Effects of process variables on physical characteristics of tri-component elastic-conductive composite yarns (t-ECCYs) using a modified ring frame

The fabrication procedure of tri-component elastic-conductive composite yarns (t-ECCYs) with distinctive architecture,which employs elastane filament as a core and stainless steel filament combining with rayon assemblies as a helicalwinding around the extensible core, was demonstrated. Then, a single factorial-analysis technique was applied toinvestigate the effects of processing variables, i.e., strand spacing, twist level and spindle speed, on some physicalcharacteristics and spinning geometries of the resultant yarns, in terms of breaking tenacity, extension at break,elasticity, hairiness, unevenness, and visual features. Then, the electrical behavior was conducted. It is well establishedthat the preparatory process variables play a significant role in deciding the physical characteristics of the final yarns.The Relationship between spinning geometries and yarn properties were highlighted. Experimental results revealed thatthe optimized physical performances of t-ECCYs were obtained at 10.5 mm strand spacing, 700 T/m twist, and 7000rpm spindle speed. The resultant t-ECCYs could be a high-valuable proposition for special purposes in electrical textiles.The yarn itself is available as a base sensor element with substantial stretch and high conductivity, and such yarns couldbe easily processed into fabrics by conventional textile means offering fabrics with good shape preservation based onsuperior elasticity, even electromagnetic shielding effectiveness with metal monofilament inside, and can thus be appliedas lightweight miniature electronics in the future.