High-foaming-performance terry bath towel fabric and preparation method thereof

Abstract

The invention discloses a looped pile bath towel fabric with high foaming performance and a preparation method thereof, the looped pile bath towel fabric comprises a base cloth layer and a looped pile layer, the looped pile layer adopts chemically treated 300D / 10F polyester filament yarn to weave inclined looped piles with consistent height, the looped piles and the base cloth layer form an included angle of 30-45 degrees, regular triangular holes with side length of 0.5-1 mm are formed between adjacent looped piles, and the thickness of the looped pile layer is 1-5 mm. And the base cloth layer is made of 100D common polyester filament yarns. According to the invention, the coarse denier fibers are adopted and matched with the looped pile structure, so that the water-repellent and absorption-repellent bath foam characteristics of the fabric are obviously improved, and the fabric has high foaming performance. Coarse denier fibers are selected to be combined with a unique looped pile structure, so that a large amount of foam (geometric progression) can be quickly generated when the foaming looped pile fabric is used. The chemical treatment process further guarantees the bonding strength between the fibers and uniform covering of a film layer, the problems that traditional coarse denier fibers are poor in cohesive force and difficult to stably weave into loops are solved, and the foamed terry fabric has excellent durability and comfort while maintaining good foaming performance.

Description

Technical Field

[0001] The present invention relates to the field of textile technology, in particular to a terry bath towel fabric with high foaming performance and a preparation method thereof, and is particularly suitable for a cleaning cloth that foams quickly and has rich foam. Background Art

[0002] Traditional bath sprays or bath strips are extruded in one go using a screw extruder. While they can generate foam through physical compression, they require repeated kneading to produce foam. The foam volume is typically small, the mesh structure is simple, and the foam volume is insufficient. The foam structure is loose, resulting in poor foam stability. The mesh easily deforms after use, causing hardening, and the material has poor fatigue resistance.

[0003] In the prior art, there is also a fabric design using a terry cloth structure as a bath cloth (such as a towel or bath towel). However, since the fiber monofilament of the terry cloth is relatively fine, usually 150D (48F-96F), it has no water or bath liquid repellency, and therefore cannot produce large foam, and the amount of foam is also relatively small.

[0004] Currently, there's no functional bath cloth on the market that can maintain a terry structure while producing significantly rich foam. The main reasons are as follows: Due to material limitations, ordinary polyester filament or cotton yarn cannot achieve the foam-amplifying effect. If coarse-denier, low-porosity polyester filament (such as 300D / 10F) is used, the monofilament is thicker (30D / monofilament), resulting in loose fiber bundles and poor cohesion, making it difficult to stably weave a terry structure and increasing the weaving difficulty. If twisting is used to enhance cohesion, the fiber bundles become tighter, thus losing the foam-amplifying function.

[0005] Therefore, there is an urgent need for a new type of bath towel fabric that can significantly improve the foaming efficiency while maintaining comfort. Summary of the Invention

[0006] The invention provides a terry bath towel fabric with high foaming performance and a preparation method thereof, which can be woven stably and have improved foaming performance. The fabric can be used to make foaming bath towels, bath bars, and bath flowers.

[0007] To achieve the above-mentioned purpose, the present invention adopts the following technical solution: a high-foaming performance terry bath towel fabric, comprising a base fabric layer and a terry layer, the terry layer is woven into highly consistent inclined terry using chemically treated 300D / 10F polyester filaments, the terry loops and the base fabric layer form an angle of 30-45°, and regular triangular pores with a side length of 0.5-1mm are formed between adjacent terry loops, and the base fabric layer uses ordinary 100D polyester filaments to provide fabric skeleton support.

[0008] The tilted loops formed by chemically treated 300D / 10F polyester filaments not only maintain excellent fiber cohesion but also, through their specific tilt angle and pore structure, significantly enhance foam generation and stability. The angled loops and base fabric layer ensure more effective contact and friction with the skin during use. Furthermore, the regular triangular pores provide channels for even foam distribution and penetration, further enhancing cleansing effectiveness. The 30-45° tilt angle optimizes foam generation efficiency (approximately 15% higher than vertical loops), and the triangular pore structure, with a side length of 0.5-1mm, forms stable foam-generating units. The angle between the loop and base fabric layers creates varying foam sizes, with larger bubbles forming at the top of the angle and smaller, denser bubbles at the base. This allows the looped fabric to rapidly generate abundant and exponentially more foam when used in finished products.

[0009] Furthermore, the base fabric layer uses ordinary polyester filaments, which not only provide the fabric's basic structural support and dyeability, but also ensure the durability and stability of the foaming terry cloth. The entire design significantly improves foaming efficiency while ensuring comfort, meeting the user's dual needs for foaming terry cloth's cleaning performance and comfort.

[0010] Furthermore, the terry structure has a height of 8-12mm and a density of 40-50 loops / cm². This 8-12mm loop height represents the optimal foaming range; exceeding this range results in insufficient durability, insufficient foaming efficiency, and poor foam richness. A terry density of 40-50 loops / cm² ensures sufficient friction while avoiding skin irritation caused by excessive density. This ensures foam stability and efficiency while also ensuring the durability and comfort of the terry fabric.

[0011] Furthermore, the triangular pores have a depth-to-width ratio of 1:1.2-1.5 and a vertex angle of 55-65°. This depth-to-width ratio maximizes foam duration, and a vertex angle of 55-65° optimizes foam stability.

[0012] Furthermore, the chemical treatment forms a PU film with a 30-50% coverage on the surface of the monofilament, with a thickness of 0.5-1.2 μm. This PU film not only strengthens the cohesion between the fiber bundles, making the loop structure more stable and less prone to deformation, but also, through its unique surface properties, enhances the fiber's contact with water and cleansing products such as shower gel, thereby promoting rapid foam generation. Furthermore, the appropriate film thickness ensures uniformity and durability of the treatment, avoiding the problems of too thick a film resulting in a stiff feel or too thin a film failing to effectively improve fiber performance.

[0013] The preparation method of the above-mentioned high-foaming terry bath towel fabric is that the terry layer 300D / 10F polyester filament is chemically treated before weaving to enhance the cohesive force. The specific fiber treatment process is to immerse the 300D / 10F polyester filament in a treatment liquid containing 3-8% water-based polyurethane, 0.5-2% cross-linking agent, and 0.1-0.5% penetrant, and then dry it in stages after squeezing the liquid to form a partially covered adhesive film on the surface of the monofilament.

[0014] The selection of the concentration of waterborne polyurethane in the treatment liquid is critical. Too low a concentration may lead to insufficient cohesion between fibers, while too high a concentration may affect subsequent processing performance and the feel of the finished product. The addition of a cross-linking agent is intended to promote chemical bonding between the PU film and the fiber, enhancing the adhesion and durability of the film. The appropriate use of a penetrant ensures that the treatment liquid can evenly penetrate into the fiber, improving the treatment effect.

[0015] During the staged drying process, temperature and time must be strictly controlled to avoid excessively thick or thin film layers, which could affect the performance of the final product. Proper drying conditions also ensure uniform curing of the PU film, further improving the stability and durability of the fiber bundles.

[0016] Furthermore, the specific process of fiber chemical treatment is as follows: During the dipping process, the filaments pass through the treatment solution at a speed of 5-10 m / min, with a bath ratio of 1:10-1:15 and a temperature of 25-40°C; The residual rate after squeezing is controlled at 70-80% to avoid excessive liquid causing fiber adhesion; Drying is carried out in stages: pre-drying at 80℃ for 2 minutes → baking at 120℃ for 1 minute to form PU film and partially cross-link it; Cooling is done by standing at room temperature for 24 hours to allow the treatment agent to fully solidify.

[0017] Furthermore, the PU film coverage of the monofilament surface needs to reach 30-50%.

[0018] Furthermore, the waterborne polyurethane is anionic, with a molecular weight of 10,000-50,000. Anionic waterborne polyurethanes have excellent dispersibility and stability, allowing them to be evenly dispersed in the treatment solution, ensuring consistent treatment results. The molecular weight range selected ensures sufficient film-forming properties while preventing excessive viscosity of the treatment solution due to excessive molecular weight, which could affect impregnation and mangling. Furthermore, anionic waterborne polyurethanes exhibit excellent water resistance, chemical resistance, and abrasion resistance, significantly enhancing the durability and service life of the foamed terry cloth.

[0019] Furthermore, the chemically treated fibers are knitted using a 20-needle to 24-needle warp knitting machine, with the hook depth adjusted to 1.3-1.7 mm and the machine speed 350-400 rpm, and the let-off ratio of the terry yarn to the base fabric yarn is 1.2:1 to 1.5:1.

[0020] Machines with more than 24 needles struggle to reliably pick up 300D / 10F coarse filaments, causing the loops to easily fall off. High-precision terry warp knitting machines with fewer than 24 needles (preferably 20 or 24 needles) ensure stable loop formation. This not only ensures tight arrangement of the loops and improves foaming, but also avoids deep hooks that can make the loops too stiff and affect comfort. 300D / 10F filaments are very rigid, and high speeds can easily lead to yarn breakage or loop deformation. Controlling the machine speed to 350-400 rpm (lower than the 500-600 rpm of ordinary terry cloth) ensures that the filaments remain intact during the weaving process, reduces yarn breakage, and ensures the uniformity and aesthetics of the loops.

[0021] In summary, the present invention utilizes coarse denier fibers in combination with a terry structure, significantly improving the fabric's foaming properties. The use of coarse denier fibers not only enhances the durability and friction of the foaming terry cloth, but also, combined with the unique terry structure, significantly improves the fabric's water-repellent and bath lotion-repellent properties, resulting in high foaming performance and enabling the foaming terry cloth to quickly produce large amounts (geometric amounts) of foam during use. Bath cloths made from this material are an iterative product of traditional bath flowers and bath strips, and are a new material for making foaming bath towels. The chemical treatment process further ensures the bonding strength between the fibers and the uniform coverage of the film layer, resolving the issues of poor cohesion and difficulty in stable weaving of coarse denier fibers. This allows the foaming terry cloth to maintain excellent foaming performance while also possessing excellent durability and comfort. DETAILED DESCRIPTION

[0022] The following further describes in detail the specific embodiments of the high-foaming performance terry bath towel fabric and the preparation method thereof of the present invention.

[0023] A high-foaming terry bath towel fabric includes a base fabric layer and a terry layer. The terry layer is woven from chemically treated 300D / 10F polyester filaments into highly consistent inclined loops. The loops form an angle of 30-45° with the base fabric layer, and regular triangular pores with a side length of 0.5-1mm are formed between adjacent loops. The base fabric layer uses ordinary 100D polyester filaments to provide fabric skeleton support.

[0024] The tilted loops, formed from chemically treated 300D / 10F polyester filaments, not only maintain excellent fiber cohesion but also, through their specific tilt angle and pore structure, significantly enhance foam generation and stability. The angled design between the tilted loops and the base fabric layer allows for more effective contact and friction with the skin during use. Furthermore, the presence of regular triangular pores provides channels for even foam distribution and penetration, further enhancing cleansing effectiveness. The 30-45° tilt angle optimizes foam generation efficiency (approximately 15% higher than vertical loops), and the triangular pore structure, with a side length of 0.5-1mm, creates stable foam-generating units.

[0025] Furthermore, the base fabric layer utilizes ordinary polyester filaments, which not only provide the fabric's basic structural support and dyeability, but also ensure the fabric's durability and stability. This entire design significantly improves foaming efficiency while ensuring comfort, meeting the user's dual needs for both cleaning effectiveness and comfort in a foaming terry cloth.

[0026] In this embodiment, the loop structure preferably has a height of 8-12mm and a density of 40-50 loops / cm². A loop height of 8-12mm is the optimal foaming range; exceeding this range results in insufficient durability or foaming efficiency, resulting in poor foam richness. A loop density of 40-50 loops / cm² ensures sufficient friction while avoiding skin discomfort caused by excessive density. This ensures foam stability and efficiency while also ensuring the durability and comfort of the foaming terry cloth.

[0027] In this embodiment, the triangular pores preferably have a depth-to-width ratio of 1:1.2-1.5 and a vertex angle of 55-65°. This depth-to-width ratio maximizes foam duration, and a vertex angle of 55-65° optimizes foam stability.

[0028] In this embodiment, the chemical treatment preferably forms a PU film with a coverage of 30-50% on the surface of the monofilament, with a thickness of 0.5-1.2 μm. The PU film not only strengthens the cohesion between the fiber bundles, making the loop structure more stable and less prone to deformation, but also, through its unique surface properties, enhances the fiber's contact with water and cleaning products such as shower gel, thereby promoting rapid foam generation. Furthermore, the appropriate film thickness ensures uniformity and durability of the treatment, avoiding the problems of too thick a film resulting in a stiff feel or too thin a film failing to effectively improve fiber properties.

[0029] The preparation method of the above-mentioned high-foaming terry bath towel fabric is that the terry layer 300D / 10F polyester filament is chemically treated before weaving to enhance the cohesive force. The specific fiber treatment process is to immerse the 300D / 10F polyester filament in a treatment liquid containing 3-8% water-based polyurethane, 0.5-2% cross-linking agent, and 0.1-0.5% penetrant, and then dry it in stages after squeezing the liquid to form a partially covered adhesive film on the surface of the monofilament.

[0030] The selection of the concentration of waterborne polyurethane in the treatment liquid is critical. Too low a concentration may lead to insufficient cohesion between fibers, while too high a concentration may affect subsequent processing performance and the feel of the finished product. The addition of a cross-linking agent is intended to promote chemical bonding between the PU film and the fiber, enhancing the adhesion and durability of the film. The appropriate use of a penetrant ensures that the treatment liquid can evenly penetrate into the fiber, improving the treatment effect.

[0031] During the staged drying process, temperature and time must be strictly controlled to avoid excessively thick or thin film layers, which could affect the performance of the final product. Proper drying conditions also ensure uniform curing of the PU film, further improving the stability and durability of the fiber bundles.

[0032] In this embodiment, preferably, the specific process of fiber chemical treatment is as follows: During the dipping process, the filaments pass through the treatment solution at a speed of 5-10 m / min, with a bath ratio of 1:10-1:15 and a temperature of 25-40°C; The residual rate after squeezing is controlled at 70-80% to avoid excessive liquid causing fiber adhesion; Drying is carried out in stages: pre-drying at 80℃ for 2 minutes → baking at 120℃ for 1 minute to form PU film and partially cross-link it; Cooling is done by standing at room temperature for 24 hours to allow the treatment agent to fully solidify.

[0033] In this embodiment, preferably, the PU film coverage rate of the monofilament surface needs to reach 30-50%.

[0034] In this embodiment, the waterborne polyurethane is preferably anionic, with a molecular weight of 10,000-50,000. Anionic waterborne polyurethanes have excellent dispersibility and stability, allowing them to be evenly dispersed in the treatment fluid, ensuring consistent treatment results. The molecular weight range selected ensures sufficient film-forming properties while preventing excessive viscosity of the treatment fluid due to excessive molecular weight, which could affect impregnation and mangling. Furthermore, anionic waterborne polyurethanes exhibit excellent water resistance, chemical resistance, and abrasion resistance, significantly enhancing the durability and service life of the foamed terry cloth.

[0035] In this embodiment, the chemically treated fibers are preferably woven using a 20-24 needle warp knitting machine, with the hook depth adjusted to 1.3-1.7 mm and the machine speed 350-400 rpm, and the let-off ratio of the terry yarn to the base fabric yarn is 1.2:1 to 1.5:1.

[0036] Machines with more than 24 needles struggle to reliably pick up 300D / 10F coarse filaments, causing the loops to easily fall off. High-precision terry warp knitting machines with fewer than 24 needles (preferably 20 or 24 needles) ensure stable loop formation. This not only ensures tight arrangement of the loops and improves foaming, but also avoids deep hooks that can make the loops too stiff and affect comfort. 300D / 10F filaments are very rigid, and high speeds can easily lead to yarn breakage or loop deformation. Controlling the machine speed to 350-400 rpm (lower than the 500-600 rpm of ordinary terry cloth) ensures that the filaments remain intact during the weaving process, reduces yarn breakage, and ensures the uniformity and aesthetics of the loops.

[0037] Specific examples and comparative experiments are as follows: Example

[0038] Terry height: 10mm; Tilt angle: 35°; Pore structure: side length 0.8mm, depth-to-width ratio 1:1.3; Chemical treatment: 5% water-based PU (Mw=35000), coverage 40%; Weaving: 24-needle warp knitting machine, needle hook 1.5mm, machine speed 450rpm.

[0039] The comparison group was set up as follows: Group A was the present embodiment; Group B was 300D / 10F filament without chemical treatment using a conventional process; and Group C was fiber twisted at 60 twists / m.

[0040] Test results: Test indicators Group A Group B Group C Gap Analysis Foaming amount (mL / g) 158 82 105 This solution improves 92.7% Terry shedding rate (%) 2.1 18.3 6.5 Twisting improves but sacrifices function Foam duration (min) 36 15 22 The pore structure has obvious advantages Skin touch score 4.7 3.2 4.1 PU film improves skin-friendliness Example

[0041] Loop height 12mm; pore side length 1.0mm; let-off ratio 1.5:1.

[0042] Comparative data: Performance indicators This embodiment Regular terry cloth Technological advantages Foaming efficiency 172mL / g 50mL / g +244% Foam retention rate after washing 94% 78% +20.5% Single yarn strength (cN / dtex) 4.2 4.5 -6.7% Example

[0043] Enhancement treatment: Add 2% nano-SiO2; PU film thickness 1.0μm. Durability comparison: Example

[0044] Parameter settings: Terry height 7mm (below the lower limit); PU coverage 25% (below the lower limit).

[0045] Test results: The foaming volume dropped sharply to 95mL / g; the terry shedding rate increased to 14.6%.

[0046] From the above experimental comparison test results, we can see that: Fiber processing methods affect: Untreated filament: poor loop formation (shedding rate > 18%), but acceptable foaming capacity (82 mL / g); Twisting treatment: Although the weaving properties are improved (shedding rate 6.5%), the foam volume is reduced by 36.5% (vs. this solution); This solution's PU treatment: balances adhesion and functional retention (shedding rate 2.1%, foam volume 158mL / g).

[0047] Structural parameters: The inclination angle of the terry loop is 30-45°. The cleaning effect is reduced when the angle is less than 30°, and it is easy to fall over when the angle is greater than 45°. Pore depth-to-width ratio 1:1.2-1.5, <1.2 foam easily breaks, >1.5 difficult to form; PU coverage is 30-50%, <30% means insufficient adhesion, >50% means a hard feel.

[0048] Note: All comparative experiments were conducted under the same test conditions (temperature 25±1°C, humidity 65±3%, using the same brand of shower gel). Twisting treatment refers to applying 15-25 twists / m to 300D / 10F filament. Other parameters remained consistent with this protocol.

[0049] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiment. All technical solutions based on the concept of the present invention are within the scope of protection of the present invention. It should be noted that for those skilled in the art, various improvements and modifications that do not depart from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A high-foaming terry bath towel fabric, characterized by: It includes a base fabric layer and a terry layer. The terry layer is woven into highly consistent inclined loops using chemically treated 300D / 10F polyester filaments. The loops form an angle of 30-45° with the base fabric layer, and regular triangular pores with a side length of 0.5-1mm are formed between adjacent loops. The base fabric layer uses ordinary 100D polyester filaments to provide fabric skeleton support.

2. The high foaming performance terry bath towel fabric according to claim 1, characterized in that: The loop structure height is 8-12mm and the density is 40-50 loops / cm².

3. The high foaming performance terry bath towel fabric according to claim 1, characterized in that: The aspect ratio of the triangular pores is 1:1.2-1.5, and the vertex angle is 55-65°.

4. The high foaming performance terry bath towel fabric according to claim 1, characterized in that: The chemical treatment forms a PU film with a coverage rate of 30-50% and a thickness of 0.5-1.2 μm on the surface of the monofilament.

5. The method for preparing the high-foaming terry bath towel fabric according to any one of claims 1 to 3, characterized in that: The 300D / 10F polyester filaments of the terry layer are chemically treated before weaving to enhance the cohesive force. The specific fiber treatment process is to immerse the 300D / 10F polyester filaments in a treatment liquid containing 3-8% water-based polyurethane, 0.5-2% cross-linking agent, and 0.1-0.5% penetrant, and then dry them in stages after squeezing the liquid to form a partially covered adhesive film on the surface of the monofilament.

6. The method for preparing the high foaming performance terry bath towel fabric according to claim 4, characterized in that: The specific process of fiber chemical treatment is as follows: During the dipping process, the filaments pass through the treatment solution at a speed of 5-10 m / min, with a bath ratio of 1:10-1:15 and a temperature of 25-40°C; The residual rate after squeezing is controlled at 70-80% to avoid excessive liquid causing fiber adhesion; Drying is carried out in stages: pre-drying at 80℃ for 2 minutes → baking at 120℃ for 1 minute to form PU film and partially cross-link it; Cooling is done by standing at room temperature for 24 hours to allow the treatment agent to fully solidify.

7. The method for preparing the high-foaming performance terry bath towel fabric according to claim 4, characterized in that: The PU film coverage of the monofilament surface must reach 30-50%.

8. The method for preparing the high-foaming performance terry bath towel fabric according to claim 5, characterized in that: The waterborne polyurethane is anionic and has a molecular weight of 10,000-50,000.

9. The method for preparing the high-foaming performance terry bath towel fabric according to claim 4, characterized in that: The chemically treated fibers are woven using a 20- to 24-needle warp knitting machine with the hook depth adjusted to 1.3-1.7 mm and a machine speed of 350-400 rpm. The let-off ratio of terry yarn to base fabric yarn is 1.2:1 to 1.5:1.