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A core-spun yarn containing an ultrafine copper wire for wearable electronics-oriented applications has been manufactured using a modified vortex spinning system for the first time. The copper wire is fed into the spinning nozzle through a groove on the surface of the top front roller and an orifice through the fiber guiding member in sequence. Scanning electron micrographs confirm that the copper wire locates in the core region and is tightly wrapped by the helical staple fibers of the outer layer in the core-spun yarn, owing to the special yarn formation mechanism of the vortex spinning system. The vortex core-spun yarn containing a copper wire has a strength higher by 86.6% and a breaking extension lower by 70.2% compared to the copper wire, while its strain sensitivity in the workable strain range is not affected by either the yarn manufacturing process or the existence of staple fibers. The vortex core-spun yarn containing a metal wire could be a promising candidate for the conductive tracks of wearable electronics due to its improved structure, durability, and comfort.

A core-spun yarn containing a metal wire manufactured by a modified vortex spinning system