Low weight terry fabric and a method of producing the same

Abstract

A towel is provided comprising a ground cloth having warp yarns and weft yarns in a flat weave and having first and second sides. Stripes are provided on the first and second sides of the ground cloth that are defined by alternating areas of pile loops and flat weave, the pile loops on the first side being opposed by flat weave on the second side and the flat weave on the first side being opposed by pile loops on the second side. The pile loops have a density of 60 loops per cm2. A method for manufacturing a terry towel is also provided in which the towel has a weight of less than 240 gsm using a combination of open structured 100% cotton pile yarn of finer counts with ground and weft yarns that have a proportion of synthetic fiber of from 10% to 100%; comprising: weaving a striped pattern of 100% of pile yarn on one side alternated with 100% of pile yarn on other side to create double density loop stripes, the stripes having width in the range of 2 mm to 25 mm.

Description

FIELD OF THE INVENTION[0001]The present invention relates to terry fabric having open structured pile yarn of finer counts with a cotton / synthetic blend in ground warp and weft yarns. Particularly, the present invention relates to terry towel preferably having 100% cotton yarn in the pile, with cotton preferably blended to 100% synthetic ground warp and weft yarns.DESCRIPTION OF THE PRIOR ART[0002]Terry fabrics belong to a group of pile fabrics in which an additional yarn is introduced or inserted in such a manner that forms loops, called “piles,” to give a distinct appearance. These fabrics can be produced either by weaving or by knitting.[0003]Most conventional terry towels are woven from all cotton or a combination of cotton and polycotton yarns, primarily because cotton is inexpensive and has the property of high absorbency. Using cotton for the manufacture of terry towels has been found to be advantageous in many respects, such as good moisture absorption durability, and easy a...

AI Technical Summary

Benefits of technology

This patent describes a new type of terry towel that was made using a special weaving technique. The towel has loops made up of yarn that are open-structured and have low twist or no twist. The pile yarn has a twist multiplier of less than 2.4, which allows for quicker drying of the towel. The size of the loops is about 0.8 mm, making the towel bulkier. The loops have a diameter of 1.6 mm, making it highly absorbent. The towel is made using a combination of cotton and synthetic fiber yarns, which results in a low weight, highly absorbent product. The weaving process involves weaving a striced pattern of pile yarn on one side alternated with pile yarn on the other side to create a double density loop stripes, which keeps the loops upright and prevents them from falling down due to lack of space around the loop.

Problems solved by technology

However, it also presents several drawbacks, one being slow release of absorbed moisture, resulting in the drying time for cotton towels being relatively longer.

When thicker and heavier yarns are used to make towels, the time required for drying increases.

Slow drying is disadvantageous because it results in increase in time between the instances when the towels can be used, and promotes the souring of towels and mildew formation.

It also results in increased energy consumption to dry the towels.

Further, in the case of conventionally heavier towels, there is a limitation on the number of towels that can be loaded in a washing machine.

The conventional terry toweling process reduces the absorbency and the inherent soft nature of cotton.

Conventionally, terry towels with weight below 300 gsm are not produced, since low weight does not result in sufficient absorbency and further does not provide sufficient strength or durability.

When yarns of counts finer than 16 s Ne are used for all the warps and weft to reduce the weight, the fabric does not have sufficient strength to withstand vigorous laundering especially in institutional use.

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