A method for producing high-quality blended yarn

Abstract

This invention discloses a method for producing high-quality blended yarn. Polyester and viscose fibers are sequentially and independently processed through opening and cleaning to obtain polyester and viscose fiber streams. These streams are then fed to a mixing feeder according to the required blending ratio using a cotton distributor. The mixing feeder is equipped with rear, middle, and front cotton boxes. The blended fiber streams are vibrated and tumbled in the upper rear cotton box before being conveyed to the lower rear cotton box. There, they are uniformly processed and laid flat on the conveying curtain while maintaining a uniform density before being conveyed to the middle cotton box. In the middle cotton box, the two fibers are vertically grasped and mixed by a corner nail curtain along the thickness direction. The fibers are then conveyed to the front cotton box by the corner nail curtain. There, they are uniformly processed and vibrated for uniform output. The yarn then directly enters a single-beater lap machine to produce a polyester-viscose blended lap. The yarn is then finely carded, impurities removed, and slivered by a carding machine. It is then uniformly processed by two drawing frames, drafted and twisted by a roving frame, and drafted and twisted by a spinning frame to form the desired blended yarn.

Description

Technical Field

[0001] This invention relates to the field of novel yarn technology, and in particular to a method for producing high-quality blended yarn. Background Technology

[0002] With the development of society and the economy, and the continuous improvement of people's living standards, consumers are increasingly focusing on the fashion and functionality of clothing textiles, in addition to comfort. They seek unique styles and various functions, such as antibacterial and antistatic properties. To meet this consumer demand, continuously developing new yarns and fabrics has become an important task for the textile industry. With the advancement of science and technology, competition in the textile market is becoming increasingly fierce. To maximize profits, manufacturers are constantly moving towards higher-end, higher-quality, more technologically advanced, and higher-value-added products. Summary of the Invention

[0003] The purpose of this invention is to provide a method for producing high-quality blended yarn. The method involves using a cotton feeder to fully mix and uniformly output polyester fiber streams that have been gripped by a cotton grabber, mixed and opened by a cotton opener, and opened and cleaned by a carding and beater opener. This achieves efficient and uniform mixing of the two types of fibers, thereby enabling the development of blended yarn with excellent yarn quality.

[0004] This invention provides a method for producing high-quality blended yarn, comprising the following steps:

[0005] Step 1: Cotton blending: When blending cotton, select the production area as the main body to keep the spinning production and yarn quality stable. Use 3-5 groups of labels with similar properties as the main components in the blending composition. The main components account for more than 70%, and the number of blending teams should be 6-8.

[0006] Step 2: Opening and cleaning: The selected polyester fibers and viscose fibers are sequentially picked up by the cotton picker according to the required mixing ratio. The cotton picker mixes, opens, and removes impurities from the picked fibers. The carding beater cotton picker combs, opens, and removes impurities from the fibers fed in by the cotton picker, thereby obtaining polyester fiber stream and viscose fiber stream respectively.

[0007] Step 3: Polyester and viscose blending and rolling: The polyester fiber stream and viscose fiber stream obtained in Step 1 are fed to the blending feeder by the electric cotton distributor according to the required blending ratio of the two fibers in the blended yarn. The blending feeder is equipped with a rear cotton box, a middle cotton box and a front cotton box in sequence from back to front along the fiber conveying direction. The rear cotton box includes a rear upper cotton box and a rear lower cotton box. A cotton conveying curtain is set between the rear lower cotton box and the middle cotton box, and a corner nail curtain is set between the middle cotton box and the front cotton box.

[0008] The mixed fibers are conveyed to the upper cotton box, vibrated and tumbled to mix, and then conveyed to the lower cotton box. After being uniformly sorted at a height in the lower cotton box, they are laid flat on the cotton conveying curtain and conveyed to the middle cotton box while maintaining a uniform density. In the middle cotton box, the fibers are gripped along the thickness direction by the corner nail curtain to achieve vertical gripping and mixing of the two fibers after they are laid flat. The fibers are then conveyed to the front cotton box by the corner nail curtain. After being uniformly sorted at a height in the front cotton box, they are vibrated and sorted for uniform output.

[0009] The output mixed fiber stream directly enters the single-beater lap machine to produce polyester-viscose mixed rolls;

[0010] Step 4: Carding: Using a carding machine, the polyester-viscose blend lap obtained in step 3 is finely carded, opened, impurities removed, and slivered to obtain a polyester-viscose blend sliver with a sliver structure.

[0011] Step 5: Drawing: The polyester-viscose blended raw strips obtained in step 4 are drawn and thinned through two drawing processes, and then re-drawn to obtain polyester-viscose blended cooked strips with improved strip uniformity;

[0012] Step 6: Roving: The polyester-viscose blend sliver obtained in step 5 is stretched, twisted, and wound on a roving frame to obtain polyester-viscose blend roving;

[0013] Step 7: Spinning: The polyester-viscose blended roving obtained in step 6 is stretched, thinned, twisted, and wound on a spinning machine to obtain the desired blended yarn.

[0014] In the production method of high-quality blended yarn described above, preferably, the electric cotton distributor includes a front branch pipe and a rear confluence pipe. The front branch pipe includes a left front branch pipe and a right front branch pipe. The rear end of the left front branch pipe is connected to the carding and beating opener in polyester cotton opening, and the rear end of the right front branch pipe is connected to the carding and beating opener in viscose cotton opening. The front ends of the left and right front branch pipes are interconnected with the rear end of the rear confluence pipe. A left suction fan is provided at the junction of the left front branch pipe and the rear confluence pipe, and the suction negative pressure of the left suction fan is controlled by a left control valve. A right suction fan is provided at the junction of the right front branch pipe and the rear confluence pipe, and the suction negative pressure of the right suction fan is controlled by a right control valve.

[0015] In the method for producing high-quality blended yarn as described above, preferably, a cotton condenser is provided above the upper cotton box.

[0016] In the production method of high-quality blended yarn described above, preferably, a vibrating rod is provided in the post-coating box.

[0017] In the production method of high-quality blended yarn described above, preferably, a first output roller is provided at the bottom of the rear cotton box, and the first output roller is controlled by a first switch.

[0018] In the production method of high-quality blended yarn described above, preferably, a first phototube is provided in the lower rear cotton box. When the first phototube detects that the height of the mixed fiber layer in the lower rear cotton box is less than a set value, the first switch controls the first output roller to rotate, thereby conveying the polyester and viscose blended fibers in the upper rear cotton box to the lower rear cotton box. When the first phototube detects that the height of the mixed fiber layer in the lower rear cotton box is greater than the set value, the first switch controls the first output roller to stop rotating, thereby stopping the conveying of the polyester and viscose blended fibers in the upper rear cotton box.

[0019] In the production method of high-quality blended yarn described above, preferably, a second output roller is provided at the bottom of the lower rear cotton box, the second output roller is controlled by a second switch, and the cotton conveying curtain is provided at the bottom of the second output roller, with the rear end of the cotton conveying curtain located inside the lower rear cotton box and the front end located inside the middle cotton box.

[0020] In the production method of high-quality blended yarn described above, preferably, a corner nail curtain is provided in the middle cotton box, the corner nail curtain is set in a vertically inclined state, the corner nail curtain is driven to rotate by a second motor, the angle between the bottom end of the corner nail curtain and the front end of the cotton conveying curtain is between 90 and 120 degrees, the top end of the corner nail curtain is located in the front cotton box, and a cotton stripping roller is provided above the top end of the corner nail curtain, the cotton stripping roller is controlled by a third switch to rotate or stop rotating.

[0021] In the production method of high-quality blended yarn described above, preferably, a second phototube is installed in the front cotton box. When the second phototube detects that the height of the mixed fiber layer in the front cotton box is less than a set value, a third switch controls the stripping roller to rotate, thereby conveying the polyester-viscose blended fiber grabbed by the corner nail curtain into the front cotton box. When the second phototube detects that the height of the mixed fiber layer in the front cotton box is greater than the set value, the third switch controls the stripping roller to stop rotating, thereby stopping the conveying of the polyester-viscose blended fiber in the middle cotton box.

[0022] In the production method of high-quality blended yarn described above, preferably, a vibrating plate is provided inside the front cotton box.

[0023] Compared with existing technologies, this invention employs a cotton feeder to thoroughly mix polyester and viscose fiber streams, which are respectively gripped by a cotton grabber, mixed and opened by a cotton opener, and opened and cleaned by a carding and beater opener. The mixed fibers are then uniformly output after being fed into a blended spool. The spools are then carded together to achieve efficient and uniform mixing of the two fibers. Compared with traditional sliver blending, this invention achieves mixing of the two fibers before carding, allowing for a more uniform mixing effect through carding and subsequent drawing. Unlike mixing directly at the raw material stage, this patent uses separate opening and cleaning processes for each fiber, achieving flexible opening based on their characteristics, reducing fiber damage, and thus enabling the development of blended yarns with excellent yarn quality. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the overall structure of the mixing cotton feeder provided in an embodiment of the present invention.

[0025] Explanation of reference numerals in the attached figures:

[0026] 1 - Rear upper cotton box, 2 - Rear lower cotton box, 3 - Middle cotton box, 4 - Front cotton box, 5 - Left front branch pipe, 6 - Right front branch pipe, 7 - Left suction fan, 8 - Right suction fan, 9 - Rear merging pipe, 10 - Cotton condenser, 11 - Vibrating rod, 12 - First output roller, 13 - First switch, 14 - First photoelectric tube, 15 - Second output roller, 16 - Second switch, 17 - Cotton conveying curtain, 18 - Corner nail curtain, 19 - Cotton stripping roller, 20 - Third switch, 21 - Vibrating plate, 22 - Second photoelectric tube, 23 - Cotton outlet roller. Detailed Implementation

[0027] The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0028] This invention provides a method for producing high-quality blended yarn. Polyester and viscose fibers are sequentially and independently processed by a cotton grabber, a blending and opening machine, and a carding and carding machine. The resulting polyester and viscose fiber streams are then fed to a blending feeder according to the required blending ratio in the blended yarn. The blending feeder includes a rear cotton box, a middle cotton box, and a front cotton box. The rear cotton box comprises an upper rear cotton box and a lower rear cotton box. The incoming polyester and viscose fiber streams are first vibrated and mixed in the upper rear cotton box. Then, in the lower rear cotton box, the height of the mixed fiber layer is controlled by a photoelectric tube to regulate the fiber output density. The mixed fibers in the lower rear cotton box are then conveyed into the middle cotton box via a conveying curtain. During this process, the stopping and turning of the output roller of the rear box is controlled by the rocker-rake mechanism to achieve uniform control of the output density of the mixed fibers. The mixed fibers in the middle and lower cotton boxes are grasped by the corner nail curtain and driven into the front cotton box. During the grasping process, the mixed fibers are tumbled to achieve further uniform mixing of the two types of fibers. In the front cotton box, the height of the mixed fiber layer entering the cotton box is controlled by the photoelectric tube to control the fiber output density, thereby achieving uniform control of the mixed fibers again. The uniformly output fibers after mixing are evenly lapped by the lapping machine, finely combed, impurities removed and slivered by the carding machine, uniformly finished by the two drawing frames, drafted, twisted and wound into roving by the roving frame, and drafted, twisted and wound into yarn by the spinning frame, finally obtaining the desired blended yarn, including the following steps:

[0029] Step 1: Cotton blending: When blending cotton, select the production area as the main component to keep the spinning production and yarn quality stable. Use 3-5 groups of labels with similar properties as the main components, with the main components accounting for more than 70%. Select 6-8 blending teams.

[0030] Step 2: Opening and Cleaning: The selected polyester fibers are sequentially picked up by the cotton picker according to the required blending ratio. The cotton blender mixes, opens, and removes impurities from the picked-up polyester fibers. The carding beater cotton opener combs, opens, and removes impurities from the polyester fibers fed into the cotton opener, thereby obtaining a polyester fiber stream. The selected viscose fibers are sequentially picked up by the cotton picker according to the required blending ratio. The cotton blender mixes, opens, and removes impurities from the picked-up viscose fibers. The carding beater cotton opener combs, opens, and removes impurities from the viscose fibers fed into the cotton opener, thereby obtaining a viscose fiber stream.

[0031] The opening and cleaning process follows the principles of "multiple bales for use, precise cotton grabbing, gradual opening, early removal of broken fibers, using combing instead of beating, and minimizing fiber damage." During the cotton grabbing process, the feeding operation is automated, allowing the raw cotton to be initially opened and mixed. To improve the opening effect and embody the "less grabbing" principle, the distance the serrated blade extends beyond the ribs should not be too large, ideally within 1-6mm, depending on the raw material. A larger descent distance of the cotton grabbing trolley is beneficial for increasing the output of the cotton grabbing machine, but it affects the opening effect and also increases power consumption; it should be kept within the range of 2-4mm / time, ideally smaller. A higher operating speed of the cotton grabbing trolley results in higher output and more raw material components grabbed per unit time, which is beneficial for improving mixing, but the opening effect is poor. The trolley rotation speed is set at 1. Between 4r / min and 2.3r / min; when the speed of the cotton grabber is high, the blades act violently on the cotton clumps, the cotton clumps grabbed by the blades are small, the average weight of the cotton clumps is light, and the opening effect is good, but if the speed is too high, it is easy to damage the fibers and the blades. The speed of the cotton grabber is 730-750r / min; the cotton blending and opening machine feeds the raw materials grabbed by the cotton grabber into the cotton condenser 10 through suction, and performs mixing, high opening, and impurity removal on the fed polyester or viscose fibers. The impurity removal rate is high. The distance between dust bars and between dust bars and the beater can be adjusted by setting an external adjustment device; the carding and opening machine further opens and removes impurities from the initially opened fibers by grabbing and tearing polyester or viscose fibers by the beaters on the outer circumference of the carding roller.

[0032] Step 3: Polyester-Viscose Blending and Roll Formation: The polyester fiber stream and viscose fiber stream obtained in Step 2 are fed to the blending feeder by an electric distributor according to the required blending ratio of the two fibers in the blended yarn. (Refer to...) Figure 1As shown, the electric cotton distributor includes a front branch pipe and a rear confluence pipe 9. The front branch pipe includes a left front branch pipe 5 and a right front branch pipe 6. The rear end of the left front branch pipe 5 is connected to the carding and beating opener in the polyester cotton opener, and the rear end of the right front branch pipe 6 is connected to the carding and beating opener in the viscose cotton opener. The front ends of the left front branch pipe 5 and the right front branch pipe 6 are interconnected with the rear end of the rear confluence pipe 9. A left suction fan 7 is installed at the junction of the left front branch pipe 5 and the rear confluence pipe 9. The suction negative pressure of the left suction fan 7 is controlled by a left control valve. A right suction fan 8 is installed at the junction of the right front branch pipe 6 and the rear confluence pipe 9. The suction negative pressure of the right suction fan 8 is controlled by a right control valve. In use, the suction negative pressure of the left suction fan 7 is controlled by the left control valve, and the right control valve controls the right suction fan. The suction negative pressure of fan 8 determines the amount of polyester fiber sucked in by left suction fan 7 and the amount of viscose fiber sucked in by right suction fan 8. The front end of the rear confluence pipe 9 is interconnected with the mixing feeder. Inside the mixing feeder, from back to front along the fiber conveying direction, there are a rear cotton box, a middle cotton box 3, and a front cotton box 4. The rear cotton box includes a rear upper cotton box 1 and a rear lower cotton box 2. A condenser 10 is installed above the rear upper cotton box 1. The polyester fiber and viscose fiber conveyed by the electric cotton distributor are transferred to the rear upper cotton box 1 of the mixing feeder through the suction action of the condenser 10. A vibrator 11 is installed in the rear upper cotton box 1. The polyester fiber and viscose fiber entering the rear upper cotton box 1 vibrate and tumble under the action of the vibrator 11, thereby... The initial uniform mixing of the two fibers is achieved through multiple flipping processes. A first output roller 12 is installed at the bottom of the upper rear cotton box 1, controlled by a first switch 13, thereby controlling the output of fibers within the upper rear cotton box 1. The lower rear cotton box 2 is located directly below the upper rear cotton box 1. A first phototube 14 is installed inside the lower rear cotton box 2. When the first phototube 14 detects that the height of the mixed fiber layer in the lower rear cotton box 2 is less than a set value, the first switch 13 controls the first output roller 12 to rotate, thus conveying the polyester and viscose mixed fibers from the upper rear cotton box 1 to the lower rear cotton box 2. When the first phototube 14 detects that the height of the mixed fiber layer in the lower rear cotton box 2 is greater than a set value, the first switch 13... The first output roller 12 is stopped from rotating, thereby stopping the conveying of polyester and viscose blended fibers in the upper rear cotton box 1. This allows for height control of the blended fiber layer in the lower rear cotton box 2, ensuring uniform fiber output density. A second output roller 15 is located at the bottom of the lower rear cotton box 2, controlled by a second switch 16 to control fiber output. A conveying curtain 17 is located at the bottom of the second output roller 15, with its rear end inside the lower rear cotton box 2 and its front end inside the middle cotton box 3. The conveying curtain 17 is driven by a first motor, causing the polyester / viscose blended fiber flow output from the second output roller 15 in the lower rear cotton box 2 to enter the middle cotton box 3.During this process, the rotation and stop of the second output roller 15 are controlled by the second switch 16 to achieve uniform output of the polyester-viscose mixed fiber flow from the cotton conveying curtain 17. An angled curtain 18 is installed inside the middle cotton box 3, and the angled curtain 18 is set in a vertically inclined state. The angled curtain 18 is driven to rotate by the second motor. The angle between the bottom end of the angled curtain 18 and the front end of the cotton conveying curtain 17 is between 90 and 120 degrees. The top end of the angled curtain 18 is located inside the front cotton box 4. The polyester-viscose mixed fiber flow conveyed by the cotton conveying curtain 17 is then gripped by the angled curtain 18 along the thickness direction. The process achieves vertical grasping and mixing of the two fibers after they are laid flat. Simultaneously, the grasping process causes the polyester-viscose mixed fiber flow to tumble, thus achieving a second uniform mixing effect between the two fibers. A stripping roller 19 is installed at the top of the corner nail curtain 18. The stripping roller 19 is controlled by a third switch 20 to rotate or stop rotating. When the stripping roller 19 rotates, it strips the polyester-viscose mixed fiber flow grasped by the corner nail curtain 18 into the front cotton box 4. When the stripping roller 19 stops rotating, the polyester-viscose mixed fiber flow grasped by the corner nail curtain 18 continues to move along the corner nail curtain 18. The system rotates in a cycle. A second phototube 22 is installed inside the front cotton box 4. When the second phototube 22 detects that the height of the mixed fiber layer inside the front cotton box 4 is less than a set value, a third switch 20 controls the stripping roller 19 to rotate, thereby conveying the polyester-viscose mixed fibers grabbed by the corner nail curtain 18 into the front cotton box 4. When the second phototube 22 detects that the height of the mixed fiber layer inside the front cotton box 4 is greater than a set value, the third switch 20 controls the stripping roller 19 to stop rotating, thereby stopping the conveying of the polyester-viscose mixed fibers in the middle cotton box 3, and thus realizing the conveying of the mixed fibers in the front cotton box 4... The height of the fiber layer is controlled to ensure uniform fiber output density in the front cotton box 4. A vibrating plate 21 is installed inside the front cotton box 4. The vibration of the vibrating plate 21 achieves the vibrational output of the polyester / viscose mixed fiber stream within the front cotton box 4. A cotton exit roller 23 is installed below the vibrating plate 21, which ensures uniform output of the polyester / viscose mixed fiber stream. The polyester / viscose mixed fiber stream, uniformly output by the mixing feeder, is then conveyed through a cotton conveying pipe to a single-beater lap-forming machine for further loosening, impurity removal, and production into a polyester / viscose mixed lap for use in the carding machine.

[0033] Step 4: Carding: Using a carding machine, the polyester / viscose blend lap obtained in Step 3 is finely carded, opened, impurities removed, and formed into slivers to produce a polyester / viscose blend sliver with a sliver structure. The carding machine should be of high mechanical quality, adhering to the "five sharp points and one accurate" principle, and employing the process principles of "high speed, tight spacing, and strong carding." All channel components should be clean and free of oil stains, and there should be no cotton lint or accumulation during operation, in order to produce a sliver with a clear cotton web, uniform sliver, low weight unevenness, and few cotton knots and impurities. In terms of process, the saw teeth or carding cloth should be sharp, the spacing accurate, and the speed reasonable to ensure that the moisture content and impurity content of the cotton lap are appropriate, resulting in a good cotton lap structure and stable quality.

[0034] Step 5: Drawing: The polyester / viscose blend sliver obtained in Step 4 is drawn and thinned through two drawing processes, and then re-drawn to obtain a polyester / viscose blend finished sliver with improved evenness. Both drawing processes use 8 fibers to help control yarn unevenness below 2%. The quantitative selection of the two drawing processes adopts the design principle of gradually reducing the weight. Because polyester / viscose fibers have good uniformity, longer length, and more crimp than cotton fibers, the friction coefficient between fibers and metal is larger. Therefore, a larger drafting force is used during the drafting process. The process adopts the design principles of "heavy pressure, large spacing, smooth channel, and anti-tangling and anti-clogging" to ensure the quality of the fiber sliver. The second drawing process is a quality control process, focusing on controlling the evenness CV value and weight unevenness. Because the drafting in the back zone is small, the drafting in the front zone is concentrated. The back zone roller spacing can be increased, while the front zone roller spacing should be kept tight to strengthen the control of the pressure bar on the slow fibers and move the speed change point forward.

[0035] Step 6: Roving: The polyester / viscose blend sliver obtained in Step 5 is drawn, twisted, and wound onto a roving frame to produce polyester / viscose blend roving. The roving frame, on the one hand, continues to improve fiber straightness through drafting, and on the other hand, performs twisting to create conditions for the high drafting of the spinning frame. The roving process design aims to improve roving quality, achieving stable elongation, small weight variation, uniform yarn evenness, compact structure, and good forming. For roving, mechanical finishing quality must be improved, drafting gears must mesh normally, roller bending and rubber roller eccentricity must meet specifications, and there should be no oil shortage. The cotton collector openings must be consistent and the installation position appropriate, the rubber rollers must rotate flexibly, and the starting position of the rollers must be accurate to ensure stable elongation, maintain a clean spindle shell, normal operation, and no cotton snagging in the channels, in order to improve... It improves roving evenness, reduces weight unevenness, and minimizes yarn defects. The drafting system employs a four-roller, double-short-ring drafting method. The main drafting is located in the middle zone, equipped with a ring control element consisting of upper and lower pins, upper and lower rings, upper pin springs, and spacer blocks. The front zone uses a tension drafting of 1.05-1.1 times the yarn tension, while the rear zone uses 1.06-1.53 ​​times the yarn tension. The rear zone straightens the fibers in the fed polyester-viscose blend sliver, generating slight tension, and then the fibers continuously pass through the main drafting zone of the upper and lower rings in a parallel state. The front zone is the finishing zone, and the middle zone is the main drafting zone. There is no collector in the main drafting zone, but collectors are installed after the other three rollers. This design features no bundling in the drafting zone and no drafting in the bundling zone, resulting in smoother and more reliable fiber movement.

[0036] Step 7: Spinning: The polyester / viscose blended roving obtained in Step 6 is drafted, twisted, and wound onto a spinning machine to produce the desired blended yarn. The purpose of the spinning process design is to improve the quality of the yarn. It is essential to rationally configure the draft ratio. Under the premise of appropriate drafting force, the process principle of "large spacing, heavy pressure, small back zone drafting, and small nip" is adopted. Appropriate rings and travelers are used, and a reasonable twist coefficient is configured according to the intended use of the fabric to improve yarn strength and evenness, reduce yarn breakage, and minimize yarn defects. The drafting system adopts a three-roller, long and short apron, double-zone drafting knot. The task of back zone drafting is to prepare for front zone drafting, so as to give full play to the role of the rubber ring in controlling fiber movement and to make the sliver fed into the front zone as compact as possible. This achieves both an increase in the front zone drafting ratio and an increase in yarn quality. The back zone drafting of the ring spinning machine uses V-type drafting, and the back zone drafting ratio is kept relatively small to provide a yarn with a uniform structure in the front zone. Because the ring spinning machine uses V-type drafting, the control of the fibers is increased. The center distance of the back zone rollers is appropriately reduced, and the front drafting process uses a small roller center distance to strengthen the effective control of floating fibers and reduce yarn evenness.

[0037] Taking the preparation of Siro blended yarn with a linear density of 14.6 tex (40S) and a blending ratio of T / R 65 / 35 as an example, the corresponding process parameters are as follows:

[0038] (1) Raw material selection

[0039] Key Indicators of Selected Polyester

[0040]

[0041] Key Indicators of Selected Adhesive

[0042]

[0043] Polyester blended with cotton and performance indicators of each cotton bale

[0044]

[0045]

[0046] Viscose blended cotton and performance indicators of each cotton bale

[0047]

[0048] (2) The process flow design is as follows

[0049] This invention:

[0050] Polyester T: FA002 cotton grabber → FA035E cotton opener → FA106 carding beater cotton opener; Viscose R: FA002 cotton grabber → FA035E cotton opener → FA106 carding beater cotton opener

[0051] Polyester-viscose blend: Electric cotton feeder → Mixing feeder → A076 lap forming machine → FA201B carding machine → FA306 drawing frame (first drawing) → FA311F drawing frame (second drawing) → FA458 roving frame → FA506 spinning frame

[0052] Traditional strip mixing:

[0053] Viscose R: FA002 cotton grabber → FA035E cotton opener → FA106 carding and beater cotton opener → FA046A vibrating cotton box feeder → A076 lap machine → FA201B carding machine

[0054] Polyester T: FA002 cotton grabber → FA035E cotton opener → FA106 carding and beater cotton opener → FA046A vibrating cotton box feeder → A076 lap machine → FA201B carding machine → FA306 drawing frame

[0055] Polyester-viscose blend: FA306 drawing frame (first drawing) → FA306 drawing frame (second drawing) → FA311F drawing frame (third drawing) → FA458 roving frame → FA506 spinning frame

[0056] (3) Design of key process parameters

[0057] Adhesive cleaning:

[0058] FA002 type disc cotton grabber

[0059]

[0060] FA035E Mixing and Opening Cotton Machine

[0061]

[0062] FA106 carding beater cotton opener

[0063]

[0064] Polyester opening and cleaning:

[0065] FA002 type disc cotton grabber

[0066]

[0067] FA035E Mixing and Opening Cotton Machine

[0068]

[0069] FA106 carding beater cotton opener

[0070]

[0071]

[0072] Mixed into rolls:

[0073] Mixing cotton feeder

[0074]

[0075] A076E Single-hand Rolling Machine

[0076]

[0077] Combing:

[0078] FA201B Carding Machine

[0079]

[0080]

[0081] Parallelism:

[0082] Drawing process design table

[0083]

[0084] Coarse yarn:

[0085] Roving Frame Process Design Table

[0086]

[0087]

[0088] Fine yarn:

[0089] Process Design Table for Spinning Frame

[0090]

[0091] (4) Yarn quality testing:

[0092] Yarn quality indicators

[0093]

[0094] As can be seen from the test results, compared with the blended yarn processed by the traditional method, the blended yarn processed by the production method of the present invention has improved overall quality, especially the yarn evenness CV, the yarn defects are reduced, and the breaking strength is improved. This is because the present invention cleans and opens the two fibers separately before mixing them, thereby achieving a more uniform mixing effect by carding both fibers together.

[0095] The above description, based on the embodiments shown in the figures, details the structure, features, and effects of the present invention. The above description is only a preferred embodiment of the present invention, but the present invention is not limited to the scope of implementation shown in the figures. Any changes made in accordance with the concept of the present invention, or equivalent embodiments modified to have equivalent changes, that do not exceed the spirit covered by the specification and figures, should be within the protection scope of the present invention.

Claims

1. A method for producing high-quality blended yarn, characterized in that, Includes the following steps: Step 1: Cotton blending: When blending cotton, select the production area as the main component to keep the spinning production and yarn quality stable. Use 3-5 groups of labels with similar properties as the main components in the blending composition. The main components should account for more than 70%. Select 6-8 blending teams. Step 2: Opening and cleaning: The selected polyester fibers and viscose fibers are sequentially picked up by the cotton picker according to the required mixing ratio. The cotton picker mixes, opens, and removes impurities from the picked fibers. The carding beater cotton picker combs, opens, and removes impurities from the fibers fed in by the cotton picker, thereby obtaining polyester fiber stream and viscose fiber stream respectively. Step 3: Polyester and viscose blending and rolling: The polyester fiber stream and viscose fiber stream obtained in Step 1 are fed to the blending feeder by the electric cotton distributor according to the required blending ratio of the two fibers in the blended yarn. The blending feeder is equipped with a rear cotton box, a middle cotton box and a front cotton box in sequence from back to front along the fiber conveying direction. The rear cotton box includes a rear upper cotton box and a rear lower cotton box. A cotton conveying curtain is set between the rear lower cotton box and the middle cotton box, and a corner nail curtain is set between the middle cotton box and the front cotton box. The mixed fibers are conveyed and then vibrated and tumbled in the upper cotton box before being conveyed to the lower cotton box by the first output roller. After being uniformly sorted in the lower cotton box, they are laid flat on the cotton conveying curtain and conveyed to the middle cotton box while maintaining a uniform density. In the middle cotton box, the fibers are gripped along the thickness direction by the corner nail curtain to achieve vertical gripping and mixing of the two fibers after they are laid flat. Driven by the corner nail curtain, the fibers are then conveyed to the front cotton box by the stripping roller. After being uniformly sorted in the front cotton box, they are vibrated and uniformly output. The output mixed fiber stream directly enters the single-beater lap machine to produce polyester-viscose mixed rolls; Step 4: Carding: Using a carding machine, the polyester-viscose blend lap obtained in step 3 is finely carded, opened, impurities removed, and slivered to obtain a polyester-viscose blend sliver with a sliver structure. Step 5: Drawing: The polyester-viscose blended raw strips obtained in step 4 are drawn and thinned through two drawing processes, and then re-drawn to obtain polyester-viscose blended cooked strips with improved strip uniformity; Step 6: Roving: The polyester-viscose blend sliver obtained in step 5 is stretched, twisted, and wound on a roving frame to obtain polyester-viscose blend roving; Step 7: Spinning: The polyester-viscose blended roving obtained in step 6 is stretched, thinned, twisted, and wound on a spinning machine to obtain the desired blended yarn.

2. The method for producing high-quality blended yarn according to claim 1, characterized in that, The electric cotton distributor includes a front branch pipe and a rear confluence pipe. The front branch pipe includes a left front branch pipe and a right front branch pipe. The rear end of the left front branch pipe is connected to the carding and beating opener in polyester cotton opening, and the rear end of the right front branch pipe is connected to the carding and beating opener in viscose cotton opening. The front ends of the left and right front branch pipes are interconnected with the rear end of the rear confluence pipe. A left suction fan is installed at the junction of the left front branch pipe and the rear confluence pipe. The suction negative pressure of the left suction fan is controlled by a left control valve. A right suction fan is installed at the junction of the right front branch pipe and the rear confluence pipe. The suction negative pressure of the right suction fan is controlled by a right control valve.

3. The method for producing high-quality blended yarn according to claim 1, characterized in that, A cotton condenser is installed above the upper cotton box.

4. The method for producing high-quality blended yarn according to claim 1, characterized in that, A vibrating rod is installed inside the upper rear cotton box.

5. The method for producing high-quality blended yarn according to claim 1, characterized in that, A first output roller is provided at the bottom of the upper cotton box, and the first output roller is controlled by a first switch.

6. The method for producing high-quality blended yarn according to claim 5, characterized in that, A first phototube is installed in the lower rear cotton box. When the first phototube detects that the height of the mixed fiber layer in the lower rear cotton box is less than a set value, the first switch controls the first output roller to rotate, thereby conveying the polyester and viscose mixed fibers in the upper rear cotton box to the lower rear cotton box. When the first phototube detects that the height of the mixed fiber layer in the lower rear cotton box is greater than the set value, the first switch controls the first output roller to stop rotating, thereby stopping the conveying of the polyester and viscose mixed fibers in the upper rear cotton box.

7. The method for producing high-quality blended yarn according to claim 1, characterized in that, A second output roller is provided at the bottom of the lower rear cotton box. The second output roller is controlled by a second switch. The cotton conveying curtain is provided at the bottom of the second output roller. The rear end of the cotton conveying curtain is located inside the lower rear cotton box, and the front end is located inside the middle cotton box.

8. The method for producing high-quality blended yarn according to claim 1, characterized in that, The corner nail curtain is installed inside the middle cotton box. The corner nail curtain is installed in a vertically inclined state. The corner nail curtain is driven to rotate by a second motor. The angle between the bottom end of the corner nail curtain and the front end of the cotton conveying curtain is between 90 and 120 degrees. The top end of the corner nail curtain is located inside the front cotton box. A cotton stripping roller is installed on the upper part of the top end of the corner nail curtain. The cotton stripping roller is controlled by a third switch to rotate or stop rotating.

9. The method for producing high-quality blended yarn according to claim 8, characterized in that, A second phototube is installed in the front cotton box. When the second phototube detects that the height of the mixed fiber layer in the front cotton box is less than a set value, a third switch controls the cotton stripping roller to rotate, thereby conveying the polyester-viscose mixed fiber grabbed by the corner nail curtain into the front cotton box. When the second phototube detects that the height of the mixed fiber layer in the front cotton box is greater than the set value, the third switch controls the cotton stripping roller to stop rotating, thereby stopping the conveying of the polyester-viscose mixed fiber in the middle cotton box.

10. The method for producing high-quality blended yarn according to claim 1, characterized in that, A vibrating plate is installed inside the front cotton box.

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