Multi-layer towels with excellent absorbency that can be dyed twice in one bath

Abstract

This invention relates to a multi-layer towel with excellent absorbency and dyeability that retains a soft touch even after repeated washing, and a method for manufacturing a multi-layer towel that can be dyed twice in one bath, thereby simplifying the manufacturing process of multi-layer towels, saving energy, and allowing for dyeing into a variety of patterns.

Description

Technical Field

[0001] The present invention relates to a multi-layered towel with excellent water absorption that can be dyed in one bath, and more specifically, to a multi-layered towel that can be dyed into a variety of patterns by double dyeing a terry fabric woven from alternating first and second pile yarns in one bath. Background Technology

[0002] Recently, the fiber industry has been actively researching complex, high-performance fibers with various functions. In particular, the technological development trend of raw yarns and fabrics is moving towards differentiation and further enhancing the functionality of clothing. Furthermore, to improve the quality of life, the industry is developing functional materials, including safe, healthy, and high-quality products. This development of functional materials is taking place across various sectors of the fiber industry, including everyday consumer goods.

[0003] Importantly, everyday essentials like towels, which come into direct contact with the skin, need to have a soft feel, good absorbency, and maintain a clean appearance. Furthermore, due to the frequent washing required for their intended use, durability against washing is also necessary. For these reasons, cotton fibers are primarily used as the material for towels. Although cotton fibers have high moisture absorption, the cellulose backbone, which is the main component of cotton, contains a large number of hydroxyl groups (-OH) that act as hydrophilic groups. Therefore, there are problems with the ability to quickly remove absorbed moisture and with the feel deteriorating due to repeated washing.

[0004] In addition, towels used to remove moisture or sweat after bathing or exercise typically need to quickly remove residual moisture or sweat from the skin without causing irritation, but there are limitations when using 100% cotton yarn.

[0005] To address this issue, although there are methods that utilize blended yarns of synthetic and natural fibers or blended yarns of bamboo and synthetic fibers, color differences in the finished product are caused by the differences in dyeability and fastness between synthetic and natural fibers, and some parts become white due to repeated washing and rubbing.

[0006] Existing technical documents

[0007] Patent documents

[0008] Patent Publication No. 10-2004-0016620

[0009] Patent Registration Publication No. 10-1595874 Summary of the Invention

[0010] This invention provides a multi-layer towel with excellent absorbency and dyeability that retains a soft touch even after repeated washing, as well as a method for manufacturing a multi-layer towel that can be dyed twice in one bath, thereby simplifying the manufacturing process of multi-layer towels, saving energy, and allowing for dyeing into a variety of patterns.

[0011] The present invention for achieving the stated purpose provides a multi-layer towel comprising a terry fabric woven from ground warp yarns containing cotton fibers, weft yarns containing cotton fibers, and pile yarns, and subjected to a first dyeing and a second dyeing. The pile yarns comprise a first pile yarn containing cellulose fibers, and a second pile yarn comprising one or more yarns (filaments) selected from a cluster consisting of blended yarns of polyester and cotton fibers, blended yarns of polyester fibers and regenerated cellulose fibers, and polyester yarns, as well as a nylon / polyester split composite yarn.

[0012] In one aspect of the invention, the second pile yarn may include a polyester-cotton blended yarn and a nylon / polyester split composite yarn.

[0013] In one aspect of the invention, the polyester-cotton blended yarn may include an initial twist of 300 to 500 TPM.

[0014] In one aspect of the invention, the nylon / polyester split composite yarn may include an initial twist of 300 to 500 TPM.

[0015] In one aspect of the invention, the polyester-cotton blend yarn including primary twisting may include secondary twisting.

[0016] In one aspect of the invention, the nylon / polyester split composite yarn including primary twisting may include secondary twisting.

[0017] In one aspect of the invention, the number of initial twists and the number of secondary twists may satisfy the following formula 1.

[0018] [Formula 1]

[0019] 0.5≤T2 / T1<1,

[0020] In the formula, T1 represents the number of initial twists, and T2 represents the number of secondary twists.

[0021] In one aspect of the invention, the second pile yarn may include a tertiary twisting process, which combines and twists a blended yarn of polyester and cotton including a second twist and a split-type nylon / polyester composite yarn including the second twist.

[0022] In one aspect of the invention, the number of three twists can satisfy the following formula 2.

[0023] [Equation 2]

[0024] 0.005≤T3 / T1≤0.09

[0025] In the formula, T3 means the number of three twists, and T1 means the number of the first twist.

[0026] In one aspect of the invention, the cellulose fiber may include one or more fibers selected from a cluster consisting of cotton fiber, hemp fiber, rayon fiber, lyocell fiber, and a blend of polynosic fiber and cotton fiber.

[0027] Another aspect of the present invention relates to a method for manufacturing a multi-layer towel, the method comprising: a terry fabric manufacturing step of manufacturing a terry fabric from a ground warp yarn containing cotton fibers, a weft yarn containing cotton fibers, and a pile yarn; a primary dyeing step of dyeing the manufactured terry fabric with a disperse dye; and a secondary dyeing step of dyeing the primary dyed terry fabric with a reactive dye, wherein the pile yarn comprises a first pile yarn containing cellulose fibers, and a second pile yarn comprising one or more yarns (filaments) selected from a cluster consisting of a blended yarn of polyester and cotton, a blended yarn of polyester and regenerated cellulose fibers, and polyester yarn, and a nylon / polyester split composite yarn.

[0028] In one aspect of the invention, prior to the terry fabric manufacturing step, a twisting step of twisting the pile warp yarns may be included.

[0029] In one aspect of the invention, the twisting step may include a primary twisting process, a secondary twisting process, and a tertiary twisting process.

[0030] In one aspect of the invention, the initial twisting process and the secondary twisting process can twist the material to satisfy the following formula 3.

[0031] [Formula 3]

[0032] 0.5≤T2 / T1<1,

[0033] In the formula, T1 means the number of twists assigned in the initial twisting process, and T2 means the number of twists assigned in the secondary twisting process.

[0034] In one aspect of the invention, the initial twisting process and the tertiary twisting process are twisted to satisfy the following formula 4.

[0035] [Formula 4]

[0036] 0.005≤T3 / T1≤0.09

[0037] In the formula, T3 means the number of twists assigned in the three twisting processes, and T1 means the number of twists assigned in the first twisting process.

[0038] The multi-layer towel of the present invention has excellent water absorption and dehumidification properties, can be dyed into a variety of patterns, and can maintain a soft touch even after repeated washing.

[0039] The manufacturing method according to the present invention can produce multi-layered towels that not only have excellent moisture absorption and dehumidification properties but can also be dyed into various patterns. Furthermore, the manufacturing method of the present invention has the advantage of enabling dual dyeing in a single bath without interference between reactive dye dyeing and disperse dye dyeing. In addition, it simplifies the dyeing process, thereby saving energy in the manufacturing process. Attached Figure Description

[0040] Figure 1 This is a diagram of a multi-layered towel according to the present invention. Detailed Implementation

[0041] The specific examples or embodiments below are merely for the purpose of illustrating the invention in detail. The invention is not limited thereto and can be implemented in various forms.

[0042] Furthermore, unless otherwise defined, all technical and scientific terms have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used in this invention is intended only to effectively describe specific instances and is not intended to limit the invention.

[0043] Furthermore, unless otherwise specified in the context, the singular form used in the specification may also be intended to include the plural form.

[0044] Furthermore, when a part is referred to as "including" a constituent element, unless otherwise stated to the contrary, it means that other constituent elements may also be included, rather than excluding other constituent elements.

[0045] Furthermore, when describing the constituent elements of the present invention, terms such as first, second, (A), (B), (a), (b), etc., may be used. These terms are only used to distinguish the constituent element from other constituent elements, and the nature, order, or sequence of the constituent elements are not limited by these terms.

[0046] In this manual, the term "filament yarn" means that each filament is composed of one or more continuous fibers in the form of a filament of the overall length of the running yarn. "Strand" can be understood as forming multiple filament yarns twisted together.

[0047] The term "terry fabric" as used in this invention is generally referred to as warp pile fabric, which is a fabric in which individual pile warps are arranged to form pile or tufts on the fabric surface, with the warp and weft yarns forming the base (weave structure). More specifically, it refers to a multi-layered warp pile fabric in which special warp yarns, called terry piles, form loops at the base.

[0048] The following is a detailed description of the multi-layer towel and its manufacturing method according to the present invention.

[0049] This invention provides a multi-layer towel. According to the invention, the ground warp and pile yarns are first wound onto separate warp beams. The ground warp is then hung on a loom with a weft device under strong tension, while the pile yarns are hung under weak tension. At this point, the ground warp and pile yarns are arranged alternately. The invention also includes a terry fabric where the first weft yarn is inserted between the warp yarns and then the shuttle is dropped, and the second weft yarn is inserted between the warp yarns and then the shuttle is dropped forcefully, so that the pile yarns are pushed forward and form loops on both sides of the bottom.

[0050] The terry cloth can be initially dyed with disperse dyes and then secondarily dyed with reactive dyes, thus allowing it to be dyed into a variety of patterns.

[0051] The bottom (weave) can be formed by weaving ground warp and weft yarns. The ground warp and weft yarns can comprise cotton fibers, and can be cotton yarns manufactured from cotton fibers using conventional cotton spinning processes. The fineness of the cotton yarn can be 20 to 40 cotton yarn number, and using cotton yarns with this fineness ensures weaveability and mechanical strength, which is advantageous for manufacturing, resulting in multi-layered towels with good morphological stability, and is preferred for the excellent absorbency of multi-layered towels.

[0052] The pile yarn may include a first pile yarn and a second pile yarn.

[0053] The first pile yarn may include cellulose fibers, and the cellulose fibers may include one or more fibers selected from a group consisting of cotton fibers, linen fibers, rayon fibers, lyocell fibers, and blends of Polinosic fibers and cotton fibers. For the morphological stability, absorbency, and dyeing into various patterns of the multi-layer towel, it may be made of cotton fibers or lyocell fibers. The first pile yarn may be a yarn containing cellulose fibers, and the yarn may be spun using conventional textile processes.

[0054] The second pile yarn may contain one or more yarns (filaments) selected from a cluster of polyester and cotton blended yarns, polyester and regenerated cellulose blended yarns, and polyester yarns, as well as nylon / polyester split composite yarns. For the absorbency, soft feel, and dyeing of multiple layers of towels into various patterns, it may include polyester and cotton blended yarns and nylon / polyester split composite yarns.

[0055] The blended yarn of the polyester and cotton fibers can be a mixture of 70 to 80% by weight of polyester fibers and 30 to 20% by weight of cotton fibers, spun using conventional textile processes. For the absorbency of multi-layer towels and to allow for dyeing into various patterns, they can be composed of 70% by weight of polyester fibers and 30% by weight of cotton fibers, but are not limited thereto.

[0056] The nylon / polyester split microfiber yarn has a nylon to polyester weight ratio of 2:8 to 3:7, and the microfiber yarn is formed by a splitting process, which can be performed during the dyeing process. The splitting is achieved by reducing the polyester component in the nylon / polyester yarn. The polyester reduction can be 5% to 7% by weight, but when the polyester reduction exceeds 7% by weight, there is a potential decrease in the strength of the microfiber yarn.

[0057] The weight reduction process can also be applied to conventional weight reduction processes. For example, alkali-soluble weight reduction processes can also be applied, but are not limited to this. In terms of fiber strength, it is preferable to prevent the intrusion of components other than the elution resin by minimizing alkaline hydrolysis.

[0058] The nylon / polyester split-type microfiber yarn refers to yarn composed of 30 to 70 filaments and split into filament yarns with a total fineness of 40 to 100 denier, thus achieving a thickness of 0.01 to 1 denier per filament. This splitting process creates finer spacing between fibers, thereby increasing the fiber surface area and significantly increasing the moisture absorption capacity.

[0059] The blended yarn of the polyester fiber and the cotton fiber may include an initial twist of 300 to 500 TPM. The initial twist may be an S-twist or a Z-twist.

[0060] After the initial twisting, a high-pressure steam treatment is performed to fix the twist. The fixed polyester and cotton blend yarn then undergoes a detwisting process to untwist the twist. The blend yarn after the detwisting process includes a secondary twisting in the opposite direction to the initial twisting. For example, if the initial twisting is in the S direction, the secondary twisting is in the Z direction, and if the initial twisting is a Z twist, the secondary twisting is an S twist.

[0061] The nylon / polyester split microfiber yarn may include the same primary twisting and secondary twisting as the blended yarn of the polyester fiber and the cotton fiber.

[0062] This can include a three-stage twisting process, where polyester fibers are combined with cotton fibers in the same twist direction and with the same number of twists, and nylon / polyester split-type microfiber yarn is twisted in the same direction as the initial twist. When polyester fibers are combined with cotton fibers and nylon / polyester split-type microfiber yarn and twisted, a strand is formed. That is, it can be a strand comprising polyester and cotton fibers blended with nylon / polyester split-type microfiber yarn.

[0063] The number of twists in the first twist (T1) can be greater than the number of twists in the second twist (T2), and the number of twists in the second twist (T2) can be greater than the number of twists in the third twist (T3).

[0064] The initial twisting and the secondary twisting can satisfy the following formula 1.

[0065] [Formula 1]

[0066] 0.5≤T2 / T1<1,

[0067] In the formula, T1 represents the number of initial twists, and T2 represents the number of secondary twists.

[0068] The T2 / T1 ratio can be less than 0.8, and when 0.5 ≤ T2 / T1 ≤ 0.7, the fixed crimp morphology of the initial twist can be maintained for more than 80%.

[0069] The initial twisting and the third twisting can satisfy the following formula 2.

[0070] [Equation 2]

[0071] 0.005≤T3 / T1≤0.09

[0072] In the formula, T1 represents the number of the first twist, and T3 represents the number of the third twist.

[0073] The T3 / T1 ratio is preferably 0.01 or higher and 0.05 or lower, and when T3 / T1 is 0.01 or higher and 0.02 or lower, the crimp morphology of the first twist and the second twist can be maintained at more than 80%.

[0074] When T2 / T1 and T3 / T1 satisfy the stated numerical range, a rotating cavity or groove is formed in the longitudinal direction of the pile yarn. Therefore, moisture can be absorbed and dehumidified solely by the pile yarn. Furthermore, the pile yarn satisfying the stated numerical range is difficult to detach from the structure of the terry fabric. Thus, even with repeated washing when using multiple layers of towels, it can maintain its shape, thereby solving the problem of towels turning white due to repeated washing and friction during use. In addition, the water absorption rate of multi-layered towels made from terry fabric containing pile yarns satisfying the stated numerical range can be 40% to 60%, or 45% to 55%.

[0075] In the method for manufacturing a multi-layer towel according to the present invention, the ground warp yarn, the first pile yarn, and the second pile yarn (twistd three times) of cotton yarn are first wound onto separate warp beams. The ground warp yarn is then hung on a loom equipped with a weft yarn device under strong tension, while the first pile yarn and the second pile yarn are hung under weak tension. At this time, the ground warp yarn and the first pile yarn are arranged in parallel, and the ground warp yarn and the second pile yarn are arranged in parallel, so that the ground warp yarn and the pile yarn are arranged alternately. The process includes the steps of inserting the first weft yarn between the ground warp yarns and then casting the shuttle, and inserting the second weft yarn between the ground warp yarns and then casting the shuttle with force, so that the first pile yarn and the second pile yarn are pushed forward and form loops on both sides of the bottom. When the first pile yarn forms loops on the bottom surface, the second pile yarn forms loops on the bottom back surface, or the first pile yarn forms loops on the bottom back surface and the second pile yarn forms loops on the bottom surface to manufacture a terry fabric, and the step of dyeing the manufactured terry fabric.

[0076] The composition of the materials used for the ground warp yarn, the weft yarn, and the pile yarn is the same as described above, so its specific details are omitted.

[0077] Before the terry fabric manufacturing step, the process further includes a twisting step of twisting the pile warp yarns, and the twisting step may include a primary twisting process, a secondary twisting process, and a tertiary twisting process.

[0078] The initial twisting process can be performed on polyester / cotton blended yarns and nylon / polyester split microfiber yarns using 300 to 500 TPM with either S-twist or Z-twist. When the required twist count is met, a rotating cavity or groove can be easily formed in the longitudinal direction of the second pile yarn, while maintaining the strength of the second pile yarn.

[0079] Following the initial twisting process, a high-pressure steam treatment step may be included to fix the twist. In this high-pressure steam treatment step, any apparatus capable of performing high-pressure steam treatment is not limited, and the high-pressure steam treatment is preferably carried out at a temperature of 130 to 150°C for a period not exceeding 10 minutes. When the high-pressure steam treatment temperature exceeds 150°C, polyester / cotton blended yarns and nylon / polyester split microfiber yarns may experience heat deformation leading to reduced strength, and when the high-pressure steam treatment time exceeds 10 minutes, excessive fiber shrinkage may occur, resulting in an uneven appearance of the final product.

[0080] After fixing the twist shape, a detwisting process is performed to untwist the twists applied to the polyester / cotton blended yarn and the nylon / polyester split microfiber yarn. Following the detwisting process, a secondary twisting process is performed, twisting in the opposite direction to the initial twisting. At this time, the secondary twisting process is performed to maintain at least 80% of the crisp shape of the fixed twist. In this secondary twisting process, if the tension is applied such that the crisp shape is maintained at less than 80%, the crisp on the filament yarn disappears, resulting in a decrease in moisture absorption and desiccation capacity.

[0081] The secondary twisting in the secondary twisting process is formed by twisting in the opposite direction to the twisting direction formed in the primary twisting process. The number of secondary twists may be less than the number of primary twists in the primary twisting process, and may satisfy the following formula 3.

[0082] [Formula 3]

[0083] 0.5≤T2 / T1<1,

[0084] In the formula, T1 means the number of twists assigned in the initial twisting process, and T2 means the number of twists assigned in the secondary twisting process.

[0085] The T2 / T1 ratio can be less than 0.8, and when 0.5 ≤ T2 / T1 ≤ 0.7, the fixed crimp morphology of the initial twist can be maintained for more than 80%.

[0086] The primary twisting process and the secondary twisting process are performed on blended yarns of polyester and cotton fibers and split-type microfiber yarns of nylon / polyester, respectively.

[0087] The fibers that have undergone the second twisting process are combined with cotton fiber blended yarn and nylon / polyester split microfiber yarn, and then a third twisting process is performed in the same direction as the first twisting.

[0088] The number of twists imparted in the three-twisting process may be less than the number of twists imparted in the two-twisting process, and may also be less than the number of twists imparted in the first-twisting process.

[0089] The three-stage twisting process can be performed to satisfy the following formula 4.

[0090] [Formula 4]

[0091] 0.005≤T3 / T1≤0.09

[0092] In the formula, T1 means the number of twists assigned in the initial twisting process, and T3 means the number of twists assigned in the third twisting process.

[0093] When T2 / T1 and T3 / T1 satisfy the stated numerical range, a rotating cavity or groove is formed in the longitudinal direction of the pile yarn. Therefore, moisture can be absorbed and dehumidified solely by the pile yarn. Furthermore, the pile yarn satisfying the stated numerical range is difficult to detach from the structure of the terry fabric. Thus, even with repeated washing when using multiple layers of towels, it can maintain its shape, thereby solving the problem of towels turning white due to repeated washing and friction during use. In addition, the water absorption rate of multi-layered towels made from terry fabric containing pile yarns satisfying the stated numerical range can be 40% to 60%, or 45% to 55%.

[0094] Upon completion of the terry fabric manufacturing step, a primary dyeing step is performed to dye the second pile yarn. The dye used in this primary dyeing step is not limited to any dye capable of dyeing the nylon / polyester split composite yarn contained in the second pile yarn. For the fastness of the multi-layered towel, disperse dyes are preferably used. When using disperse dyes in the primary dyeing step, since disperse dyes are generally insoluble or poorly soluble in water, a pretreatment step can be performed to promote dyeing. This pretreatment step may use a pretreatment solution containing a scouring agent, carrier, dispersant, and leveling agent mixed in the dyeing water. The dyeing water is purified water, preferably with a water hardness of 30 to 100 ppm, but not limited to this.

[0095] The scouring agent is used to remove various impurities adhering to the fiber surface. It is preferably a nonionic surfactant such as polyoxyalkylene ether, or an anionic surfactant such as alkylbenzene sulfonate or fatty alcohol sulfate mixed in the nonionic surfactant.

[0096] The dispersing agent is a pharmaceutical agent for removing various impurities adhering to the fiber surface. Preferably, it is a sodium naphthalene sulfonate-formalin condensate, alkyl naphthalene sulfonate or its formalin condensate, sodium phenol sulfonate and sodium naphthol sulfonate formalin condensate, alkyl diphenyl ether disulfonate, sodium lignin sulfonate, polyoxyethylene alkyl (allyl) ether as a nonionic surfactant, a mixture of nonionic and anionic surfactants, sulfonated nonionic surfactants, sodium polyacrylate, olefin-sodium maleate copolymers, aqueous dispersants such as condensed phosphates and carboxymethyl cellulose, alkylbenzene (naphthalene) sulfonates, sodium dioctyl sulfone maleate, partially amidated or partially esterified styrene-maleic anhydride copolymers, fatty acid amides, polyoxyethylene alkylamines, acetates or fatty acid salt alkylamines, alkyl secondary (tertiary) amines or amides and alkyl imidazolines, etc., and non-aqueous dispersants.

[0097] The carrier increases the water solubility of the fibers by causing a swelling effect that relaxes the fiber structure composed of the ground warp yarns, weft yarns, and first and second pile yarns. Furthermore, when using conventional disperse dyes, the dye bath temperature varies depending on the fiber, but is typically carried out at temperatures above 120°C. This is because cavities form in the fibers above these temperatures, creating conditions that allow dye penetration. However, using a carrier as in this invention offers the advantage of efficiently performing the dyeing process with less energy.

[0098] Trichlorobenzene, methylnaphthalene, o-phenylphenol, N,N-dimethyl sulfoxide, and N-methyl-2-pyrrolidone are preferably used as carriers that can be used in this invention.

[0099] The leveling agent, used to inhibit rapid dyeing and prevent staining during the initial dyeing step, is preferably sodium sulfate, sodium chloride, or sodium carbonate.

[0100] Furthermore, the pretreatment solution may also include an acid, which serves to further lower the pH of the pretreatment solution to improve the color intensity of the staining. The acid may be any acid commonly used in the art.

[0101] The pretreatment solution preferably comprises 1 to 2% by weight of scouring agent, 0.1 to 1% by weight of carrier, 0.1 to 1% by weight of dispersant, 1 to 2% by weight of leveling agent and the balance of water, and more preferably further comprises 0.01 to 0.1% by weight of acid.

[0102] The pretreatment step involves immersing the terry fabric in a bath containing the pretreatment solution and performing it at 90 to 110°C, preferably 95 to 100°C, for 10 to 30 minutes, which is preferred because it facilitates the penetration of the disperse dye.

[0103] The dyeing method for the initial dyeing step can utilize conventional and well-known dyeing methods for dyeing velvet yarn using disperse dyes.

[0104] The disperse dye, as a dye having one or more various chromophores, may be anzo dyes, anthraquinone dyes, quinoline ketone dyes, naphthimide dyes, naphthoquinone dyes, and nitro dyes, etc., and for example, CI disperse yellow 3, CI disperse yellow 5, CI disperse yellow 64, CI disperse yellow 160, CI disperse yellow 211, CI disperse yellow 241, CI disperse orange 29, CI disperse orange 44, CI disperse orange 56, CI disperse red 60, CI disperse red 72, CI disperse red 82, CI disperse red 388, CI disperse blue 79, CI disperse blue 165, CI disperse blue 366, CI disperse blue 148, CI disperse violet 28, and CI disperse green 9.

[0105] In addition, disperse dyes can be selected from appropriate databases (e.g., "Color Index"). Details and other examples of disperse dyes are described in "Industrial Dyes," edited by Klausenger, Wiley-VCH, Weinheim, 2003, pp. 133–158. Therefore, these can be consulted for selection. Furthermore, disperse dyes can be used in combination of two or more.

[0106] In addition to disperse dyes, additives such as antioxidants, pH adjusters, surface tension reducers, thickeners, humectants, concentrated chlorinating agents, preservatives, antifungal agents, antistatic agents, metal ion blocking agents, and antireduction agents may be used in the primary dyeing solution composition to impart other functions.

[0107] The primary dyeing solution composition preferably comprises 1 to 3% by weight of disperse dye, 1 to 5% by weight of additives, and the balance being water.

[0108] The initial dyeing step is performed at 90 to 110°C, preferably at 95 to 100°C, and most preferably at 96 to 98°C, whereby the carrier expands the unshaped portion of the filament to facilitate smoother dyeing and improve fastness. Furthermore, the initial dyeing step is preferably performed for 1 to 2 hours, which results in uniform dyeing.

[0109] When the initial dyeing step is completed, the dye solution is removed from the bath, and a refining and bleaching step is performed directly in the same bath. This refining and bleaching step, as a common process for both the fibers forming the base and the fibers forming the pile yarn, not only removes foreign matter and unreacted pigments but also improves water absorption.

[0110] The refining agent used in the refining and bleaching step can be an inorganic or organic refining agent commonly used in this technical field. For example, sodium hydroxide (NaOH), sodium carbonate (Na2CO3), sodium bicarbonate (NaHCO3), trisodium bicarbonate (Na2CO3NHCO32H2O), sodium silicate (xNa2Si4O9+yNa2Si2O3+zH2O), lime (Calcium Oxide (CaO), calcium hydroxide (Ca(OH)2), etc.

[0111] The bleaching agent used in the refining and bleaching step plays a role in decomposing pigment substances through oxidation-reduction. For example, chlorine-based bleaching agents such as bleaching powder (Ca(OCl)2), sodium hypochlorite (NaClO), and sodium chlorite (NaClO2) are preferred; peroxide-based bleaching agents such as hydrogen peroxide (H2O2), sodium peroxide (Na2O2), sodium perborate (NaBO3·4H2O), and potassium permanganate (KMnO4) are preferred; and sulfurous acid gas (SO2), acidic sodium sulfite (NaHSO3), and sodium hyposulfite (Na2S2O4) are preferred.

[0112] In addition, chelating agents such as aminopolycarboxylic acid (EDTA), hydroxy polycarboxylic acid (Citric Acid), aminomethylphosphonic acid (EDTMP), polycarboxylic acid (Oxalic Acid), sodium hexametaphosphate, etc., or stabilizers such as polysilicates and polyacrylates, etc., may be added to the treatment liquid composition used in the refining and bleaching steps.

[0113] The refining and bleaching steps are performed at 90 to 98°C, preferably at 95 to 98°C, and most preferably at 96 to 98°C. Exceeding these ranges does not adequately remove foreign matter, unreacted dyes, etc., and may also cause the yarn dyed in the initial dyeing step to fade.

[0114] The treatment liquid composition preferably comprises 1 to 5% by weight of a refining agent, 1 to 5% by weight of a bleaching agent, 0.1 to 5% by weight of an additive, and the balance being water.

[0115] According to the multi-layer towel manufacturing method of the present invention, after the second pile yarn is dyed with disperse dye in the initial dyeing step, the residue of disperse dye can be discharged and the fastness of the second pile yarn can be increased while undergoing a refining process using sodium hydroxide, a dyeing process suitable for cellulose fibers, and multiple post-treatment processes.

[0116] When the refining and bleaching steps are completed, a second dyeing step is performed.

[0117] Similar to the refining and bleaching step, the secondary dyeing step can also be performed by simply replacing the treatment solution and in the same bath.

[0118] The secondary dyeing step dyes the ground warp, weft, and first pile yarn, preferably using dyeing methods and dyes for cellulosic fibers. For example, it is preferred to use one or more dyes selected from direct dyes, sulfur dyes, vat dyes, azo dyes, acid dyes, basic dyes, and reactive dyes. The dyes used in the secondary dyeing step are preferably reactive dyes in terms of fastness to multi-layered towels, and the type of reactive dye is not limited as long as the dyeing method used is reactive dye that can be dyed by dip dyeing, cold pad-batch (CPB) or continuous dyeing.

[0119] The reactive dye consists of a pigment matrix and reactive groups. However, the adsorption rate of the same reactive group can vary greatly depending on the molecular structure of the pigment matrix. Therefore, it is preferable to use a reactive dye that combines a pigment matrix with excellent fastness to specific reactive groups. Furthermore, compared to reactive dyes containing a monofunctional group, using reactive dyes containing two or more functional groups can prevent the towels from turning white due to friction and repeated washing during use.

[0120] The preferred reactive group is one with a vinylsulfone or triazine base, which is inexpensive, not limited by the dyeing method, forms a stable bond between the fiber and the reactive dye, and has excellent fastness and evenness.

[0121] The reactive dyes used in this invention may include, for example, Ciba Specialty Chemicals' Lanasol CE, Yellowlight, Orange light, Blue light, Navy light, Red light, Rose light, Lemon light, Skylight, Cibacron FN, Red FN-3G, Red FN-G, and Cibacron LS; Nippon Kayaku Co., Ltd.'s Blue P-NFB liquid 50, Yellow P-N3R liquid 33, and Red P-4BN liquid 25; Sumitomo Chemical Co., Ltd.'s Sumifix HF type; DyStar's Srius plus, Realan, and Reanova CA; Mitsubishi Chemical-Horror's Remazol RU-N; Jelicon's Procion CX; and Clariant's Optizal series dyes. These dyes all possess high fixation rates of over 80% and excellent wet fastness, and are therefore suitable for this invention. Of course, two or more of the reactive dyes may also be used in combination.

[0122] Even when selecting one or more of the aforementioned reactive dyes and choosing any of the immersion dyeing, CBP, or continuous dyeing methods, the formulation and amount of dye used are determined according to the desired color intensity. The alkaline solution can be prepared by comprising 5 to 10 g / L sodium carbonate and 80 to 120 g / L sodium silicate, and mixing 10 to 30 g / L of reactive dye and distilled water to prepare the dyeing solution. In this case, the sodium silicate acts as a buffer to uniformly adjust the pH of the dyeing solution and to reduce color concentration differences in the fabric. A secondary dyeing composition containing the alkaline solution and dyeing solution in a 4:1 volume ratio can be used to represent medium shades of color.

[0123] To dye fabrics to a dark (or light) shade, a reactive dye of 30 g / L or higher, sodium silicate of 80 to 120 g / L, and sodium carbonate of 10 to 20 g / L can be used. The secondary dyeing composition is prepared such that the amount of dyeing solution used to prepare the dyeing solution by dissolving the reactive dye in an alkaline solution containing sodium silicate and sodium carbonate and distilled water is 4:1 (preparation solution: dyeing solution) by volume ratio.

[0124] The terry fabric is immersed in a secondary dyeing composition at 50 to 90°C for more than 1 hour so that the reactive dye can be fixed on the ground warp, weft, and first pile yarn of the terry fabric.

[0125] When unfixed dye remains on terry cloth soaked for more than 1 hour, the fastness of multi-layered towels deteriorates. Therefore, after dyeing, the terry cloth is soaked in a 5-10% by weight sodium hydroxide aqueous solution at 90°C for 1-10 minutes or 3-7 minutes, followed by rinsing with running water to remove sodium carbonate and sodium hydroxide, and then dried at 10-130°C for 60-90 seconds to complete a secondary dyeing step. This process decomposes and removes unfixed dye while covalently bonding the reactive dye fixed to the fibers with the fibers. During this process, the polyester component of the nylon / polyester split composite yarn can partially flow out, thereby constituting the splitting of the split composite yarn and thus the ultrafineness of the nylon / polyester split composite yarn.

[0126] The secondary dyeing composition may also contain a mordant and a scouring agent.

[0127] The mordant performs the function of promoting color development and dyeing the pigment onto the fiber. Preferably, aluminum mordants such as alum (potassium aluminum sulfate, AlK(SO4)2·12H2O), aluminum acetate, and aluminum chloride, copper mordants such as copper acetate or copper sulfate, and sodium mordants such as anhydrous sodium sulfate are used, but are not limited thereto, and any mordant commonly used by those skilled in the art can be used.

[0128] The scouring agent removes impurities to allow the dye to be well adsorbed onto the fiber, and is preferably selected from a group consisting of alkyl sulfates, alkyl phosphates, alkyl sulfonates, alkyl polyoxyethylene ether sulfonates and alkyl polyoxyethylene ether phosphates or mixtures thereof, but is not limited thereto.

[0129] The secondary dyeing composition may contain 1 to 5% by weight of mordant and 1 to 5% by weight of scouring agent.

[0130] A soaping process can also be performed after the secondary dyeing step.

[0131] The soaping process, used to remove unfixed dyes remaining after dyeing, is preferably performed at a temperature of 90 to 110°C for 20 minutes to 1 hour.

[0132] The soaping solution composition used in the soaping process can be prepared by adding a soaping agent to ordinary water at the stated temperature. Preferably, the soaping agent used is PROTEPON RSA or PROTEPONNRC from PROTEX (Korea), but it is not limited to these. Furthermore, the soaping agent is preferably added at a rate of 1 to 5 g per 1 liter of water to prevent the re-adhesion of impurities while maintaining the blocking effect of metal ions, thereby improving the fastness of the dye.

[0133] At the end of the soaping process, the soaping liquid composition is removed from the bathtub, and a softening treatment may also be included in the same bathtub. The softening treatment imparts resilience, smoothness, bulkiness, and a soft touch to the manufactured towels, and is performed using methods commonly used in the art. Furthermore, the softening treatment preferably involves performing the softening liquid composition at 20 to 60°C for 10 to 60 minutes.

[0134] The softener composition may use any softener commonly used in this art. For example, CSE-920 from CSCtech Corporation of Korea may be used, but it is not limited thereto, and preferably 1 to 5% is added on the weight of fiber (owf).

[0135] When the softening process is complete, the remaining treatment liquid, moisture, etc. on the terry cloth can be removed by washing and drying processes, and the cloth can be cut according to the sales conditions to manufacture towels according to the invention.

[0136] When the dyeing step is completed, a process of attaching herbal extracts may also be included.

[0137] The herbal extract according to the present invention may use any one of the following, or a mixture thereof, selected from Schisandra chinensis, Coptis chinensis, Houttuynia cordata, Anemarrhena asphodeloides, Taraxacum mongolicum, Paeonia lactiflora, Forsythia suspensa, and Lonicera japonica. This herbal extract has the effect of imparting a specific natural fragrance to the manufactured towel and minimizing skin irritation.

[0138] The herbal extract can be extracted using common methods, such as heating or using a solvent, and can be concentrated if necessary.

[0139] Preferably, the herbal extract is attached to the fiber surface using an adhesive. The adhesive is hydrophilic and is not limited to any particular type, as long as it does not significantly impair the physical properties of the manufactured towel.

[0140] As the adhesive, preferably, polycarboxylic acids such as aliphatic polycarboxylic acids, alicyclic polycarboxylic acids, aromatic polycarboxylic acids, saturated aliphatic dicarboxylic acids, unsaturated aliphatic dicarboxylic acids, aromatic dicarboxylic acids, and alicyclic dicarboxylic acids can be used; ethylene glycol polymers such as polyethylene glycol or polypropylene glycol can also be used.

[0141] The herbal extract can be applied using common methods available in the art, such as impregnation, spraying, coating, etc., and impregnation is preferred.

[0142] The herbal extract and the adhesive may adhere in a liquid form containing a solvent. Preferably, the herbal extract is added at a content of 1 to 10% (owf) and the adhesive at a content of 5 to 20%. Furthermore, the solvent may be a conventional solvent capable of dissolving both the adhesive and the herbal extract, and the invention is not limited thereto.

[0143] After the steps described above are completed, remove any moisture that may remain on the terry cloth and manufacture multi-layer towels in different sizes according to sales conditions.

[0144] In the following examples and comparative examples, the physical properties were measured as follows.

[0145] Example 1

[0146] Manufacturing of warp yarn and terry yarn

[0147] After applying an S-twist of 300 TPM to 45D / 30F N / P (nylon / polyester) split microfiber yarn, the yarn is subjected to high-pressure steam treatment at 130°C for 5 minutes to untwist the twist. Tension is then applied to apply a Z-twist of 180 TPM, so that the crimp morphology of the twist is maintained at 80%.

[0148] After applying an S-twist of 300 TPM to a polyester / cotton blend yarn comprising 70 wt% polyester and 30 wt% cotton, the yarn is subjected to high-pressure steam treatment at 130°C for 5 minutes, followed by untwisting. Tension is then applied to apply a Z-twist of 180 TPM, such that the crimp morphology of the twist is maintained at 80%.

[0149] A second pile yarn is prepared by applying a 5 TPM S-twist to the N / P type split microfiber yarn to which the secondary twist is applied and to the blended yarn of polyester and cotton fibers to which the secondary twist is applied.

[0150] Prepare cotton yarn with a count of 30 containing 100% cotton fiber for use as ground warp yarn, weft yarn, and first pile yarn.

[0151] Terry fabric manufacturing steps

[0152] The ground warp yarns and the first and second pile yarns are wound onto separate warp beams, and the ground warp yarns are alternately arranged with the first pile yarn and the second pile yarn. On a loom equipped with a weft device, the ground warp yarn is held with strong tension, while the first and second pile yarns are held with weak tension. After the first weft yarn is inserted between the ground warp yarns, the shuttle is launched, and after the second weft yarn is inserted between the ground warp yarns, the shuttle is launched, so that the first and second pile yarns are pushed forward, thereby weaving a terry fabric in which the pile yarns form on both sides of the bottom.

[0153] Primary staining steps

[0154] A primary dye liquor composition was prepared, consisting of 3% by weight of disperse dye (CI Disperse Red 60, LG Chemical Co., Ltd.), 1% by weight of carrier (trichlorobenzene), and 98% by weight of water. A woven terry fabric was added to the secondary dye liquor composition, and the mixture was treated at 98°C for 1 hour.

[0155] Without rinsing the initially dyed terry fabric, the initial dyeing liquor composition is drained from the bath and a scouring and bleaching treatment solution is directly added to perform the scouring and bleaching step. At this time, the temperature of the treatment solution is 98°C, the treatment time is 30 minutes, and the treatment solution consists of 1% by weight of scouring agent (sodium hydroxide), 1% by weight of bleaching agent (sodium hypochlorite), and 98% by weight of water.

[0156] Secondary staining steps

[0157] After the refining and bleaching steps are completed, the treatment solution is drained from the same bath, and the secondary dyeing solution composition is added to the bath to perform the secondary dyeing step. At this time, the secondary dyeing solution is prepared to a concentration of 10 g / L by mixing 10 g of reactive dye (Lanasol CE, Ciba Specialty Chemicals) with distilled water.

[0158] After preparing an alkaline solution containing 7 g / L sodium carbonate and 80 g / L sodium silicate, a secondary dyeing composition was prepared by mixing the alkaline solution with a dyeing solution at a volume ratio of 4:1. The terry fabric was immersed in the dyeing composition at 60°C for 1 hour to perform the secondary dyeing step. The terry fabric was removed from the dye bath and the water was removed. The dehydrated terry fabric was then immersed in a 10% by weight sodium hydroxide solution for 7 minutes. At this time, the temperature of the sodium hydroxide solution was 90°C. The terry fabric removed from the sodium hydroxide solution was washed in running water for at least 10 minutes. After removing the water from the washed terry fabric, a soaping solution containing 1% by weight of soaping agent (PROTEPON RSA, PROTEX Corporation, Korea) was added and the mixture was washed at 98°C for 30 minutes.

[0159] After the soaping process was completed, the soaping solution was removed, and then a softener solution containing 1% fabric softener (CSE-920, CSCTech, Korea) based on owf was added and the mixture was treated at 40°C for 30 minutes. After the softener treatment, the mixture was thoroughly washed with water and dried to prepare a sample. The feel, fastness, and water absorption of the sample were measured and recorded in Table 1 below.

[0160] After all the processes are completed, the manufactured multi-layered towels have the following characteristics: Figure 1 The pattern shown is a dyed pattern divided into areas represented by reactive dyes and areas represented by disperse dyes.

[0161] Comparative Example 1

[0162] Except for the three twisting processes in Example 1, which were treated with 15 TPM, the process was carried out in the same manner.

[0163] Comparative Example 2

[0164] Except for the three twisting processes in Example 1, which were performed with 1 TPM, the process was carried out in the same manner.

[0165] Comparative Example 3

[0166] The procedure was performed in the same manner, except that a pile yarn made solely of split nylon and polyester microfiber (with a fineness of 60D / 72F) was used instead of the first pile yarn and the second pile yarn used in Example 1.

[0167] 1. Water absorption rate test

[0168] The water absorption rate of the terry fabrics manufactured in the examples and comparative examples was measured according to method KS K 0815.

[0169] 2. Fastness test

[0170] Wash fastness was measured according to the KS K 0430 method.

[0171] Friction fastness was measured according to the KS K 0650 method.

[0172] Table 1

[0173]

[0174] As shown in Table 1, compared to the case without a second pile yarn satisfying Formulas 1 and 2 (or 3 and 4), the case with a second pile yarn satisfying Formulas 1 and 2 (or 3 and 4) exhibits significantly higher water absorption, as well as significantly higher wash fastness and rubbing fastness. In particular, compared to Example 1, the multi-layer towel comprising a terry cloth fabric containing a pile yarn composed of nylon / polyester blended yarn exhibits significantly lower water absorption, wash fastness, and rubbing fastness.

[0175] It is believed that this is because by applying three twists to the second pile yarn, a rotating cavity and a rotating groove are generated in the longitudinal direction of the fiber, thereby increasing the water absorption and making it easier for the dye to be adsorbed, thus forming a more solid bond between the fiber and the dye.

Claims

1. A multi-layered towel, comprising: A terry cloth fabric, said terry cloth fabric is woven from ground warp yarns containing cotton fibers, weft yarns containing cotton fibers, and pile yarns, and undergoes primary dyeing and secondary dyeing. The pile yarn includes a first pile yarn containing cellulose fibers, and a second pile yarn containing a blended yarn selected from polyester and cotton fibers and a nylon / polyester split composite yarn. The blended yarn of the polyester fiber and the cotton fiber includes an initial twist of 300 to 500 TPM. The nylon / polyester split composite yarn includes an initial twist of 300 to 500 TPM. The blended yarn of polyester and cotton fibers, including the one that has undergone initial twisting, includes a second twisting process. The nylon / polyester split-type composite yarn, including the initial twisting, includes secondary twisting. The number of twists in the initial twist and the number of twists in the secondary twist satisfy the following equation 1. [Formula 1] 0.5≤T2 / T1<1, In the formula, T1 represents the number of initial twists, and T2 represents the number of secondary twists.

2. The multi-layer towel as described in claim 1, comprising a tertiary twisting process involving a blended yarn of polyester and cotton fibers including the secondary twisted yarn and a split-type nylon / polyester composite yarn including the secondary twisted yarn.

3. The multi-layer towel as described in claim 2, wherein the number of twists in the three twists satisfies the following formula 2. [Equation 2] 0.005≤T3 / T1≤0.09 In the formula, T3 means the number of three twists, and T1 means the number of the first twist.

4. The multi-layer towel as claimed in claim 1, wherein the cellulose fiber comprises one or more fibers selected from a group consisting of cotton fiber, hemp fiber, rayon fiber, lyocell fiber, and a blend of Polinosic fiber and cotton fiber.

5. A method for manufacturing a multi-layered towel, comprising: The steps for manufacturing terry fabrics from ground warp yarns containing cotton fibers, weft yarns containing cotton fibers, and pile yarns. The initial dyeing step involves dyeing the manufactured terry fabric with disperse dyes. as well as A secondary dyeing step involves dyeing the initially dyed terry fabric with a reactive dye. The pile yarn includes a first pile yarn containing cellulose fibers, and a second pile yarn containing a blended yarn selected from polyester and cotton fibers and a nylon / polyester split composite yarn. Prior to the terry fabric manufacturing step, the process also includes a twisting step of twisting the pile yarn. The twisting process includes an initial twisting process, a secondary twisting process, and a tertiary twisting process. The initial twisting process and the secondary twisting process twist the material to satisfy the following formula 3. [Formula 3] 0.5≤T2 / T1<1, In the formula, T1 means the number of twists assigned in the initial twisting process, and T2 means the number of twists assigned in the secondary twisting process.

6. The method for manufacturing a multi-layer towel as described in claim 5, wherein the initial twisting process and the third twisting process twist the towel to satisfy the following formula 4. [Formula 4] 0.005≤T3 / T1≤0.09 In the formula, T3 means the number of twists assigned in the three twisting processes, and T1 means the number of twists assigned in the first twisting process.

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