Intensive and straight terry fabric for cleaning and weaving method and special auxiliary needle hook of dense and straight terry fabric

Abstract

The invention discloses a dense and straight terry fabric for cleaning and a weaving method and special auxiliary needle hooks thereof, a plurality of auxiliary needle hooks are inserted into a reed and are connected in series through a pin insertion pin seat on a temple seat, and during weaving, auxiliary weft yarns are inserted into upper sheds formed by two groups of terry warp yarns in sequence respectively, so that the auxiliary needle hooks hook the auxiliary weft yarns, and the auxiliary needle hooks are inserted into the upper sheds respectively, so that the auxiliary weft yarns are formed. The auxiliary weft is hung on the looped pile warp located on the upper layer in the upper layer shed, and the non-hung part of the looped pile warp hung by the auxiliary needle hook is interwoven with the body warp and the base cloth weft of the base cloth, so that the part of the looped pile warp hung by the auxiliary weft forms a looped pile, and the non-hung part is woven into the base cloth; releasing the fixed end of the auxiliary weft yarn located on one side of the fabric, and pulling the auxiliary weft yarn away from the fabric at the same time. The method thoroughly gets rid of dependence on height fixing pieces, complex mechanical actions and chemical water-soluble materials, the terry forming mechanism is attributed to simple hooking-releasing mechanical actions, the principle is clear, and implementation is easy.

Description

Technical Field

[0001] This invention relates to the field of textile technology for cleaning fabrics with a terry loop structure, and more particularly to a dense, straight terry loop cleaning fabric, its weaving method, and a special auxiliary needle hook. Background Technology

[0002] Terry cloths, due to their fluffy, absorbent loop structure, are widely used in products such as bath towels, cleaning cloths, and scrubbing pads. For functional cleaning fabrics, especially scrubbing products that require strong abrasion, stain removal, and durability, not only is a high density of loops required, but also that the loops be of uniform height and stand upright to ensure even, powerful, and long-lasting cleaning power.

[0003] Currently, the mainstream technical methods used in the industry to create this type of straight, bouncy fringe mainly include: 1. Fixed-height plate method: During the weaving process, metal or plastic fixed-height plates of a specific height are inserted into the warp layer, and the loop warp yarns surround the fixed-height plates to form loops. Although this method can directly control the loop height, it has problems such as high consumption of fixed-height plates, cumbersome management, easy to aggravate reed wear and potential damage to yarn. It has poor adaptability in high-speed weaving and low production efficiency.

[0004] 2. Mechanical Action Method: This method uses complex mechanical mechanisms, such as moving the weft insertion point (weft movement) or changing the beat-up stroke (long and short beat-up), to create a relative displacement difference between the warp and weft yarns to form loops. This method places extremely high demands on the loom's mechanical structure, resulting in expensive equipment manufacturing costs, complex process adjustments and maintenance, and significant difficulty in controlling the stability and consistency of loop height.

[0005] 3. Water-soluble weft yarn method: Water-soluble chemical fibers (such as PVA) are introduced as temporary supporting weft yarns during weaving. After weaving, the fabric is immersed in hot water to dissolve the weft yarns, thereby releasing the loops. This method can form good loops, but it involves environmental issues such as water consumption, energy consumption, and wastewater treatment. It also increases raw material costs and post-processing steps, and lengthens the production process.

[0006] In summary, existing technologies generally face challenges such as complex equipment, high costs, limited production efficiency, or insufficient environmental friendliness. Therefore, the industry urgently needs a novel, simple, efficient, and environmentally friendly technical solution that can stably produce high-quality, straight terry fabrics. Summary of the Invention

[0007] The purpose of this invention is to provide a dense, straight terry cloth for cleaning, its weaving method, and a dedicated auxiliary needle hook, aiming to overcome the aforementioned deficiencies of the prior art. The core objective of this invention is to completely eliminate reliance on physical height plates, complex weft insertion / stretching mechanisms, and chemically water-soluble yarns, providing a revolutionary solution that offers low equipment modification costs, simple process principles, stable operation, environmental friendliness, and efficient production of dense, straight, and highly uniform terry cloth.

[0008] The above-mentioned technical objective of the present invention is achieved through the following technical solution: The present invention, in a first aspect, provides a special auxiliary needle hook for weaving dense, straight terry fabrics, wherein the auxiliary needle hook is an elongated, sheet-like component independent of the reed of the loom, comprising: The front end of the auxiliary hook is a forward section that can be inserted between the teeth of the reed; The rear end of the auxiliary needle hook is provided with a connecting part for connecting multiple auxiliary needle hooks at the same height and front and rear positions, and a guiding part for guiding the weft yarn. The connecting part at the rear end of the auxiliary needle hook is also provided with a waist-shaped elongated hole. Through the waist-shaped elongated hole, the pin of the pin seat installed on the side support of the loom connects multiple auxiliary needle hooks in series. Furthermore, the hook portion located between the guide portion and the leading portion is a hook-shaped structure with its opening facing the weft inlet direction. The hook-shaped structure is used to hook the introduced weft yarn during weft insertion.

[0009] Using the above technical solution, based on the required transverse distribution density of the loops, multiple auxiliary needle hooks are arranged and fixed along the length of the shuttle reed at equal intervals (e.g., intervals of 2 mm, 5 mm, 10 mm, 20 mm, or 50 mm) or in a specific non-uniform pattern. During installation, the leading edge of the auxiliary needle hook is inserted into the gap between the reed teeth, with the opening of the hook-shaped structure of the needle hook facing the weft inlet and slightly tilted downwards. The leading edge of the needle hook can withstand reliable weft-beating impacts and long-term friction from the back-and-forth swing of the reed; the internal dimensions of the hook-shaped structure of the needle hook are slightly larger than the diameter of the auxiliary weft yarn used to ensure smooth hooking and temporary locking of the weft yarn being beaten in. By guiding the weft yarn through the hook section, subsequent weft yarns can "squeeze" or "replace" the previous weft yarn from the hook section, thus achieving alternating hooking. The rear end of the hook mainly serves the functions of installation positioning and overall reinforcement, and enhances the overall rigidity of the hook. By passing the pin of the pin seat through the waist-shaped elongated hole of the connecting part of all auxiliary hooks arranged along the length of the reed, all auxiliary hooks can be connected and fixed together, ensuring that the guiding bottom of the hook-shaped structure of all hooks is at the same upper warp position height. This is the core mechanical basis for ensuring that all loops on the final fabric have a uniform height. More importantly, through the pin connection of the pin seat, the auxiliary hook can also float across the future loops of the dense and straight loop fabric that has just been woven, cooperating to ensure that it can smoothly hook into and temporarily hold the weft yarn that has been driven in.

[0010] Preferably, the front section of the auxiliary hook is flat and wedge-shaped, and the middle section has a barb-like or slightly protruding structure.

[0011] Using the above technical solution, the front section of the auxiliary needle hook is designed as a flat wedge shape, allowing the auxiliary needle hook to be tightly and floatingly inserted into the gap between the reed teeth on the loop. This design ensures that the needle hook itself will not loosen, shift, or fall off under the impact of the reed's high-speed back-and-forth swing and strong weft striking, maintaining absolute positional stability.

[0012] In this application, a second aspect provides a method for weaving a dense, straight terry fabric using the aforementioned auxiliary needle hook, comprising the following steps: S1: Configure a warp and weft yarn system, wherein the warp yarn system includes at least ground warp yarns and at least two sets of terry cloth warp yarns; the weft yarn system includes auxiliary weft yarns and base fabric weft yarns; S2: Prepare an auxiliary needle hook as described in any one of claims 1-2 and a loom capable of forming stable upper and lower sheds; S3: Arrange the multiple auxiliary needle hooks along the length of the reed of the loom. During installation, insert the leading edge of the auxiliary needle hook into the gap between two adjacent reed teeth. The auxiliary needle hook can be suspended on the upper layer of the fabric surface, and the opening of the hook-shaped structure of the hook hook part faces the direction of the weaving. Pass the pin of the pin seat through the waist-shaped elongated hole of the multiple auxiliary needle hook connecting parts along the length of the reed of the loom. Fix the pin seat at the side support of the loom, and make the bottom of the hook-shaped structure of all auxiliary needle hooks at the same horizontal level on the upper warp position line. S4: Execute the weaving cycle, each cycle containing: a) Opening: The two sets of looped warp yarns are positioned in the upper and lower layers respectively, so that one set of looped warp yarns is first located at the top of the upper shed, and the other set of looped warp yarns is located at the bottom of the lower shed; the two sets of ground warp yarns form the lower shed, and are exchanged front and back to form an opening for weaving. b) Weft insertion: Introduce an auxiliary weft yarn into the upper shed and a base fabric weft yarn into the lower shed; c) Weft insertion and hooking: The steel reed pushes the auxiliary weft yarn and the base fabric weft yarn towards the weft hole, and the auxiliary weft yarn is hooked by the hook-shaped structure of the corresponding auxiliary needle hook, thereby supporting the previous group of loop warp yarns located on it; while the base fabric weft yarn is introduced into the lower shed formed by the two groups of ground warp yarns and the shed formed by the loop warp yarns at the bottom of the lower shed to form the lower base fabric; d) Changing the shed: Raise the terry warp yarn at the bottom of the lower shed to the top of the upper shed; lower the terry warp yarn at the top of the upper shed to the bottom of the lower shed; raise the ground warp yarn at the second-lowest level of the lower shed to the second-upper level of the lower shed; introduce the second auxiliary weft yarn into the upper shed; and introduce the second base fabric weft yarn into the lower shed. The base fabric weft yarn and the two sets of ground warp yarns exchange the shed and a set of loop warp yarns at the bottom of the lower shed interweave the base fabric. S5: In the subsequent weaving cycle, the newly introduced auxiliary weft yarn pushes out the hook-shaped structure of the auxiliary weft yarn that was hooked in the previous cycle. The pushed-out auxiliary weft yarn moves forward with the fabric, and the previous group of loop warp yarns above it will form a hanging line segment on the fabric surface; the new auxiliary weft yarn hooks the next group of new loop warp yarns that are currently located at the top of the uppermost layer of the upper shed. S6: After weaving is completed, the fixed end of the auxiliary weft yarn at one edge of the upper fabric is cut open and released, and at the same time, the auxiliary weft yarn is pulled out of the main body of the fabric from the other side of the fabric.

[0013] Using the above technical solution, this method is implemented on looms capable of forming stable, independent upper and lower sheds (such as double-shed ribbon looms, double-layer rapier looms equipped with double sheathing and weft insertion devices, etc.). Its core technological principle lies in using relatively fixed auxiliary hooks in conjunction with alternately introduced auxiliary weft yarns to perform periodic "hooking-holding-transfer-release" mechanical actions on the loop warp yarns at the weft edge, thereby forming highly controlled loops within the fabric structure. The following detailed explanation uses a complete two-weft (shuttle) cycle as an example: Cycle 1 (First Dimension): 1. Formation of the shed: The heddle lifting device moves to raise the first set of looped warp yarns to the top of the upper shed.

[0014] The second set of terry warp yarns is lowered to the bottommost position of the lower shed.

[0015] At the same time, the first set of ground warp yarns is raised to the second-upper position of the lower shed, so that it forms a clear lower channel (i.e., the lower shed) between the second set of ground warp yarns (or other specially designed bottom warp yarns) in the second-lower position and the second set of terry warp yarns descending to the lowest position of the lower shed.

[0016] 2. Introduce the weft yarn: The upper weft inserter (such as a rapier or a rapier shuttle) introduces the first auxiliary weft yarn into the upper shed.

[0017] The lower weft inserter (such as a rapier or a rapier shuttle) introduces the first base fabric weft yarn into the lower shed.

[0018] 3. Weft insertion and initial hooking: The reed moves forward (towards the weave opening), striking the first auxiliary weft yarn of the upper layer and the second base fabric weft yarn of the lower layer together toward the weave opening.

[0019] Key Action: At the moment of weft termination, the first auxiliary weft yarn is pushed against the weft thread by the reed, and under the combined effect of the warp tension and slight rebound, it falls precisely into the hook-shaped structure of the corresponding auxiliary needle hook and is reliably hooked. Since this auxiliary weft yarn is located below the first group of loop warp yarns that are lifted within the upper shed, it "supports" or "hooks" this group of loop warp yarns, achieving an initial temporary grip and upward lifting and positioning of this part of the loop warp yarns.

[0020] At the same time, the first base fabric weft yarn of the lower layer interweaves normally with all the ground warp yarns and the second set of terry warp yarns located in the lower shed (e.g., plain weave), and begins to form the basic structure of the fabric (base fabric 7).

[0021] Cycle Two (Second Latitude): 1. Changing the shed: The heddle lifting device changes its movement, raising the second set of looped warp yarns to the top of the upper shed.

[0022] The first set of terry warp yarns is lowered to the bottom of the lower shed.

[0023] The second set of ground warp yarns is raised to the second-upper position of the lower shed, forming a new lower shed with the first set of ground warp yarns and the first set of terry warp yarns, which are at the bottom and descend to the bottommost position of the lower shed.

[0024] 2. Introduce the weft yarn again: Introduce the second auxiliary weft yarn into the upper shed.

[0025] The second base fabric weft yarn is introduced into the lower shed.

[0026] 3. Handover of weft insertion and hook hanging: The reed is then weft-inserted again.

[0027] Key Action: The second auxiliary weft yarn is driven towards the weft insertion point and enters the hook-shaped structure of the same auxiliary needle hook. At this time, because the woven fabric is being continuously pulled forward with constant tension by the take-up device, the first auxiliary weft yarn, which was previously hooked, is subjected to a continuous forward horizontal tension. When the second auxiliary weft yarn enters the hook-shaped structure of the auxiliary needle hook and squeezes and pushes the first auxiliary weft yarn, the first auxiliary weft yarn, with the assistance of this forward tension, smoothly slips out of the hook-shaped structure, moves forward with the fabric along the guide section of the auxiliary needle hook, and is finally wound into the take-up roller.

[0028] Meanwhile, the newly introduced second auxiliary weft yarn occupies the hook portion of the auxiliary needle hook and begins to "hook" and hold the newly lifted second set of loop warp yarns. The first set of loop warp yarns, which has just been released, has its lower part interwoven and fixed with the base fabric weft yarn, while its upper part is released from a tense hooked state, thus forming a relaxed hanging line segment on the fabric surface with a height equal to the distance from the bottom of the needle hook to the base fabric structure—that is, the prototype of the loop.

[0029] Repeated cycles and fabric shaping: The process of "Cycle One" and "Cycle Two" described above is repeated continuously. Two (or more) sets of terry warp yarns are periodically and intermittently pulled upwards and then released within the fabric as the auxiliary weft yarns alternately hook and transfer on fixed needles. The lower part of all terry warp yarns continues to be tightly interwoven with the base fabric weft yarns and ground warp yarns, forming a solid bottom base fabric; while the upper part, through the aforementioned pulling and releasing actions, accumulates to form a series of draped segments of equal height and spacing. During the weaving process, a series of parallel auxiliary weft yarns are always embedded within the fabric, temporarily serving to support the future terry shape.

[0030] In this application, a third aspect provides a selvage structure and a post-processing method for yarn pulling. Includes the following steps, S1: In step S1 of the weaving method described in claim 3, additional edge-locking warp yarns are configured, and two sets of edge-locking warp yarns of upper and lower layers are laid on each side of the left and right sides of the fabric. While the auxiliary weft yarns pass through the two sets of loop warp yarns, they also pass through the two sets of edge-locking warp yarns on each side of the left and right sides of the fabric. While steps S2 and S3 of claim 4 are being performed, the two ends of all auxiliary weft yarns are interwoven with the edge-locking warp yarns on the left and right sides of the fabric to form a solid edge. S2: During or after weaving, the terry fabric produced by the weaving method according to claim 4 shall have one side of all auxiliary weft yarns cut off to release the corresponding ends of the auxiliary weft yarns. S3: Pull the uncut edge of the fabric on the other side to continuously pull away all auxiliary weft yarns.

[0031] By adopting the above technical solution, a strong selvage is woven at both ends of the auxiliary weft yarn to lock the ends of the auxiliary weft yarn, which can prevent the auxiliary weft yarn from slipping off from both sides of the fabric during weaving and transfer. Furthermore, after cutting off one side of the selvage to release the weft yarn end, the auxiliary weft yarn can be removed as a whole by pulling the other side of the selvage, without having to pull it out one by one, which is more convenient and efficient. At the same time, the auxiliary weft yarn can be recycled, further reducing costs.

[0032] Preferably, step S2 of the above method specifically includes using selvage scissors to cut one side of the fabric selvage from the main body of the fabric during or after weaving.

[0033] Using the above technical solution, during the weaving process, a precision edge shear is used to continuously cut along the inner edge of one side of the fabric (the side closest to the main width of the fabric). This operation releases the ends of all auxiliary weft yarns on one side of the fabric.

[0034] Preferably, step S3 in the selvage structure and post-processing yarn drawing method specifically includes separately rolling up the other side of the selvage that has not been cut, and continuously drawing the auxiliary weft yarn laterally from the main body of the fabric by pulling the selvage.

[0035] Using the above technical solution, the selvage that still completely wraps and locks all the auxiliary weft yarn ends is individually guided and wound onto an independent, speed-adjustable waste selvage take-up roller (or yarn draw reel).

[0036] Since one end of the auxiliary weft yarn is free, while the other end, locked by the selvage, is continuously wound and pulled away from the fabric, all auxiliary weft yarns are smoothly, continuously, and completely pulled laterally from the main body of the fabric. This process is similar to disassembling a knitted fabric and does not damage the formed loop drapes and dense base fabric structure. After extraction, the dense, straight loop fabric greige described in this invention is obtained.

[0037] Preferably, the dense, straight terry cloth fabric produced according to the present invention comprises: The dense base fabric layer is woven from the ground warp yarns, the lower section of the loop warp yarns, and the base fabric weft yarns; The upright terry loop layer consists of draped loops of uniform height formed by the upper section of the terry warp yarns and perpendicular to the plane of the base fabric.

[0038] The above technical solution is particularly suitable for high-end products with stringent requirements for cleaning performance.

[0039] Preferably, the fabric contains no residue of any height-fixing plates, water-soluble yarns, or other temporary support materials used for forming loops.

[0040] By adopting the above technical solution, the reliance on fixed-height sheets and chemical water-soluble materials is completely eliminated, the process is simplified, and the cost is reduced. Moreover, after weaving, there is no need for chemical dissolution and large-scale water washing to dissolve water-soluble chemical fibers, and there is no wastewater discharge, which meets the requirements of clean production.

[0041] Preferably, the distribution density of the loops corresponds to the spacing of the auxiliary needle hooks during weaving.

[0042] By adopting the above technical solution, the density of the loops can be flexibly adjusted by changing the lateral installation spacing of the needle hooks.

[0043] In summary, the beneficial effects of the present invention include: 1. Innovative Principles and Simplified Processes: It completely eliminates the reliance on fixed-height plates, complex mechanical movements (weft insertion and length adjustment), and chemically water-soluble materials. The terry loop formation mechanism is reduced to a simple and clear "hook-release" mechanical interaction. The principle is clear and easy to implement on existing looms for modification and process control.

[0044] 2. Superior product quality: The height of the loops is mechanically positioned by fixed needle hooks, and is not affected by process parameters such as yarn tension fluctuations and loom speed changes. Therefore, the uniformity, uprightness and consistency of the loops far exceed those of existing processes, making it particularly suitable for high-end products with stringent cleaning performance requirements.

[0045] 3. Significant cost and efficiency advantages: No expensive long / short weft insertion or fabric movement mechanisms are required; it can be achieved simply by adding a low-cost, specially designed needle hook assembly and selvage treatment device to a standard double-shed loom, resulting in extremely low equipment modification costs. The process boasts high stability, making it highly suitable for high-speed continuous production. The auxiliary weft yarns used (typically inexpensive synthetic filaments) are recyclable and reusable, further reducing raw material costs.

[0046] 4. Green and environmentally friendly: The entire production process does not require chemical dissolution or large-scale water washing, and there is no wastewater discharge, which meets the requirements of clean production and sustainable development.

[0047] 5. High design flexibility: By replacing hooks with different hook depths or adjusting the installation height of the hooks, products with different loop heights can be easily set and produced within the double-layer spacing allowed by the loom. Loop density can be flexibly adjusted by changing the lateral installation spacing of the hooks. This flexibility is difficult to achieve with the traditional fixed-height plate method (one height corresponds to one fixed-height plate). Attached Figure Description

[0048] Figure 1 This is a schematic diagram of the structure of the dense, straight-shaped terry cloth for cleaning obtained by the present invention;

[0049] Figure 2 This is a schematic diagram of a specific embodiment of the auxiliary needle hook of the present invention;

[0050] Figure 3 A side sectional view showing the positional relationship of various components during key stages of weaving is provided to illustrate the installation of the needle hook on the reed.

[0051] Figure 4 This is a schematic diagram of the weft section of the fabric; Figure 5 This is a schematic diagram of the selvage structure and auxiliary weft yarn extraction process during the fabric weaving process of the present invention.

[0052] Figure labels: 1-Base fabric layer; 2-Terry layer; 3-Reed; 4-Auxiliary needle hook; 5-Upper warp yarn position line during weaving; 6-Terry warp yarn; 7-Base fabric; 8-Hook-shaped structure position of auxiliary needle hook and hook relationship between terry warp yarn and auxiliary weft yarn at that location; 9-First group of ground warp yarns; 10-Second group of ground warp yarns; 11-Base fabric weft yarn; 12-Auxiliary weft yarn; 13-Left side of upper layer; 14-Right side of upper layer; 15-Edge yarn scissors; 16-Waste edge take-up turntable; 17-Fabric section where auxiliary weft yarn has not yet been pulled out; 18-Fabric section where auxiliary weft yarn has been pulled out (terry loops visible).

[0053] X - indicates the length and related dimensions of the front end of the hook; Y - indicates the length and related dimensions of the hook shank and hook; Z - connecting rod; T - pin seat. Detailed Implementation

[0054] The following description is merely a preferred embodiment of the present invention, and the scope of protection is not limited to this embodiment. All technical solutions falling within the scope of the present invention should be considered within the protection scope of the present invention. It should also be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the protection scope of the present invention.

[0055] See Figure 2 , Figure 3 A special auxiliary needle hook 4 is used for weaving dense, straight terry fabrics. The auxiliary needle hook 4 is an additional functional component independent of the original reed 3 on the loom. It is elongated and flat, and is made entirely of high-strength spring steel strip or stainless steel through precision stamping, bending, and heat treatment to withstand weft-beating impact and long-term friction. Its thickness is approximately 0.3 mm. Its total length is X+Y+5 mm (from the wedge-shaped front end to the center of the waist-shaped hole at the rear end).

[0056] Where X is the distance from 0 degrees to 180 degrees of back-and-forth swing of the reed 3 on the upper warp yarn position line, Y is 2X. 5 mm is the safe length of the auxiliary needle hook to prevent it from falling off when the reed 3 swings backward.

[0057] In terms of structure, the auxiliary hook 4 can be divided into two functional parts, front and rear, centered on its core functional component—the hook-shaped structure: Front end: The front end of the auxiliary needle hook 4 is the leading edge, designed to withstand reliable weft-beating impacts and long-term friction from the back-and-forth swinging of the reed 3. The leading edge of the auxiliary needle hook 4 is designed as a flat wedge shape with a gradually narrowing width. The widest part of the auxiliary needle hook 4 is approximately 10 mm wide, and its thickness is about one-third of the gap between the reed teeth of the reed 3, allowing it to be tightly and floatingly inserted into the gap between the reed teeth of the reed 3. This design ensures that the needle hook itself will not loosen, shift, or fall off under the impact of the high-speed back-and-forth swinging and strong weft-beating of the reed 3, maintaining absolute positional stability.

[0058] The needle hook body and hook section extend rearward from the leading edge (i.e., towards the rear of the loom) to form a sheet-like body. Near the weft insertion area of ​​this sheet-like body, a crucial hook-like structure is stamped. The opening of this hook-like structure faces the weft insertion direction and is slightly inclined downwards. The hook depth (from opening to bottom) of this hook-like structure is approximately 2 mm, slightly larger than the 0.8 mm diameter polyester monofilament (auxiliary weft yarn 12) to be used subsequently, ensuring smooth hooking and temporary locking of the incoming auxiliary weft yarn 12. Simultaneously, this dimension also allows the subsequently inserted auxiliary weft yarn 12 to "squeeze out" or "replace" the previous auxiliary weft yarn from the hook section, thereby achieving alternating hooking.

[0059] The rear end of the auxiliary needle hook: The main body of the auxiliary needle hook 4 has a connecting part with a width of about 15 mm and an oblong hole with a length of about 30 mm and a width of about 10 mm. This hole is used to connect with the pin Z and pin seat T installed on the loom side support. The connecting part mainly serves the functions of installation positioning and overall reinforcement. During installation, the pin Z is passed through the oblong hole of the connecting part of all the auxiliary needle hooks 4 arranged along the length of the reed 3, so that all the auxiliary needle hooks 4 can be connected in series. Then, the pin seat T is inserted into both ends of the pin Z, and the pin seat T is fixed at the loom side support. The height of the auxiliary needle hooks 4 can be adjusted by the pin Z and the pin seat T. It is necessary to ensure that the bottom of the hook-shaped structure of all auxiliary needle hooks is at the same absolute horizontal height on the upper warp position line. This is the core mechanical basis for ensuring that the height of all loops on the final fabric is absolutely uniform. More importantly, through the connection of the pin seat T and the pin Z, the auxiliary needle hook 4 can float across the future loop of the dense and straight terry fabric that has just been woven, and cooperate to ensure that it can be hooked in smoothly and temporarily hold the weft yarn that is being hit. At the same time, by adjusting the position of the pin seat T in the waist-shaped hole, the front and back positions of the needle hooks can be finely adjusted to ensure that the bottom of the hook-shaped structure of all the needle hooks 4 connected by the pin Z is precisely aligned on the same horizontal line and is always inserted into the reed teeth of the reed 3 without falling out due to the back and forth swing of the reed 3.

[0060] During installation, according to the product design (e.g., 5 loops per centimeter in lateral density), insert the hooks 4 one by one into the gaps between the reed teeth of the steel reed 3 at equal intervals of 20 mm. Then, use the pins z to lock the rear ends of all the hooks in series. The guide part is located between the hook part and the connecting part of the auxiliary hook 4. This part mainly undertakes the functions of installation positioning and overall reinforcement. Firstly, it is equipped with a guide part, the outline of which is straight or slightly curved, which helps to guide the weft yarn and enhance the overall rigidity of the hooks.

[0061] See Figure 3 A method for weaving dense, straight terry fabric using the aforementioned auxiliary hook 4 is described. This method is implemented on a loom capable of forming stable, independent upper and lower sheds (e.g., a double-shed ribbon loom, a double-layer rapier loom equipped with double sheathing and weft insertion devices, etc.). The core technological principle lies in the use of the relatively fixed auxiliary hook 4 in conjunction with the alternately introduced auxiliary weft yarns 12 to perform a periodic "hooking-holding-transfer-release" mechanical action on the terry warp yarns 6 at the weft insertion point, thereby forming highly controlled terry loops within the fabric structure. The following detailed explanation uses a complete two-weft (shuttle) cycle as an example: Raw material preparation: Terry cloth warp yarn: 6:7.5 English count / 2 strands of pure cotton yarn.

[0062] Ground warp yarn: 20-count / 2-ply pure cotton yarn.

[0063] Base fabric weft yarn 11: 20 English count / 2 strand pure cotton yarn.

[0064] Auxiliary weft yarn 12: 75D / 36F polyester low elastic yarn (smooth surface, easy to pull out).

[0065] Overlock warp yarn: 20-count / 2-ply pure cotton yarn.

[0066] Warp arrangement and heddle threading: From left to right: 12 upper left overlock warp yarns + 24 lower left overlock warp yarns → [(2 ground warp yarns + 2 terry warp yarns 6) x N cycles, determined according to width] → + 24 lower left overlock warp yarns → At a distance of 1cm from the effective width on the right, insert 12 right overlock warp yarns. The terry warp yarns 6 are divided into odd and even groups and inserted into different heald frames.

[0067] Install auxiliary needle hooks 4: According to the required transverse distribution density of the loops, arrange and fix multiple auxiliary needle hooks 4 at intervals along the length of the reed 3 of the loom. During installation, insert the tip of the needle hook into the gap between two adjacent reed teeth of the reed 3, and make the opening of the hook-shaped structure of the hook part face the direction of the weaving and tilt slightly downward. Then, pass the pin Z through the waist-shaped hole of the connecting part of all the auxiliary needle hooks 4 arranged along the length of the reed 3, and then put the pin seat T on both ends of the pin Z. Then fix the pin seat T at the side support of the loom. The pin Z connects and fixes all the auxiliary needle hooks 4 together, so that the bottom of the hook-shaped structure of all the needle hooks is at the same absolute horizontal height. Adjust the position of the pin seat T in the waist-shaped hole to fine adjust the front and back position of the needle hooks, and ensure that the bottom of the hook-shaped structure of all the needle hooks connected by the pin Z is precisely aligned on the same horizontal line.

[0068] The following is a detailed explanation using a complete two-way (shuttle) cycle as an example: Cycle 1: 1. Forming the shed: The heald frame is activated, and the first heald frame (odd number of terry warp yarns 6) is raised to the top of the upper shed; the second heald frame (even number of terry warp yarns 6) is lowered to the bottom of the lower shed; the third heald frame (odd number of ground warp yarns) is raised to the second-to-top position of the lower shed, so that it forms a clear lower channel (i.e., the lower shed) between itself and the even number of ground warp yarns (or other specially designed bottom layer warp yarns) at the bottom.

[0069] 2. Weft insertion: An auxiliary weft yarn 12 is introduced into the upper shed from the upper rapier; a base fabric weft yarn 11 is introduced into the lower shed from the lower rapier.

[0070] 3. Beating-in and Initial Hooking: The reed 3, carrying the auxiliary hook 4, swings forward (towards the weft insertion point), beating the first auxiliary weft yarn 12 of the upper layer and the second base fabric weft yarn 11 of the lower layer together towards the weft insertion point. At the moment the beating-in ends, the first auxiliary weft yarn 12 is pushed against the weft insertion line by the reed, and under the combined action of the warp tension and slight rebound, it falls precisely into the hook-shaped structure of the corresponding auxiliary hook 4 and is reliably hooked. Since this auxiliary weft yarn 12 is located below the odd-numbered loop warp yarns 6 that are lifted within the upper shed, it "supports" or "hooks" the odd-numbered loop warp yarns 6, achieving the initial temporary grip and upward lifting and positioning of the odd-numbered loop warp yarns 6.

[0071] At the same time, the first base fabric weft yarn 11 of the lower layer interweaves normally with all the ground warp yarns and the even-numbered terry warp yarns 6 located in the lower shed (e.g., plain weave), and begins to form the basic structure of the fabric (base fabric).

[0072] Cycle Two (Second Latitude): Changing the shed: The heddle lifting device changes its action, raising the even array of looped warp yarns 6 to the topmost position of the upper shed.

[0073] The odd-numbered terry warp yarns 6 are lowered to the bottommost position of the lower shed.

[0074] The even-numbered ground warp yarns are raised to the second-upper position of the lower shed, forming a new lower shed with the odd-numbered ground warp yarns at the bottom.

[0075] 2. Introduce the weft yarn again: Introduce the second auxiliary weft yarn 12 into the upper shed.

[0076] The second base fabric weft yarn 11 is introduced into the lower layer shed.

[0077] 3. Handover of weft insertion and hook hanging: Transfer and Release: The reed 3 beats in the weft again, beating the second auxiliary weft yarn 12 towards the weft inlet and into the hook-shaped structure of the same auxiliary needle hook 4. At this time, because the woven fabric is being continuously pulled forward with constant tension by the take-up device, the first auxiliary weft yarn 12, which was previously hooked, is subjected to a continuous forward horizontal pull. When the second auxiliary weft yarn 12 enters the hook-shaped structure of the auxiliary needle hook 4 and squeezes and pushes the first auxiliary weft yarn 12, the first auxiliary weft yarn 12, with the assistance of the forward pull, smoothly slips out of the hook-shaped structure and moves forward with the fabric, eventually being wound into the take-up roller.

[0078] Meanwhile, the newly introduced second auxiliary weft yarn 12 occupies the hook-like structure of the auxiliary needle hook and begins to "hook" and hold the newly lifted second set of loop warp yarns 6. The lower part of the first set of loop warp yarns 6, which has just been released, has been interwoven and fixed with the base fabric weft yarn 11, while the upper part is released from a tense state of being hooked, thus forming a relaxed hanging line segment on the fabric surface with a height equal to the distance from the bottom of the needle hook to the base fabric structure—that is, the prototype of the loop.

[0079] Repeated cycles and fabric shaping: The process of "Cycle One" and "Cycle Two" described above is repeated continuously. Two (or more) sets of terry warp yarns 6 are periodically and intermittently pulled upwards and then released in the fabric as the auxiliary weft yarns 12 alternately hook and transfer on fixed needles. The lower part of all the terry warp yarns 6 is continuously and tightly interwoven with the base fabric weft yarns 11 and the ground warp yarns, forming a solid lower base fabric 7; while the upper part, through the aforementioned pulling and releasing actions, accumulates to form a series of hanging segments of equal height and spacing. During the weaving process, a series of parallel auxiliary weft yarns 12 are always embedded inside the fabric, and these weft yarns temporarily assume the role of supporting the future terry shape.

[0080] See Figure 4 A selvage structure and post-processing yarn pulling method are proposed to facilitate the smooth removal of the auxiliary weft yarn 12.

[0081] Special selvage design: To prevent the auxiliary weft yarn 12 from slipping off during weaving and to ensure that it can be completely and continuously pulled out, reinforced selvage is designed on both sides of the fabric.

[0082] Selvage Formation: During the two cycles described above, in addition to the normal selvage weaving of the lower base fabric 7, the 12 selvage warp yarns on the left side interweave with the left end of each introduced auxiliary weft yarn 12 in a plain weave, forming a secure left selvage 13 that "locks" the left ends of all auxiliary weft yarns 12. Similarly, the selvage warp yarns on the right side interweave with the right end of each auxiliary weft yarn 12 in a plain weave. At this point, both ends of each auxiliary weft yarn 12 are securely locked into the left and right selvages respectively, while its segment in the middle of the fabric is hooked by the auxiliary hook 4.

[0083] Online selvage cutting: A high-speed rotating selvage shear 15 runs close to the inner edge of the right selvage 14 (approximately 1 mm from the loop area of ​​the main fabric), precisely cutting and separating the right selvage 14 from the main fabric while weaving is in progress. This operation frees the right ends of all auxiliary weft yarns 12.

[0084] Continuous yarn pulling: The cut-off right-side selvage 14 is collected as waste. Simultaneously, the complete left-side selvage 13, still wrapped around the left ends of all auxiliary weft yarns 12, is individually guided and wound onto a separately driven, slow-speed take-up turntable 16. This turntable continuously takes the left-side selvage 13 to the left at a linear speed matching the main take-up roller. Since the right ends of the auxiliary weft yarns 12 are now free, and the left ends are pulled to the left, all auxiliary weft yarns 12 are smoothly pulled laterally from the fabric body. The loops 2 in the fabric section 18 where the auxiliary weft yarns have been pulled out are fully upright, while the loops in the unpulled portion 17 are not yet visible due to the constraint of the auxiliary weft yarns 12. This process is similar to disassembling a knitted fabric and does not damage the already formed loop 2 drapes and the dense base fabric 7 structure. After the auxiliary weft yarns 12 of the fabric are completely pulled out, the dense, upright loop fabric greige described in this invention is obtained.

[0085] Finishing: The terry cloth that has fallen from the loom and from which the auxiliary weft yarn 12 has been removed undergoes routine inspection, cutting, and hemming processes to produce the final cleaning cloth. The removed and recycled auxiliary weft yarn 12 (polyester filament) and left and right selvage waste can be collected and processed.

[0086] The above method completely eliminates the reliance on fixed-height plates, complex mechanical movements (weft insertion and length adjustment), and chemically water-soluble materials. It reduces the loop formation mechanism to a simple "hook-release" mechanical action, with a clear principle and easy implementation, representing a revolutionary simplification of the process. Only a low-cost, specially designed needle hook and a customized selvage device need to be added to a standard double-shed webbing machine, resulting in extremely low equipment modification costs. The process is stable and suitable for high-speed continuous production.

[0087] The dense, upright terry fabric produced by the above weaving method comprises: a dense base fabric layer 1, woven from the ground warp yarns, the lower section of the terry warp yarns 6, and the base fabric weft yarns 11; and an upright terry layer 2, consisting of draped terry loops of uniform height formed by the upper section of the terry warp yarns 6 and perpendicular to the plane of the base fabric 7. The fabric contains no residue of any height-fixing plates, water-soluble yarns, or other temporary support materials used for forming the terry loops. The distribution density of the terry loops corresponds to the spacing of the auxiliary needle hooks 4 during weaving. The terry loop height is mechanically positioned by fixed needle hooks and is unaffected by process parameters such as yarn tension fluctuations and loom speed changes. Therefore, the uniformity, uprightness, and consistency of the terry loops far exceed those of existing processes, making it particularly suitable for high-end products with stringent cleanliness requirements. The entire production process requires no chemical dissolution or extensive washing, resulting in no wastewater discharge and meeting clean production and sustainable development requirements. The terry loop density can be flexibly adjusted by changing the lateral installation spacing of the needle hooks.

Claims

1. A special auxiliary needle hook for weaving dense, straight terry fabrics, characterized in that, The auxiliary needle is a slender, sheet-like component independent of the reed of the loom, and includes: The tip of the hook is a forward portion that can be inserted between two adjacent teeth of the reed; The rear end of the auxiliary needle hook is provided with a connecting part for connecting multiple auxiliary needle hooks at the same height and front and rear positions, and a guiding part for guiding the weft yarn. The connecting part at the rear end of the auxiliary needle hook is also provided with a waist-shaped elongated hole. Through the waist-shaped elongated hole, the pin of the pin seat installed on the side support of the loom connects multiple auxiliary needle hooks in series. In addition, there is a hook-and-loop portion located between the guide portion and the leading portion, the hook-and-loop portion having a hook-shaped structure with an opening facing the weft inclination direction, the hook-shaped structure being used to hook the introduced auxiliary weft yarn during beat-up.

2. The special auxiliary needle hook for weaving dense, straight terry fabric according to claim 1, characterized in that, The auxiliary hook has a flat wedge-shaped front section and a barbed or slightly protruding middle section.

3. A method for weaving a dense, straight terry fabric, characterized in that, Includes the following steps: S1: Configure a warp and weft yarn system, wherein the warp yarn system includes at least ground warp yarns and at least two sets of terry warp yarns; the weft yarn system includes auxiliary weft yarns and base fabric weft yarns. S2: Prepare an auxiliary needle hook as described in any one of claims 1-2 and a loom capable of forming stable upper and lower sheds; S3: Arrange the multiple auxiliary needle hooks along the length of the reed of the loom. During installation, insert the leading edge of the auxiliary needle hook into the gap between two adjacent reed teeth. The auxiliary needle hook can be suspended on the upper layer of the fabric surface, and the opening of the hook-shaped structure of the hook hook part faces the direction of the weaving. Pass the pin of the pin seat through the waist-shaped elongated hole of the multiple auxiliary needle hook connecting parts along the length of the reed of the loom. Fix the pin seat at the side support of the loom, and make the bottom of the hook-shaped structure of all auxiliary needle hooks at the same horizontal level on the upper warp position line. S4: Execute the weaving cycle, each cycle containing: a) Opening: The two sets of looped warp yarns are positioned in the upper and lower layers respectively, so that one set of looped warp yarns is first located at the top of the upper shed, and the other set of looped warp yarns is located at the bottom of the lower shed; the two sets of ground warp yarns form the lower shed, and are exchanged front and back to form an opening for weaving. b) Weft insertion: Introduce an auxiliary weft yarn into the upper shed and a base fabric weft yarn into the lower shed; c) Weft insertion and hooking: The steel reed inserts the weft, pushing the auxiliary weft yarn and the base fabric weft yarn toward the weft, and the auxiliary weft yarn is hooked by the hook-shaped structure of the corresponding auxiliary needle hook, so that the auxiliary weft yarn hooks a group of loop warp yarns located on the uppermost layer of the shed above it. The base fabric weft yarn and the two sets of ground warp yarns form a shed, and another set of loop warp yarns at the bottom of the lower shed interweave with the base fabric. d) Changing the shed: Raise the terry warp yarn at the bottom of the lower shed to the top of the upper shed, lower the terry warp yarn at the top of the upper shed to the bottom of the lower shed, raise the ground warp yarn at the second-lowest level of the lower shed to the second-upper level of the lower shed, introduce the second auxiliary weft yarn into the upper shed, and introduce the second base fabric weft yarn into the lower shed; The base fabric weft yarn and the two sets of ground warp yarns exchange the shed and a set of loop warp yarns at the bottom of the lower shed interweave the base fabric. S5: In the subsequent weaving cycle, the newly introduced auxiliary weft yarn pushes out the hook-shaped structure of the auxiliary weft yarn that was hooked in the previous cycle. The pushed-out auxiliary weft yarn moves forward with the fabric, and the previous group of loop warp yarns above it will form a hanging line segment on the fabric surface; the new auxiliary weft yarn hooks the next group of new loop warp yarns that are currently located at the top of the uppermost layer of the upper shed. S6: After weaving is completed, the fixed end of the auxiliary weft yarn at one edge of the upper fabric is cut open and released, and at the same time, the auxiliary weft yarn is pulled out of the main body of the fabric from the other side of the fabric.

4. A selvage structure and a post-processing method for yarn drawing, characterized in that, Includes the following steps, S1: In step S1 of the weaving method of claim 3, additional edge-locking warp yarns are configured, and two sets of edge-locking warp yarns of upper and lower layers are laid on each side of the left and right sides of the fabric. While the auxiliary weft yarns pass through the two sets of loop warp yarns of the upper layer, they also pass through the two sets of edge-locking warp yarns on each side of the left and right sides of the upper fabric. While steps S3 and S4 of the weaving method of claim 3 are being carried out, the two ends of all auxiliary weft yarns are interwoven with the edge-locking warp yarns on the left and right sides of the fabric to form the selvage. S2: During or after the weaving process of the terry fabric made by the weaving method described in claim 3, one side of all auxiliary weft yarns is cut off to release the corresponding ends of the auxiliary weft yarns. S3: Pull the uncut edge of the fabric on the other side to continuously pull away all auxiliary weft yarns.

5. The selvage structure and post-processing yarn-drawing method according to claim 4, characterized in that, Step S2 specifically includes: using selvage scissors to cut one side of the fabric edge from the main body of the fabric during or after weaving.

6. The selvage structure and post-processing yarn-drawing method according to claim 4, characterized in that, Step S3 specifically includes: taking the uncut side of the fabric separately and pulling the auxiliary weft yarn laterally and continuously from the main body of the fabric by pulling the side of the fabric.

7. A dense, straight terry fabric produced by the weaving method according to claim 3, characterized in that, include: The dense base fabric layer is woven from the ground warp yarns, the lower section of the loop warp yarns, and the base fabric weft yarns; The upright terry loop layer consists of draped loops of uniform height formed by the upper section of the terry warp yarns and perpendicular to the plane of the base fabric.

8. The dense, straight terry fabric according to claim 7, characterized in that, The fabric contains no residue of any height-fixing plates, water-soluble yarns, or other supporting materials used to form loops.

9. The dense, straight terry fabric according to claim 7, characterized in that, The distribution density of the loops corresponds to the spacing of the auxiliary needle hooks during weaving.

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