The manufacture and Physical properties of Hanji Composite nonwovens utilizing the Hydroentanglement process

This study aims to develop the new Hanji paper composite nonwovens that positively affect the antimicrobial activity, deodorization, and comfort functionality of natural materials of cotton and rayon that have high consumer preference and to manufacture new sanitary goods and facial mask sheets utilizing the hydroentanglement process. The results of the study through the evaluation analysis of functionality and properties of the composite nonwovens developed in this study are as follows. The manufactured composite nonwovens have improved functionalities of absorption velocity, antimicrobial activity, and deodorization from the base materials of C45 (Cotton (45 g/m²)) and R53 (Rayon/PET (53 g/m²)). Also, physical properties such as tensile strength, breaking extension, and tearing strength have improved significantly. The texture of composite nonwovens of Mulberry 70 %/Pulp 30 %(15) of Hanji paper weight 15 g/m² with base material did not show a significant difference compared to the nonwovens of C45 and R53. However, the soft texture of composite nonwovens of Mulberry 70 %/Pulp 30 %(25) of Hanji paper weight 25 g/m² with base material showed somewhat of a decrease compared to the nonwovens of C45 and R53. When considering the marketability, the composite nonwovens of Mulberry 70 %/Pulp 30 %+C45 and Mulberry 70 %/Pulp 30 %+R53 were estimated to be a positive development for use in female sanitary products and facial mask sheet products. These newly developed Hanji composite nonwovens could contribute to the development of high value added products that would satisfy the consumers.     

Influence of the core-sheath weight ratio and twist on the tensile strength of the ring core yarns with high tenacity filaments

Core spun yarns are applied for various purposes that especially require the multi-functional performance. This research reports on the core spinning effect on the yarn strength. We prepared various core yarns by combining different kinds of high tenacity filaments in core with cotton staples in sheath with various twist levels in the ring spin system. And the tensile strength was tested to investigate the contribution of the core-sheath structure to the core yarn strength. The influence of the twist level was also checked up on the relationship between the core-sheath structure and the yarn strength. Results turned out that the core-sheath weight ratio had influence on the tensile properties of the ring core-spun yarns in different ways according to the core filaments used for the yarn. Increasing the twists yielded a monotone decreasing strength for the aramid and the basalt core yarns, while the PET core yarns showed almost unchanged strength, which could be ascribed to the extensional property of the filaments.     

Investigation of Parameters for Preparing Nanofiber Yarn via a Stepped Airflow-assisted Electrospinning

Electrospinning is a simple and cost-effective method to prepare fiber with nanometer scale. More importantly, 3D flexible nanofiber yarns that fabricated by electrospinning have shown excellent application prospects in smart textiles, wearable sensors, energy storage devices, tissue engineering, and so on. However, current methods for preparing electrospinning nanofiber yarns had some limitations, including low yarn yield and poor yarn structure. In this paper, a stepped airflow-assisted electrospinning method was designed to prepare continuously twisted nanofiber yarn through introducing stepped airflow into traditional electrospinning system. The stepped airflow could not only help to improve nanofiber yield, but also good for controlling the formed nanofibers to be deposited in a small area. In addition, the experimental methods of single factor variables were used to study the effects of stepped airflow pressure, applied voltage, spinning distance, solution flow rate, air pumping volume and friction roller speed on nanofiber yarn yield, nanofiber diameter, yarn twist and mechanical property. The results showed that prepared nanofiber yarns exhibited perfect morphologies and the yield of nanofiber yarn could reach to a maximum of 4.207 g/h. The breaking strength and elongation at break of the prepared yarn could reach to 23.52 MPa and 30.61 %, respectively.     

Multiple response optimization of rotor yarn for strength,unevenness, hairiness and imperfections

In this study, a multiple response optimization model based on response surface methodology was developed to determine the best rotor speed and yarn twist level for optimum rotor yarn strength and unevenness, and minimum yarn hairiness and imperfections. Cotton yarn of 30 tex, was produced on rotor spinning machine with different twist levels (i.e. 500, 550, 600 and 700 tpm) at different rotor speeds (i.e. 70000, 80000, 90000 and 100000 rpm). Yarn quality characteristics were determined for all the experiments. Based on the results, multiple response optimization model was developed using response surface regression on MINITAB® 16 statistical tool. Optimization results indicate that with the quality of raw material selected for this study, top 50 % quality level, according to USTER® yarn quality benchmarks, can be achieved with 100 % desirability satisfaction for all the selected yarn quality parameters at rotor speed of 77,800 rpm and yarn twist of 700 twists per meter.     

Design of traverse cam for yarn winding on twisting machine

A twisting machine is to twist yarns for improving yarn strength. After twisting yarns, the twisting machine winds yarns into a bobbin. The traverse mechanism is very important part of winding mechanism. Because it performs uniform winding onto the bobbin. the traverse cam is the main part of the traverse mechanism. This paper proposes design method of the traverse cam using the relative velocity method [4,5]. The relative velocity method is used to calculate the relative velocity of the follower versus the cam at the center of roller, and then to determine the contact point using the geometric relationship and kinematical constraints. Finally, we present examples verifying the accuracy of the proposed methods.     

Effect of strand spacing and twist multiplier on structural and mechanical properties of Siro-spun yarns

The effect of strand spacing and twist multiplier on strength of Siro-spun yarns with reference to the yarn structural parameters was investigated. Of the various structural parameters for staple yarns, fiber migration has a crucial influence on the yarn strength, which in turn to a considerable extent is influenced by the strand spacing and twist multiplier. Achieving the objectives of this research, the yarns were produced from lyocell fibers at five strand spacings and four different twist multipliers. Tracer fiber technique combined with image analysis were utilized to study the yarn migration parameters. Afterwards, the yarns were subjected to uniaxial loading by a CRE tensile tester. The measured results are presented in forms of diagrams and tables. The findings reveal that, as strand spacing is increased, yarn tenacity increases up to strand spacing of 8 mm beyond which it reduces. Analysis of the results indicates that the higher tenacity values at the strand spacing of 8 mm can be attributed to the higher mean fiber position, higher migration factor, higher proportion of broken fibers and lower hairiness.     

Properties of wool/spandex core-spun yarn produced on modified woolen spinning frame

Spandex has been successfully applied on modified worsted spinning system to produce spandex core spun yarn. However it’s difficult to produce wool/spandex core-spun yarn on woolen spinning system with the same modified device because the drafting device of the two systems is quite different. A new method is introduced to apply spandex on woolen spinning system in this paper. Core-spun yarn produced in this way has good appearance and quality by comparing with normal yarn. A series of experiments were carried out to study the influence of spandex drafting ratio and yarn twist factor on tensile properties and elasticity of core-spun yarns. The results indicate that core-spun yarn with spandex drawing ratio of 2.5 and twist factor of 13.63 has highest value of tenacity and breaking elongation.     

Continuous twisted nanofiber yarns fabricated by double conjugate electrospinning

In order to fabricate continuously twisted nanofiber yarns, double conjugate electrospinning had been developed using two pairs of oppositely charged electrospinning nozzles. The principle and process of this novel yarn spinning method were analyzed, and the effect of applied voltage, nozzle distance between positive and negative, solution flow rate and funnel rotating speed on the diameters, twist level and mechanical properties of resultant PAN nanofiber yarns were investigated in this paper. The results indicated that electrospun nanofibers aggregated stably and bundled continuously at the applied voltage of 18 kV, the nozzle distance of 17.5 cm between positive and negative, the overall flow rate of 3.2 ml/h and the flow ratio of 5/3 for positive and negative nozzles. The resultant nanofiber yarns had favorable orientation and uniform twist distribution, and the twist level of nanofiber yarns increased with the increase of the ratio of funnel rotating speed and winding speed. The diameters and mechanical properties of nanofiber yarns depended on their twist level. The diameters of prepared PAN nanofiber yarns ranged from 50 µm to 200 µm, and the strength and elongation of PAN nanofiber yarns at break were 55.70 MPa and 41.31%, respectively, at the twist angle of 41.8 °. This method can be also used to produce multifunctional composite yarns with two or more components.     

An investigation of methodology and apparatus to assess twist liveliness of spun yarns

A methodology and apparatus have been proposed to indirectly evaluate twist liveliness of spun yarns by measuring the number of snarl turns formed of a yarn submerged in a water bath. A comparative study was carried out to evaluate the effectiveness of water in the measurement of yarn snarls. T tests showed that water has a significant effect in the snarl forming and testing results. Systematic studies were then carried out in the intra and inter laboratories to evaluate the feasibility and accuracy of the proposed measurement system. The analysis of variance (ANOVA) for the studies showed that there is no significant difference in measuring twist liveliness between the operators in the same laboratory and between the operators from different laboratories, respectively. The largest variance in the tests is attributed to the expected variation in the level of snarl turns in different yarn specimens. The experimental results showed that the developed yarn snarling apparatus has made accurate and repeatable measurements of twist liveliness over a range of 100 % cotton ring spun yarn counts.     

Cotton yarn engineering using robust regression and criteria of Mallow’s Cp

The main purpose of the present study was to predict yarn’s important properties i.e., tensile, unevenness, hairiness, and imperfections of cotton yarn with minimum random errors and maximum accuracy. In this work, cotton fiber properties were measured from rovings carefully untwisted. HVI system and evenness tester of Premier were used to measure the various properties. All yarns (108 samples) were spun at yarn counts of 16, 20, 24, 28, and 32 Ne with optimum twist factor. The robust regression and criteria of Mallow’s Cp were used to evaluate the data. Optimal equations with appropriate variables and relative importance of various variables were also investigated. After the goodness of fit, desirable Cp and very large adjusted R² values were observed. Furthermore, the analysis of variance tables showed that the obtained equations were significant at usual significance levels.     

Study on the liquid flow behaviour of cotton wick

The present paper reports the interaction effect of yarn twist, yarn count and number of plies on wicking behaviour of plied cotton yarn. A three-variable factorial design technique proposed by Box & Behnken was used to investigate the combined interaction effect of the above variables. Both the vertical as well as horizontal wicking experiments were carried out with liquids of varying surface tensions, like distilled water, saline water and petrol. Each wick samples were subjected to nine different types of wicking related tests. The yarn count and number of plies in the cotton wick was found to play major role in wicking related properties, whereas the effect of twist in plied cotton wick was not that prominent when the twist per unit length of single and plied yarns were the same and in opposite direction. The rate of vertical wicking for saline water was found to be significantly lower than that of distilled water. The rate of horizontal wicking for distilled water was less than that of vertical wicking of distilled water. Use two or three parallel strands instead of one resulted in marked increase of vertical wicking.     

Effect of fiber friction, yarn twist, and splicing air pressure on yarn splicing performance

The impact of fiber friction, yarn twist, and splicing air pressure on mechanical and structural properties of spliced portion have been reported in the present paper. The mechanical properties include the tensile and bending related properties and, in the structural properties, the diameter and packing density of the splices are studied. A three variable three level factorial design approach proposed by Box and Behnken has been used to design the experiment. The results indicate that there is a strong correlation between retained spliced strength (RSS) and retained splice elongation (RSE) with all the experimental variables. It has been observed that RSS increases with the increase in splice air pressure and after certain level it drops, whereas it consistently increases with the increase in yarn twist. The RSE increases with the increase in both fiber friction and yarn twist. It has also been observed that the yarn twist and splicing air pressure have significant influence on splice diameter, percent increase in diameter and retained packing coefficient, but the fiber friction has negligible influence on these parameters. Yarn twist and splicing air pressure has a strong correlation with splice flexural rigidity, where as poor correlation with retained flexural rigidity.     

Optimisation of spinning parameters for processing of 100% sunnhemp fibers

This study was an attempt to spin 100% sunnhemp fibers, grown in Akola district of Maharashtra, India, on Jute spinning system. The sunnhemp fibers were first sprayed with oil and then softened. These fibers were then processed through various machine sequence by varying the number of carding and drawing machines. The yarn was spun in each case and tested for Count Strength Product and Evenness. This yarn was then used as a weft yarn to weave a 3/1-drill fabric with a cotton warp and tested for tensile strength. It was concluded that the set III with three carding and three drawing sequence gave an even yarn. The optimum twist per inch in the yarn was found to be 6.0.     

Study on the strength retention of technical cord yarn

This research studies the factors which influence the tensile strength of tire cords. Five yarn samples are made by changing the spinning conditions and viscosity to get various physical properties. Different twisting methods are introduced and the yarns are twisted under different processing conditions for each twisting process. With the experimental results, various analyses are performed to find the important factors in retaining strength after the twisting process. SEM and optical microscopic photographs are taken along with some measurements to assist the analysis.     

Study on Spinning triangles in the common ring spinning and Super draft ring spinning systems

In the paper, one kind of super draft ring spinning frame with four drafting rollers and corresponding three drafting zones were introduced. The yarn qualities spun by the super draft ring spinning frame were analyzed by studying the shape of spinning triangles. Using the high speed camera system OLYMPUS i-speed3 and one kind of transparent front top roller, the spinning triangles were captured, and the geometry size of spinning triangle were measured. Then, according to the theoretical model of fiber tension in the spinning triangle, fiber tension distributions in the spinning triangles were presented by using Matlab software. Using the combed roving of 350 tex as raw material, three kinds of cotton yarns, 27.8 tex (21^S), 18.2 tex (32^S) and 14.6 tex (40^S), were spun in the common ring spinning frame with three different suitable spindle speeds, travelers and twist factors. Using the combed roving of 350 tex and 500 tex as raw material, 14.6 tex cotton yarns were spun in the super draft ring spinning frame with three different drafting ratios at back zone. It is shown that with the increasing of spindle speed, a more asymmetric shape of spinning triangle would be produced, and lead to worsen yarn evenness. With the decreasing of traveler weight, the height and horizontal deviation of the spinning triangle is decreased, and may lead to better yarn evenness and less long hairiness. By taking suitable large yarn twist factors, the comprehensive qualities can be improved. Comparing with the common ring spinning, the spinning triangle is larger in the super draft ring spinning. That is, in the super draft ring spinning, the fibers in the strand in the front roller nip are more dispersed, and not benefit for yarn qualities. Therefore, the compact device was introduced into the super draft ring spinning, and the cotton pure yarns and blend yarns were spun, and the yarn qualities were measured and analyzed.     

Performance of cotton single yarns and knitted fabrics produced by a 2-step spinning method

A low torque spinning method has been recently developed by integrating the ring spinning process with false twisting techniques. As a result of false twist and true twist, a novel single yarn of low torque and soft handle is generated. Based on the similar spinning principle, this paper proposed a 2-step spinning method, which is composed of twisting-anduntwisting operation and can be considered as a variant of the low torque spinning method. The proposed spinning method separates the false twisting process into twisting and untwisting processes which are combined in one step in the low torque spinning method. In this paper, physical properties of yarns produced by the proposed spinning method were evaluated and compared with the conventional yarns. Influences of various spinning parameters on the properties of 2-step yarns were also examined. Furthermore, a systematic study of the physical properties of the 2-step yarns and resultant fabrics with respect to the conventional and low torque ones was carried out. The experimental results showed that the 2-step yarns exhibit slightly higher tenacity, lower wet snarl and much less hairiness than the conventional yarns, which, however, are inferior to the low torque yarns, particularly the evenness. The fabrics made by the 2-step yarns show the softest handle feeling, best airpermeability and moderate spirality angle with acceptable pilling resistance.     

An experimental investigation of yarn tension in simulated ring spinning

Yarn tension is a key factor that affects the efficiency of a ring spinning system. In this paper, a specially constructed rig, which can rotate a yarn at a high speed without inserting any real twist into the yarn, was used to simulate a ring spinning process. Yarn tension was measured at the guide-eye during the simulated spinning of different yarns at various balloon heights and with varying yarn length in the balloon. The effect of balloon shape, yarn hairiness and thickness, and yarn rotating speed, on the measured yarn tension, was examined. The results indicate that the collapse of balloon shape from single loop to double loop, or from double loop to triple etc, lead to sudden reduction in yarn tension. Under otherwise identical conditions, a longer length of yarn in the balloon gives a lower yarn tension at the guide-eye. In addition, thicker yarns and/or more hairy yarns generate a higher tension in the yarn, due to the increased air drag acting on the thicker or more hairy yarns.     

Preparation and characterization of electro-conductive rotor yarn by in situ chemical polymerization of pyrrole

This work describes a novel method for preparing electro-conductive rotor yarns by in situ oxidative chemical polymerization of pyrrole. The effects of different process parameters on electrical resistivity of the yarn were studied by using Box-Behnken response surface design. The concentration of monomer, polymerization time and polymerization temperature were found to influence the electrical resistivity of the yarn. It was observed that electrical resistivity of the yarn increased linearly with increase of measuring length of it. Whereas the effects of yarn twist and tensile strain found to had negative correlation with electrical resistivity of electro-conductive rotor yarns. Microscopic image analysis showed that there was uniform distribution of PPy polymer on the surface of cotton fibres and FTIR analysis depicted possible chemical interaction between polypyrrole and cellulose.     

An investigation on the effects of twist on geometry of the electrospinning triangle and polyamide 66 nanofiber yarn strength

The formation of a symmetric electrospinning triangle zone (E-triangle) via a technique based on using two oppositely charged nozzles is described for fabricating continuous twisted nanofiber yarn of polyamide (Nylon 66). This study shows how changing the dimensions and geometry of the E-triangle influences the distribution of nanofiber tension and diameter in this zone, and consequently how it affects the nanofiber yarn strength. The twist effect on the E-triangle geometry was investigated by changing the rotational speed of the twister plate of values of 96, 160, 224 and 288 rpm. The results showed that by increasing the twist rate, the apex angle of the E-triangle increased, whereas the height and width of the Etriangle decreased. An energy method was adopted to study the distribution of tension on nanofibers in the E-triangle. Considering a constant spinning tension, it was observed that the gradient of the nanofiber tension curve was steeper and the extreme values of tension on nanofibers were increased by increasing the twist rate. Furthermore, the mean diameter reduction of nanofibers confirmed these results. It is concluded that mechanical properties of nanofiber yarn have been considerably improved by increasing the twist rate and changing the shape of the E-triangle.     

A comparative study of finer conventional and modified cotton yarns and their resultant woven fabrics

A modified ring spinning technique has been recently developed by incorporating false twisting devices into the conventional ring frame. Its application on the coarser yarn counts (7–32 Ne) showed notable advantages in modified yarn and fabric performance. More recently, it was noted that this technique can also be applied for producing finer cotton yarns. Thus this paper aims to carry out a systematic study of the physical properties of the finer modified yarns (80 Ne) and woven fabrics with respect to the conventional ones. Physical properties of conventional and modified single yarns were evaluated and compared. These two types of single yarn were used for the production of woven fabrics. Moreover, the above two types of single yarn were also plied and used for the production of woven fabrics under a commercial condition. All woven fabrics were assessed in terms of fabric tensile strength, tearing strength, abrasion resistance, fabric weight, and air-permeability as well as other fabric performance measured by the Kawabata Evaluation System (KES). Experimental results showed that finer modified yarns and fabrics exhibit higher strength, lower hairiness, and improved abrasion resistance, slightly better compression property, and smoother surface with relatively larger thickness.