Fiber membrane homogeneous fully-coated composite spinning device and method and yarn product

Abstract

The invention discloses a fiber membrane homogeneous fully-coated composite spinning device and method and a yarn product. Belongs to the technical field of textile processing, and comprises a package can, a conveyor belt, a front roller jaw, a yarn guide hook, a spray head, a spindle, a steel wire ring and a bobbin, the conveyor belt and the package can are connected through a spring to realize zero-interval adjoining, and stable conveying of a strip is ensured. The spinning method comprises the steps that a fiber film is cut into strips and packaged, the strips are conveyed through a conveying belt, a functional agent is sprayed on the lower-layer strips, fiber filaments are clamped at the same time, and the fiber film homogeneity fully-wrapped composite yarn product is formed through twisting. Compared with the prior art, the yarn product prepared by the invention has multiple properties such as high strength, high toughness, damage resistance, air permeability and liquid repellency, is suitable for high-end fields such as medical sutures, fireproof materials and filtering materials, breaks through the bottleneck that'toughness and function 'of the traditional core-spun yarn are difficult to obtain at the same time, and has a wide application prospect.

Description

Technical Field

[0001] This invention relates to the field of textile processing technology, and in particular to a fiber membrane uniform full-coverage composite spinning device, method and yarn product. Background Technology

[0002] With the widespread application of high-performance fiber materials in aerospace, medical, protective, and energy fields, higher requirements are placed on the mechanical properties, functional integration, and environmental adaptability of yarn structures. Traditional core-spun yarns or composite yarns are mostly based on single fibers or simple coverings in terms of structure, which have problems such as weak interfacial bonding, easy slippage, loose structure, and single function, making it difficult to meet the multi-functional integration requirements of high-end application scenarios such as high strength, high toughness, and resistance to environmental corrosion.

[0003] Currently, some technologies have attempted to improve yarn performance by introducing fiber films, functional coatings, or composite twisting. For example, Chinese patent CN111636130A discloses a flexible fabric for oscillating electromagnetic induction power generation, which achieves energy conversion by encapsulating magnetic powder in the yarn and combining it with conductive fabric. However, this type of method mainly targets the development of functional fabrics and has not yet solved the structural problems of high-stiffness and high-brittleness filaments (such as basalt fiber and carbon fiber) during processing, such as easy breakage, uneven coating, and poor interfacial bonding.

[0004] Furthermore, existing spinning equipment often suffers from unstable tension control, resulting in the strip being suspended or shifted, leading to membrane shrinkage, loose coating, and even "core leakage" during the conveying of fiber film strips. This severely affects the mechanical properties and service life of the yarn. Simultaneously, the application of functional agents is mostly done through impregnation or overall coating, making precise control difficult, easily leading to resource waste or performance overkill, and can clog membrane pores, affecting its intrinsic functions such as air permeability and liquid repellency.

[0005] Therefore, there is an urgent need to develop a new yarn product structure and its supporting spinning equipment and methods, which can achieve precise composite of fiber film and high-performance filament, interface strengthening and functional integration, solve the contradiction of the traditional core-spun yarn's inability to achieve both "strength and toughness" and "functionality", and meet the multiple performance requirements of yarn materials in high-end application fields. Summary of the Invention

[0006] In order to overcome the shortcomings of the prior art, the present invention aims to provide a fiber membrane uniform full-coverage composite spinning device, method and yarn product.

[0007] To achieve the above-mentioned objectives, the present invention adopts the following technical solution:

[0008] A fiber membrane homogeneous full-coverage composite spinning device, comprising:

[0009] The system includes a sliver roll, a conveyor belt, a front roller nip, and a yarn guide hook. The beginning of the conveyor belt is connected to the sliver roll with zero gap via a spring, and the end is aligned with the front roller nip. A gap is provided between the two sliver rolls to facilitate the passage of fiber filaments. A nozzle is provided in the middle of the conveyor belt and the sliver roll for spraying epoxy resin onto the upper surface of the lower layer of the sliver. The system also includes a spindle, a traveler, and a yarn tube for twisting the composite structure to form a uniformly covered composite yarn product and winding it into the yarn tube.

[0010] The spinning method for a fiber membrane homogeneous fully coated composite yarn product is as follows:

[0011] Step 1: Place the fiber film in a cutting machine, cut it into strips, and individually roll them into a roll.

[0012] Step 2: The roll sliver is placed adjacent to the head end of the conveyor belt with zero clearance. The end of the conveyor belt is aligned with the front roller jaws. During the unwinding process of the two fiber film strips from the roll sliver, functional agents are simultaneously sprayed onto the upper surface of the lower fiber film strip through the nozzle. The fiber filaments are sandwiched between the two fiber film strips and transported to the head end of the conveyor belt. They are fed into the front roller and then twisted through the yarn guide hook and steel wire ring to form a uniformly covered composite yarn product, which is then wound into the yarn tube.

[0013] The width of the strips cut into them is 1-5cm.

[0014] The functional agent is at least one of epoxy resin, silane coupling agent, waterborne polyurethane resin, silver dispersion, and silica sol; the spraying amount of the functional agent is 1-20 mg / m.

[0015] The conveyor belt speed is 7.8-8 m / min.

[0016] The front roller output speed is 5-20 m / min.

[0017] The spindle speed is 1000-5000 rpm and the twist is set to 5-200 twists / 10cm.

[0018] The fiber membrane is at least one of the following: microporous filter membrane, synthetic polymer membrane, elastomer membrane, photocatalytic functional membrane, antibacterial functional membrane, biodegradable membrane, natural polymer membrane, high-temperature resistant separation membrane, conductive composite membrane, paper-based material, non-woven material, inorganic fiber paper, and engineering membrane.

[0019] Preferably, the fiber membrane is at least one of the following: PTFE air filter membrane, polyacrylonitrile membrane, polyurethane membrane, titanium dioxide composite fiber membrane, zinc oxide doped fiber membrane, chitosan fiber membrane, cellulose fiber membrane, polyethersulfone fiber membrane, polylactic acid fiber membrane, polyaniline composite fiber membrane, polycaprolactone fiber membrane, aramid paper, polyimide nonwoven fabric, polypropylene nonwoven fabric, ceramic fiber paper, cellulose filter paper, and polyetheretherketone membrane.

[0020] The fiber filament is at least one of organic fiber, inorganic non-metallic fiber, and metallic fiber.

[0021] The fiber filament is at least one of the following: basalt filament, carbon fiber filament, aramid filament, polyimide filament, polyvinyl alcohol filament, regenerated cellulose filament, stainless steel filament, silicon carbide fiber, polyethylene filament, polytetrafluoroethylene filament, nickel-chromium alloy wire, and quartz fiber.

[0022] This invention first introduces a conveyor belt design for transporting strips, aiming to solve problems such as uneven tension, easy shrinkage, and uneven coverage during traditional strip transport. By setting the conveyor belt and the roll strip adjacent to each other with zero gap and using a spring connection structure, the strip maintains stable tension and adhesion during transport, avoiding shaking, offset, and shrinkage caused by suspended sections. This achieves continuous and stable feeding of the fiber film strip, providing a structural foundation for subsequent compounding and twisting.

[0023] Building upon this foundation, the present invention further optimizes the conveyor belt's operating speed, particularly by setting a speed difference between it and the output speed of the front roller. The improvement lies in precisely controlling the relative speed before and after twisting to create appropriate pre-tension, ensuring the basalt filaments are fully straightened before lamination, eliminating fiber curl, and preventing fiber breakage or membrane shrinkage due to excessive tension. This speed difference, while ensuring structural stability, improves the tightness and uniformity of the membrane coating, making it a key process parameter for achieving high-performance composite yarns.

[0024] Furthermore, this invention adds a nozzle device between the conveyor belt and the spool, and introduces a functional agent spraying process. The improvement lies in the precise injection of functional materials such as epoxy resin into the micropores and fiber gaps of the PTFE membrane through directional spraying, constructing a three-dimensional anchoring network. This strengthens the membrane-fiber interface bonding and improves interlayer shear strength and peel resistance. This step not only improves the mechanical properties of the composite structure but also endows the yarn with greater durability and environmental adaptability.

[0025] Finally, this invention optimizes the coating amount to determine the optimal amount. The improvement lies in ensuring the continuity and permeability of the adhesive film while avoiding pore blockage and increased brittleness caused by excessive coating. This coating amount, while ensuring interface strengthening, also takes into account the yarn's flexibility, air permeability, and the ability to fix the functional modifier, achieving synergistic optimization of structural performance and functional characteristics, and breaking through the technical bottleneck of traditional core-spun yarns where "increased strength and toughness lead to decreased functionality."

[0026] Compared with existing technologies, it has the following advantages:

[0027] 1) This invention introduces a zero-gap adjacent design between the conveyor belt and the roll sliver, combined with a spring connection structure, to achieve stable tension control of the sliver during the conveying process, avoid suspension and deviation, and ensure that the fiber film sliver continuously and tightly wraps the fiber filaments, effectively solving the problems of easy core leakage and loose wrapping in traditional core-spun yarn.

[0028] 2) This invention optimizes the speed difference between the conveyor belt and the front roller, so that the fiber filaments and strips can obtain appropriate pretension before lamination, fully straighten and flatten, and reduce stress concentration; at the same time, with the directional spraying of functional agents, a three-dimensional anchoring network is formed, which significantly improves the interlayer shear strength and anti-peel performance, and achieves a synergistic improvement in strength and elongation at break.

[0029] 3) By precisely controlling the amount of coating, this invention strengthens the interface while preserving the pore structure of the membrane material, taking into account air permeability, liquid repellency, and the ability to fix functional modifiers. This allows the yarn products to maintain high strength and toughness while possessing good environmental adaptability and multi-functional integration potential, making them suitable for high-end fields such as medical sutures, fireproof materials, and filter materials. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the spinning device structure for the fiber membrane uniformly fully covered composite yarn product used in Example 1;

[0031] 1. Yarn roll; 2. Conveyor belt; 3. Front roller; 4. Spring; 5. Nozzle; 6. Yarn guide hook; 7. Spindle; 8. Traveling wire; 9. Yarn tube;

[0032] Figure 2 This is an enlarged perspective view of the spraying feed area in Example 1;

[0033] Figure 3 Microscopic image of the surface of the fiber membrane homogeneous fully covered composite yarn product prepared in Example 1;

[0034] Figure 4 Microscopic image of the surface of the fiber membrane homogeneously fully covered composite yarn product prepared in Comparative Example 3;

[0035] Figure 5This is a cross-sectional microscope image of the fiber membrane homogeneous fully covered composite yarn product prepared in Example 1.

[0036] Figure 6 This is a cross-sectional microscope image of the fiber membrane homogeneous fully covered composite yarn product prepared in Example 6.

[0037] Figure 7 This is a cross-sectional microscope image of the fiber membrane homogeneous fully covered composite yarn product prepared in Example 7.

[0038] Figure 8 This is a cross-sectional microscope image of the fiber membrane homogeneous fully covered composite yarn product prepared in Example 8. Detailed Implementation

[0039] PTFE air filter membrane, specifications: width 2400mm, thickness 5um, pore size 0.2um, Zhejiang Kangbikai Trading Co., Ltd.

[0040] Basalt filaments: 200tex, 80F, supplied by Huierjie Basalt Co., Ltd.

[0041] Epoxy resin, viscosity: 12000-15000 (mPas), grade: E-51, Guangzhou Zhuqing Chemical Co., Ltd.

[0042] Aramid paper, item number: CF11100, thickness: 0.05mm, Shenzhen Changfeng Insulation Materials Co., Ltd.

[0043] Polyurethane film, 0.15mm.

[0044] Polypropylene nonwoven fabric, 0.16mm thick.

[0045] Carbon fiber filament, item number: STS40-24K, brand: Toho, Japan.

[0046] Aramid filament, thickness: 200D, Dongguan Sovit Special Wire & Tape Co., Ltd.

[0047] The raw materials used in the embodiments and comparative examples of this invention are all commercially available products.

[0048] Example 1

[0049] The spinning method for a fiber membrane homogeneous fully coated composite yarn product is as follows:

[0050] Step 1: Place the PTFE air filter membrane in a cutting machine and cut it into strips with a width of 2 cm. Roll them up individually into a strip can to form a roll strip 1.

[0051] Step 2: The roll spool 1 and the beginning of the conveyor belt 2 are adjacent with zero gap. The end of the conveyor belt 2 is aligned with the jaws of the front roller 3. During the unwinding process of the two bundles of PTFE air filter membrane strips from the roll spool 1, epoxy resin is sprayed onto the upper surface of the lower PTFE air filter membrane strips simultaneously through the nozzle 5. The spraying amount is 10mg / m. A basalt filament is sandwiched between the two bundles of PTFE air filter membrane strips and conveyed to the beginning of the conveyor belt 2. It is then fed into the front roller 3 and twisted through the yarn guide hook 6 and the wire ring 8 to form a uniformly covered composite yarn product. It is then wound into the yarn tube 9. The speed of the conveyor belt 2 is 7.928m / min, the output speed of the front roller 3 is 8m / min, the spindle 7 speed is 2000rpm, and the twist is set to 25 twists / 10cm.

[0052] Example 2

[0053] The spinning method of a fiber membrane uniformly fully covered composite yarn product is basically the same as that in Example 1, except that the conveyor belt speed is 8m / min.

[0054] Example 3

[0055] The spinning method of a fiber membrane uniformly fully covered composite yarn product is basically the same as that in Example 1, except that the conveyor belt speed is 7.856 m / min.

[0056] Example 4

[0057] The spinning method of a fiber membrane uniformly fully coated composite yarn product is basically the same as that in Example 1, except that the coating amount is 2 mg / m.

[0058] Example 5

[0059] The spinning method of a fiber membrane uniformly fully covered composite yarn product is basically the same as that in Example 1, except that the coating amount is 18 mg / m.

[0060] Example 6

[0061] The spinning method of a fiber membrane uniformly fully covered composite yarn product is basically the same as that in Example 1, except that the PTFE air filter membrane is replaced with aramid paper and cut into strips with a width of 1.3 mm.

[0062] Example 7

[0063] The spinning method of a fiber membrane uniformly fully covered composite yarn product is basically the same as that in Example 1, except that the PTFE air filter membrane is replaced with a polyurethane film and cut into strips with a width of 5 mm.

[0064] Example 8

[0065] The spinning method of a fiber membrane uniformly fully covered composite yarn product is basically the same as that in Example 1, except that the PTFE air filter membrane is replaced with polypropylene nonwoven fabric, which is cut into strips with a width of 7mm.

[0066] Example 9

[0067] The spinning method of a fiber membrane uniformly fully covered composite yarn product is basically the same as that in Example 1, except that the basalt filament is replaced with carbon fiber filament.

[0068] Example 10

[0069] The spinning method of a fiber membrane uniformly fully covered composite yarn product is basically the same as that in Example 1, except that the basalt filament is replaced with polyethylene filament.

[0070] Example 11

[0071] The spinning method of a fiber membrane uniformly fully covered composite yarn product is basically the same as that in Example 1, except that the basalt filament is replaced with aramid filament.

[0072] Comparative Example 1

[0073] The spinning method of a fiber membrane uniformly fully coated composite yarn product is basically the same as that in Example 1, except that no spraying is performed.

[0074] Comparative Example 2

[0075] The spinning method for a fiber membrane homogeneous fully coated composite yarn product is as follows:

[0076] Step 1: Place the PTFE air filter membrane in a cutting machine and cut it into strips with a width of 2 cm. Roll them up individually into a strip can to form a roll strip 1.

[0077] Step 2: After the two bundles of PTFE air filter membrane strips are unwound from the roll spool 1, epoxy resin is simultaneously sprayed onto the upper surface of the lower PTFE air filter membrane strips through the nozzle 5. The spraying amount is 10mg / m. A basalt filament is sandwiched between the two bundles of PTFE air filter membrane strips and directly fed to the nip of the front roller 3. Through the yarn guide hook 6 and the wire traveler 8, it is twisted to form a uniformly covered composite yarn product, which is then wound onto the yarn tube 9. The output speed of the front roller 3 is 8m / min, the spindle speed of the spindle 7 is 2000rpm, and the twist is set to 25 twists / 10cm.

[0078] Comparative Example 3

[0079] The spinning method for a fiber membrane homogeneous fully coated composite yarn product is as follows:

[0080] Step 1: Place the PTFE air filter membrane in a cutting machine and cut it into strips with a width of 2 cm. Roll them up individually into a strip can to form a roll strip 1.

[0081] Step 2: After the two bundles of PTFE air filter membrane strips are unwound from the roll spool 1, a basalt filament is sandwiched in the middle and directly fed to the nip of the front roller 3. Through the yarn guide hook 6 and the wire traveler 8, they are twisted to form a uniform, fully covered composite yarn product, which is then wound onto the yarn tube 9. The output speed of the front roller 3 is 8m / min, the spindle speed of the spindle 7 is 2000rpm, and the twist is set to 25 twists / 10cm.

[0082] Test Example 1

[0083] Mechanical property testing

[0084] The strength and elongation at break of the fiber membrane homogeneous fully-covered composite yarn products prepared in Examples 1-8 and Comparative Examples 1-3 of this invention were tested using an Instron tensile strength tester. Each group was tested 20 times, and the average value was taken. The tests were conducted under standard experimental conditions, namely a temperature of 23±5℃ and a humidity of 65±15%RH. Detailed test data are shown in Table 1.

[0085] Table 1

[0086] Experimental protocol Strong (cN) Elongation at break (%) Example 1 9742.83 8.52 Example 2 9250.65 8.90 Example 3 9025.43 7.85 Example 4 9350.24 8.15 Example 5 9412.37 8.80 Example 6 9933.91 5.74 Example 7 7319.72 4.74 Example 8 7555.24 3.79 Comparative Example 1 9338.90 7.60 Comparative Example 2 8650.22 7.50 Comparative Example 3 7920.18 6.20

[0087] Test Example 2

[0088] Mechanical property testing after knotting

[0089] The fiber membrane homogeneous fully-covered composite yarn products prepared in Examples 1-8 and Comparative Examples 1-3 of this invention were subjected to strength testing using an Instron strength tester after a knot was tied in the middle of the test sample. Each group underwent 20 tests, and the average value was taken. The tests were conducted under standard experimental conditions, namely, temperature 23±5℃ and humidity 65±15%RH. The reduction rate was calculated.

[0090] Reduction rate (%) = (Strength before knot (cN) - Strength after knot (cN)) / Strength before knot (cN) × 100%

[0091] Detailed test data can be found in Table 2.

[0092] Table 2

[0093] Experimental protocol Strong after knotting (cN) Reduction rate (%) Example 1 3195.47 67.2 Example 2 2750.25 70.3 Example 3 2615.84 71.0 Example 4 2750.4 70.6 Example 5 3000.66 68.1 Example 6 3511.96 64.65 Example 7 4236.85 42.12 Example 8 3656.36 51.60 Comparative Example 1 2250.37 75.9 Comparative Example 2 1950.75 77.4 Comparative Example 3 1520.51 80.8

[0094] Example 1 achieves a triple structural optimization by precisely setting the conveyor belt speed to 7.928 m / min, creating a 1% speed difference with the front roller output speed. This pretension of the basalt filaments, below their elongation at break threshold of 3%, results in axial fiber straightening, zero-shrinkage membrane coating, and precise interface coupling. This pretension not only eliminates stress concentration caused by fiber curling but also, through the zero-gap design between the conveyor belt and the sliver, allows the fiber film to maintain its original width under the control of the conveyor belt, forming a continuous, defect-free coating layer. Simultaneously, the precise filling of epoxy resin constructs a three-dimensional anchoring network, effectively eliminating the risk of core leakage. In terms of mechanical properties, the 1% speed difference keeps the basalt fibers within the elastic deformation range, avoiding plastic damage. Furthermore, the "pinning effect" of the adhesive film enhances interfacial shear strength, achieving a synergistic improvement in strength and elongation at break. Moreover, this structure exhibits the lowest strength loss rate in the knotted state, thanks to the stress redistribution mechanism between the fiber film and the adhesive film. This speed difference serves as the golden balance point between tension control and structural preservation, avoiding both loose wrapping caused by an excessively small speed difference and micro-damage to the fibers caused by an excessively large speed difference.

[0095] Example 1, employing an epoxy resin spraying amount of 10 mg / m, achieves optimal performance of the fiber membrane-uniformly fully coated composite yarn product. The core mechanism lies in achieving a three-dimensional balance between interface strengthening, structural integrity, and functional preservation. At this spraying amount, the resin forms a continuous film, fully penetrating the micropores of the PTFE membrane and the gaps between basalt fibers, constructing a three-dimensional anchoring network. This significantly enhances interlayer shear strength and eliminates local slippage by uniformly dispersing tensile stress, preventing insufficient spraying. Simultaneously, this film thickness exerts a "pinning effect" during stretching, maximizing interfacial bonding and preventing pore blockage caused by excessive spraying. Pore blockage easily leads to increased air bubbles, thereby increasing the risk of yarn defects. In the knotted state, the film, through plastic deformation energy dissipation and the synergistic effect of the fiber membrane structure, forms a gradient modulus transition zone, effectively preventing crack propagation and converting local tensile stress into radial compressive stress. This reduces the knot strength reduction rate to 67.2%, significantly better than other spraying amount schemes. Furthermore, a coating amount of 10 mg / m² ensures film continuity while maintaining >65% porosity, and also balances air permeability, liquid repellency, and the ability to fix functional modifiers (such as nano-silver and carbon nanotubes), avoiding functional degradation caused by excessive coating. This coating amount precisely solves the technical contradiction of traditional core-spun yarns where "increased strength leads to decreased functionality," achieving a synergistic breakthrough in structural strengthening and functional preservation.

Claims

1. A fiber membrane uniform full-coverage composite spinning device, characterized in that, include: The package includes a sliver roll (1), a conveyor belt (2), a front roller (3) jaw, and a yarn guide hook (6). The head end of the conveyor belt (2) is connected to the sliver roll (1) with zero gap through a spring (4), and the end end is aligned with the front roller (3) jaw. A gap is provided between the two sliver rolls (1) to facilitate the passage of fiber filaments. A nozzle (5) is provided in the middle of the conveyor belt (2) and the sliver roll (1) for spraying epoxy resin onto the upper surface of the lower layer of the sliver. The package also includes a spindle (7), a wire traveler (8), and a yarn tube (9) for twisting the composite structure to form a fiber membrane uniformly fully covered composite yarn product and winding it into the yarn tube (9).

2. A method for preparing fiber membrane homogeneous fully coated composite yarn products using the spinning apparatus as described in claim 1, characterized in that, The method is as follows: Step 1: Place the fiber film in a cutting machine, cut it into strips, and individually roll them into a strip can to form a rolled strip can (1). Step 2: The roll sliver (1) and the head of the conveyor belt (2) are adjacent with zero gap. The end of the conveyor belt (2) is aligned with the jaws of the front roller (3). During the unwinding process of the two fiber film strips from the roll sliver 1, the functional agent is sprayed onto the upper surface of the lower fiber film strip through the nozzle (5). The fiber filaments are sandwiched between the two fiber film strips and transported to the head of the conveyor belt (2). They are fed into the front roller (3) and then twisted through the yarn guide hook (6) and the wire ring (8) to form a fiber film uniformly fully covered composite yarn product, which is then wound into the yarn tube (9).

3. The method as described in claim 2, characterized in that, The width of the strips cut into them is 1-5cm.

4. The method as described in claim 2, characterized in that, The functional agent is at least one of epoxy resin, silane coupling agent, waterborne polyurethane resin, silver dispersion, and silica sol; the spraying amount of the functional agent is 1-20 mg / m.

5. The method as described in claim 2, characterized in that, The speed of the conveyor belt (2) is 7.8-8 m / min.

6. The method as described in claim 2, characterized in that, The output speed of the front roller (3) is 5-20 m / min.

7. The method as described in claim 2, characterized in that, The spindle (7) has a rotation speed of 1000-5000 rpm and a twist of 5-200 twists / 10cm.

8. The method as described in claim 2, characterized in that, The fiber membrane is at least one of the following: microporous filter membrane, synthetic polymer membrane, elastomer membrane, photocatalytic functional membrane, antibacterial functional membrane, biodegradable membrane, natural polymer membrane, high-temperature resistant separation membrane, conductive composite membrane, paper-based material, non-woven material, inorganic fiber paper, and engineering membrane.

9. The method as described in claim 2, characterized in that, The fiber filament is at least one of organic fiber, inorganic non-metallic fiber, and metallic fiber.

10. A fiber membrane uniformly fully covered composite yarn product, characterized in that, It is prepared by the method described in any one of claims 2-9.

Images