 includes a front top roller 321c, a drive top roller 323c, and a bridge component 322c connecting the front top roller 321c and the drive top roller 323c. The front top roller 321c is configured to drive the bridge component 322c to make the drive top roller 323c rotate synchronously. The drive top roller 323c is in contact with the grid circle 315c and is configured to drive the grid circle 315c to rotate forward. A middle of the drive top roller 323c is provided with a roller groove 324c with a certain width, and protrusions at two ends of the drive top roller 323c are convenient for pressing the grid circle 315c and driving grid circle 315c to rotate and convey. The roller groove 324c is convenient for the widened strands and the core yarn F1 to pass between the drive top roller 323c and the grid circle 315c. A width of the roller groove 324c is preferably one third of a width of the drive top roller 323c.

[0136] In some specific embodiments, a bridge gear exists in the bridge component 322c, which is connected with a shaft core of the front top roller 321c and a shaft core of the drive top roller 323c to realize power transmission.

[0137] Specifically, the feeding unit further includes a front roller 16c disposed at an input end of the auxiliary core-wrapping unit 30. The staple fiber feeding unit 10 includes a bell mouth 11c, a rear roller 12c, a rear top roller 13c, a middle roller 14c and a middle top roller 15c, which are sequentially arranged along a feeding direction of the roving S1 in that order. After the roving S1 is stretched into staple fiber strand S11 by the staple fiber feeding unit 10, the staple fiber strand S11 are output to the special shaped pipe 314 through the front roller 16c, and are absorbed on the grid circle 315c by the negative pressure suction port 3133c. The staple fiber strands are widened and expanded to form widened strands or even a fiber layer with a more uniform structure. The core yarn feeding unit 20 includes a godet 21c is configured to change an angle of the core yarn F1. The core yarn F1 is guided by the godet 21c, is output from a nip formed by engaging the front roller 16c and the front top roller 321a at a certain angle, and converges with the widened strands on the grid circle 315c in the wrapping area 34 at a certain angle. The core yarn F1 rotates to drive the widened strands absorbed by the grid circle 315c to wrap around an outer layer of the core yarn F1 to form the wrapped-core yarn S2.

[0138] The godet 21c of the core yarn feeding unit 20 can change the angle of the core yarn F1 to control a range of an included angle between the core yarn F1 and the widened strands in the wrapping area to be 5-65, so that the widened strands can better rotate and wrap the surface of the core yarn F1. The staple fiber feeding unit 10 is configured to stretch the roving S1 to obtain the staple fiber strand S11, and the obtained staple fiber strand S11 are fed into the core yarn feeding unit 20 to widen and expand the staple fiber strand S11 and thereby form widened strands. The yarn guiding rod 331c is disposed on a path for outputting the wrapped-core yarn of the auxiliary core-wrapping assembly 31, and the position of the yarn guiding rod 331c satisfies a condition that an angle of the staple fiber strand S11 when staple fiber strand S11 are input into the auxiliary core-wrapping unit 30 is the same as an angle of the widened strand when the widened strands are transported in the auxiliary core-wrapping unit 30. As such, the widened strands can be conveyed in a natural state in the auxiliary core-wrapping unit 30 without changing the angle thereof. In this way, not only the integrity of the widened strands or the formed fiber layer can be maintained and aggregation thereof is avoided, but also it is beneficial for the core yarn F1 to drive the widened strands to cover a surface of the core yarn F1 and form the wrapped-core yarn S2.

[0139] Limitation of the position of the yarn guiding rod 331c play the same role as limitation of the position of the heating groove 332b in the yarn guiding assembly 33 in the embodiment 2.

[0140] Compared with the core spinning device in the related art, the calculus spinning device of this embodiment of the disclosure has the same advantages as in the embodiment 1. In addition, when the staple fiber strand S11 encounter breakage or other operational issues, the difficulty for workers to repair is lower, and no additional unnecessary operations on the calculus spinning device are required.

[0141] As illustrated in FIG. 18, FIG. 18 illustrates a schematic diagram of a calculus spinning method, which is implemented by the calculus spinning device according to the embodiment 4. The specific method is as follows.

[0142] The staple fiber feeding unit 10 stretches the roving S1 into the staple fiber strand S11 and feeds the staple fiber strand S11 into the auxiliary core-wrapping assembly 31 of the auxiliary core-wrapping unit 30. The staple fiber strand S11 are absorbed on the grid circle 315c by the negative pressure suction port 3133c on the special shaped pipe 314. The staple fiber strand S11 are widened and expended to form widened strands. The grid circle 315c is driven by the pressure/conveying assembly 32 to rotate forward, and the widened strands attached to the surface of the grid circle 315c are driven to transport forward.

[0143] Simultaneously, the core yarn F1 is guided by the godet 21c, is output at a certain angle through a nip of the front roller 16c, and converges with the widened strands on the grid circle 315c at a certain angle in the wrapping area 34. Then the core yarn F1 rotates to drive the widened strands absorbed by the grid circle 315c to wrap around an outer layer of the core yarn F1 to form a wrapped-core yarn S2.

[0144] A transmission path of the wrapped-core yarn S2 is changed by the yarn guiding rod 331c, so that a structure of the wrapped-core yarn S2 is more stable, and the wrapped-core yarn S2 is conveyed to the guide hook 41c of the yarn winding unit 40, and the wrapped-core yarn S2 is wound on a ring bobbin 44c by the traveler 42c rotating at higher speed on a steel ring 43c, thereby the steady-state wrapped-core yarn process is completed.

[0145] In particular, a spacing between the wrapping area 34 and the nip of the front roller 16c is greater than a fiber length of the staple fiber strand S11. A spacing between the wrapping area 34 and the nip of the front roller 16c, a spacing between the core yarn F1 and the staple fiber strand S11, and an included angle between the core yarn F1 and the staple fiber strand S11 are basically the same as those in the embodiment 2.

[0146] In this calculus spinning method, after being guided by the godet 21c, the core yarn F1 is separated from the staple fiber strand S11 by a certain spacing, and then the core yarn F1 is fed to the front roller 16c. Then the core yarn F1 is output through the nip of the front roller 16c, and converges with the widened strands conveyed forward by the grid circle 315c in the wrapping area 34 at a certain angle, so that the core yarn F1 can be rotated to drive the widened strands adsorbed by the grid circle 315c to wrap around an outer layer of the core yarn F1 to form a wrapped-core yarn with a uniform covering structure. In addition, the spacing between the wrapping area 34 and the nip of the front roller 16c is greater than the fiber length of the staple fiber strands, so that the widened strands can be wrapped on the outer layer of the core yarn F1 by better utilizing the rotation of the core yarn F1. Further, the high-speed rotation of the core yarn F1 can also produce a certain stretching effect on the widened strands, further improving the yarn quality of the wrapped-core yarn.

[0147] As illustrated in FIG. 18, FIG. 18 illustrates a basalt wrapped-core yarn with a linear density of 43.57 tex spun by the spinning method of the calculus spinning device in the embodiment 4 under 35 times magnification using a 3D microscope. A material of a core yarn of the basalt wrapped-core yarn is 25 tex basalt filament and 50 D flame retardant polyester filament. A material of a staple fiber strand is 735 tex cotton fiber roving. Process parameters are as follows: a spindle speed is 11000 r/min, a twist is 90 T/10 cm, a speed of a front roller is 12.22 m/min, a total drafting multiple is 56.24, and a back zone drafting multiple is 1.15. A core yarn ratio of the basalt wrapped-core yarn is 70%.

[0148] It can be clearly seen from FIG. 19 that when the core yarn ratio is 70%, the wrapped-core yarn is completely covered by the outer fibers in the basalt wrapped-core yarn without exposure. The overall yarn coating effect is good, and the parallelism of the outer coated fiber is higher.

Embodiment 5

[0149] The embodiment 5 provides a calculus spinning device and method. Compared with the embodiment 4, in the embodiment 5, a material of a core yarn is 12 tex basalt filament and 20 D flame-retardant nylon filament, a material of a staple fiber strand is 600 tex flame retardant nylon, aramid fiber 1313 and flame retardant viscose composite staple fiber roving (a blending ratio is 55/35/10). In the embodiment 5, process parameters are as follows: a spindle speed: is 8500 r/min, a twist is 75 T/10 cm, a speed of the front roller is 11.33 m/min, a total drafting multiple is 63.36, and a back zone drafting multiple is 1.65.

[0150] As illustrated in FIG. 20, FIG. 20 illustrates a basalt wrapped-core yarn with a linear density of 23.67 tex spun by the spinning method of the calculus spinning device in the embodiment 5 under 50 times magnification using a 3D microscope. A core yarn ratio of the basalt wrapped-core yarn is 60%. As can be seen from FIG. 20 that when the core yarn ratio is 60%, the core yarn is completely covered by the outer fibers in the basalt wrapped-core yarn without exposure. The overall yarn coating effect is good, and the parallelism of the outer coated fiber is higher.

Comparative Example 5

[0151] The comparative example 5 provides a wrapped-core yarn device and a method thereof. The wrapped-core yarn device is a conventional ring spinning device without the auxiliary core-wrapping assembly 31 as in the embodiment 4. The method in the comparative example 5 includes: gathering staple fiber strands around a core yarn and twisting the staple fiber strands to obtain a wrapped-core yarn. A material of a core yarn is 162 D blue polyester yarn. A material of a staple fiber strand is 653 tex red colored cotton roving. Process parameters are as follows: a spindle speed is 11000 r/min, a twist is 104 T/10 cm, a speed of a front roller is 10.58 m/min, a total drafting multiple is 54.42, a linear density of cortical cotton fiber is 12.00 tex, and a back zone drafting multiple is 1.25. A core yarn of the wrapped-core yarn is 60%.

[0152] As can be seen from FIG. 21, compared with the embodiment 5, in the case of the same core yarn ratio, an outer fiber of the conventional ring spinning wrapped-core yarn cannot completely cover the core yarn, and there is a serious exposure phenomenon. The overall yarn coating effect is poorer. This wrapped-core yarn is difficult to be applied in practical production. To improve this situation, the core yarn ratio can only be sacrificed. Therefore, the core yarn ratio of the traditional ring spinning wrapped-core yarn is relatively lower, it is possible to obtain a wrapped-core yarn with an outer fiber well wrapped around the core yarn when the core yarn ratio is about 15%.

Embodiment 6

[0153] As illustrated in FIG. 22 through FIG. 25B, the core yarn feeding unit 20 is provided with an electrostatic fiber opening assembly 22 and a threaded guide rod. The electrostatic fiber opening assembly 22 is configured to electrostatically open a core yarn F1 (which is a multifilament) to form expanded ribbon-like filaments F11, and the ribbon-like filaments F11 are input into the auxiliary core-wrapping unit 30 through the threaded guide rod. The staple fiber feeding unit 10 stretches a roving S1 into staple fiber strand S11 and feeds the staple fiber strand S11 into the auxiliary core-wrapping unit 30. The ribbon-like filaments F11 formed after electrostatic filament opening partially or completely overlap with the staple fiber strand S11 in the auxiliary core-wrapping unit 30. The auxiliary core-wrapping assembly 31 is a negative pressure absorption assembly 3132d. The negative pressure absorption assembly 3132d opens the staple fiber strand S11 fed into the auxiliary core-wrapping unit 30, further expands the ribbon-like filaments F11 fed into the auxiliary core-wrapping unit 30, and embeds or partially embeds the staple fiber strand S11 with the ribbon-like filaments F11 to form a wrapped-core yarn S2. The wrapped-core yarn S2 is collected and wound by the yarn winding unit 40.

[0154] In particular, for the calculus spinning device of the embodiment 6, the electrostatic fiber opening assembly 22 is disposed in the core yarn feeding unit 20 and is used to open the core yarn F1 to obtain the ribbon-like filaments F11, and the auxiliary core-wrapping unit 30 is used to open the staple fiber strand S11 and further expand the ribbon-like filaments F11, so that the staple fiber strand S11 and the ribbon-like filaments F11 are completely or partially overlapped and embedded with each other, and then automatically wrapped by the rotation of the ribbon-like filaments F11 and the acting force between the staple fiber strand S11 to form a wrapped-core yarn with a sandwich structure, which greatly increases the proportion of the ribbon-like filaments F11 in the wrapped-core yarn and its mechanical properties, while reducing a hairiness index. The calculus spinning method and the calculus spinning device of the disclosure overcome the technical problems of poorer wrapping effect and higher hairiness index caused by the fact that the staple fiber strand S11 and the filament (i.e., core yarn) of the traditional ring spinning wrapped-core yarn cannot be spread and are difficult to hold, and are of great significance for improving the comprehensive performance of the wrapped-core yarn.

[0155] As illustrated in FIG. 23, the auxiliary core-wrapping assembly 31 is a negative pressure absorption assembly 3132d. The negative pressure absorption assembly 3132d includes a special shaped air suction plate 316d, a drive roller 317d, a grid circle 315d sleeved on outer surfaces of the special shaped air suction plate 316d with grid holes shown in FIG. 13 and the drive roller 317d. The air suction assembly absorbs the staple fiber strand S11 and the ribbon-like filaments F11 on the surface of the grid circle 315d under negative pressure. The pressurizing/conveying assembly 32 includes a transmission gear 35d and an auxiliary conveying component disposed opposite to the grid circle 315d. The grid circle 315d is powered by the transmission gear 35d and the auxiliary conveying component, rotates and transports forward along the special shaped air suction plate 316d, and drives the staple fiber strand S11 and the ribbon-like filaments F11 attached to the grid circle 315d to transport forward. In this way, the negative pressure adsorption assembly 3132d of the auxiliary core-wrapping unit 30 is used to open the staple fiber strand S11, which does not generate a gathering force on the staple fiber strand S11, and at the same time, the ribbon-like filaments F11 is further expanded by the negative pressure adsorption assembly 3132d, so that the staple fiber strand S11 and the ribbon-like filaments F11 are partially or completely overlapped and embedded on a surface of the grid circle 315d. The rotation of the ribbon-like filaments F11 drives the staple fiber strand S11 embedded with the ribbon-like filaments F11 to be wrapped on the surface of the ribbon-like filaments F11, and the ribbon-like filaments F11 and the staple fiber strand S11 are further wrapped by the force between the staple fiber strand S11 to form a wrapped-core yarn S2 with a sandwich structure.

[0156] Specifically, the negative pressure adsorption assembly 3132d further includes the special shaped air suction plate 316d with surface grid holes shown in FIG. 13. The special shaped air suction plate 316d is covered by the grid circle 315d, and a narrowest width of the negative pressure suction port 3133d is not less than a width of the staple fiber strand S11 and is not less than a width of the ribbon-like filaments F11. The negative pressure adsorption assembly 3132d is configured to adsorb the staple fiber strand S11 and the ribbon-like filaments F11 to a surface of the grid circle 315d through the negative pressure suction port 3133d, so that the staple fiber strand S11 are opened and the ribbon-like filaments F11 are further expanded. In this way, by defining the shape and size of the negative pressure suction port 3133d, when the staple fiber strand S11 and the ribbon-like filaments F11 pass through the grid circle 315d, no twist is exerted by the grid circle 315d on the staple fiber strand S11 and the ribbon-like filaments F11, the staple fiber strand S11 and the ribbon-like filaments F11 do not gather, and the grid circle 315d only plays the role of supporting and conveying the staple fiber strand S11 and the ribbon-like filaments F11. At the same time, under the guiding spreading effect of negative pressure air flow, the fiber opening of the staple fiber strand S11 is realized to obtain the staple fiber strands with a certain width, uniform fiber distribution and certain interaction force. The staple fiber strands are completely or partially overlapped and embedded with the ribbon-like filaments F11, and the ribbon-like filaments F11 are wrapped by the surrounding staple fiber strands by the rotation of the ribbon-like filaments F11, and at the same time, the ribbon-like filaments F11 and the staple fiber strands are further twisted and wrapped by the acting force between the staple fiber strands, and finally a layered structure wrapped-core yarn with tight clamping between the ribbon-like filaments F11 and the staple fiber strand S11 is formed, which improves the mechanical properties of the wrapped-core yarn and has application value in the fields of high-grade sewing, textile clothing, military uniform, protective clothing and the like.

[0157] In an embodiment, the negative pressure suction port 3133d has air inlets with a same width along a conveying direction of the staple fiber strand S11 and the ribbon-like filaments F11, or the negative pressure suction port 3133d has air outlets gradually widened along the conveying direction of the staple fiber strand S11 and the ribbon-like filaments F11, so as to realize the fiber opening of the staple fiber strand S11 and the expansion of the ribbon-like filaments F11. A narrowest width of the negative pressure suction port 3133d is 5-10 mm.

[0158] The core yarn feeding unit 20 further includes a godet 21d configured to change an angle of the core yarn F1. After being guided by the godet 21d, the core yarn F1 is input into the electrostatic fiber opening assembly 22 at a certain angle, and the core yarn F1 is electrostatically opened to form ribbon-like filaments F11. Excess static electricity of the ribbon-like filaments F11 is eliminated through the threaded guide rod, after that, the ribbon-like filaments F11 enter the auxiliary core-wrapping unit 30, and partially or completely overlap and embed with the staple fiber strand S11 fed by the staple fiber feeding unit 10, and the ribbon-like filaments F11 rotate to drive the staple fiber strand S11 to wrap and form the wrapped-core yarn S2.

[0159] In some specific embodiments, the threaded guide rod is disposed at an outlet of the electrostatic fiber opening assembly 22, and the ribbon-like filaments F11 obtained after yarn opening pass through the threaded guide rod, so that the static electricity carried by the ribbon-like filaments F11 can be eliminated, the negative influence of static electricity on the further expansion of the ribbon-like filaments F11 can be avoided, and the safety of the subsequent spinning process can also be ensured.

[0160] The auxiliary conveying component includes a front top roller 321d, a drive top roller 323d, and a bridge component 322d connecting the front top roller 321d and the drive top roller 323d. The front top roller 321d is configured to drive the bridge part 322d to synchronously rotate the drive top roller 323d. The drive top roller 323d is in contact with the grid circle 315d, and is configured to drive the grid circle 315d to rotate and transport forward stably. In this way, the auxiliary conveying component is disposed above the negative pressure adsorption assembly 3132d, and the drive top roller 323d is contact with the grid circle 315d, such that the grid circle 315d is driven to rotate by the joint action of the drive top roller 323d and the transmission gear 35d, and the transmission of the grid circle 315d is more stable, which provides stable conditions for the wrapping process of the ribbon-like filaments F11 and the staple fiber strand S11, and is beneficial to the successful preparation of industrial wrapped-core yarn.

[0161] Specifically, the feeding unit further includes a front roller 16c disposed at an input end of the auxiliary core-wrapping unit 30. The staple fiber feeding unit 10 includes a bell mouth 11d, a rear roller 12d, a rear top roller 13d, a middle roller 14d, a middle top roller 15d and a front top roller 217, which are sequentially arranged along a feeding direction of the roving S1 in that order. The front roller 16c and the front top roller 321d are engaged to form a front roller nip, and both the staple fiber strand S11 and the ribbon-like filaments F11 are input into the auxiliary core-wrapping unit 30 through the front roller nip formed by the meshing of the front roller 16c and the front top roller 321d.

[0162] A calculus spinning method is provided, which is implemented by the calculus spinning device in the embodiment 6. The method specifically includes steps S1 to S4:

[0163] In step S1, the staple fiber feeding unit 10 stretches the roving S1 into the staple fiber strand S11, and inputs staple fiber strands into the auxiliary core-wrapping unit 30 through the front roller nip between the front roller 16d and the front top roller 321d. After the core filaments F1 is guided by the godet 21d, the core filaments F1 is electrostatically opened by the electrostatic fiber opening assembly 22 to form ribbon-like filaments F11, and ribbon-like filaments F11 are fed into the front roller nip through the threaded godet and input into the auxiliary core-wrapping unit 30 through the front roller nip.

[0164] In step S2, the negative pressure absorption assembly 3132d in the auxiliary core-wrapping unit 30 absorbs the staple fiber strand S11 and the ribbon-like filaments F11 on the surface of the grid circle 315d under negative pressure, so that the staple fiber strand S11 are opened and the ribbon-like filaments F11 are further expanded. The staple fiber strand S11 and ribbon-like filaments F11 are partially or completely overlapped and embedded with each other.

[0165] In step S3, the grid circle 315d is powered by the transmission gear 35d and the auxiliary conveying component, and rotates and transports forward along the special shaped air suction plate 316d and the drive roller 317d, and drives the staple fiber strands S11 and the ribbon-like filaments F11 attached to the grid circle 315d to transport forward. During the conveying process, filaments in the ribbon-like filaments F11 rotates to drive the staple fiber strand S11 embedded with the filaments to be wrapped around the outer layer of the filaments, and the staple fiber strand S11 and the filaments are further wrapped by the acting force between the staple fiber strand S11 to form a wrapped-core yarn S2.

[0166] In step S4, a transmission path of the wrapped-core yarn S2 is changed through the yarn guiding assembly 33, so that a structure of the wrapped-core yarn S2 is more stable, and the wrapped-core yarn is wound around a guide hook 41d, a steel ring 43d and a traveler 42d of the yarn winding unit 40 in turn, and finally wound on the ring bobbin 44d of the yarn winding unit 40, thus completing the double-opening and embedded spinning process of staple fiber strands and filaments. The yarn guiding assembly 33 is a yarn guiding rod.

[0167] Specifically, a spacing between an axis of the staple fiber strand S11 along a length direction thereof at the front roller nip and an axis of the ribbon-like filaments F11 along a length direction thereof at the front roller nip is 0-5 mm, so as to realize partial or complete overlapping and embedding of the staple fiber strand S11 and the ribbon-like filaments F11 in the auxiliary core-wrapping unit 30. In this embodiment, firstly, the core yarn F1 is opened by the electrostatic fiber opening assembly 22 to form ribbon-like filaments F11 with a certain width, and then the spacing between the ribbon-like filaments F11 and the staple fiber strand S11 obtained by stretching before entering the auxiliary core-wrapping unit 30 through the front roller nip between the front roller 16d and the front top roller 321d is controlled. When the axis of the staple fiber strand S11 at the front roller nip and the axis of the ribbon-like filaments F11 at the front roller nip coincide, the yarn guiding rod, the axis of the staple fiber strand S11, and the axis of the ribbon-like filaments F11 are arranged on the same straight line. When a spacing between the axis of the staple fiber strand S11 at the front roller nip and the axis of the ribbon-like filaments F11 at the front roller nip is not zero, the yarn guiding rod is arranged at a position where the wrapped-core yarn is output from the auxiliary core-wrapping unit 30 at an angle of 5-30.

[0168] In this way, by adjusting the spacing between the axis of the staple fiber strand S11 at the front roller nip between the front roller 16d and the front top roller 321d and the axis of the ribbon-like filaments F11 at the front roller nip between the front roller 16d and the front top roller 321d, that is, adjusting the position where the staple fiber strand S11 and the ribbon-like filaments F11 enter the front roller nip, the staple fiber strand S11 and the ribbon-like filaments F11 are partially or completely overlapped and embedded in the auxiliary core-wrapping unit 30. By limiting the position of the yarn guiding rod, the automatic winding of the ribbon-like filaments F11 and staple fiber strand S11 is realized, so that the preparation of wrapped-core yarns with different structures is realized, and the application of wrapped-core yarns with different requirements is specifically met.

[0169] As illustrated in FIG. 24A through FIG. 24C, FIG. 24A through FIG. 24C illustrate a schematic diagram of a preparation process and a structure of a wrapped-core yarn when an axis of staple strand S11 and an axis of the ribbon-like filaments F11 coincide and are input at the front roller nip. In FIG. 24A, after opening and expanding through the negative pressure suction port 3133d, a width of the ribbon-like filaments F11 is larger than that of the staple strand S11, a wrapped-core yarn having a core layer composed of embedded staple fiber strands and filaments and an outer layer composed of filaments is formed, and the wrapped-core yarn shows an excellent wear resistance. In FIG. 24B, after opening and expanding through the negative pressure suction port 3133d, a width of ribbon-like filaments F11 is equal to a width of staple strand S11, a wrapped-core yarn is formed in which staple fiber strands and filaments are completely embedded, and the wrapped-core yarn has good mechanical properties, less surface hairiness, larger locking cohesion between filaments and staple fiber strands, and stable and durable yarn structure. In FIG. 24C, after opening and expanding through the negative pressure suction port 3133d, a width of the ribbon-like filaments F11 is smaller than that of the staple fiber strand S11, a wrapped-core yarn having a core layer composed of embedded staple fiber strands and filaments and an outer layer composed of staple fiber strands is formed, and wrapped-core yarn has the appearance and hand feel of a staple fiber yarn on the outside, and a stable structure with filaments holding the staple fiber strands in the core.

[0170] As illustrated in FIG. 25A and FIG. 25B, FIG. 25A and FIG. 25B illustrate a schematic diagram of a preparation process and a structure of a wrapped-core yarn when an axis of staple fiber strand S11 at the front roller nip and an axis of ribbon-like filaments F11 at the front roller nip are separated by a certain spacing. As shown in FIG. 25A, a spacing between the axis of the staple fiber strand S11 at the front roller nip and the axis of the ribbon-like filaments F11 at the front roller nip is 1-5 mm, and the yarn guiding rod is disposed at a side close to the staple fiber strand S11; and after the opening and expansion of the negative pressure suction port 3133d, a three-layer wrapped-core yarn is obtained, in which a core layer is composed of filaments, a shell layer is composed of embedded filaments and staple fiber strands, and a surface layer is composed of staple fiber strands. In FIG. 25B, a spacing between the axis of the staple fiber strand S11 at the front roller nip and the axis of the ribbon-like filaments F11 at the front roller nip is 1-5 mm, and the yarn guiding rod is disposed at a side close to the ribbon-like filaments F11; and after the opening and expansion of the negative pressure suction port 3133d, a two-layer wrapped-core yarn is obtained, in which a core layer is composed of embedded staple fiber strands and filaments, and an outer layer is composed of filaments.

[0171] In the wrapped-core yarn spun in this embodiment, the core yarn F1 is scattered to form ribbon-like filaments F11 with filaments, and the ribbon-like filaments F11 and the staple fiber strand S11 are twisted and embraced, so that the clamping cohesion between the filaments and the staple fiber strand S11 is effectively improved, and the formed wrapped-core yarn has stable structure, good mechanical properties and less hairiness. In practical application, the spinning device of this embodiment only needs to adjust an input spacing between the axis of the staple fiber strand S11 at the front roller nip between the front roller 16d and the front top roller 321d and the axis of the ribbon-like filaments F11 at the front roller nip between the front roller 16d and the front top roller 321d, and adjust the position of the yarn guiding rod accordingly, so that wrapped-core yarns with various structures can be obtained without changing the device itself, thus realizing the diversified preparation of wrapped-core yarns, and the comprehensive performance of wrapped-core yarns is good; wrapped-core yarn with outstanding performance in a certain aspect can also be specially prepared according to requirements; and the double-opening and mutual-embedding spinning device and process method of staple fiber and filament have industrial application value.

[0172] In the embodiment 6, a pure cotton staple fiber and a nylon filament as shown in FIG. 24A are used for calculus spinning, the axis of staple fiber strand S11 and the axis of ribbon-like filaments F11 are set to be coincided at the front roller nip, a yarn surface is a nylon filament, and a core layer is smooth and wear-resistant yarn with nylon filament and cotton fiber embedded and twisted.

[0173] A conventional ring spindle compact wrapped-core yarn device is used to make cotton staple fiber strands and nylon filaments be completely overlapped and twisted to obtain a conventional compact wrapped-core yarn, in which a yarn surface is cotton fiber strands, and a core layer is nylon filaments. Performances of the conventional compact wrapped-core yarn are compared with performances of the wrapped-core yarn spun in the embodiment 6, and test results show that compared with the conventional compact wrapped-core yarn, a hairiness index and a wear resistance of the smooth and wear-resistant yarn obtained in the embodiment 6 are respectively improved by 92% and 67%.

Embodiment 7

[0174] A cotton staple fiber and a nylon filament as shown in FIG. 25A are used for calculus spinning, a spacing between the axis of staple fiber strand S11 and the axis of ribbon-like filaments F11 is 5 mm at the front roller nip, and a three-layer composite wrapped-core yarn with higher strength, overall wear resistance, and softness and comfort is formed. A surface layer of the three-layer composite wrapped-core yarn is composed of soft and comfortable cotton fibers, a core layer of the three-layer composite wrapped-core yarn is composed of nylon filaments, and a shell layer between the surface layer and the core layer is composed of embedded nylon filaments and cotton fibers.

[0175] A conventional ring-spun Sirofil spinning device is used to set a spacing between cotton staple fiber strands and nylon filaments to be 5 mm at a front roller nip, and is used to twist the cotton staple fiber strands and the nylon filaments to obtain a filament wrapping yarn with cotton fiber and nylon filament twisted together. Performance of filament wrapping yarn are compared with performances of the wrapped-core yarn spun in the embodiment 7, and test results show that a strength of the three-layer composite wrapped-core yarn obtained in the embodiment 7 is improved by 30% and a wear resistance of the three-layer composite wrapped-core yarn obtained in the embodiment 7 is improved by 42% compared with the filament wrapping yarn obtained by using the conventional ring-spun Sirofil spinning device.

Embodiment 8

[0176] As illustrated in FIG. 36 through FIG. 41, the feeding unit further includes a front roller 16f disposed at an input end of the auxiliary core wrapping unit 30. The core yarn feeding unit 20 is configured to simultaneously feed at least one core yarn F1 and at least one wrapping yarn F2 into the auxiliary core wrapping unit 30, and the core yarn F1 and the wrapping yarn F2 are set apart from each other. The staple fiber feeding unit 10 is configured to feed at least one staple fiber roving S1 at intervals into the auxiliary core wrapping unit 30. The wrapping yarn F2 is overlapped with a staple strand after drafting of the staple fiber roving S1 close to the core yarn F1, and a spacing between the core yarn F1 and the staple strand close to the core yarn F1 is 2-5 mm on the front roller 16f In this way, the core yarn F1 and the staple fiber strand are separated by a certain spacing when passing through the front roller 16f, and will not be directly entangled, which provides conditions for the smooth transportation of the staple fiber strand to the subsequent auxiliary core-wrapping unit 30, and at the same time provides favorable conditions for the subsequent y-shaped structure.

[0177] The auxiliary core-wrapping assembly 31 is a negative pressure absorption assembly 3132f, and the pressurizing/conveying assembly 32 includes a transmission gear 35f and an auxiliary conveying component. The negative pressure adsorption assembly 3132f includes a special shaped air suction plate 316f, a drive roller 317f and a grid circle 315f wrapped on surfaces of the special shaped air suction plate 316f and the drive roller 317f. The special shaped air suction plate 316f is provided with a negative pressure suction grid hole zone with a width greater than or equal to a width of the staple fiber strand. The grid circle 315f only allows airflow to pass therethrough, which plays a role in supporting and transporting the staple fiber strand. The front roller 16f, the transmission gear 35f and the drive roller 317f are in meshing connection. In this way, the following effects are obtained. Firstly, the front roller 16f rotates to drive the transmission gear 35f to rotate, thereby driving the drive roller 317f to rotate, and further driving the grid circle 315f on the surface of the drive roller 317f to rotate; secondly, the staple fiber strand input through the front roller 16f is conveyed to the grid circle 315f and pass through the negative pressure suction port 3133f. Because the width of the negative pressure suction port 3133f is greater than or equal to the width of the staple fiber strand, the staple fiber strand is evenly spread on the grid circle 315f with a certain width and fiber parallelism without accumulation. Thirdly, under the continuous transportation of the grid circle 315f, the staple fiber strand finally converges with the core yarn F1 and the wrapping yarn F2 output from the front roller 16f at the wrapping area 34, and twisting formed by the spindle rotation of the ring frame makes the core yarn F1 rotate, which drives the staple fiber strand and the wrapping yarn F2 to wrap around an outer layer of the core yarn F1 to form a wrapped-core yarn S2. Then, the wrapped-core yarn S2 is transmitted to the yarn winding unit 40 for twisting and winding.

[0178] As illustrated in FIG. 36 through FIG. 39, the core yarn feeding unit 20 simultaneously feeds at least one core yarn F1 (when the at least one core yarn F1 is multiple in number, core yarns F1 overlap) and at least one wrapping yarn F2 (when the at least one wrapping yarn F2 is multiple in number, the wrapping yarns F2 overlap), which are arranged at intervals. The staple fiber feeding unit 10 feeds one staple fiber strand S11 into the auxiliary core wrapping unit 30, and the wrapping yarn F2 is arranged within of a width of the staple fiber strand S11 close to the core yarn F1. A spacing between the core yarn F1 and an end of the staple fiber strand S11 near the core yarn F1 is 2-5 mm on the front roller 16f. The staple fiber strand S11 and the wrapping yarn F2 intersect with the core yarn F1 at the wrapping area 34. A staple fiber strand S113 near the core yarn F1, the wrapping yarn F2 and a staple fiber strand S14 far away from the core yarn F1 are sequentially wrapped and wound to an outer layer of the core yarn F1 at the wrapping area 34, thereby forming a wrapped-core yarn S2 with the wrapping yarn F2 and the core yarn F1 holding the staple fiber strand S13 close to the core yarn F1 as a core and with the staple fiber strand S14 far away from the core yarn F1 as a sheath. Specifically, the core yarn F1 rotates, so that the core yarn F1, the wrapping yarn F2 and the staple fiber strand S13 close to the core yarn F1 are twisted with each other to form a core layer in which the wrapping yarn F2 and the core yarn F1 clamp the staple fiber strand S13 close to the core yarn F1; then, the staple fiber strand S14 far away from the core yarn F1 is wrapped and wound on the core layer under the rotation of the core yarn F1. In this process, the evenly spread staple fiber strand S11 is adsorbed on the grid circle 315f without rotating, and then the staple fiber strand S11 is wrapped under the cooperative action of the core yarn F1 and the wrapping yarn F2 to form a wrapped-core yarn S2 with a special structure.

[0179] As illustrated in FIG. 40 and FIG. 41, the core yarn feeding unit 20 simultaneously feeds at least one core yarn F1 and at least one wrapping yarn F2, which are arranged at intervals. The staple fiber feeding unit 10 simultaneously feeds a staple fiber strand S11 and a second staple fiber strand S12, which are sequentially far away from the core yarn F1. The wrapping yarn F2 coincides with the staple fiber strand S11. A spacing between the core yarn F1 and an end of the staple fiber strand S11 close to the core yarn F1 is 2-5 mm on the front roller 16f. The staple fiber strand S11, the second staple fiber strand S12 and the wrapping yarn F2 intersect and converge with the core yarn F1 at the wrapping area 34, and the staple fiber strand S1, the wrapping yarn F2 and the second staple fiber strand S12 are sequentially wrapped and wound to an outer layer of the core yarn F1 at the wrapping area 34 to form a wrapped-core yarn S2 with the staple fiber strand S11 sandwiched by the wrapping yarn F2 and the core yarn F1 as a core and with the second staple fiber strand S12 as a sheath. Specifically, the core yarn F1 rotates, so that the core yarn F1, the wrapping yarn F2 and the staple fiber strand S11 are twisted with each other to form a core layer in which the wrapping yarn F2 and the core yarn F1 clamp the staple fiber strand S11; and then, the second staple fiber strand S12 is wrapped around the core layer under the rotation of the core yarn F1.

[0180] The negative pressure suction port 3133f is a structure having an equal width from top to bottom or a structure narrower at the top and wider at the bottom, so that the staple fiber strand S11 and the second staple fiber strand S12 are evenly laid on the grid circle 315f with a certain width and fiber parallelism. Preferably, the negative pressure suction port 3133f is the structure narrower at the top and wider at the bottom, that is, an end of the negative pressure suction port 3133f close to the feeding unit is narrower (still not less than the width of the staple fiber strand S11 and not less than the width of the second staple fiber strand S12 conveyed by the front roller 16f), and an end of the negative pressure suction port 3133f far away from the feeding unit is wider. In this way, when the staple fiber strand S11 and the second staple fiber strand S12 pass through the negative pressure suction port 3133f with a narrower top and a wider bottom, the air suction assembly at the negative pressure suction port 3133f stretches the staple fiber strand S11 and the second staple fiber strand S12 in width and length directions, and the staple fiber strand S11 and the second staple fiber strand S12 are stretched to both sides, so as to be evenly laid. At the same time, the staple fiber strand S11 and the second staple fiber strand S12 are also stretched by a stretching force in the conveying direction, so that each single fiber is straightened. Under the coordinated stretching forces in both the width and length directions, the staple fiber strand S11 and the second staple fiber strand S12 will neither be over-stretched to create gaps nor will they be pulled apart. Finally, a fiber layer with a certain width and higher parallelism and uniform distribution is obtained on the grid circle 315f, which results in a significantly better wrapping effect for the core yarn F1 and provides favorable conditions for obtaining a structurally uniform wrapped-core yarn S2. Additionally, the negative pressure suction port 3133f can also capture uncontrolled floating fibers from the staple fiber strand S11 and the second staple fiber strand S12.

[0181] Particularly, as shown in FIG. 36 and FIG. 39, the wrapped-core yarn S2 formed in the wrapping area 34 is in a straight line with the core yarn F1 conveyed to the grid circle 315f, and the wrapped-core yarn S2 formed in the wrapping area 34 forms a y-shaped structure with each of the staple fiber strand S11, the wrapping yarn F2 and the second staple fiber strand S12 conveyed to the grid circle 315f. In this way, since the wrapped-core yarn S2 is in a straight line with the core yarn F1 conveyed to the grid circle 315f, a twist formed by the rotation of airflow is transmitted to the wrapping area 34 from bottom to top, and then most of the twist is transmitted to the core yarn F1, so that a twist and a tension of the core yarn F1 are much greater than those of each of the staple fiber strand S11 and the second staple fiber strand S12, making the core yarn F1 dominant in the twisting process and provides the core yarn F1 with enough rotation, and at the same time keeping the core yarn F1 in a straightened state. However, only a small part of the twist is transferred to the staple fiber strand S11 and the second staple fiber strand S12, and at the same time, the twist of each of the staple fiber strand S11 and the second staple fiber strand S2 is further reduced by a suction force of the negative pressure suction port 3133f, so that the staple fiber strand S11 and the second staple fiber strand S2 are laid flat on the grid circle 315f and are uniformly wrapped around the core yarn F1 by the rotation of the core yarn F1.

[0182] Before entering into the wrapping area 34, the staple fiber strand S11 is in a straight line, and the second staple fiber strand S12 in in a straight line, which further hinders the twist transmission of the staple fiber strand S11 and the second staple fiber strand S12, and further reduces the twist and the tension of each of the staple fiber strand S11 and the second staple fiber strand S12 again.

[0183] Before entering the wrapping area 34, an extension line of the core yarn F1 input to the grid circle 315f is not in a straight line with the fed core yarn F1 from the core yarn feeding unit 20, so that the core yarn F1 is input to the grid circle 315f in a broken line form, which further increases the tension of the core yarn F1, provides auxiliary conditions for ensuring that the core yarn F1 is in a straight state at the wrapping area 34, and improves the wrapping effect.

[0184] In some embodiments, a spacing between the wrapping area 34 and the nip of the front roller 16f is greater than a fiber length of the staple fiber strand S11 and is greater than a fiber length of the second staple fiber strand S12. In this way, firstly, a single fiber in the staple fiber strand S11 and the second staple fiber strand S12 can be stretched sufficiently to be straightened; secondly, a longer wrapping length within the wrapping area 34 further improves the twist and tension of the core yarn F1, which is beneficial to the rotation of the core yarn F1 to drive the staple fiber strand S11 and the second staple fiber strand S12 to wrap; and thirdly, a high-speed rotation of the core yarn F1 can also produce a certain stretching effect on the staple fiber strand S11 and the second staple fiber strand S12, which further improves the yarn quality.

[0185] The auxiliary conveying component includes a front top roller 321f, a drive top roller 323f and a bridge component 322f disposed between the front top roller 321f and the drive top roller 323f. A shaft core of the front top roller 321f and the bridge component 322f are connected with a shaft core of the drive top roller 323f, and the bridge component 322f can play a role in structural fixing and positioning the front top roller 321f and the drive top roller 323f. As shown in FIG. 37, the front top roller 321f is arranged vertically corresponding to the front roller 16f, and the drive top roller 323f is arranged vertically corresponding to the drive roller 317f. The drive top roller 323f is in contact with the grid circle 315f, and the grid circle 315f is driven to rotate by the joint action of the drive top roller 323f and the transmission gear 35f. This arrangement makes the transmission of the grid circle 315f more stable and provides stable conditions for the wrapping process.

[0186] In some embodiments, a middle of the drive top roller 323f is provided with a roller groove 324f for the wrapped-core yarn S2 to pass through. A width of the roller groove 324f is smaller than a width of the grid circle 315f and larger than one third of a width of the drive top roller 323f. In this way, convex structures of two ends of the drive top roller 323f are more convenient to press the grid circle 315f and drive the grid circle 315f to rotate and convey. At the same time, the roller groove 324f facilitates the wrapped-core yarn S2 to pass between the drive top roller 323f and the grid circle 315f.

[0187] The yarn guiding assembly 33 is a yarn guiding rod 331f, and a middle of the yarn guiding rod 331f is provided with a yarn groove 3311f for positioning the wrapped-core yarn S2. The yarn groove 3311f is configured to make the wrapped-core yarn S2 pass therethrough, and is further configured to position a yarn forming path. Specifically, the yarn guiding rod 331f moves left and right to adjust an offset of a path of the core yarn F1, thereby adjusting the y-shaped structure. The yarn guiding rod 331f moves up and down in a direction perpendicular to the yarn forming path, which can not only adjust a tension of the wrapped-core yarn S2 to the grid circle 315f, but also eliminate the yarn lateral movement caused by airflow, making a structure of the wrapped-core yarn S2 more stable, and also adjust the tension and twist of the core yarn F1.

[0188] The staple fiber feeding unit 10 includes a bell mouth 11f for feeding the staple fiber strand S11 and the second staple fiber strand S12, a rear roller 12f, a rear top roller 13f, a middle roller 14f and a middle top roller 15f The core yarn feeding unit 20 includes a godet 21f for guiding the core yarn F1 and the wrapping yarn F2.

[0189] the yarn winding unit 40 includes a guide hook 41f, a traveler 42f, a steel ring 43f and a ring bobbin 44f. The wrapped-core yarn S2 enters a balloon twisting section through the guide hook 41f, and fibers in an outer layer of the wrapped-core yarn S2 are further twisted and tightly held in this process, and finally wound on the ring bobbin 44f through the rotation of the traveler 42f on the steel ring 43f.

[0190] The working principle of the spinning device is as follows: firstly, the roving is unwound and enters the staple fiber feeding unit through the bell mouth 11f, the roving is stretched by the rear roller 12f, the rear top roller 13f, the middle roller 14f and the middle top roller 15f to obtain a staple fiber strand S11, and the staple fiber strand S11 is further stretched by the front roller 16f and then output; secondly, the staple fiber strand S11 and the second staple fiber strand S12 are absorbed onto the grid circle 315f by the air suction assembly in the special shaped air suction plate 316f. In this process, the rotation of the front roller 16f drives the transmission gear 35f to rotate, which in turn drives the drive roller 317f to rotate. At the same time, the auxiliary conveying component presses down, and the drive top roller 323f presses on the drive roller 317f, which further drives the grid circle 315f to rotate, so that the staple fiber strand S11 and the second staple fiber strand S12 are conveyed forward. The core yarn F1 and the wrapping yarn F2 with a certain spacing are unwound and fed into the nip formed between the front roller 16 f and the front top roller 321f under the guidance of the godet 21f for output, so as to ensure that the wrapping yarn F2 is located within of the width of the staple fiber strand S11 close to the core yarn F1 or that the wrapping yarn F2 overlaps with the staple fiber strand S11, and a spacing between the core yarn F1 and an end of the staple fiber strand S11 close to the core yarn F1 is 2-5 mm on the front roller 16f. The staple fiber strand S11 is conveyed forward under the support of the grid circle 315f, and the staple fiber strand S11, the wrapping yarn F2 and the second staple fiber strand S11 are sequentially wrapped and wound to an outer layer of the core yarn F1 at the wrapping area 34 by the rotation of the core yarn F1 to form a wrapped-core yarn S2. After passing through the yarn guiding rod 331f and the guide hook 41f, the wrapped-core yarn S2 is wound on the ring bobbin 44f by the traveler 42f rotating at higher speed on the steel ring 43f.

[0191] A calculus spinning method is provided, which is implemented by the calculus spinning device in the embodiment 8. The method specifically includes steps S1 to S3.

[0192] In step S1, at least one staple fiber strand S11, at least one wrapping yarn F2 and at least one core yarn F1, which are arranged at intervals, are fed from the feeding unit to the auxiliary wrapping unit 30.

[0193] In step S2, the wrapping yarn F2 is overlapped with a staple fiber strand of the at least one staple fiber strand S11 close to the core yarn F1, and the staple fiber strand of the at least one staple fiber strand S11 close to the core yarn F1 keeps a spacing of 2-5 mm from the core yarn F1 at a front nip formed by the meshing of the front roller 16f and the front top roller 321f, and is output to the grid circle 315f through the front nip. The staple fiber strand S11 is held by the suction assembly at the negative pressure suction port 3133f, and evenly spread on the grid circle 315f with a certain width and fiber parallelism. The rotation of the core yarn F1 drives the staple fiber strand and the wrapping yarn F2 to wrap around an outer layer of the core yarn F1 in turn at the wrapping area 34 to form a wrapped-core yarn S2.

[0194] In step S3, The wrapped-core yarn S2 is twisted and wound by the yarn winding unit 40.

[0195] As shown in FIG. 36 through FIG. 39, the core yarn feeding unit 20 of the embodiment 8 feeds one core yarn F1 and one wrapping yarn F2 at the same time, and the staple fiber feeding unit 10 feeds one staple fiber strand S11. Technical parameters of a corresponding calculus spinning process are as follows: the core yarn F1 is a black nylon filament with a fiber fineness of 81 D, the wrapping yarn F2 is a white nylon filament with a fiber fineness of 50 D, and the staple fiber strand S11 is a pink cotton fiber roving with a linear density of 450 tex; a speed at which the front roller 16f outputs the staple fiber strand S11 is 9.48 m/min; a rotating speed of the ring bobbin 44f is 11,000 r/min; a twist is 80 T/10 cm; a total drafting multiple (that is, a drafting ratio of the front roller rotational linear speed to the back roller rotational linear speed during stretching the staple fiber strand S11) is 57.40, a linear density of cortical cotton fiber (that is, a linear density of a roving after stretching) is 7.84 tex; a back zone drafting multiple (that is, a ratio of a rotational linear speed of the middle roller to a rotational linear speed of the back roller) is 1.25, a double-core yarn (core yarn F1 and wrapping yarn F2) accounts for 65% of the total yarn; a spacing between the wrapping yarn F2 and the core yarn F1 on the front roller 16f is 6.5 mm, and a spacing between the core yarn F1 and the staple fiber strand S11 on the front roller 16f is 5 mm; and the wrapping yarn F2 is fed at a position slightly to the right of a center of the staple fiber strand S11 (as shown in FIG. 36).

[0196] FIG. 42 illustrates an image of the wrapped-core yarn spun in the embodiment 8 under 35 times magnification using a 3D microscope. As can be seen from FIG. 42, in the obtained wrapped-core yarn, an outer cotton fiber completely covers a core yarn and a wrapping yarn, and the overall yarn covering effect is good, and there is no filament exposure. In addition, the parallelism of the outer coated fiber is higher.

Embodiment 9

[0197] As shown in FIG. 40 and FIG. 41, the core yarn feeding unit 20 of the embodiment 9 feeds one core yarn F1 and at least one wrapping yarn F2 at the same time, and the staple fiber feeding unit 10 feeds one staple fiber strand S11 and one second staple fiber strand S12 (at this time, the staple fiber feeding unit 10 needs to feed a roving 50 and a roving S1). The staple fiber strand S11 is close to the core yarn F1, and the wrapping yarn F2 overlaps with the staple fiber strand S11. Technical parameters of a corresponding calculus spinning process are as follows: the core yarn F1 is a black nylon filament with a fiber fineness of 81 D, the wrapping yarn F2 is a white nylon filament with a fiber fineness of 50 D, the staple fiber strand S11 is a pink cotton fiber roving with a linear density of 450 tex, and the second staple fiber strand S12 is a pink cotton fiber roving with a linear density of 450 tex; a speed at which the front roller 16f outputs the staple fiber strand S11 and the second staple fiber strand S12 is 9.48 m/min; a rotating speed of the ring bobbin 44f is 11,000 r/min; a twist is 80 T/10 cm; a total drafting multiple (that is, a drafting multiple of a ratio of the front roller rotational linear speed to the back roller rotational linear speed during stretching the staple fiber strand S11) is 57.40; a linear density of cortical cotton fiber (that is, a linear density of a roving after stretching) is 7.84 tex; a back zone drafting multiple (that is, a ratio of a rotational linear speed of the middle roller to a rotational linear speed of the back roller) is 1.25; a double-core yarn (core yarn F1 and wrapping yarn F2) accounts for 70% of the total yarn; a spacing between the wrapping yarn F2 and the core yarn F1 on the front roller 16f is 5 mm, and a spacing between the staple fiber strand S11 and the second staple fiber strand S12 on the front roller 16f is 5 mm (that is, a spacing between a left edge of the staple fiber strand S11 and a right edge of the second staple fiber strand S12 in FIG. 41); a spacing between aside of the staple fiber strand S11 close to the core yarn F1 and the core yarn F1 on the front roller 16f is 3.5 mm; and the wrapping yarn F2 is fed at a center of the staple fiber strand S11 (as shown in FIG. 41).

Comparative Example 6

[0198] Compared with the embodiment 8, the difference is that in the comparative example 6, the core yarn feeding unit 20 only feeds one core yarn F1, and the other parameters are basically the same as those of the embodiment 1, which will not be described herein.

[0199] Although the wrapped-core yarn obtained in the comparative example 6 does not have a very serious core yarn exposure, compared to the embodiment 8, occasional core yarn exposure occurs, and it is easy to slide and fall off between the core yarn F1 and the staple fiber strand S11.

Comparative Example 7

[0200] In the comparative example 7, a traditional ring core spinning device is used for core spinning, and the auxiliary core-wrapping unit 30 is not provided. The other parameters are basically the same as those in the embodiment 8, which will not be described herein.

[0201] FIG. 43 illustrates an image of a wrapped-core yarn spun in the comparative example 7 under 35 times magnification using a 3D microscope. As can be seen from FIG. 43, the wrapped-core yarn of the comparative example 7 has serious core yarn exposure, and it can be clearly seen that multiple filaments are exposed.

Comparative Example 8

[0202] In the comparative example, through the adjustment of the yarn guiding rod and the core yarn feeding unit, the wrapped-core yarn S2 formed in the wrapping area 34 is not in a straight line with the core yarn F1 conveyed to the grid circle 315f, and the wrapped-core yarn S2 formed in the wrapping area 34 is not in a straight line with the staple fiber strand S11 conveyed to the grid circle 315f, thus destroying the y-shaped structure. The other parameters are basically the same as those in the embodiment 8, and will not be described herein.

[0203] FIG. 44 illustrates an image of a wrapped-core yarn spun in the comparative example 8 under 35 times magnification using a 3D microscope. As can be seen from FIG. 44, the wrapped-core yarn spun in comparative example 8 has a morphological structure of plied yarn after the y-shaped structure was destroyed, and the core yarn F1, the wrapping yarn F2 and the staple fiber strand S11 are twisted and wrapped with each other, and the filaments are exposed.

Embodiment 10

[0204] Compared with the embodiment 8, the core yarn feeding unit 20 of the embodiment 10 simultaneously feeds a fine-denier flat core yarn F1 and a fine-denier flexible wrapping yarn F2, which are arranged at intervals.

[0205] Specifically, in the process of yarn formation, the fine-denier flat core yarn F1 rotates to form a uniform spiral structure, and at the same time, the rotation of the core yarn F1 causes the core yarn F1, the wrapping yarn F2 and a part of staple fiber strand S13 close to the core yarn F1 to twisted together, and the wrapping yarn F2 and the part of staple fiber strand S13 near the core yarn F1 reinforce and shape the spiral structure formed by the rotation of the core yarn F1. At the same time, uniform pores are formed between the spiral structure, the wrapping yarn F2 and the part of staple fiber strand S13 close to the core yarn F1, so as to obtain a spiral, uniform and fluffy core layer in which the wrapping yarn F2 and the core yarn F1 clamp the part of staple fiber strand S13 close to the core yarn F1; then, under the rotation of the core yarn F1, a part of the staple fiber strand S13 far away from the core yarn F1 is further wrapped and wound on the core layer to obtain a soft and wear-resistant yarn.

[0206] A single filament width of the fine-denier flat core yarn F1 is 10-80 m, and the single filament width of the core yarn F1 is controlled within a narrower range to obtain the following effects. On the one hand, a spiral degree of the spiral structure formed by the self-rotation of the core yarn F1 is more compact and uniform, so that the core layer is more uniform and stable. On the other hand, a fineness of the obtained wrapped-core yarn S2 is controlled in a fine range, so that the obtained soft and wear-resistant yarn has higher softness and wear resistance.

[0207] The core yarn F1 is a water-soluble fiber or a water-insoluble fiber. When the core yarn F1 is the water-soluble fiber, after washing, the core yarn F1 is dissolved and removed to form a hollow structure, thus making the core structure fluffier and the obtained yarn softer.

[0208] A single filament fineness of the fine-denier flexible wrapping yarn F2 is 0.3-1.0 dtex. First of all, a width of the wrapping yarn F2 is also controlled within a narrower range, which not only makes the widths of the wrapping yarn F2 and the core yarn F1 more matched, but also makes the winding of the wrapping yarn F2 and the core yarn F1 firmer and improves the wear resistance. In addition, a fineness of the obtained wrapped-core yarn S2 can be controlled in a finer range. Moreover, the wrapping yarn F2 is flexible, which will not restrain the spiral structure while reinforcing the spiral structure of the core layer, thus not affecting the torsion of the spiral structure, and further not affecting the softness of the obtained soft wear-resistant yarn.

[0209] The staple fiber strand S11 input to the front roller 16f is expanded. A width of the staple fiber strand S11 is also controlled within a certain range, so as to ensure the wrapping and not over-wrap, thereby improving the softness of the soft and wear-resistant yarn.

[0210] A width of the negative pressure suction port 3133f is greater than or equal to the width of the staple fiber strand S11, and in the wrapping process, the wrapped-core yarn is wrapped more evenly and thinly, so that the obtained wrapped-core yarn is thinner and the spiral structure is uniform.

[0211] When the negative pressure suction port 3133f is narrower at the top and wider at the bottom, the staple fiber strand S11 on the grid circle 315f can be laid more smoothly, lightly and uniformly, so that the spiral structure and the peripheral wrapping structure of the obtained soft wear-resistant yarn are more uniform and the performance is better.

[0212] Compared with the wrapped-core yarn made by conventional core-spun composite spinning under the same technological parameters, a softness and a wear resistance of the soft and abrasion-resistant yarn spun in the embodiment 10 are improved by more than 20% and 30% respectively. In addition, a fineness (i.e., linear density) of a finest yarn of the soft wear-resistant yarn is 2.1 tex.

[0213] In the embodiment 10, the core yarn F1 is a viscose filament fiber with a single filament width of 80 m, the wrapping yarn F2 is a nylon filament fiber with a fineness of 1.0 dtex, and the staple fiber strand S11 is a pure cotton fiber. A speed at which the front roller 16f outputs the staple fiber strand S11 is 9.48 m/min; a rotating speed of the ring bobbin 44f is 11,000 r/min, a twist is 80 T/10 cm; a total drafting multiple (that is, a drafting multiple of a ratio of the front roller rotational linear speed to the back roller rotational linear speed during stretching the staple fiber strand S11) is 57.40; a linear density of cortical cotton fiber (that is, a linear density of a roving after stretching) is 7.84 tex; a back zone drafting multiple (that is, a ratio of a rotational linear speed of the middle roller to a rotational linear speed of the back roller) is 1.25; a spacing between the wrapping yarn F2 and the core yarn F1 on the front roller 16f is 6.5 mm, and a spacing between the core yarn F1 and the staple fiber strand S11 on the front roller 16f is 5 mm; and the wrapping yarn F2 is fed at a position slightly to the right of a center of the staple fiber strand S11 (as shown in FIG. 36). For comparison, under the condition that other parameters are unchanged, the wrapping yarn F2 and the core yarn F1 are first overlapped, and then are fed to a middle of the staple fiber strand S11 to overlap with the staple fiber strand S11, thereby forming a traditional wrapped-core yarn. Test is performed on the traditional wrapped-core yarn and the wrapped-core yarn obtained in the embodiment 10 and a corresponding test result shows that compared with the traditional wrapped-core yarn, a softness of the wrapped-core yarn obtained in the embodiment 10 is improved by 22%, and a wear resistance of the wrapped-core yarn obtained in the embodiment 10 is improved by 30.1%.

Embodiment 11

[0214] Compared with the embodiment 10, the differences are that in the embodiment 11, a single filament width of the core yarn F1 is 10 m, a fineness of the wrapping yarn F2 is 0.3 dtex, the staple fiber strand S11 is a fine cashmere roving, a fineness of a wrapped-core yarn spun in the embodiment 11 is 2.1 tex, and the wrapped-core yarn spun has a good wear resistance and a smooth surface. For comparison, under the condition that other parameters are unchanged, the wrapping yarn F2 and the core yarn F1 are first overlapped, and then are fed to a middle of the staple fiber strand S11 to overlap with the staple fiber strand S11, thereby forming a traditional wrapped-core yarn. Test is performed on the traditional wrapped-core yarn and the wrapped-core yarn obtained in the embodiment 10 and a corresponding test result shows that the traditional wrapped-core yarn can't catch a few external staple fibers for yarn formation, and the traditional wrapped-core yarn is a twisted yarn in which the core yarn F1 and the wrapping yarn F2 are twisted into a tightly-knit structure, and a softness of the traditional wrapped-core yarn is significantly lower than that of the yarn obtained in the embodiment 10.

Embodiment 12

[0215] As illustrated in FIG. 26 through FIG. 30, the feeding unit further includes a front roller 16e disposed at an input end of the auxiliary core-wrapping unit 30. A spacing between the core yarn F1 and the staple fiber strand S11 on the front roller 16e is 2-5 mm, and a setting principle of this spacing is basically the same as that in the embodiment 8, which is not repeated herein.

[0216] The auxiliary core-wrapping unit 30 also includes a negative pressure air flow guide assembly 36 disposed above the auxiliary core-wrapping assembly 31 and configured to provide a diffusion air flow for the staple fiber strand S11. With the cooperation of the auxiliary core-wrapping assembly 31 and the negative pressure air flow guide assembly 36, the staple fiber strand S11 is differentially dispersed and spread into a highly straight and fully dispersed single fiber paving belt. The differentially spread staple fiber strand S11 intersects and converges with the core yarn F1 at the wrapping area 34, and the core yarn F1 rotates to drive the differentially spread staple fiber strand S11 to wrap around an outer layer of the core yarn F1 under the yarn twisting, thereby forming a wrapped-core yarn S2. Compared with a traditional ring-spun wrapped-core yarn, the wrapped-core yarn S2 exhibits a stronger wrapping tightness (with an increase of over 20% compared to the traditional ring-spun wrapped-core yarn), a higher wrapping coverage (100% full coverage), a larger core yarn ratio (up to 70%), and superior quality.

[0217] As shown in FIG. 26, the staple fiber feeding unit 10 includes a bell mouth 11e, a rear roller 12e, a rear top roller 13e, a middle roller 14e and a middle top roller 15e, which are sequentially arranged along a feeding direction of the roving S1 in that order. The auxiliary core-wrapping assembly 31 includes a front top roller 321e disposed above the front roller 16e, and a spacing between the core yarn F1 and the staple fiber strand S11 is 2-5 mm in a front roller nip formed by the meshing of the front roller 16e and the front top roller 321e. The roving S1 is gradually formed into a staple fiber strand S11 under a stretching action of a spinning frame stretching system composed of the back roller 12e, the back top roller 13e, the middle roller 14e, the middle top roller 15e, the front roller 16e, and the front top roller 321e. The staple fiber strand S11 is output through the front roller nip formed by the meshing of the front roller 16e and the front top roller 321e, and is fed to the auxiliary core-wrapping unit 30. In this process, by controlling rotating speeds of the front roller 16e, the middle roller 14e and the rear roller 12e, an overall drafting multiple is adjusted so that the staple fiber strand S11 with a certain amount required by the process can be continuously and smoothly fed to the auxiliary core-wrapping unit 30.

[0218] The core yarn feeding unit 20 includes a core yarn unwinding unit 23, a tension adjusting frame 24 and a godet 21e, which are sequentially arranged along an advancing direction of the core yarn F1 in that order.

[0219] Specifically, the core yarn unwinding unit 23 includes a pair of unwinding rollers that rotate in a same direction, and the pair of unwinding rollers are engaged with a winding roller for winding the core yarn F1. In this way, the core yarn F1 is actively unwound by the rotation of the unwinding roller. The tension adjusting frame 23 includes tension adjusting rods arranged in parallel. In this process, first, the core yarn unwinding unit 23 actively unwound the core yarn F1 from the winding roller, then, a tension of the core yarn F1 is stabilized under the adjustment of the tension adjusting frame 24 and the core yarn F1 is continuously conveyed to the godet 21e, and finally, under the guidance of the godet 21e, the core yarn F1 is fed to the front roller nip formed by the meshing of the front roller 16e and the front top roller 321.

[0220] In some embodiments, the core yarn feeding unit 20 adopts an existing spandex yarn positive feeding mechanism of elastic wrapped-core yarn.

[0221] As shown in FIG. 26 and FIG. 27, the auxiliary core-wrapping assembly 31 is a negative pressure absorption assembly 3132e. The negative pressure absorption assembly 3132e includes a special shaped air suction plate 316e, a drive roller 317e and a grid circle 315e sleeved on outer surfaces of the special shaped air suction plate 316e and the drive roller 317e. In order to make the grid circle 315e tense, the negative pressure absorption assembly 3132e also includes a tensioning mechanism (not shown), and the grid circle 315e is sleeved on outer surfaces of the special shaped air suction plate 316e, the drive roller 317e and the tensioning mechanism. The special shaped air suction plate 316e has a hollow structure inside. The special shaped air suction plate 316e is provided with a negative pressure suction port 3133e with a width greater than or equal to that of the staple fiber strand S11, and an air suction assembly is arranged at the negative pressure suction port 3133e. The air around the negative pressure suction port 3133e is gathered towards negative pressure suction port 3133e under the action of the air suction assembly. The grid circle 315e only allows airflow to pass therethrough, and plays a role in supporting and transporting the staple fiber strand S11. In this process, the staple fiber strand S11 output through the front roller nip is conveyed to the grid circle 315e and passes through the negative pressure suction port 3133e. Because the width of the negative pressure suction port 3133e is greater than or equal to the width of the staple fiber strand S11, the staple fiber strand S11 with a certain width and fiber parallelism is widened and spread evenly on the grid circle 315e to prevent the differential fiber of the staple fiber strand S11 from shaking and reunion. In addition, the negative pressure suction port 3133e can also capture uncontrolled floating fibers in the staple fiber strand S11.

[0222] The shape setting principle of the negative pressure suction port 3133e is the same as that of negative pressure suction port 3133f of the embodiment 8.

[0223] The negative pressure air flow guide assembly 36 is disposed above the special shaped air suction plate 316e, and includes a diversion housing 361 and rows of diffusion guide holes 362 and 363 obliquely arranged on the diversion housing 361. A shape of the diversion housing 361 of the negative pressure air flow guide assembly 36 is consistent with that of the special shaped air suction plate 316e (that is, as shown in FIG. 28, aside of the diversion housing 361 close to the special shaped air suction plate 316e is curved), and an airflow pipeline is arranged on a side of the diversion housing 361 facing the special shaped air suction plate 316e. The boss is perpendicular to a running direction of the staple fiber strand S11, and a height of the boss is 1.0-3.0 mm. The thicker the staple fiber strand S11 used in spinning, the greater the height of the boss; or the thinner the staple fiber strand S11 used in spinning, the smaller the height of the boss. The negative pressure suction port 3133e on the special shaped air suction plate 316e corresponds to the diffusion guide holes 362, so that the airflow enters the negative pressure suction port 3133e through the diffusion guide holes 362. In this way, a negative pressure formed inside the special shaped air suction plate 316e makes the air surrounding the special shaped air suction plate 316e gather towards the special shaped air suction plate 316e, and at the same time, the negative pressure air flow guide assembly 36 makes the gathered air flow pass through the diffusion guide holes 362 to form a diffusion air flow, that is, after the air flow passes through the diffusion guide holes 362, the diffusion air flow will be formed between the special shaped air suction plate 316e and the diversion housing 361, so that the flexible fiber (i.e., the staple fiber strand S11 output through the front roller nip) passing between the special shaped air suction plate 316e and the diversion housing 361 is differentially widened to form a fiber flat strand of a certain width and then is adsorbed onto the grid circle 315e. Specifically, the air surrounding the negative pressure suction port 3133e and the negative pressure air flow guide assembly 36 forms a diffusion air flow under the action of the diffusion guide holes 362, and the diffusion air flow further opens and widens the staple fiber strand S11. With the cooperation of the diffusion guide holes 362 and the air suction assembly, on the one hand, the staple fiber strand S11 is stretched to both sides (in a width direction), and then is evenly spread on the grid circle 315e; on the other hand, the staple fiber strand S11 is also stretched by a stretching force in the conveying direction, so that each single fiber is straightened. Under the coordinated stretching forces in both the width and length directions, the staple fiber strand S11 opens and widens to the greatest extent, which will neither be over-stretched to create gaps nor will they be pulled apart. Finally, the staple fiber strand S11 will be spread evenly on the grid circle 315e with a certain width and fiber parallelism. At the same time, the airflow passing through the diffusion guide holes 362 can further firmly adsorb the slightly differentiated and dispersed staple fiber strand S11 on the grid circle 315e, so as to prevent the slightly differentiated and dispersed staple fiber strand S11 from accumulating and shaking, and the evenly spread staple fiber strand S11 are adsorbed on the grid circle 315e without rotating, and finally, the staple fiber strand S11 is wrapped by winding revolution twisting under the action of the stretched and self-rotating twisted core yarn F1, thus forming a winding wrapped-core yarn S2 with a special structure.

[0224] As shown in FIG. 28, there are two rows of diffusion guide holes 362 in this embodiment, and inclination angles of the diffusion guide holes in the same row gradually increase from the middle to two opposite sides, and the inclination angle is in a range from 0 to 60. After the air flow around the negative pressure absorption assembly 3132e passes through the inclined diffusion guide holes 362, the air flow changes from a disordered state to a stable state to spread to the two sides, so as to widen and smooth the staple fiber strand S11 to the two sides.

[0225] The negative pressure air flow guide assembly 36 further includes rows of airflow stabilizing holes 363 vertically arranged on the diversion housing 361, and the diffusion guide holes 362 and the airflow stabilizing holes 363 are sequentially arranged along an advancing direction of the core yarn F1 and the staple fiber strand S11. The airflow stabilizing holes 363 are used to further attach the widened and flattened staple fiber strand S11 to the surface of the grid circle 315e under the action of a vertical airflow. As shown in FIG. 28, a diameter of each airflow stabilizing hole 363 remains constant from top to bottom, or a tail end along an airflow direction of the airflow stabilizing hole 363 is horn-shaped. When the tail end along an airflow direction of the airflow stabilizing hole 363 is horn-shaped, the horn shape at the tail end can obtain a wider range of stable airflow, so that the widened and smoothed staple fiber strand S11 can be more firmly attached to the surface of the grid circle 315e.

[0226] As shown in FIGS. 26 and 27, the pressurizing/conveying assembly 32 includes a transmission gear 35e and an auxiliary conveying component. Specifically, the front roller 16e, the transmission gear 35e and the drive roller 317e are engaged. The auxiliary conveying component includes a front top roller 321e, a drive top roller 323e and a bridge component 322e disposed between the front top roller 321e and the drive top roller 323e. A shaft core of the front top roller 321e and the bridge component 322e are connected with a shaft core of the drive top roller 323e (that is, the bridge component 322e connects the shaft cores of the front top roller 321e and the drive top roller 323e to make them integrated). The front top roller 321e and the front roller 16e are arranged up and down correspondingly, and the drive top roller 323e and the drive roller 317e are arranged up and down correspondingly. The drive roller 323e is in contact with the grid circle 315e. A rotation process of the grid circle 315e driven by the pressurizing/conveying assembly 32 is the same as that in the embodiment 8. Under the continuous transportation of the grid circle 315e, the staple fiber strand S11 and the core yarn F1 are finally transmitted to the core yarn F1 at the wrapping area 34 under the cooperative twisting action of the steel ring, the traveler and a spindle, so that the stretched core yarn F1 is twisted by rotation, which drives the differential dispersed staple fiber strand S11 to spread into a highly straight and fully dispersed flat ribbon-shaped single fiber, which is wrapped around an outer layer of the self-rotating twisted core yarn F1 in an orderly revolution one by one, and the staple fiber strand S11 is wrapped around the core yarn F1 to a wrapped-core yarn S2. The whole process adopts the principle of differentiating first and then integrating.

[0227] In some embodiments, a roller groove 324e is provided in a middle of the drive top roller 323e. A width arrangement and an arrangement advantage of the roller groove 324e are the same as those of the roller groove 324f in the embodiment 8.

[0228] The diversion housing 361 is embedded below the bridge component 322e and connected with the shaft core of the front top roller 321e, so that there is a certain gap between the diversion housing 361 and the grid circle 315e, which is convenient for the staple fiber strand S11 and the core yarn F1 to pass therethrough.

[0229] As shown in FIG. 30, the wrapped-core yarn S2 formed in the wrapping area 34 is in a straight line with the core yarn F1 fed into the grid circle 315e, and merges with the staple fiber strand S11 fed into the grid circle 315e to form a y-shape. The staple fiber strand S11 before entering the wrapping area 34 is in a straight state. In this way, since the wrapped-core yarn S2 from bottom to top is in a straight line with the core yarn F1 conveyed to the grid circle 315e, a twist formed by the rotation of airflow is transmitted to the wrapping area 34 from bottom to top, and then most of the twist is transmitted to the core yarn F1, so that a twist and a tension of the core yarn F1 are much greater than those of the staple fiber strand S11, making the core yarn F1 dominant in the twisting process and provides the core yarn F1 with enough rotation, and at the same time keeping the core yarn F1 in a straightened state. Further, the twist is difficult to be transmitted to the staple fiber strand S11 along an axial direction of the staple fiber strand S11. At the same time, the straightness, parallelism and expansion of staple fibers in the staple fiber strand S11 are further improved by the action of the negative pressure suction port 3133e and the negative pressure air flow guide assembly 36, so that the staple fiber strand S11 spreads on the grid circle 315e, the staple fibers in the staple fiber strand S11 only undergoes revolution and wrapping motion without self-rotation twisting under the drive of the core yarn F1, and the staple fiber strand S11 is uniformly and tightly wrapped around the core yarn F1 in a core-winding manner. In addition, the staple fiber strand S11 in the wrapping area 34 being tightly adsorbed on the grid circle 315e further hinders the twist transmission of the staple fiber strand S11, and ensures that the staple fiber strand S11 is tensioned and highly parallel and oriented in the untwisted state.

[0230] Before entering the wrapping area 34, the staple fiber strand S11 is in a straight line. Before entering the wrapping area 34, an extension line of the core yarn F1 input to the grid circle 315e is not in a straight line with the fed core yarn F1 from the core yarn feeding unit 20, so the core yarn F1 input to the grid circle 315e before entering the wrapping area 34 needs to be configured with a large tension. The principle and function of the above arrangement are the same as those in the embodiment 8.

[0231] A spacing between the wrapping area 34 and the nip of the front roller 16 is greater than a fiber length of the staple fiber strand S11. The principle and function of this setting are the same as in the embodiment 8.

[0232] The yarn guiding assembly 33 includes a connecting member 333 and a compliant reinforced component 334. The connecting member 333 is connected with the bridge component 322e, and the compliant reinforced component 334 is connected with the connecting member 333. The compliant reinforced component 334 includes a heating compliant block 3341 and a reinforcing block 3342 which are sequentially arranged along an advancing direction of the wrapped-core yarn S2 in that order.

[0233] Specifically, the heating compliant block 3341 is made of a heated ceramic block, which can be heated to a temperature of 130-220 C. when energized. The temperature can be adjusted to a corresponding glass transition temperature according to a material characteristic of the heated ceramic block. At a higher temperature, the staple fiber strand S11 at an outer layer of the preliminarily formed wrapped-core yarn S2 can be softened, and the staple fiber strand S11 can be further adhered to the core yarn F1 through the twisting rotation of the core yarn F1, thus improving the yarn quality. The middle part of the heating compliant block 3341 is provided with an arc groove 3343, which is convenient for clamping the wrapped-core yarn S2 and positioning the yarn forming path at the same time, thus playing a yarn forming guiding role and making the yarn forming process more stable.

[0234] The reinforcing block 3342 includes a fixing block 33421 and a tension adjusting plate 33422. The wrapped-core yarn S2 passes through between the fixing block 33421 and the tension adjusting plate 33422, and at the same time, the wrapped-core yarn S2 is in contact with the tension adjusting plate 33422 with a certain tension, so that fibers on a surface layer of the wrapped-core yarn S2 can be more closely attached to the core yarn F1 during twisting rotation by friction, thereby improving the smoothness of a yarn body and reducing a yarn hairiness. By increasing or decreasing the number of tension adjusting plates 33422, a friction force between tension adjusting plates 33422 and wrapped-core yarn S2 can be adjusted to adapt to different raw material characteristics. It can be seen that after the wrapped-core yarn S2 passes through the compliant reinforced component 334, the staple fiber coating of its outer layer is more closely attached to the outer layer of the core yarn F1 under the action of higher temperature and pressure.

[0235] As shown in FIG. 27 and FIG. 30, the compliant reinforced component 334 is disposed on an axial left side of the calculus spinning device, so that when the core yarn F1 converges with the staple fiber strand S11 in the wrapping area 34 to form yarn, the whole structure further forms a y-shaped structure.

[0236] the yarn winding unit 40 includes a guide hook 41e, a traveler 42e, a steel ring 43e and a ring bobbin 44e. The wrapped-core yarn S2 enters a balloon twisting section through the guide hook 41e, and fibers in the outer layer of the wrapped-core yarn S2 are further twisted and tightly held, and finally wound on the ring bobbin 44e through the rotation of the traveler 42e on the steel ring 43e.

[0237] A calculus spinning method is provided, which is implemented by the calculus spinning device in the embodiment 12. The method specifically includes steps S1 to S3.

[0238] In step S1, the roving S1 is stretched into the staple fiber strand S11 by the staple fiber feeding unit 10 and fed to the auxiliary core-wrapping unit 30, and the core yarn F1 is fed to the auxiliary core-wrapping unit 30 through the core-covering unit 20.

[0239] In step S2, the core yarn F1 and the staple fiber strand S11 are fed into the front roller nip formed by the meshing of the front roller 16e and the front top roller 321e, the core yarn F1 and the staple fiber strand S11 are separated with a spacing of 2-5 mm, and then the core yarn F1 and the staple fiber strand S11 are output to the grid circle 315e through the front roller nip at a speed required by the process. With the cooperation of the air suction assembly and the negative pressure air flow guide assembly 36, the staple fiber strand S11 is evenly spread on the grid circle 315e with a certain width and fiber parallelism. The rotation of the core yarn F1 drives the staple fiber strand S11 to wrap around an outer layer of the core yarn F1 in turn at the wrapping area 34 to form a wrapped-core yarn S2.

[0240] In step S3, the wrapped-core yarn S2 passes through the yarn guiding assembly 33, the staple fiber strand of the wrapped-core yarn S2 is more tightly attached to the outer layer of the core yarn F1 under the high temperature environment and pressure friction, and then the wrapped-core yarn S2 is transmitted to the yarn winding unit 40 for twisting and winding.

[0241] The calculus spinning device and the calculus spinning method are used to carry out lossless calculus spinning processing on inorganic fiber materials, and the calculus spinning processing of fiber materials can achieve a core yarn ratio up to 70% and a higher yarn quality. The prepared wrapped-core yarn S2 can be applied to clothes, fire blankets and ropes in the field of firefighting; casual clothes, sportswear, curtains and bed sheets in the field of clothing and home; tents, clothing, shoes and boots in the military field; and automobile interior fabrics, aerospace seat covers, high-speed rail seat covers, aviation insulation blankets in the field of transportation. For example, when the staple fiber strand S11 is a PI fiber and the core yarn F1 is an inorganic basalt filament, the prepared wrapped-core yarn S2 can be applied to clothes, ropes and other equipment in the firefighting field; when the staple fiber strand S11 is a cotton fiber and the core yarn F1 is a polyester filament, the prepared wrapped-core yarn S2 can be applied to products such as casual wear, sportswear, bed sheets and the like in the field of clothing and home.

[0242] Technological parameters of the calculus spinning process in the embodiment 12 are specifically as follows: the core yarn F1 is a twisted yarn formed by compounding a basalt filament with a linear density of 12 tex and a flame-retardant nylon filament with a fiber fineness of 20 D, and the roving S1 is a flame-retardant fiber blended roving with a linear density of 520 tex; a speed at which the front roller 16e outputs the staple fiber strand S11 and the core yarn F1 is 12.22 m/min; a rotating speed of the ring bobbin 44e is 11,000 r/min; a twist is 90 T/10 cm; a total drafting multiple (that is, a drafting multiple of the staple fiber strand S11 by the staple fiber feeding unit 10) is 62.58; a linear density of sheath flame retardant fiber blended roving (that is, that is, a linear density of a roving after stretching) is 8.31 tex; a back zone drafting multiple (that is, a ratio of a rotation speed of the middle roller 14e to a rotation speed of the back roller 12e) is 1.25; a spacing between the core yarn F1 and the staple fiber strand S11 on the front roller is 5 mm; a diameter of each airflow stabilizing hole remains constant from top to bottom; and the heating compliant block 3341 is started, a temperature of the heating compliant block 3341 is set to 180 C., and the core yarn F1 in the wrapped-core yarn S2 accounts for 70% of the whole yarn.

[0243] FIG. 31 illustrates an image of wrapped-core yarn spun in the embodiment 12 under 35 times magnification using a 3D microscope. As can be seen from FIG. 31, in the obtained wrapped-core yarn, the core yarn material is completely covered by the outer flame-retardant fiber, and the overall yarn covering effect is good, without filament exposure, and the overall yarn covering effect is good. In addition, at the same time, the parallelism of the outer coated fiber is higher, and the surface forms a better yarn appearance.

Embodiment 13

[0244] Compared with the embodiment 12, the difference is that in the embodiment 13, a tail end along an airflow direction of the airflow stabilizing hole 363 is horn-shaped, and the others are basically the same as those of the embodiment 12, so the details are not repeated here. The core yarn F1 in the wrapped-core yarn S2 accounts for 70% of the total yarn.

[0245] FIG. 32 illustrates an image of wrapped-core yarn spun in the embodiment 13 under 35 times magnification using a 3D microscope. As can be seen from FIG. 32, the wrapped-core yarn obtained in the embodiment 13 has a neater appearance and less hairiness compared with the embodiment 12, which shows that when the tail end along an airflow direction of the airflow stabilizing hole 363 is horn-shaped, the core yarn is more covered by the outer fiber.

Comparative Example 9

[0246] In the comparative example 9, a traditional ring spinning core-spun device is used for wrapped-core yarn, and the auxiliary core-wrapping unit 30 is not provided. The other parameters are basically the same as those in the embodiment 12, so they will not be described here. The core yarn F1 in the wrapped-core yarn S2 accounts for 72% of the total yarn (during the spinning process, some staple fibers are sucked away by the negative pressure suction port to escape, thus increasing the proportion of filaments (i.e., the core yarn ratio) in the final yarn).

[0247] FIG. 33 illustrates an image of a wrapped-core yarn spun in the comparative example 9 under 35 times magnification using a 3D microscope. As can be seen from FIG. 33, in the wrapped-core yarn obtained in the comparative example 9, there is obvious yarn leakage phenomenon, basalt is exposed, and the yarn has more apparent hairiness.

Comparative Example 10

[0248] Compared with the embodiment 12, the difference is that in the comparative example 10, the negative pressure airflow guide assembly 36 is not provided, and the other parts are basically the same as the embodiment 12, so they will not be described herein. The core yarn F1 in the wrapped-core yarn S2 accounts for 70% of the total yarn.

[0249] FIG. 34 illustrates an image of a wrapped-core yarn spun in a comparative example 10 under 35 times magnification using a 3D microscope. As can be seen from FIG. 34, there is no core leakage in the yarn obtained in the comparative example 10, but the overall covering effect is slightly worse than that in the embodiment 12.

Comparative Example 11

[0250] Through the adjustment of the yarn guiding assembly 33, the wrapped-core yarn S2 formed in the wrapping area 34 is not in a straight line with the core yarn F1 conveyed to the grid circle 315e, thus destroying the y-shaped structure. The other parameters are basically the same as those in the embodiment 12, and will not be described herein.

[0251] FIG. 35 illustrates an image of a wrapped-core yarn spun in the comparative example 11 under 35 times magnification using a 3D microscope. As can be seen from FIG. 35, in the wrapped-core yarn spun obtained in the comparative example 11, because the y-shaped structure was not formed during yarn formation, the overall yarn formation structure was similar to the form of a strand, the core yarn and the staple fiber strand are intertwined, and the core yarn was exposed on the surface of the yarn body, resulting in serious yarn leakage.

[0252] The wrapped-core yarns obtained in the embodiments 12-13 and the comparative examples 9-11 are tested for yarn basic indexes, and the obtained data are averaged for data comparison. The specific results are as follows.

TABLE-US-00003 TABLE 3 Tensile fracture properties of wrapped-core yarns Breaking Elongation Example strength (CN) at break (%) Embodiment 12 1441.66 6.71 Embodiment 13 1590.22 5.63 Comparative 933.91 13.35 example 9 Comparative 1398.79 6.24 example 10 Comparative 1075.21 10.57 example 11

[0253] It can be seen from Table 3 that the breaking strengths of the wrapped-core yarns spun in the embodiments 12 and 13 are obviously higher than those of the wrapped-core yarns spun in the comparative examples 9 and 11. This is mainly because, in the wrapped-core yarns with basalt core yarn spun coated by flame-retardant fiber in the embodiments 12 and 13, the rigid basalt core yarn is in a straight state in the yarn body, with higher breaking strength and lower elongation at break; however, in the wrapped-core yarns with basalt core yarn coated by flame-retardant fiber spun by the traditional ring spinning core-spun method in the comparative example 9, the basalt core yarn is spirally distributed, and the rigid basalt core yarn is easier to break under the shear force during stretching, so the breaking strength thereof is lower. The wrapped-core yarn in the comparative example 11 is similar to a stranded yarn. During the stretching process, the wrapped-core yarn and the staple fiber strand are jointly stressed, and the core yarn and the staple fiber strand are twisted together, so the breaking strength is reduced.

TABLE-US-00004 TABLE 4 Number of yarn hairiness of wrapped-core yarn Example 1 mm 2 mm 3 mm 4 mm 5 mm 6 mm 8 mm 10 mm Embodiment 427.90 36.20 6.30 3.90 0.80 0.10 0.00 0.00 12 Embodiment 552.00 51.20 7.80 1.50 0.50 0.10 0.00 0.00 13 Comparative 1073.31 149.40 24.00 5.15 1.15 0.30 0.20 0.35 example 9 Comparative 597.85 67.35 8.75 3.75 0.90 0.10 0.00 0.00 example 10 Comparative 859.37 97.83 19.65 4.10 1.10 0.30 0.20 0.10 example 11

[0254] As can be seen from Table 4, the hairiness of the wrapped-core yarns spun in the embodiments 12 and 13 is greatly improved compared with the wrapped-core yarns spun in the comparative example 9. The hairiness with a length of 3 mm of the wrapped-core yarns with basalt core yarn coated by flame-retardant fiber spun in the embodiments 12 and 13 is basically eliminated, and the number of short hairiness with a length of 1 mm is also reduced by about 50% compared with that of the comparative example 9.

TABLE-US-00005 TABLE 5 yarn evenness of wrapped-core yarn Coefficient Uneven of Fine rate U variation end Slub Nep Example (%) CV (%) (50%) (+50%) (+200%) Embodiment 7.18 9.44 five five 0 12 Embodiment 6.77 8.68 0 five 0 13 Comparative 11.34 14.80 55 95 60 example 9 Comparative 8.04 10.28 0 five five example 10 Comparative 10.57 12.67 35 50 15 example 11

[0255] As can be seen from Table 5, the yarn evenness of the wrapped-core yarns spun in the embodiments 12 and 13 is better than that of the wrapped-core yarn in the comparative example 11. The fine end ((50%), the slub (+50%) and the nep (+200%) of the wrapped-core yarns with basalt core yarn coated by flame-retardant fiber spun in the embodiments 12 and 13 are basically eliminated, while the wrapped-core yarn of the wrapped-core yarn with basalt core yarn coated by flame-retardant fiber spun in the comparative example 9 has more yarn defects in the fine end ((50%), the slub (+50%) and the nep (+200%).

[0256] To sum up, the disclosure provides a calculus spinning device and method. The calculus spinning device is provided with an auxiliary core-wrapping unit with a special structure, so that a staple fiber strand forms staple fiber strands with a certain width and a uniform structure in the auxiliary core-wrapping assembly. By cooperating with a feeding unit, other components of the auxiliary core-wrapping unit and a yarn winding unit, the auxiliary core-wrapping assembly realizes the tight integral wrapping of the staple fiber strands on a core yarn, so as to obtain a wrapped-core yarn with a good covering effect and a relatively larger core yarn ratio, which maximizes the utilization of the staple fiber and reduces the raw material cost of the wrapped-core yarn; and solves the problem that the core yarn is easily exposed on a ring spinning machine, and the core yarn ratio is lower.

[0257] The above embodiments are only used to illustrate the technical solutions of the disclosure, but not to limit it. Although the disclosure has been described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that the technical solutions of the disclosure can be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the disclosure.