There are currently five practical and highly concerned spinning methods in the field of cotton spinning, namely traditional ring spinning, rotor spinning, air-jet spinning, vortex spinning and improved ring spinning – compact spinning.
The ring spinning method has a history of more than a century and a half, and the latter four have been developed in recent decades or even in recent years, and are collectively referred to as new spinning methods. method. Different spinning methods have their own unique characteristics in terms of output, quality, and yarn structure and characteristics.
1. Comparison of yarn forming mechanisms
01 Traditional ring spinning
Ring spinning is a spinning method that performs drafting, twisting and winding at the same time. The roving is drafted to the required yarn count in the drafting system. The whiskers are then twisted and wound by steel rings and travelers to form a yarn. Due to the drafting effect, the width of the sliver in the main drafting zone is several times the diameter of the yarn being spun. At this time, each fiber is in a free state when it reaches the front nip line. When these fibers leave the front nip line, they are twisted together, thus forming a spinning twisting triangle. This spinning twist triangle area prevents the edge fibers from completely entering the yarn body, and some edge fibers break away from the main body to form fly flowers. More edge fibers are twisted into the yarn body at one end, and hairiness is formed at the other end. These fibers not only have a negative effect on the uniformity, elasticity and other properties of the yarn, but are also extremely detrimental to the strength of the yarn. In addition, during twisting, the fibers outside the triangular area are subject to the greatest tension, while the fibers in the center are subject to the smallest tension. Therefore, the initial tensions of these fibers are not equal when the yarn is formed, thus affecting the strength of the yarn. These are defects caused by the spinning triangle of traditional ring spinning.
02 Rotor spinning
Rotor spinning is also called open-end spinning and belongs to open-end spinning. method. The cotton sliver that is directly fed into the spinning device is combed into single fibers by the opening roller. The fibers are separated from the surface of the opening roller by the centrifugal force of the opening roller and the negative pressure air flow in the spinning rotor and enter the spinning rotor through the cotton conveying pipe. , and forms a complete fiber ring in the condensation groove. The fiber ring rotates at high speed with the spinning rotor. Under the action of the splicing yarn, the twist is continuously transferred and the fiber bundle is continuously peeled off to form a yarn.
03 Air-jet spinning
Air-jet spinning Spinning is represented by the MJS (Murata Jet Spinner) model manufactured by Japan’s Murata Company. The cotton sliver is directly fed into the drafting device, and the drawn sliver enters the nozzle. High-speed rotating airflow in two opposite directions falsely twists the sliver and wraps it into yarn. After the sliver is drawn out, defects are removed by an electronic yarn clearer. Then it is wound on the bobbin.
04 Vortex spinning
Vortex spinning is a new generation launched by Murata after MJS Air-jet spinning technology MVS. The yarn forming principle of vortex spinning is that the cotton sliver is directly fed into the drafting device. The drafted sliver is output from the front roller jaws and is immediately sucked in by the negative pressure generated by the vortex in the direct nozzle of the spinning device to form core fibers. When the end of the fiber breaks away from the front roller, it expands due to the eddy current, covers the surface of the hollow spindle, and rotates along the fixed hollow inner wall. As the yarn moves forward, the fiber end wraps around the yarn core to obtain the yarn. Twisted to form yarn.
05 Improved ring spinning – compact spinning
Compact spinning is also called compact spinning. It mainly adds a fiber agglomeration area in front of the drafting device of the ring spinning machine. The fiber bundles migrated from the nip line of the front roller of the drafting device are gathered on one line, basically eliminating the need for space between the front roller and the twisting point. The spinning twisting triangle area can effectively solve the key problems of traditional ring spinning such as yarn strength, hairiness and fly, and bring a series of benefits to subsequent processing and product quality. Different machine manufacturers have provided a variety of patents for agglomerating these fibers, but the principles are basically the same. They are all designed to effectively control the fibers in the strands, especially the edge fibers and floating fibers, through agglomeration, which greatly Reduce the width of the drafting whisker strip, thereby basically eliminating the spinning twist triangle and producing a new type of high-quality compact ring-spun yarn.
2. Comparison of yarn structure and form
Different spinning methods have different yarn formation mechanisms, the arrangement of fibers in the yarn and the tightness of the yarn are also different.
01 Traditional ring spinning yarn structure
The fibers in traditional ring-spun yarn are basically arranged in a spiral. Due to the existence of the spinning twisting triangle, all the fibers cannot be twisted into the yarn body, and more edge fibers are twisted at one end. Twisted into the yarn body, the other end is exposed outside the yarn to form hairiness. Therefore, although the structure of the ring-spun yarn is relatively tight, the surface of the yarn appears relatively messy and has a poor finish.
02 Rotor spinning yarn structure
Rotor yarn� Small, but also has good post-processing characteristics.
05 Anti-pilling
Vortex yarn knitted fabric has good wear resistance and anti-pilling grade high. This is because the middle of the vortex yarn is a straight core yarn, and the outer layer is covered with winding fibers. The fiber orientation is obvious, the yarn friction coefficient is large, the friction between the yarns in the fabric is good, and relative slippage is not easy to occur, and the wear resistance is improved. In addition, pilling is also closely related to the hairiness of the yarn. Through the pilling test, it can be seen that the vortex yarn fabric is grade 4 to 4.5, the air-jet yarn is grade 4, the traditional ring yarn is grade 2, the rotor yarn is grade 2 to 3, and the compact yarn is grade 3 to 4.
4. Yarn application comparison
01 Ring yarn
Despite the emergence of many new spinning methods, to this day ring spinning still has an indisputable advantage and occupies a dominant position among all yarns , products are widely used. This is due to the simple ring spinning mechanism, wide spinning range and good yarn quality.
However, the ring spinning process is long and further quality improvement is limited. In particular, the yarn has high hairiness, which affects its application in some products, such as high-end shirt fabrics.
02 Rotor yarn
The application fields of rotor spinning products are relatively wide, especially in denim The two series of fabrics, namely cloth and knitted fabric, have unique advantages in application. Because rotor spinning mostly produces coarse-count yarns, the yarn structure that is loose on the outside and tight on the inside can obtain better dyeing fastness and deeper color, thus forming a unique style of blue and white in denim fabrics. At present, the application ratio of rotor yarn in weaving and knitting in my country is about 9:1. With the advancement of technology and the introduction of high-end rotor spinning equipment, the application of rotor yarn in the knitting field will be greatly enhanced, and its ratio is expected to be Reached 6:4.
03 Air-jet yarn
Air-jet yarn and vortex yarn can completely eliminate the torque and skew of knitted fabrics. Therefore, it became a mainstream application product in the knitting market as soon as it appeared. Air-jet yarn knitted fabrics have high pilling resistance, no skew, few streaks, low shrinkage, and a smooth and plump cloth surface. Its products mainly include sportswear, double-sided casual wear, children’s clothing, knitted T-shirts and underwear, etc. The raw materials are mainly polyester-cotton blended varieties.
Since air-jet yarn has the advantages of less hairiness and fewer evenness defects, although its strength is lower than that of ring-spun yarn, its strength CV value is small, which is exactly what is needed for shuttleless looms. The yarn standard is suitable for use on shuttleless looms. Generally, the use of air-jet yarn can increase the efficiency of the loom by 2% to 3%. There are two main categories of air-jet yarn woven products: one is apparel fabric products, and the other is home textile products. According to reports, more than 50% of home textile products and uniform fabrics in the US market are made of air-jet yarn.
In addition, air-jet yarn is more suitable for processing 10,000 meters of knotless sewing thread.
Although traditional air-jet spinning technology is not suitable for producing pure cotton yarn, it has unique advantages for chemical fibers, especially fine-denier chemical fibers and other differentiated fibers. As the world’s population increases, the dependence on chemical fibers will become more obvious. The proportion of chemical fibers in clothing fabrics, decorative fabrics and industrial fabrics will increase rapidly. Therefore, air-jet spinning technology and its products will also be developed accordingly.
04 Vortex yarn
Vortex spinning can process pure cotton yarn and has spinning speed Due to its high advantages, it developed rapidly in the early 21st century. Vortex yarn has a ring-spun yarn structure and has more functions and popular features. It has very little yarn hairiness, reduced fabric pilling, good dyeing performance and abrasion resistance, smooth fabric appearance, good hygroscopicity, and quick drying. . Therefore, vortex yarn fabrics are mostly used in knitted sweatshirts, casual clothing, home textile products, etc., with a wide range of product applications.
05 Compact yarn
The emergence of compact yarn first gained the attention of those who pay attention to the quality of life and love high-end pure yarns. Cotton clothing is highly sought after by Europeans. According to relevant information, 80% of compact yarn in Europe is used for men’s shirt fabrics. European users now regard compact yarn as the standard for high quality yarns. This is due to the characteristics of compactly spun yarn with low hairiness and high strength. It is particularly suitable for spinning high-count combed yarn for weaving high-grade pure cotton shirts, anti-feather fabrics, etc. It also has low sizing costs, less weaving fly, and high weaving efficiency. With the advantages of high fabric gloss, clear appearance and enhanced color contrast, the application of compact yarn will bring the quality of textile products to a new level.
Of course, compact yarn also has strong advantages when used in certain types of knitted fabrics. For example, it can often eliminate the singeing process and process high-end T-shirts and other products. Currently, due to its compactness, The cost of spinning equipment is high, and ordinary knitted fabrics are still unable to afford the higher yarn prices, which restricts the application of compact yarns to a certain extent.
5. Conclusion
Different spinning methods produce different yarn structure and yarn properties.
Each spinning method has its own characteristics, and the yarn structure has its own characteristics. If its advantages are properly utilized to overcome its disadvantages, there will be many types of products that can be developed. In order for a certain spinning method to be popularized and applied, the key depends on whether it can develop distinctive, marketable and viable products.
The prospects of different spinning methods will be determined according to the market demand for fabric styles, that is, it depends on the application fields of yarns with different structural characteristics. The future spinning market will present a trend of coexistence of multiple spinning methods and diversified product structures.
With the development of science and technology, various spinning methods will penetrate and complement each other, and various yarn characteristics will be further integrated and developed, which will bring more advantages to yarn products. Application development brings huge scope.
��Spinning methods will penetrate and complement each other, and various yarn characteristics will be further integrated and developed, which brings huge space for the application and development of yarn products. </p
