Wool / algal fiber racephir compact core-in-sheath composite yarn and preparation method thereof

Abstract

The application discloses a wool / kelp fiber sirofil tight core-in-sheath composite yarn and a preparation method thereof. The sirofil tight core-in-sheath process is adopted, which is composed of double roving, middle filament and tight aggregation. The double wool / kelp blended roving is symmetrically fed, and the filament is synchronously drafted and tightly aggregated under negative pressure, so that the core filament is accurately centered and tightly covered by double helix. The process can effectively solve the problems of asynchronous drafting of blended fibers and brittle breakage of kelp fibers, significantly reduce the hairiness of the yarn, improve the uniformity of the yarn and the stability of the structure, avoid the phenomena of core exposure and delamination, greatly improve the breaking strength and anti-pilling performance of the yarn, and fully synergize the functional properties of wool and kelp fibers. The method has high process integration, can realize stable mass production after the transformation of a conventional spinning machine, and is more suitable for the efficient preparation of wool / kelp fibers which are difficult to spin and have brittle functional fibers.

Description

Technical Field

[0001] This invention relates to the technical field of composite fiber preparation methods, and in particular to a wool / seaweed fiber serofir tightly spun core composite yarn and its preparation method. Background Technology

[0002] Wool fiber is a commonly used high-end natural fiber in the textile industry. It has good crimp properties and excellent elasticity, and the fabrics woven from it are soft to the touch, have good drape, and are highly comfortable to wear. It is often used in high-end clothing and home textile products. However, in actual production and use, it has been found that pure wool yarn has low wet strength, and the fabric is prone to deformation after getting damp. In addition, wool itself does not have antibacterial or bacteriostatic functions, and long-term wear and storage can easily breed mites and bacteria, making it difficult to meet the current market demand for healthy and functional textiles.

[0003] Seaweed fiber is a new type of biomass fiber that has been promoted and applied in recent years. The raw material is derived from marine algae and has good antibacterial, anti-mite, moisture-wicking and breathable properties. It is also skin-friendly and suitable for making close-fitting fabrics. However, seaweed fiber itself has poor mechanical properties, low single fiber strength, and insufficient crimp. Pure spun yarn has poor bulk, warmth retention and abrasion resistance. The fabric does not retain its shape well and is prone to loosening and wrinkling after washing. Therefore, it cannot be used alone for high-end, durable textiles.

[0004] To leverage the advantages of both fibers, the industry commonly employs blending or conventional core-spun processes to produce wool / seaweed fiber composite yarns. Conventional blending simply involves a physical mixing of the two fibers without targeted optimization of the yarn structure, making it difficult to simultaneously utilize the warmth and elasticity of wool and the antibacterial and moisture-wicking properties of seaweed fiber. Traditional core-spun processes are often multi-step, involving first creating the outer roving and then separately forming the core, resulting in cumbersome procedures and poor equipment compatibility. Furthermore, conventional spinning lacks a fiber-aggregate structure, leading to yarn hairiness, large evenness fluctuations, and insufficient tightness of the yarn. This results in significant shortcomings in the appearance and durability of the finished fabric, hindering the quality improvement and large-scale application of this type of composite yarn.

[0005] Based on actual production conditions, the existing wool / seaweed fiber composite spinning technology mainly has the following problems: First, the core-spun structure lacks stability. Traditional single-strand wrapping methods have a single wrapping angle, resulting in insufficient bonding between the fiber and the core yarn and weak internal yarn cohesion. During subsequent weaving, dyeing, finishing, and washing processes, core yarn misalignment and exposure can easily occur, along with delamination and shedding of the outer fibers, causing fabric pilling, defects, and low product qualification rate and lifespan.

[0006] Secondly, the appearance and mechanical properties of the yarn are generally poor. Conventional ring spinning processes exhibit a distinct twisting triangle zone with numerous free fibers at the edges, resulting in a large number of yarn hairs with a disordered distribution of long and short hairs. This leads to poor yarn evenness and a high CV value. Not only are the fabrics prone to pilling and lacking smoothness, but the yarn strength is also unstable, causing frequent yarn breaks during high-speed weaving and resulting in low production efficiency.

[0007] Third, the production process is cumbersome and mass production stability is poor. Most existing composite yarns are produced in segments, with blending, pre-spinning, core-spun, and twisting processes operating independently. This results in a long production process with numerous intermediate transfers and manual interventions, leading to high equipment energy consumption and production costs. Furthermore, the parameters of each process are difficult to coordinate and match, resulting in significant performance differences between different batches of yarn and making standardized mass production challenging.

[0008] Fourth, the raw material ratios and process parameters lack targeted optimization. Currently available processes mostly use general ratios and spinning parameters, without adapting them to the specific performance characteristics of wool and seaweed fibers. This easily results in finished yarns that are either insufficiently warm and elastic or have weak antibacterial and moisture-wicking properties, making it difficult to achieve a balanced match of various performance characteristics. Summary of the Invention

[0009] This invention addresses the practical problems existing in the production of wool / seaweed fiber composite yarn, such as core delamination, large amount of hairiness, uneven yarn, insufficient strength, single function, and poor mass production stability, by making overall improvements to the yarn structure and spinning process.

[0010] The main objectives of this invention are: first, to improve the core-spun yarn structure and forming method, solving the defects of traditional processes such as easy core exposure, easy delamination, and excessive hairiness, thereby improving the appearance quality and structural stability of the yarn; second, to integrate Sirofil spinning, negative pressure compact spinning, and core-spun yarn processes into one, optimizing the forming mechanism and simultaneously improving yarn dryness, strength, and tightness of the wrapping; third, to optimize the ratio of wool to seaweed fiber and the complete set of process parameters, so that the finished yarn has both the warmth and elasticity of wool and the antibacterial and moisture-absorbing advantages of seaweed fiber, resulting in a more balanced overall performance; and fourth, to simplify the production process, enabling continuous production by modifying ordinary spinning machines, reducing production costs, improving batch stability, and making it suitable for industrial mass production.

[0011] The present invention adopts the following technical solution: A method for preparing a wool / seaweed fiber Sirofil compact core-spun composite yarn includes the following steps: Step 1: Open and comb the wool and seaweed fibers separately to produce directional blended roving; Step 2: Wool and seaweed fiber double rovings are fed in parallel as outer yarns with a parallel spacing of 2-5 mm. Synthetic filaments are fed in synchronously as core yarns with a tension of 5-15 cN. After being drawn by the drafting rollers, they are gathered to the negative pressure gathering device, so that the wool and seaweed fiber double strands are gathered and twisted with the core filament. The wool and seaweed fiber double strands spirally cover the outside of the core filament, forming a Sirofil tightly core-spun composite yarn.

[0012] Furthermore, in step 2, the mass ratio of wool to seaweed fiber is 65-70:30-35.

[0013] Furthermore, in step 2, the negative pressure range of the negative pressure collection device is -2kPa to -5kPa.

[0014] Furthermore, in step 2, the twist is 300–600 twists / m.

[0015] Furthermore, the synthetic filament layer completely covers the outer side of the double-core inner yarn.

[0016] A wool / seaweed fiber Sirofil compact core-spun composite yarn, comprising an inner core yarn and an outer blended covering layer; The inner layer is a high-strength synthetic filament core layer, and the outer layer uses a double-strand symmetrical wool / seaweed blended roving as the covering material. After the two rovings are gathered and flattened under negative pressure, they are tightly wrapped around the outside of the core filament in a symmetrical spiral manner.

[0017] Furthermore, the mass ratio of wool to seaweed fiber is 65-70:30-35.

[0018] Compared with the prior art, the present invention, by adopting the above technical solution, has the following advantages: 1. Synchronous and precise feeding of the double-strand roving and core filament. During production, constant tension control is applied to the core filament, with a tension control range of 5–15 cN. This prevents excessive tension from causing stretching and insufficient tension from causing slack. Simultaneously, the parallel spacing between the two blended rovings is controlled within the range of 2–5 mm to ensure symmetrical stress on both strands, precise convergence with the central core filament, and uniform coverage. This reduces issues of off-center core and exposed core from the source of production, ensuring consistent yarn quality across the entire batch.

[0019] 2. A negative pressure gathering and shaping process is added to reduce hairiness. A uniquely shaped negative pressure suction and gathering structure is installed between the drafting zone and the twisting zone, with the negative pressure stably controlled at -2 to -5 kPa. This negative pressure airflow gathers the scattered fibers at the edges of the sliver, eliminating the open twisting triangle zone of traditional spinning, significantly reducing both long and short hairiness, making the fiber sliver smoother and denser, and significantly improving the cohesion between fibers, providing a good foundation for tight coating and forming.

[0020] 3. Dynamically adjust yarn twist based on raw material ratios. Combine different fiber ratios and fabric applications to control yarn twist within the range of 300–600 twists / m. Formulas with a high wool content use a relatively low twist to retain yarn bulk and softness; after increasing the seaweed fiber content, appropriately increase the twist to enhance fiber cohesion, compensate for the relatively weak strength of seaweed fibers, prevent yarn breakage, and balance hand feel and structural stability.

[0021] 4. Achieve integrated continuous forming of drafting, fiber gathering, core wrapping, and twisting. This invention integrates the originally separate processes of drafting, fiber gathering, core wrapping, and twisting into a continuous production line, with parameters of each process matched and completed synchronously. This reduces yarn damage and parameter deviations caused by intermediate process transfers, resulting in a simpler production process, stronger overall yarn structure, and smaller batch-to-batch variations.

[0022] This invention employs a Sirofil core-spun process, combining double rovings, a centrally centered filament, and tight aggregation. This process achieves precise core centeredness and tight double-helix wrapping, offering significant technical advantages and practical value compared to traditional spinning processes. It fundamentally solves the problem of asynchronous drafting caused by the large differences in mechanical properties between seaweed fiber and wool, precisely addressing the industry pain points of low strength and brittleness inherent in seaweed fiber. The resulting yarn hairiness index H can be controlled to ≤2.3, a reduction of over 30% compared to traditional blended yarns, while the breaking strength is increased to ≥16.8 cN / tex, resulting in a mechanical property improvement of over 40%. Simultaneously, the symmetrical double-helix wrapping combined with negative pressure tight aggregation significantly enhances… This process improves yarn coverage uniformity and structural stability, resulting in finished products with no exposed core or delamination, uniform yarn evenness, and excellent anti-pilling and anti-fuzzing properties. It also fully preserves the warmth and elasticity of wool and the natural antibacterial and moisture-wicking properties of seaweed fiber, achieving a synergistic effect between the two fibers. Furthermore, the process is highly integrated, requiring only modifications to conventional spinning machines without significant additional equipment investment. Small-scale trials have been completed, demonstrating stable and controllable production, allowing for direct industrial-scale production. It is not only suitable for downstream processing in various weaving and knitting industries but also solves the spinning and processing challenges of brittle functional fibers like wool and seaweed, providing a stable and efficient preparation path for the development of functional textile materials.

[0023] The present invention will now be described in detail with reference to the accompanying drawings and embodiments. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the preparation equipment of the present invention.

[0025] The following is a list of components represented by the numbers in the attached diagram: 1. Roving; 2. Filament; 3. Roving collector; 4. Roving spacer / splitter; 5. Drafting roller; 6. Filament guide; 7. Core-spun yarn spinning system; 8. Gathering roller; 9. Control roller; 10. Gathering device; 11. Twist controller (false twister); 12. Core-spun yarn; 13. Ring Detailed Implementation

[0026] The principles and features of the present invention are described below with reference to the accompanying drawings. The examples given are only for explaining the present invention and are not intended to limit the scope of the present invention.

[0027] The method of the present invention includes the following steps: 1. Raw material pretreatment and roving preparation. Wool fibers and refined seaweed fibers with uniform quality, low impurity content, and low short fiber content are selected and subjected to opening, impurity removal, and carding processes to remove clumps, dust, and short fibers, improving fiber straightness. They are then mixed evenly according to a set ratio and processed through drawing and roving to produce a blended roving with uniform yarn consistency and stable tension for later use.

[0028] 2. Equipment Modification and Parameter Adjustment. Adaptation modifications were made to the conventional ring spinning machine, adding an active filament feeding mechanism, a tension controller, and a shaped negative pressure gathering device. Equipment operating parameters were adjusted, fixing key parameters such as the parallel spacing of the double rovings, core yarn tension, and gathering negative pressure to ensure synchronized conveying speeds of the double rovings and the center filament, and smooth operation without jamming or deviation.

[0029] 3. Roller drafting and negative pressure gathering. Two blended rovings simultaneously enter the three-roller drafting system. Progressive drafting and refining are achieved through roller speed ratio control, ensuring the fibers are fully parallel and straightened. The drafted sliver enters the negative pressure gathering area, where it is gathered and compacted under constant negative pressure, eliminating loose and disordered fibers and forming a smooth, uniform, and dense sliver.

[0030] 4. Double-strand spiral core wrapping and synchronous twisting. The two fiber slivers, after being gathered, converge symmetrically to the central filament position. Through the high-speed rotation of the spindle, ring, and traveler, the double-strand slivers evenly wrap the core filament in a spiral manner, and the twisting and setting are completed simultaneously, resulting in a tightly wrapped, core-free, and delaminated composite yarn.

[0031] 5. Finishing and Quality Inspection. The raw yarn is automatically wound to remove thick knots, thin knots, and yarn defects, and then undergoes twist stabilization treatment to eliminate internal stress and improve dimensional stability. After setting, the finished yarn is screened for evenness, strength, hairiness, and coverage through equipment testing and manual re-inspection, and then wound and stored in a standardized manner.

[0032] The present invention also designed a composite yarn structure with core layer reinforcement and double-layer dense coating. The whole is divided into two parts: inner core yarn and outer blended coating layer. It is different from the traditional single-strand coating and disordered blended structure, with better overall structure and more stable performance.

[0033] The inner layer is a high-strength synthetic filament core, which can be made of polyester or nylon filaments. These filaments have high tensile strength, good dimensional stability, and are not easily deformed. They can compensate for the shortcomings of wool and seaweed fibers, such as insufficient strength and easy deformation after washing, providing stable mechanical support for the entire yarn and improving the fabric's abrasion and wash resistance.

[0034] The outer layer uses a double-strand symmetrical wool / seaweed blended roving as the covering material. After being gathered and flattened under negative pressure, the two rovings are tightly wrapped around the outside of the core yarn in a symmetrical spiral pattern. The double-strand symmetrical wrapping method can effectively avoid local wrapping gaps and off-center core issues, resulting in better overall yarn roundness and a fluffier hand feel than ordinary single-strand core-spun yarn.

[0035] After numerous trials and adjustments, this invention has determined two practical ratios: a wool-to-seaweed fiber mass ratio of 70:30 and 65:35. The 70:30 ratio tends to retain the texture and warmth of wool, making it suitable for high-end fabrics in autumn and winter; the 65:35 ratio appropriately increases the proportion of seaweed fiber, resulting in more prominent antibacterial and moisture-wicking effects, making it suitable for use in close-fitting spring and summer fabrics.

[0036] Example 1: Warm and Textured High-End Autumn / Winter Fabric Technology This embodiment emphasizes the warmth and texture of the fabric, making it suitable for the development of high-end textiles for autumn and winter. The specific process parameters are as follows: The raw material ratio is wool:seaweed fiber = 70:30, the core yarn working tension is 10 cN, the parallel spacing of the double rovings is 3 mm, the negative pressure is -3 kPa, and the yarn twist is 450 twists / m.

[0037] Trial production and testing results show that the yarn produced under these parameters exhibits excellent overall bulkiness, a soft and full hand feel, and outstanding warmth retention. Testing revealed a yarn hairiness H-value of 1.9, a breaking strength of 18.2 cN / tex, good yarn evenness, and no core-exposed or delamination defects. The finished fabric retains the high-end texture of sheep's wool while fully utilizing the natural antibacterial and moisture-wicking properties of seaweed fibers. The overall performance is well-balanced, making it suitable for producing high-end autumn / winter formal wear, premium home textiles, and other high-quality products.

[0038] Example 2: Antibacterial and moisture-wicking spring / summer close-fitting fabric manufacturing process This embodiment focuses on enhancing the antibacterial and moisture-wicking properties of the fabric, making it suitable for the development of functional textiles that fit snugly against the skin in spring and summer. The specific process parameters are as follows: The raw material ratio is wool:seaweed fiber = 65:35, the core yarn working tension is 8 cN, the parallel spacing of the double rovings is 4 mm, the negative pressure is -4 kPa, and the yarn twist is 500 twists / m.

[0039] Trial production and testing results show that by appropriately increasing the proportion of seaweed fiber and yarn twist, the yarn structure becomes denser and smoother, and its moisture-wicking, quick-drying, antibacterial, and mite-inhibiting functions are more prominent. The yarn hairiness H-value is 2.1, the breaking strength reaches 17.5 cN / tex, and the covering structure is intact and stable. The finished fabric exhibits excellent breathability and skin-friendliness, without feeling stuffy or sticky even after long-term wear, while retaining the elasticity and softness of wool. It is suitable for developing functional knitted fabrics for spring and summer, such as underwear and loungewear.

[0040] This invention independently optimizes two sets of optimal ratios, 70:30 and 65:35, to suit different scenarios, specifically addressing the performance imbalance problem of traditional processes. It possesses new technical features in terms of structure, process, and ratio scheme.

[0041] This invention overcomes the technical limitations of traditional blended and single-strand core-spun processes. By matching a set of parameters—feeding spacing, filament tension, negative pressure, and forming twist—it systematically solves common industry problems in this type of composite yarn, such as core exposure, delamination, excessive fuzz, and unstable strength. The double-strand symmetrical wrapping combined with the negative pressure aggregation structure effectively improves fiber cohesion and overall yarn stability, achieving a synergistic improvement in multiple properties, including warmth retention, elasticity, antibacterial properties, and strength. This overall improvement solution is not a mere superposition of conventional technologies in the field and possesses significant inventiveness.

[0042] This invention's overall process can be achieved with minor modifications to traditional spinning machines, eliminating the need for specialized large-scale equipment, resulting in low modification costs and strong adaptability. Trial production and testing have shown that the yarn hairiness (H-value) can be stably controlled below 2.3, significantly reducing hairiness compared to traditional processes; the breaking strength is no less than 16.8 cN / tex, demonstrating a significant improvement in mechanical properties. The finished yarn is free of core exposure and delamination, exhibiting uniform yarn evenness, few defects, good stability during weaving, and a low yarn breakage rate, effectively improving production efficiency and finished product qualification rate. The process allows for continuous and standardized production with minimal batch-to-batch variation, making it suitable for large-scale industrial promotion and possessing broad market application prospects.

[0043] Examples of the best embodiments of the invention are provided, and any parts not described in detail are common knowledge to those skilled in the art. The scope of protection of this invention is determined by the claims, and any equivalent modifications made based on the technical teachings of this invention are also within the scope of protection of this invention.

Claims

1. A method for preparing a wool / seaweed fiber Sirosfil tightly spun core-spun composite yarn, characterized in that, Includes the following steps: Step 1: Open and comb the wool and seaweed fibers separately to produce directional blended roving; Step 2: Wool and seaweed fiber double rovings are fed in parallel as outer yarns with a parallel spacing of 2-5 mm. Synthetic filaments are fed in synchronously as core yarns with a tension of 5-15 cN. After being drawn by the drafting rollers, they are gathered to the negative pressure gathering device, so that the wool and seaweed fiber double strands are gathered and twisted with the core filament. The wool and seaweed fiber double strands spirally cover the outside of the core filament, forming a Sirofil tightly core-spun composite yarn.

2. The method for preparing wool / seaweed fiber Sirosfil tightly spun core-spun composite yarn according to claim 1, characterized in that, In step 2, the mass ratio of wool to seaweed fiber is 65-70:30-35.

3. The method for preparing wool / seaweed fiber Sirosfil tightly spun core-spun composite yarn according to claim 1, characterized in that, In step 2, the negative pressure range of the negative pressure collection device is -2kPa to -5kPa.

4. The method for preparing wool / seaweed fiber Sirosfil tightly spun core-spun composite yarn according to claim 1, characterized in that, In step 2, the twist is 300–600 twists / m.

5. The method for preparing wool / seaweed fiber Sirosfil tightly spun core-spun composite yarn according to any one of claims 1-4, characterized in that, The synthetic filament layer completely covers the outside of the double-core inner yarn.

6. A wool / seaweed fiber Sirosfil tightly spun core-spun composite yarn, characterized in that, Includes an inner core yarn and an outer blended covering layer; The inner layer is a high-strength synthetic filament core layer, and the outer layer uses a double-strand symmetrical wool / seaweed blended roving as the covering material. After the two rovings are gathered and flattened under negative pressure, they are tightly wrapped around the outside of the core filament in a symmetrical spiral manner.

7. The wool / seaweed fiber Sirosfil tightly spun core-spun composite yarn according to claim 6, characterized in that, The mass ratio of wool to seaweed fiber is 65-70:30-35.

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