Abstract

Composite ring spinning, an advanced physical method, is extensively used for preparing required yarns because of its structural architecture. However, the existing staple fiber/filament composite ring-spun yarns involve more hairiness, lower coverage, and weaker tensile strength, limiting further development. Herein, we proposed a novel specialized multifilament-spreading apparatus to fabricate high-coverage, low-hairiness, and self-reinforcing structural composite yarns. The key idea is to realize the cylindrical-shaped multifilament into a quasi-single layer (q-SL) form by using a herringbone-groove spreading roller (HGSR). After that, the q-SL is twisted with the traditional staple fibers, and finally the multifilament spread composite-structural yarn (FS-CSY) can be controllably prepared. To verify the practicality and feasibility of the proposed spinning method, the FS-CSY and the common bi-component composite yarn (b-CY) were systematically compared and analyzed. The results indicate that the FS-CSY shows a uniform q-SL wrapping structure on cotton fibers with the coverage rate of 61.98% compared with that of b-CY. Furthermore, the q-SL wrapping structure results in a lower hairiness (20.9 units) and higher cover probability (32.98%) than that of b-CY, representing excellent surface and evenness of the as-prepared FS-CSY. In addition, comparing FS-CSY and b-CY, the FS-CSY had a better self-reinforcement, with an enhanced braking tenacity (21.27% higher) and initial modulus (45.05% higher). This fundamental work represents an important step towards the large-scale production of FS-CSY and an attempt to improve the comprehensive quality of ring-spun yarns.

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