Fluffy, durable and tough towel fabric and preparation method thereof

Abstract

The invention relates to the field of spinning, in particular to a fluffy, durable and tough towel fabric and a preparation method thereof. The towel fabric is formed by weaving ground warps, wool warps and weft yarns. According to the fabric, the design of two layers of base cloth is adopted, the pile warps and the weft yarns of the upper-layer gauze weave (the upper-layer base cloth) are interwoven to generate the pile loops, the bottom-layer consolidation pile loop weave (the lower-layer base cloth) is hidden at the roots of the pile loops, and the pile loops are further consolidated and supported. By adopting the structure, the ground warp quilt is ingeniously divided into two independent layers, so that the structural stability of the towel is enhanced, and more space is provided for weaving of looped piles.

Description

Technical Field

[0001] The invention relates to the field of textiles, and in particular to a fluffy, durable and strong towel fabric and a preparation method thereof. Background Art

[0002] In the textile field, especially in the towel industry, towel products on the market generally adopt a design in which the wool warp forms single-sided or double-sided terry loops on the surface. Although this design can provide good water absorption performance, it has some disadvantages. The main problem is that the interweaving points between the wool warp and the base fabric are not tight enough, which causes the terry loops to fall off easily during use when they are formed on the surface of the base fabric, which is the so-called hair pulling phenomenon. In addition, since the wool warp yarn usually uses yarn with a smaller twist, this increases the risk of snagging and hairiness during the use of the towel. Over time, the terry loops tend to lose their original fluffiness, which not only affects the feel of the product, but also reduces the aesthetics and service life of the towel.

[0003] To solve these problems, developers in the home textile manufacturing industry are faced with the challenge of improving the visual effect of towel products, enhancing the hooking and pulling force of the terry loops, reducing the phenomenon of hair pulling and shedding, and improving the fluffiness of the products. Designing towel products that have both novel appearance and soft and fluffy characteristics, and are not easy to hook in daily use, is an important challenge faced by the towel weaving field.

[0004] The industry is in urgent need of a new weaving technology and tissue design to overcome the limitations of existing technologies and produce towel products with higher grade and stronger market competitiveness. This requires towels to have a more stable structure while maintaining good water absorption and hand feel, reduce the phenomenon of hair extraction and feather shedding in daily use, and maintain the fluffiness and softness of the terry for a long time. Through these improvements, towel products will be more durable and provide consumers with a better experience in terms of vision and touch. Therefore, developing a towel product with innovative structure and superior performance is of great significance to meet market demand and enhance corporate competitiveness. Summary of the invention

[0005] In view of the problems of the prior art, the present invention provides a fluffy, durable and strong towel fabric and a preparation method thereof. The towel fabric is woven from a ground warp, a wool warp and a weft yarn. The fabric of the present invention adopts a two-layer base fabric design, the wool warp and the weft yarn of the upper gauze structure (upper base fabric) are interwoven to produce terry loops, and the bottom layer of consolidated terry loop structure (lower base fabric) is hidden at the root of the terry loops, which further consolidates and supports the terry loops. With this structure, the ground warp is cleverly divided into two independent layers. This design not only enhances the structural stability of the towel, but also provides more space for the weaving of the terry loops.

[0006] The specific technical solutions of the present invention include:

[0007] The invention discloses a fluffy, durable and strong towel fabric, which is woven from ground warp, wool warp and weft yarn, and adopts a two-layer base fabric design, wherein the wool warp passes through a bottom layer consolidated terry tissue and is interwoven with the weft yarn of an upper layer gauze tissue (upper base fabric) to produce terry, and the bottom layer consolidated terry tissue (lower base fabric) is hidden at the root of the terry, which plays a further consolidation and support role for the terry.

[0008] These loops not only run through the two layers of base fabric, but also through specific weaving techniques, the upper and lower layers of base fabric are tightly connected together.

[0009] Preferably, in order to achieve the fluffy effect of the terry loops, the upper gauze tissue adopts a plain weave or a double plain weave.

[0010] When the towel fabric is a double-layer terry fabric, preferably, the warp yarns of the lower terry fabric are only interwoven with the weft yarns of the bottom consolidated terry fabric to produce the lower terry fabric.

[0011] Preferably, the ground warp and wool warp yarn are fed into the steel reed in a circular arrangement of 1 wool warp and 2 ground warps into one reed tooth. Different from the traditional method (one wool warp and one ground warp into one reed tooth), the ground warp is doubled, so the strength and durability of the product are greatly improved. By adopting a double-layer ground warp design, the number of ground warps is twice that of ordinary towels, which significantly improves the tearing strength of the product. The product strength is doubled and has excellent durability.

[0012] Preferably, the towel fabric has a warp density of 127 to 173 strands / cm and a weft density of 250 to 300 strands / cm.

[0013] In the present invention, in order to better prepare the above-mentioned fluffy, durable and strong towel fabric, a specific weaving process is adopted, specifically: 6-weft method is adopted for weaving, wherein 5-weft is short weft and 1-weft is long weft. When the weft is long weft, the 5-weft weft yarn is pushed to the weaving opening, so that the wool warp forms a loop between the two layers of the base fabric, and the bottom layer consolidated loop structure is hidden at the root of the loop, which plays a supporting role for the loop.

[0014] Preferably, when the fluffy, durable and strong towel fabric is woven, the ground warp is divided into two areas when the weft is drawn into the machine to form an upper gauze structure and a bottom consolidated terry structure. This improvement makes the manufacturing of the present invention more reasonable and efficient.

[0015] Preferably, the drawing-in method during weaving of the fluffy, durable and tough towel fabric is as follows: one warp tissue cycle consists of 4 ground warp yarns and 2 wool warp yarns, wherein 2 ground warp yarns support the terry loops and 2 base fabric ground warp yarns form a flat cloth structure to support the terry loops; the specific drawing-in sequence is as follows: a clamping ground warp for raising the terry loops is inserted into a ground warp heald, 1 wool warp is inserted into a wool warp heald, a ground warp that supports the terry loops is inserted into a ground warp heald, and the above three yarns (1 ground, 1 wool, 1 ground) are inserted into a reed tooth, and the cycle is repeated in sequence.

[0016] Preferably, the fluffy, durable and tough towel fabric is woven at a speed of 400 to 450 rpm on a multi-arm loom, with a torsion value of 95 to 110 degrees for the ground warp tension and 35 to 50 degrees for the wool warp tension. Such a setting ensures the weaving efficiency and the quality of the towel.

[0017] The beneficial effects of the present invention are:

[0018] The towel fabric obtained by the process of the present invention uses a 6-weft weaving method during the weaving process. In each round of weaving, there are 5 short wefts and 1 long weft. The main function of the short weft is to form a basic fabric structure, while the long weft is used to push the 5 short wefts to move toward the weaving opening. In this process, the wool ground warp is cleverly guided so that the terry loops are formed and penetrate through the two layers of base fabrics. In addition, a layer of gauze is added to the root of the terry loops. The function of this layer of gauze is to provide support for the terry loops and is hidden under the terry loops. The existence of this layer of gauze ensures that the terry loops can maintain their fluffiness and will not easily fall down due to use or washing, thereby extending the service life of the fabric and maintaining the beautiful appearance and comfortable and fluffy feel of the fabric. The terry loops run through the two layers of base fabrics and form a fluffing effect on both sides of the towel fabric, thereby giving the towel fabric good water absorption performance and soft touch. The two layers of base fabrics are connected by the wool warp, and the two layers of base fabrics have almost no intersection. Therefore, after post-treatment, the towel base is softer than conventional products, and the gauze tissue at the root of the terry loop provides good support, making the terry loop more fluffy and elastic. The process of the present invention not only improves the practicality and comfort of the product, but also enhances the durability, toughness and aesthetics of the product through a special weaving structure, making the surface smooth, soft and elastic, and greatly reducing the phenomenon of hair removal during use.

[0019] In summary, the towel produced by the technology of the present invention shows excellent water absorption performance and durability in actual use. The fluffiness and softness of the terry loops provide users with a comfortable use experience, while the support of the gauze tissue ensures the stability of the terry loops. Combined with the double-layer ground warp design, the number of ground warps is doubled, showing excellent durability during use, not easy to pull hair, and extending the service life of the towel. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 This is a machine organization diagram when the towel fabric of the present invention is weaved;

[0021] Figure 2 It is a schematic diagram of the weaving raising structure of the towel fabric of the present invention;

[0022] Figure 3 It is a schematic diagram of the weaving and beating structure of towel fabric of the present invention;

[0023] Figure 4 This is a comparative diagram of the weaving of towel fabric.

[0024] Figure 5 It is a schematic diagram of the weft beating structure of comparative towel fabric weaving. DETAILED DESCRIPTION

[0025] In order to enable those skilled in the art to better understand the technical solutions in the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work should fall within the scope of protection of the present invention.

[0026] like Figure 1 As shown, the fluffy, durable and strong towel fabric of the present invention is woven from ground warp and wool warp and weft yarns. The towel fabric includes two layers of base fabric formed by interweaving the ground warp and weft yarns and terry loops formed by interweaving the wool warp and weft yarns. The terry loops run through the two layers of base fabric. In the specific preparation process, the ground warp can be divided into two areas and woven into two layers of base fabric respectively. The wool warp and the weft yarns on the lower base fabric are interwoven to form terry loops, and these terry loops are interspersed from the upper gauze tissue and connected with it. At the same time, the gauze tissue formed by interweaving is located at the root of the terry loops to provide necessary support for it. The weaving process of the fluffy, durable and strong towel fabric can be carried out according to the current conventional weaving process for organization design, warping, reeding, machine weaving, post-processing and inspection and finishing processes. It is just that the specific towel fabric organization and the implementation form of machine weaving are fundamentally different from conventional towel fabrics.

[0027] In the actual production process, in order to achieve this unique structure, the ground warp can be divided into two different areas for threading, so that two layers of base fabric can be woven separately. Then, the wool warp is interwoven with the weft yarn on one layer of the base fabric to form loops, connecting the upper and lower layers of the base fabric.

[0028] Although the weaving process of fluffy, durable and strong terry fabric can follow the current conventional weaving process, including warping, reeding, machine weaving, post-processing and inspection, it is fundamentally different from conventional terry fabric in terms of its specific terry fabric structure and the implementation form of machine weaving.

[0029] Organizational Design

[0030] like Figure 1 As shown in the figure, in the textile process, we use a unique double-layer base fabric structure to achieve the terry effect with a six-weft weaving method. Specifically, this fabric structure is designed with two layers of base fabric, and the terry is formed by interweaving the warp yarn with the weft yarn of one layer of the base fabric.

[0031] In the weaving process, a 6-weft weaving method is used. In each round of weaving, there are 5 short wefts and 1 long weft. The main function of the short weft is to form the basic fabric structure, while the long weft is used to push the 5 short wefts to move toward the cloth opening.

[0032] The process flow of preparing the towel fabric base fabric in the following embodiment or comparative example is: yarn - warping - weaving - post-processing - cutting - sewing - finished product. Except for weaving, the other processes are completed by using the existing technology. Among them, the post-processing adopts an L-type overflow machine for scalding, dyeing and softening. The specific post-processing process is as follows:

[0033] (1) Sew different pieces of grey cloth together head to tail, making sure the head and tail of each piece of cloth are seamlessly connected.

[0034] (2) Assembling the pot: Assemble the cloth assembled in step (1) and place it in the pot along the wool direction according to the principle of weaving the first end first, so as to ensure that the wool loops are flat and smooth.

[0035] (3) High temperature scouring and bleaching: This process uses specific dyeing and finishing auxiliaries and the dosage is as follows: ion membrane liquid alkali (mass number: 32%) 8g / L, H2O2 (27.5%) 7.5g / L, hydrogen peroxide stabilizer 0.07g / L, refining penetrant (JN-98, Shandong Juye Fine Chemical Co., Ltd.) 1.2g / L, temperature × time: 100℃ × 30 minutes.

[0036] (4) Drain, hot wash, neutralize, deoxidize: The treated fabrics are thoroughly cleaned, hot washed, and neutralized to remove residual chemicals. The pH value of the fabrics is then controlled to between 6.5 and 8.0, and the oxygen content is ensured to be zero.

[0037] (5) Dyeing: Dyeing is carried out using reactive dyes according to the color formula to obtain the desired color.

[0038] (6) Soap washing and hot washing: hot water washing, soap washing, warm washing and other steps are used to post-treat the dyed grey cloth to improve its color fastness.

[0039] (7) Enzyme polishing: The treated grey cloth is subjected to enzyme polishing treatment. The specific process conditions are as follows: the pH value is controlled at 6-7.5, the dosage of cellulase 8000L is 0.03%, and the treatment conditions are 50°C × 25 minutes.

[0040] (8) Softening treatment: The polished cloth is softened with a softener that helps to improve the fluffiness of the product. The specific amount of softener is DT530, 3.5g / L, and the process conditions are 35℃-40℃×30 minutes.

[0041] (9) After dehydration, the new type of vibration machine is used for vibration drying.

[0042] Example 1

[0043] like Figure 1-3 As shown, the towel fabric of this embodiment is a double-layer terry fabric, wherein:

[0044] Yarn count selection:

[0045] Ground warp: 32S / 2 pure cotton small twist (86 / 36);

[0046] Wool warp: 12s+75s (12s: 100% cotton 75s: 100% Yasser);

[0047] Weft yarn: 32S / 2 pure cotton small twist (86 / 36);

[0048] Towel weight: 585GSM;

[0049] Warp density: 130 strands / 10cm, weft density: 265 strands / 10cm, pile height: 13.0cm / 10 loops.

[0050] In the production process of terry fabrics, the G6300 multi-arm terry rapier loom is used to ensure that the torsion value of the wool warp tension torsion bar is maintained at 15 degrees, while the torsion value of the ground warp tension torsion bar is set to 95 degrees. The working speed of the loom is set to 420 rpm, which can ensure both production efficiency and stability of the weaving process.

[0051] In the weaving process, the warp density is selected with a No. 56 steel reed, and the weft density is set to 265 threads per ten centimeters. Such a density setting can ensure the durability of the towel fabric.

[0052] During the weaving process: the ground warp and wool warp yarns are fed into the reed in the manner of 1 wool warp and 2 ground warps into one reed tooth, arranged in a cycle; 6 wefts are used for weaving, of which 5 wefts are short wefts and 1 weft is long weft. When the weft is long, the 5th weft is pushed to the weaving opening, so that the wool warp forms a loop between the two layers of the base fabric.

[0053] The drawing-in method during weaving is: one warp structure cycle consists of 4 ground warp yarns and 2 wool warp yarns, of which 2 ground warp yarns support the terry loops and 2 base fabric ground warp yarns form a flat cloth structure to support the terry loops; the specific drawing-in sequence is: a ground warp for clamping the terry loops is inserted into a ground warp heald, 1 wool warp is inserted into a wool warp heald, and a ground warp that supports the terry loops is inserted into a ground warp heald, and the above three yarns (1 ground, 1 wool, 1 ground) are inserted into a reed tooth, and the cycle is repeated in sequence.

[0054] Example 2

[0055] like Figure 1-3 As shown, the towel fabric of this embodiment is a double-layer terry fabric, wherein:

[0056] Yarn count selection:

[0057] Ground warp: 32S / 2 pure cotton small twist (86 / 36)

[0058] Wool warp: 10s twisted (100% cotton)

[0059] Weft yarn: 32S / 2 pure cotton small twist (86 / 36)

[0060] Towel weight: 585GSM

[0061] Warp density: 130 strands / 10cm Weft density: 265 strands / 10cm Height: 13.0cm / 10 loops

[0062] In the production process of terry fabrics, the G6300 multi-arm terry rapier loom is used to ensure that the torsion value of the wool warp tension torsion bar is maintained at 15 degrees, while the torsion value of the ground warp tension torsion bar is set to 95 degrees. The working speed of the loom is set to 420 rpm, which can ensure both production efficiency and stability of the weaving process.

[0063] In the weaving process, the warp density is selected with a No. 56 steel reed, and the weft density is set to 265 threads per ten centimeters. Such a density setting can ensure the durability of the towel fabric.

[0064] During the weaving process: the ground warp and wool warp yarns are fed into the reed in the manner of 1 wool warp and 2 ground warps into one reed tooth, arranged in a cycle; 6 wefts are used for weaving, of which 5 wefts are short wefts and 1 weft is long weft. When the weft is long, the 5th weft is pushed to the weaving opening, so that the wool warp forms a loop between the two layers of the base fabric.

[0065] The drawing-in method during weaving is: one warp structure cycle consists of 4 ground warp yarns and 2 wool warp yarns, of which 2 ground warp yarns support the terry loops and 2 base fabric ground warp yarns form a flat cloth structure to support the terry loops; the specific drawing-in sequence is: a ground warp for clamping the terry loops is inserted into a ground warp heald, 1 wool warp is inserted into a wool warp heald, and a ground warp that supports the terry loops is inserted into a ground warp heald, and the above three yarns (1 ground, 1 wool, 1 ground) are inserted into a reed tooth, and the cycle is repeated in sequence.

[0066] Example 3

[0067] like Figure 1-3 As shown, the towel fabric of this embodiment is a double-layer terry fabric, wherein:

[0068] Yarn count selection:

[0069] Ground warp: 32S / 2 pure cotton small twist (86 / 36);

[0070] Wool warp: 21s / 2 weak twist (100% cotton);

[0071] Weft yarn: 32S / 2 pure cotton small twist (86 / 36);

[0072] Towel weight: 585GSM;

[0073] Warp density: 130 strands / 10cm, weft density: 265 strands / 10cm, pile height: 13.5cm / 10 loops.

[0074] In the production process of terry fabrics, the G6300 multi-arm terry rapier loom is used to ensure that the torsion value of the wool warp tension torsion bar is maintained at 15 degrees, while the torsion value of the ground warp tension torsion bar is set to 95 degrees. The working speed of the loom is set to 420 rpm, which can ensure both production efficiency and stability of the weaving process.

[0075] In the weaving process, the warp density is selected with a No. 56 steel reed, and the weft density is set to 265 threads per ten centimeters. Such a density setting can ensure the durability of the towel fabric.

[0076] During the weaving process: the ground warp and wool warp yarns are fed into the reed in the manner of 1 wool warp and 2 ground warps into one reed tooth, arranged in a cycle; 6 wefts are used for weaving, of which 5 wefts are short wefts and 1 weft is long weft. When the weft is long, the 5th weft is pushed to the weaving opening, so that the wool warp forms a terry loop between the two layers of the base fabric.

[0077] The drawing-in method during weaving is: one warp structure cycle consists of 4 ground warp yarns and 2 wool warp yarns, of which 2 ground warp yarns support the terry loops and 2 base fabric ground warp yarns form a flat cloth structure to support the terry loops; the specific drawing-in sequence is: a ground warp for clamping the terry loops is inserted into a ground warp heald, 1 wool warp is inserted into a wool warp heald, and a ground warp that supports the terry loops is inserted into a ground warp heald, and the above three yarns (1 ground, 1 wool, 1 ground) are inserted into a reed tooth, and the cycle is repeated in sequence.

[0078] Comparative Example

[0079] like Figure 4 and Figure 5 As shown, the towel fabric of this embodiment is a double-layer terry fabric, wherein:

[0080] Yarn count selection:

[0081] Ground warp: 32S / 2 pure cotton small twist (86 / 36);

[0082] Wool warp: 21s / 2 weak twist (100% cotton);

[0083] Weft yarn: 32S / 2 pure cotton small twist (86 / 36);

[0084] Towel weight: 585GSM;

[0085] Warp density: 130 strands / 10cm Weft density: 265 strands / 10cm Height: 13.8cm / 10 loops.

[0086] In the production process of terry fabrics, the G6300 multi-arm terry rapier loom is used to ensure that the torsion value of the wool warp tension torsion bar is maintained at 15 degrees, while the torsion value of the ground warp tension torsion bar is set to 95 degrees. The working speed of the loom is set to 420 rpm, which can ensure both production efficiency and stability of the weaving process.

[0087] In the weaving process, the warp density is selected with a No. 56 steel reed, and the weft density is set to 265 threads per ten centimeters. Such a density setting can ensure the durability of the towel fabric.

[0088] During the weaving process: the ground warp and wool warp yarns are fed into the reed in the manner of 1 wool warp and 1 ground warp into one reed tooth, arranged in a cycle; the normal 3-weft raising method is used for weaving, in which 2 wefts are short wefts and 1 weft is long weft. When the weft is long, the 2 weft weft yarn is pushed to the weaving opening, so that the wool warp forms a terry loop on the base fabric.

[0089] The drawing-in method during weaving is as follows: Normal drawing-in: one wool warp is drawn into a reed tooth one by one, in a cycle.

[0090] After subsequent product testing and comparison (test standards: appearance AATCC135, feather shedding CTL Test Method, water absorption ASTM D4772, strength ASTM D5034), the comparison results are shown in the following table:

[0091] Appearance Feather shedding rate Water absorption Tensile strength / (lbf / N) Example 3 Level 4.0 4.8‰ 98％ Warp 85.7, weft 50.5 Comparative Example Level 4.0 5.2‰ 90％ Warp 54.2, weft 49.8

[0092] The towel fabric products with different warps produced by the method of the present invention have a fluffy and soft feel, and the products with different yarn counts have unique styles. More importantly, even after washing, the performance of the product remains stable, and the physical indicators are excellent, which fully meets the needs of consumers for high-quality towel fabrics.

Claims

1. A method for preparing a fluffy, durable and strong towel fabric, wherein the towel fabric is woven from ground warp, wool warp and weft yarns, characterized in that: The design of two-layer base fabric is adopted, in which the wool warp passes through the bottom layer of consolidated terry tissue and interweaves with the weft yarn of the upper layer of gauze tissue to produce terry. The bottom layer of consolidated terry tissue is hidden at the root of the terry, which plays a role in consolidating and supporting the terry. The upper gauze fabric adopts plain weave or double plain weave.

2. The method for preparing a fluffy, durable and strong towel fabric according to claim 1, characterized in that: When the towel fabric is a double-layer terry fabric, the warp yarns of the lower terry fabric are only interwoven with the weft yarns of the bottom consolidated terry fabric to produce the lower terry fabric.

3. The method for preparing a fluffy, durable and strong towel fabric according to claim 1, characterized in that: The way of feeding the ground warp yarn and wool warp yarn into the steel reed is that 1 wool warp and 2 ground warps are fed into one reed tooth in a cyclic arrangement.

4. The method for preparing a fluffy, durable and strong towel fabric according to claim 1, characterized in that: The towel fabric has a warp density of 127 to 173 strands / cm and a weft density of 250 to 300 strands / cm.

5. The method for preparing a fluffy, durable and strong towel fabric according to claim 1, characterized in that: The specific weaving process is: weaving is carried out in a 6-weft method, among which the 5th weft is a short weft and the 1st weft is a long weft. When the long weft is used, the 5th weft yarn is pushed to the weaving mouth, so that the wool warp forms a loop between the two layers of base fabric, and the bottom layer of consolidated terry structure is hidden at the root of the loop, which supports the loop.

6. The method for preparing a fluffy, durable and strong towel fabric according to claim 5, characterized in that: During weaving, the ground warp is divided into two areas when drawing the heddle into the machine to form an upper gauze structure and a bottom consolidated terry structure.

7. The method for preparing a fluffy, durable and strong towel fabric according to claim 1, characterized in that: The drawing-in method for weaving the fluffy, durable and strong towel fabric is as follows: one warp tissue cycle consists of 4 ground warp yarns and 2 wool warp yarns, wherein 2 ground warp yarns support the terry loops and 2 base fabric ground warp yarns form a flat cloth structure to support the terry loops; the specific drawing-in sequence is as follows: a ground warp for clamping the terry loops is inserted into a ground warp heald, a wool warp is inserted into a wool warp heald, a ground warp for supporting the terry loops is inserted into a ground warp heald, and the above three yarns are inserted into a reed tooth, and the cycle is repeated in sequence.

8. The method for preparing a fluffy, durable and strong towel fabric according to claim 1, characterized in that: The fluffy, durable and strong towel fabric is woven at a speed of 400 to 450 revolutions per minute on a multi-arm loom, with a torsion value of 95 to 110 degrees for the ground warp tension and a torsion value of 35 to 50 degrees for the wool warp tension.

9. A fluffy, durable and strong towel fabric prepared according to the method according to any one of claims 1 to 8.

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