An array-spun reinforced composite yarn and a spinning method

Abstract

This invention belongs to the field of textile processing technology and provides an array-spun reinforced composite yarn and a spinning method. In this invention, the nanoarray is generated by a needle-free electrostatic array ionization device through multi-jet polarization and ionization of an unsaturated solution. By controlling the concentration and electrostatic voltage of the unsaturated solution, the surface tension and ionization state of the unsaturated solution are changed, causing the jets and droplets to become charged in an electric field and break through the Rayleigh limit to form a nanoarray. These nanoarrays, embedded in a microfiber web, are stably anchored to the surface of the microfibers with extremely high van der Waals forces and hydrogen bonds, increasing the specific surface area and inter-fiber contact area of ​​the microfibers, enhancing fiber cohesion and friction in the yarn, and achieving mechanical reinforcement (especially breaking strength) and quality improvement in regenerated fiber textiles.

Description

Technical Field

[0001] This invention relates to the field of textile processing technology, and in particular to an array-spun reinforced composite yarn and a spinning method. Background Technology

[0002] Textiles are the basic materials for clothing production. They are based on fibers and have various interweaving and weaving structures, possessing high flexibility, wearability, and durability. However, the quality of raw materials often affects the quality of the finished fabric, especially mechanical properties such as strength and stiffness.

[0003] Current textile products are made of natural or chemical fibers, with fiber diameters ranging from tens to hundreds of micrometers. The numerous advantages of fibers often become apparent through the construction of nanostructures on the fiber surface (increased specific surface area and surface energy, enhanced surface friction, and improved hydrophilicity and hydrophobicity). Therefore, the construction of nanostructures on the fiber surface is a powerful means to improve the strength and quality of yarns and fabrics. Chinese patent CN117512994A discloses a dodecanol-modified SiO2 nanoparticle superhydrophobic cotton fiber material; Chinese patent CN119530995A discloses a method for preparing PEDOT:PSS-based composite fibers with silver nanoparticles loaded on the surface; and Chinese patent CN118547503A discloses a method for preparing durable flame-retardant polyester / cotton blended fabrics by in-situ deposition. The above-mentioned prior art discloses related technologies for constructing and modifying the nanostructures on the fiber surface, such as impregnation and in-situ deposition. These methods all construct nanolattices on the fiber surface in different forms. The nanolattices constructed by impregnation and in-situ deposition have poor bonding force with the main body, resulting in poor tensile strength of the composite fibers. Summary of the Invention

[0004] In view of this, the object of the present invention is to provide an array-spun reinforced composite yarn and a spinning method thereof. The array-spun reinforced composite yarn obtained by the spinning method provided by the present invention has high breaking strength.

[0005] To achieve the above-mentioned objectives, the present invention provides the following technical solution: This invention provides a method for spinning array-spun reinforced composite yarn, comprising the following steps: The fiber raw material is carded to obtain a fiber web; The needle-free electrostatic array ionization device forms an upward-facing nanoarray of an unsaturated solution under electrostatic action; the nanoarray is embedded in the fiber web and anchored to the fiber surface to obtain a modified fiber web; The modified fiber web is bundled to obtain a composite fiber sliver; The composite fiber sliver is spun to obtain the array-spun reinforced composite yarn; The unsaturated solution is composed of the following components in mass percentage: Water-soluble polymer 2-8% and self-polymerizing emulsion 92-98%; The self-polymerizing emulsion comprises monomers, surfactants, initiators, and water.

[0006] Preferably, the fiber raw material comprises the following components in weight percentage: Suitable for spinning 50-100% fiber, recycled staple fiber 0-50%; The length of the spun fiber and the recycled short fiber are independently 20~60mm, and the diameter is independently 10~40μm; The materials of the spun fibers and regenerated short fibers independently include one or more of cotton fibers, wool fibers, polyester fibers and viscose fibers.

[0007] Preferably, the water-soluble polymer includes one or more of polyvinyl alcohol (PVA), polyvinylpyrrolidone (PVP), polyethylene oxide (PEO), and polyethyleneimine (PEI).

[0008] Preferably, the self-polymerizing emulsion comprises the following components in weight percentage: Monomer 27-39%, surfactant 0.1-2%, initiator 0.1-1%, water 60-70%; The monomer comprises the following components by mass percentage: Styrene (St) 5~30%, methyl methacrylate (MMA) 45~50%, hydroxyethyl methacrylate (HEMA) 5~7.5%, acrylic acid (AA) 5~7.5% and butyl acrylate (BA) 10~15%; The surfactant includes one or more of sodium dodecyl sulfate (SDS), hexadecyltrimethylammonium bromide (CTAB), Tween 80, and Span 60; The initiator includes potassium persulfate (KPS) and / or ammonium persulfate (APS).

[0009] Preferably, the viscosity of the unsaturated solution is less than 1500 mPa·s, and the conductivity is 10~100 μS / cm.

[0010] Preferably, the carding process is carried out in a carding machine, which includes a licker-in, a cylinder, and a doffer. The static electricity is generated by a high-voltage static electricity generator; The fiber mesh is adsorbed and supported by the negative pressure suction curtain and the negative pressure suction box; The needleless electrostatic array ionization device is located below the negative pressure suction screen. The fiber mesh is conveyed to the negative pressure suction screen through a conveyor curtain; The clustering is achieved through a clustering device.

[0011] Preferably, the speeds of the conveyor curtain and the negative pressure suction screen are independently 80-100% of the speed of the doffer, and the speed of the clustering device is 100-200% of the speed of the negative pressure suction screen.

[0012] Preferably, the voltage of the static electricity is 30~60kV; The needleless electrostatic array ionization device has 1 to 6 nozzles, and the length of the nozzle is 30 to 210 cm; the vertical receiving distance from the nozzle to the fiber web is 150 to 300 mm. The liquid supply width of the needleless electrostatic array ionization device is 20~200cm.

[0013] Preferably, the nanoarray is in the form of particles, beads, fibers, or a mixture of the three; the diameter of the particles, beads, and fibers is independently 100~1000 nm.

[0014] The present invention also provides array-spun reinforced composite yarn obtained by the spinning method described in the above technical solution.

[0015] This invention provides a spinning method for array-spun reinforced composite yarns.

[0016] The principle of this invention lies in using a needle-free electrostatic array ionization device to form a multi-jet stream from an unsaturated solution containing a self-polymerizing emulsion and a water-soluble polymer. This stream is refined and broken up. The low surface tension of the solution allows the unsaturated solution jets to be strongly charged by a high electric field, breaking the Rayleigh limit and achieving ionization and array formation. The water-soluble polymer acts as a spinning aid. During the solidification process of the jet and broken droplets, the self-polymerizing emulsion gradually forms a nanoarray. These nanoarrays are anchored to the surface of micron-sized fibers under the combined action of electric field, van der Waals forces, and hydrogen bonds. The extremely high van der Waals forces and hydrogen bonds stabilize the anchorage on the micron-sized fiber surface, increasing the specific surface area and inter-fiber contact area of ​​the fibers, enhancing fiber cohesion and friction in the yarn, and achieving mechanical enhancement (especially breaking strength) and quality improvement in regenerated fiber textiles. After the nanoarrays are anchored, the unsaturated solution gradually solidifies and undergoes a self-polymerization reaction, exhibiting water resistance. When low-quality composite fiber slivers are twisted into yarn, the nanoarrays on their surface form friction welding points, increasing the surface friction coefficient and reducing slippage between fibers. The nanoarrays can overcome their own gravity, moving at a speed greater than 10 times the force of gravity. 9 The adhesion force is twice that of micron-sized fibers to form a nanoarray, achieving a lasting reinforcement of recycled cotton yarn.

[0017] The composite yarn using nano-array anchored micron fibers in this invention incorporates needle-free electrostatic array ionization during the fiber web extension stage of carding. This eliminates the need for stringent processing conditions on textiles in post-finishing steps, reducing energy consumption and costs. It features short-process and rapid adjustment, significantly improving the quality attributes and mechanical properties of ordinary yarns.

[0018] Beneficial effects: (1) The present invention uses a needleless electrostatic array ionization device to ionize an unsaturated solution containing self-polymerizing emulsion and water-soluble polymer into the fiber web during the extension stage after fiber combing. The multiple jets are continuously emitted and break, ionize, polarize and firmly anchor on the surface of micron-sized fibers, which increases the specific surface area and surface friction coefficient of the fiber surface. The mechanical properties and quality of the modified fiber web are enhanced after it is made into yarn.

[0019] (2) The unsaturated solution of this invention uses water as a solvent, resulting in lower solvent costs. Unlike electrospinning processes that use DMF as a solvent, it has lower requirements for ambient temperature and humidity. The composite fiber sliver prepared by this invention can be flexibly applied to subsequent spinning processes, without being limited by spinning type or fiber raw materials, and can produce a variety of yarn products. It eliminates the need for impregnation finishing of textiles or adding functional auxiliaries to reinforce yarns after fiber modification, exhibiting low energy consumption, low water consumption, and low cost. The device used in this invention allows for convenient replacement of the spinning solution, eliminating the need for large-volume finishing impregnation baths and drying. It is suitable for small-scale production and rapid process changes. Attached Figure Description

[0020] Figure 1 This is a process flow diagram of the spinning method and equipment for the array-spun reinforced composite yarn of the present invention. Figure 2 This is an electron microscope image of the nanoarray on the surface of the modified fiber web obtained in step S4 of Example 1; Figure 3 The image shows an electron microscope image of the nanoarray obtained in step S4 of Example 2. The attached diagram is labeled as follows: 1-Hook roller, 2-Cylinder, 3-Doffer, 4-Conveyor curtain, 5-Negative pressure suction screen, 6-Needleless electrostatic array ionization device, 7-High voltage electrostatic generator, 8-Negative pressure suction box, 9-Gathering device. Detailed Implementation

[0021] This invention provides a method for spinning array-spun reinforced composite yarn, comprising the following steps: The fiber raw material is carded to obtain a fiber web; The needle-free electrostatic array ionization device forms an upward-facing nanoarray of an unsaturated solution under electrostatic action; the nanoarray is embedded in the fiber web and anchored to the fiber surface to obtain a modified fiber web; The modified fiber web is bundled to obtain a composite fiber sliver; The composite fiber sliver is spun to obtain the array-spun reinforced composite yarn; The unsaturated solution is composed of the following components in mass percentage: Water-soluble polymer 2-8% and self-polymerizing emulsion 92-98%; The self-polymerizing emulsion comprises monomers, surfactants, initiators, and water.

[0022] Unless otherwise specified, the raw materials used in this invention are preferably commercially available products.

[0023] This invention involves carding fiber raw materials to obtain a fiber web.

[0024] In this invention, the fiber raw material preferably comprises the following components in weight percentage: Suitable for spinning 50-100% fiber and 0-50% recycled staple fiber.

[0025] In this invention, the fiber raw material preferably comprises 50-100% spinnable fiber by weight percentage, specifically 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 100%. In this invention, the length of the spinnable fiber is preferably 20-60 mm, specifically 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, or 60 mm; the diameter is preferably 10-40 μm, specifically 10 μm, 15 μm, 20 μm, 25 μm, 30 μm, 35 μm, or 40 μm. In this invention, the material of the spinnable fiber preferably includes one or more of cotton fiber, wool fiber, polyester fiber, and viscose fiber.

[0026] In this invention, the fiber raw material preferably comprises 0-50% recycled short fibers by weight percentage, specifically preferably 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, 5%, or 0%. In this invention, the length, diameter, and material of the recycled short fibers are preferably consistent with those of the suitable fibers, and will not be elaborated further here.

[0027] In this invention, the carding process is preferably carried out in a carding machine, which preferably includes a licker-in, a cylinder, and a doffer. In this invention, during the carding process, the ratio of the linear velocity of the fiber raw material feed, the linear velocity of the cylinder, and the linear velocity of the doffer is preferably 1:500~600:6, specifically preferably 1:500:6, 1:550:6, or 1:600:6. In this invention, during the carding process, the speed of the doffer is preferably 10 m / min. In this invention, the width of the carding machine is preferably 30~210 cm. In this invention, the width of the fiber web is preferably 30~210 cm.

[0028] After obtaining the fiber web, the needleless electrostatic array ionization device of the present invention forms an upward nanoarray of unsaturated solution under the action of electrostatics; the nanoarray is embedded in the fiber web and anchored on the fiber surface to obtain a modified fiber web.

[0029] In this invention, the unsaturated solution is preferably placed in the needle-free electrostatic array ionization device.

[0030] In this invention, the viscosity of the unsaturated solution is preferably below 1500 mPa·s, more preferably 300~1000 mPa·s, and specifically preferably 300 mPa·s, 400 mPa·s, 500 mPa·s, 600 mPa·s, 700 mPa·s, 800 mPa·s, 900 mPa·s or 1000 mPa·s; the conductivity is preferably 10~100 μS / cm, and specifically preferably 10 μS / cm, 20 μS / cm, 30 μS / cm, 40 μS / cm, 50 μS / cm, 60 μS / cm, 70 μS / cm, 80 μS / cm, 90 μS / cm or 100 μS / cm.

[0031] In this invention, the unsaturated solution is composed of the following components in mass percentage: Water-soluble polymer 2-8% and self-polymerizing emulsion 92-98%.

[0032] In this invention, the unsaturated solution comprises 2-8% water-soluble polymer by mass percentage, specifically preferably 2%, 3%, 4%, 5%, 6%, 7%, or 8%. In this invention, the water-soluble polymer preferably comprises one or more of polyvinyl alcohol (PVA), polyvinylpyrrolidone (PVP), polyethylene oxide (PEO), and polyethyleneimine (PEI). In this invention, the viscosity-average molecular weight of the polyvinylpyrrolidone is preferably 1,300,000. In this invention, the polyvinyl alcohol is specifically preferably polyvinyl alcohol 1788.

[0033] In this invention, the unsaturated solution comprises 92-98% self-polymerizing emulsion by mass percentage, preferably 98%, 97%, 96%, 95%, 94%, 93%, or 92%. In this invention, the self-polymerizing emulsion comprises monomers, surfactants, initiators, and water. In this invention, the self-polymerizing emulsion comprises 27-39% monomers by mass percentage, preferably 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 35.8%, 36%, 37%, 38%, 38.7%, or 39%. In this invention, the monomers preferably comprise the following components by mass percentage: styrene (St) 5-30%, methyl methacrylate (MMA) 45-50%, hydroxyethyl methacrylate (HEMA) 5-7.5%, acrylic acid (AA) 5-7.5%, and butyl acrylate (BA) 10-15%. In this invention, based on mass percentage, the monomers include styrene (St) 5-30%, preferably 5%, 10%, 15%, 20%, 25%, or 30%; the monomers include methyl methacrylate (MMA) 45-50%, preferably 45%, 46%, 47%, 48%, 49%, or 50%; the monomers include hydroxyethyl methacrylate (HEMA) 5-7.5%, preferably 5%, 5.5%, 6%, 6.5%, 7%, or 7.5%; the monomers include acrylic acid (AA) 5-7.5%, preferably 5%, 5.5%, 6%, 6.5%, 7%, or 7.5%; and the monomers include butyl acrylate (BA) 10-15%, preferably 10%, 11%, 12%, 13%, 14%, or 15%.

[0034] In this invention, the self-polymerizing emulsion comprises 0.1-2% surfactant by mass percentage, specifically preferably 0.1%, 0.5%, 0.8%, 1%, 1.1%, 1.2%, 1.5%, 1.8%, or 2%. In this invention, the surfactant preferably comprises one or more of sodium dodecyl sulfate (SDS), hexadecyltrimethylammonium bromide (CTAB), Tween 80, and Span 60.

[0035] In this invention, the self-polymerizing emulsion comprises 0.1-1% initiator by mass percentage, specifically preferably 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, or 1%. In this invention, the initiator preferably comprises potassium persulfate (KPS) and / or ammonium persulfate (APS).

[0036] In this invention, the self-polymerizing emulsion comprises 60-70% water by mass percentage, preferably 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69% or 70%.

[0037] In this invention, the method for preparing the self-polymerizing emulsion preferably includes the following steps: A portion of the initiator, surfactant, monomer, and water are first mixed to form a pre-emulsion. After mixing the remaining initiator and the remaining water, a portion of the pre-emulsion, the remaining pre-emulsion, and the pH buffer are added sequentially to obtain the self-polymerizing emulsion.

[0038] In this invention, the temperature of the first mixing is preferably room temperature, and the time is preferably 30 minutes.

[0039] In this invention, the second mixing temperature is preferably room temperature. The mixing time is not specifically limited, as long as the remaining initiator dissolves in the remaining water. In this invention, the pH buffer is preferably Na2HPO4-NaH2PO4 buffer, NaH2PO4-Na4P2O7 buffer, or Na2HPO4-KH2PO4 buffer. The amount of pH buffer added is preferably 0.2 wt% of the total emulsion mass, where the total emulsion mass refers to the total mass of monomer, surfactant, initiator, and water. The addition temperature of the partial pre-emulsion, the remaining pre-emulsion, and the pH buffer is preferably 70°C. After adding the partial pre-emulsion, stirring for 30 minutes is preferred. The remaining pre-emulsion is preferably added via a peristaltic pump. The mass ratio of the partial initiator to the remaining initiator is preferably 1:1~2. The volume ratio of the partial water to the remaining water is preferably 1~2:1. The volume ratio of the partial pre-emulsion to the remaining pre-emulsion is preferably 1:9. In this invention, the pH value of the self-polymerizing emulsion is preferably 7~8.

[0040] In this invention, the self-polymerizing emulsion comprises monomers, surfactants, initiators, and water, which enhances the anchoring strength of the nanoarray on the fiber surface. Based on this, the integration of needle-free electrostatic ionization technology with traditional spinning techniques enables the online anchoring of micron-sized fibers by the nanoarray, representing a new direction for further improvement and functionalization of textiles.

[0041] In this invention, the method for preparing the unsaturated solution preferably includes the following steps: The water-soluble polymer and the self-polymerizing emulsion are stirred and mixed to obtain the unsaturated solution. In this invention, the stirring and mixing is preferably carried out under normal temperature and sealed conditions, and the stirring and mixing time is preferably 24 hours.

[0042] In this invention, the static electricity is preferably generated by a high-voltage static electricity generator. The voltage of the static electricity is preferably 30-60kV, specifically 30kV, 40kV, 45kV, 50kV, or 60kV.

[0043] In this invention, the fiber web is preferably adsorbed and supported by a negative pressure suction screen and a negative pressure suction box. In this invention, the needle-free electrostatic array ionization device is preferably located below the negative pressure suction screen.

[0044] In this invention, the fiber web is preferably conveyed to the negative pressure suction screen via a conveyor curtain.

[0045] In this invention, the speed of the conveyor curtain and the negative pressure suction screen is preferably 80-100% of the speed of the doffer, specifically preferably 80%, 85%, 90%, 95% or 100%.

[0046] In this invention, the number of nozzles in the needleless electrostatic array ionization device is preferably 1 to 6, and the length of the nozzle is preferably 30 to 210 cm, specifically 30 cm, 50 cm, 80 cm, 100 cm, 120 cm, 150 cm, 180 cm, 200 cm or 210 cm; the vertical receiving distance from the nozzle to the fiber web is preferably 150 to 300 mm, specifically 150 mm, 200 mm, 250 mm or 300 mm.

[0047] In this invention, the liquid supply width of the needleless electrostatic array ionization device is preferably 20~200cm, and more preferably 20cm, 25cm, 30cm, 50cm, 75cm, 100cm, 125cm, 150cm, 175cm or 200cm.

[0048] In this invention, the preferred supply rate of the unsaturated solution is 4 to 6 mL / min, specifically 4 mL / min, 5 mL / min or 6 mL / min.

[0049] In this invention, the ambient temperature of the area containing the negative pressure suction screen, the needleless electrostatic array ionization device, the high-voltage electrostatic generator, and the negative pressure suction box is preferably -10 to 40°C, specifically -10°C, -5°C, 0°C, 5°C, 10°C, 15°C, 20°C, 25°C, 30°C, 35°C, or 40°C; the relative humidity is preferably 10 to 90%, specifically 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, or 90%. In this invention, the negative pressure suction screen, the needleless electrostatic array ionization device, the high-voltage electrostatic generator, and the negative pressure suction box preferably constitute an ionization box.

[0050] In this invention, the nanoarray is preferably in the form of particles, beads, fibers, or a mixture of all three; the diameter of the particles, beads, and fibers is preferably 100-1000 nm independently. In this invention, when the mass percentage of the water-soluble polymer in the unsaturated solution is 0-3 wt%, the nanoarray preferably takes the form of particles; when the mass percentage of the water-soluble polymer is 3-8 wt%, the nanoarray preferably takes the form of particles, beads, or fibers.

[0051] In this invention, the basic principle of the needle-free electrostatic array ionization is as follows: an unsaturated solution for preparing the nanoarray is placed on the nozzle of the needle-free electrostatic ionization device and a high voltage is applied. The surface of the unsaturated solution ripples and is polarized under the high voltage to generate a Taylor cone and its conical jet. The conical jet further breaks into droplets. When the broken droplets are charged by the high voltage electric field, the charge gradually increases until it exceeds the Rayleigh limit and further breaks into nano-sized droplets. The formula for calculating the theoretical radius R of the droplet at this time is shown in Formula 1. Formula 1; In formula 1, Q max For the maximum charge, ε 0 The vacuum permittivity, γ It is the surface tension of the liquid.

[0052] Therefore, the size of the nanoarray is affected by parameters such as the concentration of the unsaturated solution, electrostatic voltage, and the distance from the nozzle to the receiving plane.

[0053] In this invention, the nanoarray is generated by multi-jet polarization and ionization of an unsaturated solution using a needle-free electrostatic array ionization device. By controlling the concentration and electrostatic voltage of the unsaturated solution, the surface tension and ionization state of the unsaturated solution are altered, causing the jets and droplets to become charged in the electric field and break apart beyond the Rayleigh limit to form the nanoarray. These nanoarrays, embedded in a microfiber web, are stably anchored to the surface of the microfibers with extremely high van der Waals forces and hydrogen bonds, increasing the specific surface area and inter-fiber contact area of ​​the microfibers. This enhances fiber cohesion and friction in the yarn, achieving mechanical reinforcement of the regenerated fiber textiles, particularly improving breaking strength and overall quality.

[0054] After obtaining the modified fiber web, the modified fiber web of the present invention is bundled to obtain composite fiber slivers.

[0055] In this invention, the clustering is preferably achieved by a clustering device. The speed of the clustering device is preferably 100-200% of the speed of the negative pressure suction screen, specifically preferably 100%, 105%, 110%, 115%, 120%, 125%, 130%, 140%, 150%, 155%, 156%, 160%, 170%, 180%, 190%, or 200%.

[0056] In this invention, the weight of the composite fiber sliver is preferably 15~30g / 5m, and more preferably 15g / 5m, 20g / 5m, 25g / 5m or 30g / 5m.

[0057] After obtaining the composite fiber sliver, the present invention spins the composite fiber sliver to obtain the array-spun reinforced composite yarn.

[0058] In this invention, the spinning process preferably includes sequentially drawing, roving, and spinning.

[0059] In this invention, the number of strips is preferably 1 to 6, and more preferably 4; the number of passes is preferably 2, 4 or 6, and more preferably 4; in a specific embodiment of this invention, the strips are preferably joined in a 4-to-4-pass manner.

[0060] In this invention, the roving speed is preferably 200-600 rpm, specifically 200 rpm, 300 rpm, 400 rpm, 500 rpm, or 600 rpm. In this invention, the roving weight obtained from spinning is preferably 3-8 g / 10m, specifically 3 g / 10m, 4 g / 10m, 5 g / 10m, 6 g / 10m, 7 g / 10m, or 8 g / 10m; the twist is preferably 3-7 T / m, specifically 3 T / m, 3.5 T / m, 4 T / m, 5 T / m, 6 T / m, or 7 T / m.

[0061] In this invention, the spindle speed of the fine yarn is preferably 10,000 to 12,000 rpm, specifically 10,000 rpm, 11,000 rpm, or 12,000 rpm. In this invention, the fineness of the fine yarn obtained from the fine yarn is preferably 10 to 50 metric count, specifically 10 metric count, 20 metric count, 30 metric count, 40 metric count, or 50 metric count; the twist coefficient is preferably 300 to 320, specifically 300, 310, or 320; and the twist is preferably 675 to 721 T / m.

[0062] The present invention does not impose specific limitations on the processes of roving and spinning; any operations well known to those skilled in the art can be used.

[0063] Figure 1This is a process flow diagram of the spinning method and equipment for the array-spun reinforced composite yarn of the present invention; by Figure 1 As shown: The fiber raw material is fed into the carding machine and passes through the carding roller 1, cylinder 2 and doffer 3 in sequence to form a fiber web; The fiber web passes through the conveyor curtain 4 and reaches the highest point. At this time, the fiber web is adsorbed and supported by the negative pressure suction curtain 5 and the negative pressure suction box 8. A needleless electrostatic array ionization device 6 is arranged below the negative pressure suction curtain 5. When the high-voltage electrostatic generator 7 is turned on to the specified voltage, the unsaturated solution on the nozzle of the needleless electrostatic array ionization device 6 generates a Taylor cone and produces upward multi-jet streams. The jets break up and form nanoarrays. Under the action of the electric field, the nanoarrays are quickly embedded into the fiber web and anchored on the fiber surface to obtain a modified fiber web. The modified fiber web is collected at point 9 of the bundling device to obtain composite fiber slivers; The composite fiber sliver is fed into the subsequent spinning process to obtain array-spun reinforced composite yarn.

[0064] The present invention also provides array-spun reinforced composite yarn obtained by the spinning method described in the above technical solution.

[0065] The array-spun reinforced composite yarn and spinning method provided by the present invention will be described in detail below with reference to the embodiments, but they should not be construed as limiting the scope of protection of the present invention.

[0066] Example 1 S1: Preparation of self-polymerizing emulsion: S1-1: The components of the self-polymerizing emulsion, calculated by parts by weight of the emulsion (500g), include: 63 parts of deionized water; Potassium persulfate (KPS) 0.2 parts; Sodium dodecyl sulfate (SDS) 1 part; 35.8 parts of monomer mixture; The components of the monomer mixture, calculated by mass parts (179g) of the mixture, include: 50 parts of methyl methacrylate (MMA); 25 parts of styrene (St); 15 parts of butyl acrylate (BA); 5 parts of hydroxyethyl methacrylate (HEMA); 5 parts acrylic acid (AA); S1-2: Preparation of self-polymerizing emulsion using seed emulsion prepolymerization method: First, prepare a mixture of 1 / 3 initiator KPS, all SDS, 2 / 3 deionized water, and monomer, and mix and dissolve it uniformly at room temperature for 30 min to form a pre-emulsion; dissolve the remaining initiator KPS in the remaining deionized water, then heat to 75℃ and add 10% of the pre-emulsion and stir for 30 min to form a light blue transparent seed emulsion; then continue to slowly add the remaining 90% of the pre-emulsion using a peristaltic pump, and finally add 0.2% of the total emulsion mass of Na2HPO4-NaH2PO4 buffer to make the pH of the system 7~8, thus obtaining the self-polymerizing emulsion.

[0067] S2: Preparation of unsaturated solution: Weigh 20g of polyvinylpyrrolidone (PVP K90) powder (purchased from Maclean Group, viscosity-average molecular weight 1,300,000) and mix with 500g of self-polymerizing emulsion. Stir in a sealed container at room temperature for 24 hours until dissolved to obtain 520g of unsaturated solution, in which the mass fraction of PVP is 4wt%, the viscosity is 800mPa·s, and the conductivity is 30μS / cm.

[0068] S3: Configuration of carding treatment for fiber raw materials: Select 50% long-staple cotton and 50% recycled short-staple cotton, and set the ratio of feeder, cylinder and doffer linear speed to 1:600:6, where the doffer speed is 10m / min, to form a fiber web.

[0069] S4: The fiber web is conveyed to the highest point of the conveyor curtain 4 and then sequentially passes through the negative pressure suction curtain 5 and the negative pressure suction box 8 to adsorb and support the fiber web; wherein, the speed of the conveyor curtain 4 is 10m / min, the speed of the negative pressure suction curtain 5 is 10m / min, and the speed of the bundling device 9 is 12m / min. Configuration of needle-free electrostatic array ionization: Prepare the unsaturated solution prepared in S2, and adjust the high-voltage electrostatic generator 7 to 50kV; at this time, the unsaturated solution on the surface of the nozzle of the needle-free electrostatic array ionization device begins to generate ripples and multiple jets; the jets ionize between the fiber web and the nozzle, forming a nanoarray, and white ionization traces are visible under illumination; under the action of the electric field, the nanoarray quickly embeds into the fiber web and anchors to the fiber surface, resulting in a modified fiber web; wherein, the vertical receiving distance from the nozzle of the needle-free electrostatic array ionization device to the fiber web is 25cm, the number of nozzles is 6, the length of the nozzle is 150cm, the liquid supply width is 25cm, and the liquid supply speed is 6mL / min; the ambient temperature of the area containing the negative pressure suction curtain, the needle-free electrostatic array ionization device, the high-voltage electrostatic generator, and the negative pressure suction box is 25℃, and the relative humidity is 35%RH.

[0070] S5: Spinning process configuration: The modified fiber web is bundled by the bundling device 9 to obtain the composite fiber sliver.

[0071] S6: The composite fiber sliver is fed into the coiler until the sliver can is full; the drawing process is 4 draws and 4 passes, the roving weight is 4g / 10m, the twist is 5T / m, and the speed is 200rpm; the fineness of the yarn is 50 metric count, the twist coefficient is 300, the twist is 675T / m, and the spindle speed is 10000rpm, to obtain the reinforced composite yarn.

[0072] The constant-speed tensile strength test of the yarn was conducted according to GB / T 3916-2013 "Determination of breaking strength and elongation at break of single yarn in packaged textiles (CRE method)". The single yarn clamping length was 500 mm, the tensile speed was 500 mm / min, and 15 sets of tests were conducted for each type of yarn. The yarn specifically refers to reinforced composite yarn. The results are shown in Table 1.

[0073] Comparative Example 1 The difference from Example 1 is that S1, S2 and S4 are omitted, that is, the fiber web is not modified. The rest is the same as Example 1, and the resulting yarn is named raw yarn.

[0074] The raw yarn was tested using the method of Example 1, and the results are shown in Table 1.

[0075] Table 1 Comparison of tensile strength of yarns

[0076] Figure 2 This is an electron microscopy image of the nanoarray on the surface of the modified fiber web obtained in step S4 of Example 1. Figure 2 It can be seen that the teardrop-shaped nanoarrays adhere to the surface of cotton fibers. When similar nanoarrays are included inside the yarn, they can increase the contact between fibers and enhance the cohesion of the fibers.

[0077] Example 2 S1: Synthesis of self-polymerizing emulsions: S1-1: The components of a self-polymerizing emulsion, calculated per 1000g emulsion mass, include: 60 parts deionized water; Potassium persulfate (KPS) 0.2 parts; Sodium dodecyl sulfate (SDS) 1.1 parts; 38.7 parts of monomer mixture; The components of the monomer mixture, calculated by mass parts (387g) of the mixture, include: 45 parts of methyl methacrylate (MMA); 30 parts of styrene (St); 10 parts butyl acrylate (BA); 7.5 parts of hydroxyethyl methacrylate (HEMA); Acrylic acid (AA) 7.5 parts; S1-2: Preparation of self-polymerizing emulsion using seed emulsion prepolymerization method: First, prepare a mixture of 1 / 2 KPS and all SDS, 1 / 2 deionized water and monomer, and mix and dissolve it uniformly at room temperature for 30 min to form a pre-emulsion; dissolve the remaining initiator in deionized water, then heat to 70℃ and add 10% of the pre-emulsion and stir for 30 min to form a light blue transparent seed emulsion; then continue to slowly add the remaining 90% of the pre-emulsion using a peristaltic pump, and finally add 0.2% of the total emulsion mass of Na2HPO4-KH2PO4 buffer to make the pH of the system 7~8, thus obtaining the self-polymerizing emulsion.

[0078] S2: Preparation of unsaturated solution: Weigh 15g of polyvinyl alcohol 1788 powder and 500g of self-polymerizing emulsion and mix them under sealed stirring at room temperature for 24 hours until dissolved to obtain 515g of unsaturated solution, in which the mass fraction of PVP is 3wt%, the viscosity is 500mPa·s, and the conductivity is 50μS / cm.

[0079] S3: Configuration of carding treatment for fiber raw materials: Select 35% viscose fiber, 35% long fiber and 30% recycled cotton linter, set the linear speed ratio of feeder, cylinder and doffer to 1:500:6, where the speed of the doffer is 10m / min, to form a fiber web.

[0080] S4: The fiber web is conveyed to the highest point of the conveyor curtain 4, and then passes through the negative pressure suction curtain 5 and the negative pressure suction box 8 in sequence to adsorb and support the fiber web; wherein, the speed of the conveyor curtain 4 is 8m / min, the speed of the negative pressure suction curtain 5 is 8m / min, and the speed of the bundling device 9 is 12.5m / min. Configuration of needle-free electrostatic array ionization: Prepare the unsaturated solution prepared in S2, and adjust the high-voltage electrostatic generator 7 to 45kV; the unsaturated solution on the nozzle surface of the needle-free electrostatic array ionization device begins to generate ripples and multiple jets; the jets ionize between the fiber web and the nozzle, forming a nanoarray, and white ionization traces are visible under illumination; under the action of the electric field, the nanoarray quickly embeds into the fiber web and anchors to the fiber surface, resulting in a modified fiber web; wherein, the vertical receiving distance from the nozzle to the fiber web of the needle-free electrostatic ionization device is 20cm, the number of nozzles is 6, the length of the nozzle is 150cm, the liquid supply width is 30cm, and the liquid supply speed is 4mL / min; the ambient temperature of the area containing the negative pressure suction curtain, the needle-free electrostatic array ionization device, the high-voltage electrostatic generator, and the negative pressure suction box is 20℃, and the relative humidity is 50%RH; The obtained nanoarray was received and characterized by electron microscopy. The results are as follows: Figure 3 As shown, Figure 3 The electron micrograph of the nanoarray obtained in step S4 is shown. Figure 3It can be seen that the widest diameter of the nanoarray is less than 1 micrometer, and the diameter distribution is relatively uniform.

[0081] S5: Spinning process configuration: The modified fiber web is bundled by the bundling device 9 to obtain composite fiber sliver.

[0082] S6: The composite fiber sliver is fed into the coiler until the sliver can is full; the drawing process is 4 draws and 4 passes; the roving weight is 5g / 10m, the twist is 3.5T / m, and the speed is 600rpm; the fineness of the yarn is 50 metric count, the twist coefficient is 320, the twist is 721T / m, and the spindle speed is 12000rpm, to obtain the reinforced composite yarn.

[0083] Comparative Example 2 The difference from Example 2 is that S1, S2 and S4 are omitted, that is, the fiber web is not modified. The rest is the same as Example 2, and the resulting yarn is named raw yarn.

[0084] Using the method of Example 1, the reinforced composite yarn obtained in Example 2 and the original yarn obtained in Comparative Example 2 were tested for constant speed tensile strength. The single yarn clamping length was 500 mm, the tensile speed was 500 mm / min, and 15 sets of tests were conducted for each type of yarn. The results are shown in Table 2.

[0085] Table 2 Comparison of tensile strength of yarns

[0086] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A method for spinning array-spun reinforced composite yarn, characterized in that, Includes the following steps: The fiber raw material is carded to obtain a fiber web; The needle-free electrostatic array ionization device forms an upward-facing nanoarray of an unsaturated solution under electrostatic action; the nanoarray is embedded in the fiber web and anchored to the fiber surface to obtain a modified fiber web; The modified fiber web is bundled to obtain a composite fiber sliver; The composite fiber sliver is spun to obtain the array-spun reinforced composite yarn; The unsaturated solution is composed of the following components in mass percentage: Water-soluble polymer 2-8% and self-polymerizing emulsion 92-98%; The self-polymerizing emulsion comprises monomers, surfactants, initiators, and water; The water-soluble polymer includes one or more of polyvinyl alcohol, polyvinylpyrrolidone, polyethylene oxide, and polyethyleneimine; The self-polymerizing emulsion comprises the following components in weight percentage: Monomer 27-39%, surfactant 0.1-2%, initiator 0.1-1%, water 60-70%; The monomer comprises the following components by mass percentage: Styrene 5-30%, methyl methacrylate 45-50%, hydroxyethyl methacrylate 5-7.5%, acrylic acid 5-7.5%, and butyl acrylate 10-15%; The surfactant includes one or more of sodium dodecyl sulfate, hexadecyltrimethylammonium bromide, Tween 80, and Span 60; The initiator includes potassium persulfate and / or ammonium persulfate.

2. The spinning method according to claim 1, characterized in that, The fiber raw material comprises the following components in weight percentage: Suitable for spinning 50-100% fiber, recycled staple fiber 0-50%; The length of the spun fiber and the recycled short fiber are independently 20~60mm, and the diameter is independently 10~40μm; The materials of the spun fibers and regenerated short fibers independently include one or more of cotton fibers, wool fibers, polyester fibers and viscose fibers.

3. The spinning method according to claim 1, characterized in that, The viscosity of the unsaturated solution is less than 1500 mPa·s, and the conductivity is 10~100 μS / cm.

4. The spinning method according to claim 1, characterized in that, The carding process is carried out in a carding machine, which includes a licker-in, a cylinder, and a doffer. The static electricity is generated by a high-voltage static electricity generator; The fiber mesh is adsorbed and supported by the negative pressure suction curtain and the negative pressure suction box; The needleless electrostatic array ionization device is located below the negative pressure suction screen. The fiber mesh is conveyed to the negative pressure suction screen through a conveyor curtain; The clustering is achieved through a clustering device.

5. The spinning method according to claim 4, characterized in that, The speeds of the conveyor curtain and the negative pressure suction screen are independently 80-100% of the speed of the doffer, and the speed of the clustering device is 100-200% of the speed of the negative pressure suction screen.

6. The spinning method according to claim 4, characterized in that, The voltage of the static electricity is 30~60kV; The needleless electrostatic array ionization device has 1 to 6 nozzles, the nozzle length is 30 to 210 cm, and the vertical receiving distance from the nozzle to the fiber web is 150 to 300 mm. The liquid supply width of the needleless electrostatic array ionization device is 20~200cm.

7. The spinning method according to claim 1, characterized in that, The nanoarray is in the form of particles, beads, fibers, or a mixture of the three; the diameter of the particles, beads, and fibers is independently 100~1000 nm.

8. The array-spun reinforced composite yarn obtained by the spinning method according to any one of claims 1 to 7.

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