Core-spun Yarn Research Articles

Structural design to improve the electromagnetic shielding effectiveness of conductive core-spun yarn woven composites

Structural design to improve the electromagnetic shielding effectiveness of conductive core-spun yarn woven composites

Moisture-wicking Janus-structure electronic knitted fabric for multimodal wearable mechanical sensing

Multimodal mechanical sensors that can recognize bending direction and exhibit excellent wearable performance are crucial for the fields of physical exercise and healthcare. This study fabricated a knitted multimodal sensor with porous and wetting gradients using hydrophobic core-spun yarns and hydrophilic CNT/WPU conductive yarns in plain stitch and partial tuck stitch. The electronic fabric demonstrated reliable strain sensing unaffected by compression disturbances and displayed a selective response to directional bending. The sensor exhibits a 50% sensing range with a GFmax of −4.41 during strain deformation detection. In terms of bending detection, one side achieves a 10% sensing range (−51.68°) with a GFmax of −6.89, while the other side achieves a 20% sensing range (73.72°) with a GFmax of 8.64. Encouragingly, deep learning incorporated with the sensor achieves an impressive recognition rate of 98.16% for mixed signals with different force levels. Furthermore, it possesses excellent wearable properties such as breathability, moisture permeability, perspiration remove, quick-drying and washability, suitable for applications like activity monitoring, medical rehabilitation evaluation, and gesture recognition. This work presents a promising pathway for the advancement of next-generation multifunctional electronic textiles.

Research on twists in core and sheath layers of staple core-spun yarn produced by coaxial roller with different diameters

Research on twists in core and sheath layers of staple core-spun yarn produced by coaxial roller with different diameters

Study on the dyeing and moisture absorption and quick-drying performance of Porel spandex core-spun yarns

Replacing cotton fiber with cationic dyeable modified polyester may effectively alleviate the pressure of cotton resource shortage. Porel is a new generation of cotton-like cationic dyeable polyester fiber with reduced modulus, rigidity, pilling, and improved softness. In this work, cationic dye dyeing process and hygroscopic and quick-drying property tests were conducted on Porel products. The findings indicated that 100 °C and 30 mins were the ideal dyeing temperature and time for Porel spandex core-spun yarns. Fastness to rubbing and washing achieved 4.5 grade, and fastness to sunlight reached 6–7 grade. Compared with cotton spandex core-spun yarn, the overall cost per ton of Porel spandex core-spun yarn can be saved by 35%. Furthermore, Porel denim was proven to have excellent moisture absorption and quick drying properties. This study introduces a novel approach to addressing the challenges associated with cotton scarcity through the development of functional cotton-like products.

Development of sustainable dual core-spun yarns using several filaments and recycled cotton sourced from pre-consumer fabric waste

Textile industries are now focusing on sustainable issues in manufacturing operations to save the environment. The study focuses on the use of cotton fibers (recycled) sourced from fabric (knitted) waste (pre-consumer) to manufacture elastic yarn (dual-core) for denim fabric. The study involves the production of yarns (dual-core) using a redesigned ring spinning method with different elastomeric components, including T400® (Polyethylene terephthalate)/Polytrimethylene terephthalate), Polybutylene terephthalate (PBT), Polyester (PES), Lycra® (elastane), virgin cotton and cotton (recycled) fiber. The study investigates various yarn (Ne 18/1) characteristics such as strength, IPI (imperfection index), elongation %, unevenness %, and hairiness. It is noticed that the elongation and strength of recycled yarn (double core) are lower and IPI (Imperfection index), unevenness %, and hairiness values are higher than 100 % cotton (virgin) yarn (double core). One-way ANOVA (statistical analysis) is employed to assess the significance of differences among yarns manufactured from various core materials and found significant variation for all characteristics. Additionally, the article introduces the MOORA (multi-objective optimization based on ratio analysis) technique as a decision-making tool to determine the best yarn among three alternatives (PES yarn, PBT yarn, and T400 yarn) based on their properties, considering attributes and finding T400 filament containing yarn as the best option. The study introduces a sustainable approach using recycled cotton in yarn (double core) production and employs decision-making tools to assess and rank the performance of different yarn alternatives.

Effect of core material draft ratio and denier on core spun yarn and denim fabric properties pre and post washing

Core-spun yarn (CSY) is utilized for better fabric characteristics like stretchability, durability, and comfortability. The study aims to investigate the influence of spandex drafts of core-spun yarn on denim fabric characteristics before and after washing treatment. Two types of denim fabrics were produced from two types of core-spun yarn, namely 16 + 40D, and 16 + 70D by applying 2.8, 3.0, 3.20 spandex drafts for 16 + 40D, and 3.40, 3.50, 3.60 spandex drafts for 16 + 70D. Prepared denim fabrics were desized, and acid-washed and the properties of denim fabric before and after washing were investigated as a function of spandex drafts and deniers. Accurate count, twist, and better elongation percentage were observed at 2.80 draft for 16 + 40D CSY and 3.4 draft for 16 + 70D CSY, but a higher imperfection index (IPI) value was obtained on those drafts. The strength of the denim fabric prepared with 16 + 40D CSY and 16 + 70D CSY were higher at 2.8 and 3.6 drafts, respectively. Higher shrinkage (%), ends per inch (EPI), and fabric weight of denim fabric was obtained after washing compared to before washing. The width of both fabrics decreased when the fabric was washed. Exploring various drafts of core material and their correlations with yarn and fabric properties provides valuable insights for textile manufacturers seeking to produce denim fabrics with optimum quality.

Induction of macrophage polarization by electrospun nano-yarn containing naproxen sodium to promote tendon repair

Excessive inflammatory response can lead to failure of the tendon repair surgery. Tendon substitutes that can effectively balance inflammatory responses and have sufficient mechanical properties are one of the key factors in promoting repair. In this study, the nanofibers containing the naproxen sodium were attached to polylactic acid micron yarn by electrospinning to obtain double-layer core-spun yarn (DY). The DY was knitted into a tendon tissue engineering scaffold with sufficient mechanical properties. This study confirmed the optimal loading concentration of naproxen sodium. The results in vitro and in vivo indicated that sustained-release naproxen sodium in scaffolds could effectively inhibit the rapid proliferation of foreign fibroblasts, accelerate the polarization of macrophages, reduce the inflammatory response, and promote tendon tissue repair. This study provides a new scaffold for tendon tissue engineering that not only serves as a substitute for tendon repair, but also serves as an anti-inflammatory agent to better promote the repair process.

Bioinspired multi-scale core-spun yarn-based solar evaporator for ultra-efficient and durable high-salinity brine desalination

Solar-driven interfacial desalination has been considered a promising and green technology for relieving worldwide water shortage because of its zero carbon emission. However, salt accumulation during evaporation results in a significant reduction in solar evaporation performance and sustained service life. High-performance and long-term salt-rejecting solar evaporators are urgently desirable. Inspired by the rapid water transfer driven by leaf transpiration and the capillary pressure in woody plants, we developed electrospun polyacrylonitrile (PAN) @carbon nanotubes (CNTs) nanofiber/cotton core-spun yarn (PCCS yarn) based solar evaporator enabled by the multi-branch microchannels and sub-microchannels for ultra-efficient and durable high-salinity brine desalination. The optimal PCCS yarn-based solar evaporator exhibits a record-high evaporation rate of 3.46 kg m−2h−1 under one sun illumination among 2D evaporators. Meanwhile, an excellent and stable brine desalination rate of ∼2.75 kg m−2h−1 for 100 h continuous solar irradiation is achieved even in 20wt% NaCl solution. The above results are attributed to the massive micro evaporation surfaces formed between nanofibers, rapid water replenishment in the radius direction, and orientational fast water transport by Laplace pressure along and across the PCCS yarn. In addition, the continuous preparation of the core-spun yarn by the conjugated electrospinning technology and the complete fabric production process in the textile industry make it possible for the practical application of the PCCS yarn-based solar evaporator. This work promotes the development of high-performance, long-term and scalable solar desalination devices.

Electrochemical self-powered strain sensor for static and dynamic strain detections

The self-powered strain sensors based on piezoelectric and triboelectric principles have been widely reported in flexible electronics, but they cannot achieve static strain detection. Inspired by electrochemical reactions, we propose and construct an electrochemical self-powered strain sensor for static and dynamic strain detections. Specifically, the sensor is composed of Cu/Al electrodes, elastic core-spun yarn coated with LiCl-carbon nanotubes (CNTs), and latex tube encapsulation. Among them, Cu and Al electrodes are used for electrochemical reactions; Elastic core-spun yarn endows the sensor with excellent tensile performance; LiCl provides conductive ions in electrochemical reactions; CNTs with good conductivity not only reduce the resistance between Cu and Al electrodes, but also facilitate good resistance strain effect; Latex tube encapsulation inhibits the evaporation of water molecules in the electrolyte. The strain sensing performance of the sensor is evaluated based on the current response. The results show that the sensor has wide strain detection range (2–100 %) and good repeatability (1000 times). By analyzing the strain voltage and current responses, as well as the morphology characterization of the sensor, the strain response mechanism of the sensor has been clarified, which is controlled by electrochemical reactions and resistance strain effect. The static strain monitoring function of the sensor is verified by monitoring finger bending. Combined with machine learning, the sensor can be used for respiratory behavior recognition. This work fundamentally contributes to developing self-powered strain sensor with static and dynamic strain detections.

A breathable and highly impact-resistant shear-thickened fluid (STF) based TENG via hierarchical liquid-flow spinning for intelligent protection

Impact resistant and force-sensitive yarns are the crucial components of intelligent wearable protective textiles. However, it is still a challenge to combine liquid impact resistant materials with yarns. In this paper, shear-thickened fluid (STF) based hierarchical wrapping core-spun yarns were produced by liquid flow spinning for the impact resistance and intelligent monitoring, which exhibited multi-superiority of protectivity, sensitivity, flexibility, breathability and washability. In terms of protection, STF fabric (STFF) performed improved impact resistance and energy absorption capacity, absorbing 73.5 % of the applied force. Numerically simulation analysis indicated that energy dissipation mechanism of STFF could be ascribed to the combination of the yarn surface deformation and STF core shear thickening of STF yarn (STFY). The STFF was still skin-friendly without breakage and leakage after 10,000 times cyclic friction. Its air permeability was up to 189 mm/s. Moreover, a STFF-based TENG was constructed by weaving with Kevlar yarn, which showed self-powered sensing ability to recognize impact force with great durability over 10,000 cycles. For energy harvesting, the fabric exhibits excellent triboelectric performance of 22 V open-circuit voltage (VOC), 225 nA short-circuit current (ISC), and 30 nC short-circuit transferred charge (QSC). In addition, STF-based TENG fabric enables the sensing of various forces, frequencies and different contact materials. Finally, the early warning, protection, motion monitoring and energy harvesting of STFF for intelligent protective applications were demonstrated, opening new avenues for the sensing function integration of protective textiles.

A Review on the Progress in Core-Spun Yarns (CSYs) Based Textile TENGs for Real-Time Energy Generation, Capture and Sensing.

This review is a critical analysis of the current state-of-the-art in core spun yarn textile triboelectric nanogenerators (CSY-T-TENGs) for self-powered smart sensing applications. The rapid expansion of wireless communication, flexible conductive materials, and wearable electronics over the last ten years is now demanding autonomous energy, which has created a new research space in the field of wearable T-TENGs. Current research is exploring T-TENGs made from CSYs as stable and reliable energy harvesters and sensing devices for modern wearable IoT platforms. CSY-TENGs are emerging as an important technology due to its simple structure, low cost, and excellent performance in converting mechanical energy into electrical energy and due to its sensing ability. This paper provides a critical review on current progress, it analyzes the unique advantages of CSYs T-TENGs over conventional T-TENGs, it describes fabrication techniques and discusses the materials used along with their properties and electrical performance characteristics, and it highlights the recent advancements in their integration with self-excitation circuits, charge storage devices and IoT-enabled smart sensing applications, such as environmental and health monitoring. In the conclusion, it discusses the challenges and future directions of CSYs T-TENGs and it provides a future road map for optimization, upscaling, and commercialization of the technology.

Mn-doped ZnO/SnO2-based yarn sensor for ammonia detection

Metal oxide semiconductor (MOS) gas sensing materials have high operating temperatures and often use rigid materials as substrates, making them difficult to be widely applied in the field of wearable electronic devices. In this work, the sheath-core structure electrospun nanofiber core-spun yarn (ES-PY) was prepared using the coaxial electrospun yarn technology, and then the poly (dopamine) was polymerized on its surface to obtain the poly (dopamine) nanofiber core-spun yarn (PDA-PY). ZnO/SnO2/Mn metal oxide semiconductor nanoparticles (ZS/Mn-NPs) were synthesized via a two-step hydrothermal process by doping Mn into ZnO/SnO2. These were subsequently loaded onto the surface of PDA-PY to produce the yarn sensor (ZS/Mn-PY).The combination of the nano-size effect of the nanofibers and the doping-promoting effect of the Mn-doped metal oxide semiconductor further increases the adsorption sites of the gas molecules so that the sensor exhibits excellent gas sensitivity to ammonia (NH3), with a response up to 13.13 (Ra/Rg) in an ammonia atmosphere at a concentration of 100 ppm, and still up to 2.61 when exposed to an ammonia atmosphere at a concentration as low as 10 ppm at room temperature. In addition, it retains the excellent flexibility and strength of the core yarn. And provides a simple and effective method for preparing flexible textile gas sensor.

Coaxial-helix MXene/PANI-based core-spun yarn towards strain-insensitive conductor and supercapacitor

Stretchable electrical conductors hold great promise in the wearable electronic devices, such as flexible display and human-machine interface. Stable conductivity is vital for wearable devices to maintain their stable performance. However, the electrical resistance of most reported yarns dramatically increases when they are deformed. Herein, we propose a design for a coaxial-helix structure by wrapping the polyaniline/MXene-based elastic core-spun yarn on itself in the form of coils. The fabricated coaxial-helix structured yarns (DCSs) exhibit excellent strain-insensitive properties, including low relative resistance change (25.4%), large strain (200%) and high quality factor (17.95). Moreover, the DCSs can be used as the stretchable electrodes for the supercapacitors, and delivers a linear specific capacitance of 256.7 mF cm−1, which is higher than most stretchable yarns. Therefore, the proposed coaxial-helix structure design creates a new approach for the strain-insensitive stretchable conductor, thereby paving the way for the development of stretchy electronics.

Effect of aramid core-spun yarn on impact resistance of aramid/epoxy composite

Introduction: The surface of aramid filament is smooth, which is a great defect for impact resistance and composite molding of aramid/epoxy composite. In this study, a new type of yarn—aramid core-spun yarn is introduced to the fabrication of compositematerials. It increases the friction among yarns and optimizes the performance of yarns.Methods: To verify the improvement of yarn in the composite material, the hand lay-up process is used, and the first layer and the fourth layer are replaced by core-spun yarns in a four-layer composite configuration.Results and Discussion: The energy absorption, and the damage of the impacted surface and the back surface are evaluated through the drop weight impact test. The yarn pull-out test can reflect the internal friction of fabric. The results show that the average energy absorption of new yarn in the first layer is 10 J cm2/g more than that in the fourth layer at a 90°/45°/-45°/0° configuration after the normalization, but the conclusion is contrary when the structure is -45°/0°/90°/45°. Under the structure of 90°/45°/-45°/0°, the damaged area of the fabric is larger when the aramid core-spun yarn is laid on the first layer, while a contrary result can be found for the structure of -45°/0°/90°/45°. The fundamental research will provide design ideas and supports for aramid composite.

Statistical modeling enabled design of high-performance conductive composite fiber materials for energy harvesting and self-powered sensing

Fiber-based triboelectric nanogenerators (TENGs) composed of conductive electrode and triboelectric materials are capable of converting mechanical energy into electricity. Core-spun yarn provides a unique structure for preparing composite fibers to resolve the problem of interfacial failure between conductive layer and triboelectric layer for fiber-based TENGs. However, the underlying relationship between interactive parameters and its performance has not been understood that hinders the further developments. Herein, a statistical modeling enabled design was developed for high-performance conductive composite fiber (CCF) for energy harvesting and self-powered sensing. Interactive preparation parameters of CCF-based triboelectric nanogenerator (CCF-TENG) was studied via a statistical strategy combing fractional factorial design (FFD) and response surface methodology (RSM) for exploring the underlying relationships between parameters and properties of CCF-TENG. The two methods could effectively reduce the number of experiments and optimize the preparation parameters, facilitating the design of high-performance CCF-TENGs. The optimized CCF-TENGs could not only be applied to drive LEDs and calculator, but also attached on human body as wearable sensors and even connected with a Bluetooth system for wireless monitoring. Our proposed statistical modeling enabled strategy provide new insights in exploring quantitative underlying relationships for advanced applications of functional materials with optimized performance and desired functionalities.

Thermal comfort properties of knitted fabrics produced from bamboo/polyester core-spun yarns

The influence of polyester content, twist and loop length on the comfort properties of single jersey knitted fabrics produced from 100% bamboo, 80:20 bamboo/polyester and 60:40 bamboo/polyester core-spun yarns has been studied. Comfort properties, such as air permeability, moisture vapour transmission, thermal conductivity and thermal resistance properties have been analyzed with three different twist levels and loop lengths. Box–Behnken, a three level three factorial design software, has been used to study the interactive effect of core-sheath ratio, twist and loop length on the comfort properties of single jersey knitted fabrics, response surface equations are derived and the design variables are optimized. It is found that the increase in bamboo content in the core yarns having high twist and loop length increases the moisture vapour transmission and thermal conductivity of the knitted fabrics. The air permeability and thermal resistance of the knitted fabrics are found to be higher as the polyester component is increased. High twist and loop length increase the thermal comfort properties of knitted fabrics.

Low-velocity impact performance of ultra-high molecular weight polyethylene/aramid-polyester core-spun yarn hybrid composites

The impact resistant composite has excellent energy absorption efficiency, but the structure and material selection of the composite have great influence on its energy absorption. In order to explore the effect of structure on the energy absorption of Ultra-high molecular weight polyethylene (UHMWPE) composites and the application potential of new aramid core-spun yarn and new polyester core-spun yarn in impact resistant composites. The UHMWPE composites with different fiber orientations and stacking sequences structure, as well as the new hybrid composites containing aramid core-spun yarn and polyester core-spun yarn were tested by low-velocity impact test and scanning electron microscope (SEM) observation. The differences of energy absorption of UHMWPE composites with different structures and the advantages of the new hybrid composites were analyzed. The results show that the energy absorption of the 45°/0°/90°/−45° UHMWPE composite is 15% and 86% higher than that of the 0°/90°/0°/90°UHMWPE composite and the 0°/90°/45°/−45° UHMWPE composite, respectively, which is the best structure among the three composites. The energy absorption performance of the composites introduced with aramid core-spun yarn and polyester core-spun yarn were improved by 223% and 202%, respectively, so that the energy absorption performance was significantly improved by new yarns.

Design of Hybrid Yarn with the Combination of Fiber and Filaments and Its Effect on the Denim Fabric Performance

Abstract Consumer choice and behavior are changing and focusing on comfortable clothing along with fitting. Elastic yarn or fabric is necessary to achieve this comfortableness. By making elastic yarn and using elastic material in fabric production, elastic cloths are produced with proper stretchability and recovery. For that, core-spun yarn was used, but due to a lack of recovery performance, dual core-spun yarn has been developed. Different elastane ratios, linear density, and filaments were used in the dual core-spun yarn according to achieve desired stretchability. In this study, denim fabric performances were evaluated by designing different composite/hybrid dual core-spun yarn with a combination of cotton fiber and filaments. Different elastane linear densities with different filaments, PET/PTT, PTT, and PET, were used, and it was found that using finer elastane in dual core-spun yarn, strength, and unevenness are increased, and elongation decreased. Using PET/PTT filament increases hairiness, and using PTT filament increases elongation. For fabrics, coarser elastane in the dual core-spun yarns has higher stiffness, elasticity, and shrinkage. Fabric with PTT showed higher weight change and stiffness, whereas PET filament-based fabric samples have good strength and low stiffness. In addition, a multiple regression analysis was carried out for yarn and fabric properties, and mathematical models were developed.

Linear flexible capacitive sensor with double helix structure based on multi-needle water-bath electrospinning technology

Capacitive flexible sensors stand out due to their advantages of simple structure, strong adaptability and low power consumption, and become the mainstream technology for the preparation of wearable flexible devices. In this study, polyamide 6 (PA6) nanofibers were coated on the surface of a silver-coated nylon (SCN) core yarn using a novel multi-needle water-bath electrospinning method. The SCN/PA6 nanofiber core-spun yarns were prepared, and linear flexible capacitive sensors with a double helix structure (double helix structure capacitive sensors, DHSCSs) were produced by winding two nanofiber core-spun yarns in parallel, with different winding densities, on elastic rubber strings. We then characterized the nanofiber core-spun yarn, analyzed its sensing performance, and explored an application in human motion monitoring. Our results confirm that a nanofiber coating with a complete structure can be formed on the surface of the SCN core yarn by multi-needle water-bath electrospinning. The nanofiber diameter was in the 80–100 nm range, which provides a soft and deformable dielectric layer for the sensor. The capacitance of the DHSCSs gradually decreased with an increase in strain. When the strain was small, it exhibited good linearity (R 2 > 0.99) and sensitivity (gauge factor of ∼4). With an increase in strain, the linearity and sensitivity of the DHSCSs gradually decreased. The capacitances of the DHSCSs were stable under extended duration cyclic stretching, and their repeatability and stability were good. At different tensile speeds, the sensing performance of the DHSCSs did not change, and the capacitance change was not affected by the tensile speed. The higher winding density of the sensor made it more sensitive. The DHSCS could monitor intermittent and continuous knee bending and walking, effectively monitoring human motion in real time. This sensor has the potential for application in flexible wearable human motion, health monitoring, and other fields.

Strength and Elasticity Properties of Denim Fabrics Produced from Core Spun Yarns

In parallel to the development of new fiber and yarn technologies, different fibers and yarns have been used in denim fabric production and breaking the market dominance of 100% cotton yarn in the denim market. In recent years, the use of elastane fibers for denim fabric production has rapidly increased thanks to their movement comfort. This study examines the strength and elasticity properties of denim fabrics containing core yarns. For this purpose, different weft yarns were used in the production of denim fabrics. While 100% cotton ring yarn was used as warp for all fabrics, cotton ring, cotton OE-rotor, cotton / PBT-elastane dual-core, cotton / elastane core and cotton-PET / elastane core yarns were used as weft. Within the scope of the study, tensile strength, tearing strength and bursting strength tests were carried out on denim fabrics. In addition, denim fabrics contain core spun yarns were tested for elasticity in the weft direction, which is the direction of core yarns used. When the results were examined, it was seen that tensile strength and breaking elongation are higher for the fabrics containing core yarn in general. Fabrics produced with dual-core yarns have the highest tearing strength values. In addition, the bursting strength values of fabrics containing core yarn are higher than fabrics without core yarn. It was seen that the elasticity values of denim fabrics produced using core yarn are generally above 50%. However, the highest growth values were seen in the fabrics with the highest elasticity.