Towel fabric and production method therefor

Abstract

A towel cloth includes a pile yarn, a warp ground yarn, and a weft ground yarn. A fiber material of the pile yarn is cotton medium-staple cotton or long-staple cotton having an average fiber length of 28.6 to 34.7 mm and a micronaire of 4.1 to 5.8 µg / inch, and a content of short fibers with an average fiber length of 17 mm or less therein is set to 10 mass% or less. The pile yarn is a non-twisted or low-twisted single siro spun yarn, and each of the pile yarn, the warp ground yarn, and the weft ground yarn is bleached.

Description

Technical Field

[0001] The present invention relates to a towel cloth using a siro spun yarn as a pile yarn and a manufacturing method thereof.Background Art

[0002] Conventionally, a towel cloth has been basically made of a pile woven fabric by using a pile yarn, a warp ground yarn, and a weft ground yarn. In addition, to allow a towel cloth to have improved water absorbency, a basis weight (mass per unit area) of the towel cloth is set relatively high, and thick yarns each having a high fineness are used as constituent yarns thereof.

[0003] In Patent Literature 1, it is proposed to use a siro span yarn of a synthetic fiber to provide a grandrelle yarn for pile. In Patent Literatures 2 and 3, it is proposed to use a low twisted siro spun yarn to provide a pile knitted fabric. In Patent Literature 4, the present inventor proposes a towel cloth using a non-twisted or low twisted siro spun yarn as a pile yarn.Citation ListPatent Literature

[0004] Patent Literature 1: Patent Publication JP-A-H10-088440 Patent Literature 2: Patent Publication JP-A-2019-137941 Patent Literature 3: Patent Publication JP-A-2019-137942 Patent Literature 4: Japanese Patent No. 7372718 Summary of Invention Technical Problem

[0005] However, the prior-art technology has a problem with regard to uprightness and a soft and puffy texture of a pile, and has been required to be further improved.

[0006] As a result of diligent study conducted to provide an unprecedentedly luxurious towel fabric, the present invention provides a towel cloth that has less unevenness and retains uprightness, a soft and puffy texture, water absorbency, and the like of a towel cloth in a freshly woven state and a manufacturing method thereof.Solution to Problem

[0007] An embodiment of the present invention relates to a towel cloth including a pile yarn, a warp ground yarn, and a weft ground yarn, wherein a fiber material of the pile yarn is cotton medium-staple cotton or long-staple cotton having an average fiber length of 28.6 to 34.7 mm and a micronaire of 4.1 to 5.8 µg / inch, a content of short fibers with an average fiber length of 17 mm or less therein is set to 10 mass% or less, the pile yarn is a non-twisted or low twisted single siro spun yarn, and each of the pile yarn, the warp ground yarn, and the weft ground yarn is bleached.

[0008] Another embodiment of the present invention relates to a manufacturing method of the towel cloth described above, wherein a fiber material of the pile yarn is cotton medium-staple cotton or long-staple cotton having an average fiber length of 28.6 to 34.7 mm and a micronaire of 4.1 to 5.8 µg / inch, and a content of short fibers with an average fiber length of 17 mm or less therein is set to 10 mass% or less by combing treatment, the pile yarn is a triple siro spun yarn that is twisted in a direction opposite to a primary twisting direction of three roving yarns, and secondary twisting is applied thereto with the number of twists equal to or larger than the number of twists of primary twisting to provide a non-twisted or low twisted single yarn, each of the pile yarn, the warp ground yarn, and the weft ground yarn is subjected to bleaching treatment, and each of the pile yarn, the warp ground yarn, and the weft ground yarn is supplied to a Jacquard loom to manufacture a towel woven cloth.Advantageous Effect of Invention

[0009] In a towel according to the embodiment of the present invention, the fiber material of the pile yarn is the cotton medium-staple cotton or long-staple cotton having an average fiber length of 28.6 to 34.7 mm and a micronaire of 4.1 to 5.8 µg / inch, the content of short fibers with the average fiber length of 17 mm or less therein is set to 10 mass% or less, the pile yarn is the non-twisted or low twisted single siro spun yarn, and each of the pile yarn, the warp ground yarn, and the weft ground yarn is bleached. Therefore, it is possible to provide the towel cloth that has less unevenness and retains uprightness, a soft and puffy texture, water absorbency, and the like of a towel fabric in a freshy woven state and a manufacturing method thereof. In other words, when the short fibers of the cotton medium-staple cotton or long-staple cotton are cut at a specific ratio, it is possible to reduce the unevenness, and the towel fabric after woven is neither bleached nor dyed afterwards, but is washed and dried to provide a towel fabric product. As a result, the quality of the towel fabric in the freshly woven state is directly reflected in the quality of the finished product to result in a high-quality towel fabric.Brief Description of Drawings

[0010] [Figure 1] Figure 1 is a schematic perspective view of a triple siro spun spinning device according to an embodiment of the present invention. [Figure 2] Figure 2A is a schematic illustrative view of a towel cloth in the embodiment of the present invention, and Figure 2B is a woven fabric structure diagram thereof. [Figure 3] Figure 3A is a schematic illustrative view of a towel cloth in another embodiment of the present invention, and Figure 3B is a woven fabric structure diagram thereof. [Figure 4] Figure 4 is a staple diagram of a card sliver (fiber bundle) to be used in the embodiment of the present invention. [Figure 5] Figure 5 is a staple diagram of a sliver (fiber bundle) combed once to be used in the embodiment of the present invention. [Figure 6] Figure 6 is a staple diagram of a sliver (fiber bundle) to be combed twice to be used in the embodiment of the present invention. [Figure 7] Figure 7 is a side view photograph (X30 magnification) of a pile portion of a towel cloth in Example 1 of the present invention. [Figure 8] Figure 8 is a side view photograph (X30 magnification) of a pile portion of a towel cloth in Comparative Example 1. [Figure 9] Figure 9 is a side view photograph (X30 magnification) of a pile portion of a towel cloth in Comparative Example 2. [Figure 10] Figure 10 is a top view photograph (X10 magnification) of the towel cloth in Example 1 of the present invention. [Figure 11] Figure 11 is a top view photograph (X10 magnification) of the towel cloth in Comparative Example 1. [Figure 12] Figure 12 is a top view photograph (X10 magnification) of the towel cloth in Comparative Example 2. Description of Embodiments

[0011] An embodiment of the present invention is a towel cloth including a pile yarn, a warp ground yarn, and a weft ground yarn. The pile yarn, which accounts for about 70% of constituent yarns of the towel cloth, is an important yarn that determines functionalities such as the uprightness of a pile and a texture and fluff dropping of the towel cloth. A fiber material of the pile yarn is cotton medium-staple cotton or long-staple cotton having an average fiber length of 28.6 to 34.7 mm and a micronaire of 4.1 to 5.8 µg / inch, and a content of short fibers with an average fiber length of 17 mm or less therein is set to 10 mass% or less. As a result, a spun yarn has less unevenness to result in a high-quality yarn. Since the cotton medium-staple cotton or long-staple cotton having the average fiber length of 28.6 to 34.7 mm and a micronaire fineness of 4.1 to 5.8 µg / inch serving as the fiber material of the pile yarn has a large number of crimps, and a crimp strength is high, when the cotton medium-staple cotton or long-staple cotton is applied to a spun yarn of siro spun in the present embodiment, a twisting habit of primary twisting and migration of the primary twisting (a phenomenon in which a single fiber comes into the inside or comes to the outside to be twisted) tends to be left, and fibers tend to get entangled with each other. In addition, since the yarns are non-twisted or low twisted, each constituent fiber is present in a free state. The "cotton long-staple cotton" mentioned above refers to the "long-staple cotton" shown below in Table 1, which is internationally recognized.

[0012] The pile yarn in the present invention is a non-twisted or low twisted single siro spun yarn. In other words, the siro spun yarn is applied with secondary twisting in a direction opposite to a primary twisting direction of a plurality of roving yarns with the number of twists equal to or larger than the number of twists of the primary twisting. As a result, the following effects are obtained. (1) Less fluff dropping (2) Bulky (3) High puffiness and a high fluffy feel before washing (4) Less likely to lose puffiness after washing, and less likely to be deteriorated by washing (5) Less rewetting and permitting comfortable wiping experience (6) Less prone to dimensional changes (less likely to shrink) (7) High drying performance

[0013] The constituent yarns (the pile yarn, the warp ground yarn, and the weft ground yarn) of the towel cloth according to the embodiment of the present invention are bleached. As a result, the quality of a towel cloth in a freshly woven state is directly reflected in the quality of a product to result in a high-quality towel fabric.

[0014] The present invention uses a siro spun yarn as the pile yarn. The siro spun yarn is a yarn in a state similar to that of a two-ply or three-ply yarn obtained by separately drafting two or three roving yarns at regular intervals and then twisting the yarns together. On a yarn surface of the siro spun yarn, fibers are more regularly arranged than on a yarn surface of the two-ply or three-ply yarn obtained by twisting a plurality of yarns together, resulting in less fluff dropping. Accordingly, the siro spun yarn in a single yarn state can be used also as the pile yarn. In addition, due to a unique yarn structure of the siro spun yarn, even when the siro spun yarn is used as a non-twisted yarn or low twisted yarn, the fibers are entangled with each other to allow the siro spun yarn to be smoothly wound with no problem, and yarn breakage is less likely to occur during weaving to ensure excellent passability through a weaving step.

[0015] Preferably, a count of the siro spun yarn mentioned above is 5 to 100 in English cotton count. To a thin cloth, a siro spun yarn with a yarn count of 100 to 40 is favorably applicable while, to a medium-thickness cloth and a thick cloth, a siro spun yarn with a yarn count of 30 to 16 and a siro spun yarn with a yarn count of 12 to 5 are favorably applicable.

[0016] A twist multiplier K of the siro spun yarn in the present invention is preferably 0 to 3.5, more preferably 0 to 3.3, and further more preferably 0 to 3.0. Note that the twist multiplier K is calculated using the following expression (Expression 1): Twist Multiplier K = t / S where t represents the number of twists (number / 25.4 mm), and S represents an English cotton count.

[0017] As a result, the pile yarn becomes a non-twisted yarn or a low twisted yarn.

[0018] Preferably, the siro spun yarn is applied with secondary twisting in a direction opposite to a primary twisting direction of a plurality of roving yarns with the number of twists equal to or larger than the number of twists of primary twisting to be non-twisted or low twisted. For example, when each of primary twisting directions of the two or three roving yarns is a Z-direction, the secondary twisting is applied in a S-direction, and the number of twists of the secondary twisting is set equal to or larger than the number of twists of the primary twisting. As a result, each constituent fiber is present in a rather free state, and accordingly a pile yarn having satisfactory uprightness and a soft and puffy texture is obtained. The "non-twisted" refers to a case where the twist multiplier K described above is zero, while the "low twisted" refers to a case where the twist multiplier K described above is in excess of zero and not more than 3.3.

[0019] The siro spun yarn is preferably a two-stranded or three-stranded (triple) siro spun yarn, and more preferably a three-stranded (triple) siro spun yarn having a round yarn cross section. The siro spun yarn is preferably made of 100% cotton. When the siro spun yarn is made of 100% cotton, both of the soft and puffy texture and absorbency can be provided.

[0020] Each of the warp ground yarn and the weft ground yarn is a ring-spun yarn using super-long-staple cotton having an average fiber length of 34.8 to 44.5 mm and a micronaire of 3.0 to 4.1 µg / inch. Each of the warp ground yarn and the weft ground yarn preferably has a high count of 10 to 50 in English cotton count. Since a pile yarn forms a loop pile, while being locked to a ground structure including the warp ground yarn and the weft ground yarn, when each of the warp ground yarn and the weft ground yarn uses the super-long-staple cotton and has a high count, it is possible to increase a locking force of the pile yarn and prevent pile pullout. Furthermore, the texture is also improved. The "super-long-staple cotton" described above is as shown below in Table 1, which is internationally recognized. [Table 1]NameCotton-Producing CountryCotton VarietyAverage Fiber Length (mm)Micronaire (µg / inchi)Super-Long Staple CottonBarbadosSea Island Cotton44.53.1EgyptGiza 7036.54.0EgyptGiza 8835.33.9ChinaXinjiang T / 14638.14.0USAAmerican Pima36.54.1PeruPeruvian Pima36.53.5IndiaSpin41.53.1IndiaDHC-3234.83.0Long-Fiber CottonPeruTangis30.25.8EgyptGiza 8632.04.3IndiaShankar 631.04.5TurkeyTurkish Cotton29.04.1Medium-Fiber CottonUSASan Joaquin29.44.1USAArizona28.65.0USAMemphis27.84.8ChinaXinjiang T / 12928.63.9AustraliaAndy28.64.7West AfricaT / Mambo27.84.5Coarse-Count-Fiber CottonPakistanAfzal26.24.9USATexas26.23.8ChinaT / 427~52727.04.2PeruAspero26.26.7

[0021] The twist multiplier K of each of the warp ground yarn and the weft ground yarn is preferably 3.5 to 4.5, more preferably 3.7 to 4.2, and further more preferably 3.8 to 4.0. Note that the twist multiplier (K) is calculated using the foregoing expression (Expression 1). Thus, it is possible to increase a yarn strength and increase a towel durability.

[0022] Preferably, the pile yarn is a combed yarn. Thus, it is possible to reduce a content of short fibers having an average fiber length of 17 mm or less to 10 mass% or less, preferably 8 mass% or less, more preferably 6 mass% or less, and further more preferably 4 mass% or less. The pile yarn in the present invention can be used as each of a warp pile yarn and a weft pile yarn, but is rather preferably used as the warp pile yarn.

[0023] A manufacturing method of a towel cloth according to an embodiment of the present invention includes the following steps.(1) Combing Step for Cotton Long-staple Cotton of Pile Yarn

[0024] As a fiber material of the pile yarn, cotton medium-staple cotton or long-staple cotton having an average fiber length of 28.6 to 34.7 mm and a micronaire of 4.1 to 5.8 µg / inch is used, and a content of short fibers with an average fiber length of 17 mm or less therein is set to 10 mass% or less. Combing treatment (the combing step) is preferably performed twice and, at this time, the number of needles of a comb is increased, a grain of a lap is adjusted to be minimum, and the combing treatment is slowly performed at a speed about one third of a normal speed. Thus, it is possible reduce the content of the short fibers having an average fiber length of 17 mm or less to 10 mass% or less, preferably 8 mass% or less, more preferably 6% or less, and further more preferably 4 mass% or less.(2) Pile Yarn Spinning Step

[0025] Using a siro spun spinning machine, the secondary twisting is applied in a direction opposite to the primary twisting direction of the two or more three roving yarns with the number of twists equal to or larger than the number of twists of the primary twisting to provide a non-twisted or low twisted single yarn. The twist multiplier K of the siro spun yarn is preferably set to 0 to 3.5.(3) Warp Ground Yarn and Weft Ground Yarn Spinning Step

[0026] As a fiber material of the warp ground yarn and the weft ground yarn, super-long-staple cotton having an average fiber length of 34.8 to 44.5 mm and a micronaire of 3.0 to 4.1 µg / inch is used to provide a spun yarn by using a ring-spinning machine. Each of the warp ground yarn and the weft ground yarn preferably has a high count of 10 to 50 in English cotton number.(4) Pile Yarn, Warp Ground Yarn, and Weft Ground Yarn Bleaching Step

[0027] The pile yarn, the warp ground yarn, and the weft ground yarn are subjected to bleaching treatment. Bleaching refers to performing scouring and decoloring a yarn in a spun yarn state. When the yarn is white, only the bleaching may be performed, or the yarn may also be dyed with a white dye and / or a fluorescent dye. When the yarn is colored, it may also be possible to add a dying step after the bleaching. The dying is preferably performed using a reactive dye at a temperature of 60 to 80°C for about 20 to 60 minutes.(5) Textile Weaving Step

[0028] To a Jacquard loom, the pile yarn, the warp ground yarn, and the weft ground yarn are supplied to weave a towel cloth having, by way of example, a three weft towel structure (three-pick terry motion structure) or a four weft towel structure (four-pick terry motion structure). Preferably, the towel cloth has the four weft towel structure. The four weft towel structure is advantageous over the three weft towel structure in that the pile yarn is fixed to the ground structure, a fluff dropping rate decreases, and the uprightness of the pile is improved, and therefore the towel cloth is bulky, highly voluminous, and quick to dry due to improved ventilation. After woven, the towel cloth was washed and dried in the form of a roll, and then subjected to hem stitching to provide a towel product. When the woven towel cloth is subjected to the scouring and decoloring, the towel cloth is unfavorably crumpled in water, unfavorably resulting in crushed or disordered loops.

[0029] The manufacturing method of the towel cloth according to the embodiment of the present invention has the following functions and effects. (1) Although the secondary twisting has been applied, a twisting habit of the primary twisting is left, migration of the primary twisting is also left, and fibers get entangled with each other. In addition, since the yarns are non-twisted or low twisted, each constituent fiber is present in a free state, and uprightness is satisfactory, resulting in a pile yarn having a soft and puffy texture. The soft and puffy texture enables soft contact with skin, and sweat and moisture can efficiently be wiped away (a texture effect, a wipe-away effect). (2) Since the pile yarn is non-twisted or low twisted, the constituent fibers easily absorb moisture while, at the same time, the puffiness causes active air movement, resulting in a higher air permeability (a water absorbency effect, an air permeation effect). (3) The entanglement between the constituent fibers can improve the fluff dropping (the fluff dropping improving effect) to reduce a texture change after washing and maintain the original soft and bulky texture (an effect of texture durability against washing). (4) When a spun yarn is manufactured, it is unnecessary to use a water-soluble fiber (e.g., water-soluble PVA) and the like, and accordingly cost can be reduced. Meanwhile, when a water-soluble fiber (e.g., water-soluble PVA) and the like are used and then removed after the cloth is manufactured, a high quality of the woven fabric is deteriorated. (5) When the spun yarn is manufactured, it is unnecessary to use a water-soluble fiber (e.g., water-soluble PVA) and the like, and therefore it is possible to reduce an environmental load due to an industrial liquid waste containing those.

[0030] A towel according to the embodiment of the present invention is appropriate for a bath towel (after-bath towel), a bathing towel, a bedding undercoat towel, a face towel, a toweling handkerchief (towel-chief), a wet hand towel, a wash towel, a hand towel, a bath mat, a sport towel, a beach towel (body towel), or the like. According to the required characteristics such as the fluff dropping property and the water absorbency, a mixing ratio of the cloth, a yarn type, yarn use, a mass per unit (basis weight), and the like are appropriately set. The basis weight can be controlled (to be larger or smaller) by changing a pile length (longer or shorter) of the pile yarn. To give examples of a preferable basis weight capable of achieving the effects of the present invention, a thin cloth having a basis weight of 100 to 250 g / m 2< , a medium-thickness cloth having a basis weight of 250 to 500 g / m 2< , and a thick cloth having a basis weight of 500 to 1000 g / m 2< are appropriate. Note that a cloth with a basis weight of less than 100 g / m 2< is thin and has no bulkiness and a cloth with a basis weight of more than 1000 g / m 2< is too thick and heavy, neither of which is preferable.

[0031] Referring to the drawings, a description will be given below. In the following drawings, the same reference signs denote the same objects. Figure 1 is a schematic perspective view of a triple siro spun spinning device in the embodiment of the present invention. In a triple siro spun spinning device 10, three roving bobbins 11a, 11b, and 11c are suspended for one weight in a creel (roving yarn supply tool), and roving yarns 12a, 12b, and 12c supplied from the three roving bobbins 11a, 11b, and 11c pass through a triplex trumpet guide 13 provided on an upstream side (roving bobbin side) of a back roller 14 to be fed in parallel to a draft device 15. The roving yarns 12a, 12b, and 12c are drafted in a state spaced apart at predetermined intervals between the back roller 14 and an apron 16 and between the apron 16 and a front roller 17, respectively, resulting in fleeces 18a, 18b, and 18c. Then, the fleeces 18a, 18b, and 18c are spun out of the front roller 17 and twisted together downstream of the front roller 17 by a twisting mechanism using rotation of a spindle 21, resulting in one spun yarn 19, which is wound to a bobbin 22 through a snail wire 20 and a traveler 21. For example, by setting a twisting direction of primary twisting of each of the three roving yarns 12a, 12b, and 12c to the Z-direction and by setting a twisting direction by the spindle 21 to the S-direction, twisting is performed in an untwisting direction. In addition, the number of twists (number of twists of secondary twisting) by the spindle 21 is set equal to or larger than the number of twists of primary twisting to provide a non-twisted or low twisted yarn.

[0032] Figure 2A is a schematic illustrative view of a towel cloth 1 according to the embodiment of the present invention. The towel cloth 1 includes warp pile yarns 2a and 2b, a weft ground yarn 3, and warp ground yarns 4a and 4b, and the warp pile yarns 2a and 2b form loop piles, while being locked to a ground structure including the weft ground yarn 3 and the warp ground yarns 4a and 4b. The obtained towel cloth 1 is cut into a predetermined size and subjected to end treatment to result in a towel. Figure 2B is a woven fabric structure diagram of the towel cloth described above. The woven fabric structure is a three weft towel structure (three-pick terry motion structure). Every time three weft ground yarns are driven in, the warp pile yarn is crossed therewith once. Warp ground yarns G and warp pile yarns P are alternately arranged. 1 to 3 for the warp yarns represent an order. In Figure 2B, when viewed from the warp yarns, black squares and crisscrossed squares represent floating yarns, while white squares represent sinking yarns.

[0033] Figure 3A is a schematic illustrative view of the towel cloth 1 according to another embodiment of the present invention. The towel cloth 1 includes the warp pile yarns 2a and 2b, the weft ground yarn 3, and the warp ground yarns 4a and 4b, and the warp pile yarns 2a and 2b form loop piles, while being locked to the ground structure including the weft ground yarn 3 and the warp ground yarns 4a and 4b. The obtained towel cloth 1 is cut into a predetermined size and subjected to end treatment to result in a towel. Figure 3B is a woven fabric structure diagram of the towel cloth described above. The woven fabric structure is a four weft towel structure (four-pick terry motion structure). Every time four weft ground yarns are driven in, the warp pile yarn is crossed therewith once. The warp ground yarns G and the warp pile yarns P are alternately arranged. The four weft towel structure is advantageous over the three weft towel structure in that the pile yarn is more solidly fixed to the ground structure, a fluff dropping rate decreases, and the uprightness of the pile is improved, and therefore the towel cloth is bulky, highly voluminous, and quick to dry due to improved ventilation. 1 to 4 for the warp yarns represent an order. In Figure 3B, when viewed from the warp yarns, black squares and crisscrossed squares represent floating yarns, while white squares represent sinking yarns.Examples

[0034] Using examples, the following will give a more specific description. The present invention is not limited to the following examples.<Evaluation of Texture of Finished Towel Cloth>(1) Evaluation of Soft Texture

[0035] Softness of a texture is determined as a degree of bulkiness which represents the softness of the texture in terms of a volume per gram of a towel cloth and is given by the following expression. As a value is higher, the texture is softer and more satisfactory. Note that a thickness was measured according to a bulkiness test described in JIS L 1096 (2010) 8.5, and a 1-m square was precisely weighed as a basis weight. Measurement was performed at five positions, and the degree of bulkiness was represented by an average value thereof. Degree of Bulkiness cm 3 / g = Thickness mm / Basis Weight g / m 2 × 1000(2) Evaluation of Puffy Texture

[0036] Using a compression tester KES-G5 (manufacture by KATO TECH CO., LTD.), the towel cloth was compressed at a given speed, and a compression workload WC = (gf.·cm 2< ) was determined. Measurement was performed at five positions, and a WC value was represented by an average value thereof.

[0037] The WC value indicates (energy) when the cloth is compressed and, as the value is larger, it is indicated that a towel is more satisfactorily compressed and puffier, and favorably gives a fluffier feel.(3) Evaluation of Washing Durability of Texture

[0038] According to the method described in JIS L-0217 (1995), 103, the towel cloth was washed 30 times using a washing machine. After drying, the compression workload WC = (gf.·cm 2< ) mentioned above was measured. The measurement was performed at five positions, and the WC value was represented by an average value thereof. As a difference between the WC values before and after the washing is smaller, the loss of the puffy texture due to the washing is smaller, and the towel cloth is favorably more durable.(4) Evaluation of Drainage in Washing

[0039] A length of a towel cloth having a width of 35 cm was cut to weigh 80 g, and the cut towel cloth was precisely weighed to one decimal place and immersed in water for 20 minutes. Then, the wet towel cloth was collected, centrifugally dewatered in a dewatering bin of a washing machine for 4 minutes, precisely weighed, and a residual moisture rate (%) of the towel cloth was determined using the following expression. As a value is smaller, drainage is more satisfactory. As the drainage is more satisfactory, a speed of subsequent drying tends to be higher. The measurement was performed at three points, and the residual moisture rate was represented by an average value thereof. (5) Drying Property Evaluation

[0040] Using the dewatered wet towel cloth prepared in (4) Evaluation of Drainage in Washing mentioned above, line drying was performed, and a weight of the cloth was measured every 30 minutes as a drying time. The time required for the cloth to reach a residual moisture rate of 10% was calculated by proportionally dividing the time. A test environment was set such that, under a standard state environment, a temperature was 20±4°C and a relative humidity was 65±4%RH.(6) Evaluation of Fluff Dropping Property of Towel Fabric After Washing

[0041] Fluff dropping after washing was measured according to the method described in JIS L0217 (1995), 103. A fluff dropping rate (%) was determined using the following expression and, as a value is smaller, fluff dropping is favorably smaller in amount. The measurement was performed at five points, and the fluff dropping rate was represented by an average value thereof. (7) Evaluation of Water Absorbency (Improved Larose Method)

[0042] According to the improved Larose method described in JIS L 1907 (2010), measurement was performed five times, and an average value thereof was determined. A Larose index (water absorption index) was calculated using the following expression. Larose Index Water Absorption Index = 2545 V × 1411 W + 79 where V represents a maximum water absorption speed (ml / s) and W represents an amount of absorbed water (ml) when a water absorption speed is maximum. As a value is higher, moisture on skin is more quickly absorbed, and a larger amount of moisture is favorably absorbed.(8) Dimensional Change Ratio

[0043] Calculation of dimensional change ratios was performed according to the method described in JIS L 1096 (2010) 8,39,6 G (method using a pulsator-type domestic electric washing machine). In other words, the dimensional change ratio was calculated from a dimension (L1, mm) measured before washing and a dimension (L2, mm) measured after 30 cycles of washing and tumble drying by using the following expression. Dimensional Change Ratio ΔL % = L 2 − L 1 / L 1 × 100(9) Water Absorption Speed (Dropping Method)

[0044] A water absorption speed of the towel cloth was measured and evaluated on the basis of a dropping method or burette method described in JIS L 1907 (2010). A test overview is such that one water droplet was dropped from a height of 10 cm onto the towel fabric, a water absorption time (seconds) until a mirror surface of the water droplet disappeared was measured three times, and an average value thereof was determined. As the time is shorter, water absorption is favorably quicker.<Rewetting Rate Test Method>

[0045] A water rewetting rate is described in Japanese Patent No. 6991633 proposed by the present applicant and, in a test method thereof, water droplets are dropped onto a test specimen of a cloth to be absorbed thereby, followed by absorption of moisture with filter paper. The test method evaluates a property of the cloth to retain moisture as the water rewetting rate and is thus consistent with evaluation of high or low absorbency of water that a person feels while using a fiber cloth such as a towel. As the water rewetting rate is lower, the absorbency of the cloth can be evaluated to be higher and more excellent.(1) Test Environment and Other Conditions

[0046] A test environment was set such that, under a standard state environment, a temperature was 20±4°C and a relative humidity was 65±4%RH. As the filter paper, filter paper that had been stored at a temperature of 20±4°C and a relative humidity of 65±4%RH under the standard state environment for 24 hours or longer was used. As the test specimen, a test specimen that had been stored at a temperature of 20±4°C and a relative humidity of 65±4%RH under the standard state environment for 24 hours or longer was used. As the water to be dropped, water at a temperature of 20±15°C (5 to 35°C) was used. (2) Operation Procedure

[0047] A size of the test specimen of the fiber towel cloth was set to be 10 cm long and 10 cm wide. The test specimen was placed on a sample stage. As the filter paper, filter paper made of JIS P 3801 (1976) Class 1 standard α-cellulose and having a diameter of 110 mm and a thickness of 0.22 mm was used, and a weight of the filter paper was measured. As the filter paper, filter paper manufactured by ADVANTEC CO., Ltd. under the trade name of "Circular Quantitative Filter Paper No. 1" was used. 0.8 ml of water was measured into a pipette, dropped onto the test specimen, and absorbed by the test specimen after 5-second waiting. The filter paper was placed, and a 1.3 kg (1274 Pa) load was placed thereon. After 5-second waiting, the load was removed. A weight of the filter paper after water absorption was measured. (3) Calculation of Water Rewetting Rate

[0048] The water rewetting rate was calculated using the following expression. W = B − A / A × 100 where W represents the water rewetting rate (%), A represents a weight (g) of the filter paper before the measurement, and B represents a weight (g) of the filter paper after the water absorption.<Pile Uprightness>

[0049] Using an optical microscope, a photograph (X30 magnification) of a side surface of a pile portion of the tower cloth was observed.<Properties of Sliver>

[0050] Properties of the sliver were measured according to JIS L 1019 (2006).<Other Properties>

[0051] Other properties were measured according to measurement methods used in the industry.(Example 1)(1) Warp Pile Yarn

[0052] As a fiber material of a warp pile yarn, cotton having an average fiber length of 30.5 mm and a micronaire of 5.6 µg / inch was used and, after the cotton was caused to pass through a carding machine, combing treatment (coming step) was performed thereon twice. At this time, the number of needles of a comb was increased to minimize a grain of a lap, and the treatment was performed at a speed about 1 / 3 of a normal speed. Thus, a content of short fibers having an average fiber length of 17 mm or less was reduced to 3.8 mass%. Table 2 shows a valid fiber length, a short-fiber content, and a cut rate after each of the steps. Figures 4 to 6 show a staple diagram of each sliver (fiber bundle). [Table 2]Valid Fiber Length (mm)Short Fiber Content (Mass%)Cutting Rate (Mass%)Drawing of Staple DiagramCard Sliver31.519. 415Figure 4Sliver Combed Once33. 015. 033Figure 5Sliver Combed Twice34.03.840Figure 6 (2) Spinning of Warp Pile Yarn

[0053] Using the triple siro spun spinning machine shown in Figure 1, a warp pile yarn was manufactured. By setting a twisting direction of primary twisting of each of the three roving yarns 12a, 12b, and 12c to the Z-direction and by setting a twisting direction by the spindle 21 to the S-direction, twisting is performed in an untwisting direction. A fineness of each of the roving yarns was set to 5 g / 6 yards (9113 decitex), and the number of twists of the roving yarn in the Z-direction was set to 5 twists / inch (twist multiplier K in terms of cotton count = 1). The spun yarn obtained had a cotton count of 16.1 and a number of twists of 11.5 twists / inch (twist multiplier K = 2.875). Physical properties of the obtained warp pile yarn are shown in Table 3.(3) Spinning of Warp Ground Yarn and Weft Ground Yarn

[0054] As a fiber material of each of the warp ground yarn and the weft ground yarn, cotton (cotton super-long-staple cotton) having an average fiber length of 36.5 mm and a micronaire of 3.5 µg / inch was used to produce a spun yarn by using a ring-spinning machine. A count of the spun yarn was set to 20 in English cotton count, and the twist multiplier K was set to 3.8.(4) Pile Yarn, Warp Ground Yarn, and Weft Ground Yarn Bleaching Step

[0055] The pile yarn, the warp ground yarn, and the weft ground yarn were subjected to bleaching treatment. Under normal conditions, the yarns were scoured by being kept in a bath of a dilute caustic soda solution added with alcohol ethoxylate at 98°C for 50 minutes. Subsequently, the yarns were decolored by being kept in a bath of a hydrogen peroxide solution at 98°C for 50 minutes and then sized at 95°C and 100 m / min. Then, the yarns were dried at 120°C to be finished (off-white finishing).(5) Weaving Step

[0056] To a Jacquard loom, the pile yarn, the warp ground yarn, and the weft ground yarn were supplied to weave a towel cloth having a four weft towel structure (four-pick terry motion structure) shown in Figures 3A to 3B. After woven, the towel cloth was washed and dried in the form of a roll, and then subjected to hem stitching to provide a towel product. A pile length was 1.18 cm. Other physical properties are shown in Table 4.(Comparative Example 1)

[0057] The same procedure as performed in Example 1 was performed except that, as the warp pile yarn, a roving yarn was used instead of a card sliver.(Comparative Example 2)

[0058] The same procedure as performed in Example 1 was performed except that the warp pile yarn was not subjected to the bleaching treatment, but was woven into a fabric and then subjected to the bleaching treatment. A result of the foregoing warp pile yarn is shown in Table 3, while a result of the towel cloth is shown in Table 4. [Table 3]Example 1Comparative Example 1Count Moisture RateStandard Weight Yarn Count (English Cotton Count)16.116.3Count Fluctuation Rate(%)1.501.77Moisture Rate(%)8.327.99Yarn UnevennessU% (%)8.3013.47IPI Value , Thin, -50% (Number / km)02IPI Value. Thick, +50% (Number / km)298Neps, +200% (Number / km)091Single Yarn Strength / Elongation DegreeAverage Strength(CN)403554Elongation Degree(%)6.94.4Slub NepC (Major Defect Class) (Number / 100,000 m)03F (Medium Defect Class) (Number / 100,000 m)08T (Minor Defect Class) (Number / 100,000 m)455TwistNumber of Twists (T / 2. 54cm)11.511.5Twist Coefficient2.8752.875Fluff3mm (Number / 10m)428.2431.650mm (Number / km)81.789.3 [Table 4] Example 1Comparative Example 1Comparative Example 2Basis Weight (g / m 2< )422422422Pile Length (cm)1.181.181.18Material100% Cotton100% Cotton100% CottonDegree of Bulkiness (cm 3< / g)12.4110.3511.30Compression Work Amount Before Washing(gf. cm 2< )6.3766.0485.514Compression Work Amount After 30 Cycles of Washing (gf. cm 2< )7.1606.6725.008Drainage in Washing, Residual Moisture Rate (%)646573Moisture Content of Cloth at Start of Drying (%)646573Time Required to Reach Residual Moisture Rate of 10%(h)2.72.94.7Fluff Dropping Rate (%)0.00180.01920.0037Improved Larose Method, Water Absorption Index1189858861Dimensional Change Rate After 30 Cycles of Washing (Long Side%)-5.8-5.9-10.7Dimensional Change Rate After 30 Cycles of Washing (Short Side%)-3.9-3.9-8.3Dropping Method. Water Absorption Speed (Second)Less than 1Less than 1Less than 1Rewetting Rate (%)12.513. 215.2Side View Photograph of Pile YarnFigure 7Figure 8Figure 9Top View Photograph of Pile YarnFigure 10Figure 11Figure 12

[0059] As is obvious from Table 4, for the towel cloth according to Example 1, the following effects were successfully confirmed, in comparison to those according to Comparative Example 1 and Comparative Example 2. (1) Less fluff dropping (2) Bulky (3) High puffiness and a high fluffy feel before washing (4) Less likely to lose puffiness after washing, and less likely to be deteriorated by washing (5) Less rewetting and permitting comfortable wiping experience (6) Less prone to dimensional changes due to washing, and less likely to shrink (7) High drying performance, and a shorter time required to reach a residual moisture rate of 10% or less. Industrial Applicability

[0060] The towel cloth according to the embodiment of the present invention is appropriate also for cloth such as a bath towel (after-bath towel), a bathing towel, a bedding undercoat towel, a face towel, a toweling handkerchief, a sport towel, a bathrobe, or a toweling blanket, or clothes, socks, rugs, bedding, or the like.Reference Signs List

[0061] 1Towel cloth 2a, 2bWarp pile yarn 3Weft ground yarn 4a, 4bWarp ground yarn 10Siro spun spinning device 11a, 11b, 11cRoving bobbin 12a, 12b, 12cRoving yarn 13Trumpet guide 14Back roller 15Draft device 16Apron 17Front roller 18a, 18b, 18cFleece 19Spun yarn 20Snare wire 21Spindle 22Bobbin

Claims

1. A towel cloth including a pile yarn, a warp ground yarn, and a weft ground yarn, wherein a fiber material of the pile yarn is cotton medium-staple cotton or long-staple cotton having an average fiber length of 28.6 to 34.7 mm and a micronaire of 4.1 to 5.8 µg / inch, and a content of short fibers with an average fiber length of 17 mm or less therein is set to 10 mass% or less, the pile yarn is a non-twisted or low twisted single siro spun yarn, each of the warp ground yarn and the weft ground yarn is a ring-spun yarn using super-long-staple cotton having an average fiber length of 34.8 to 44.5 mm and a micronaire of 3.0 to 4.1 µg / inch, and each of the pile yarn, the warp ground yarn, and the weft ground yarn is bleached.

2. The towel cloth according to claim 1, wherein a count the siro spun yarn is 5 to 100 in English cotton count.

3. The towel cloth according to claim 1, wherein a twist multiplier K of the siro spun yarn is 0 to 3.5, where the twist multiplier (K) is calculated using the following expression Twist Coefficient K = t / S where t represents the number of twists (number / 25.4 mm), and S represents an English cotton count.

4. The towel cloth according to claim 1, wherein the siro spun yarn is applied with secondary twisting in a direction opposite to a primary twisting direction of a plurality of roving yarns with the number of twists equal to or larger than the number of twists of primary twisting.

5. The towel cloth according to claim 1, wherein the siro spun yarn is a two-stranded siro spun yarn or a three-stranded (triple) siro spun yarn.

6. The towel cloth according to claim 1, wherein a count of each of the warp ground yarn and the weft ground yarn is 10 to 50 in English cotton count.

7. The towel cloth according to claim 1, wherein a twist multiplier K of each of the warp ground yarn and the weft ground yarn is 3.5 to 4.5, where the twist multiplier (K) is calculated using the foregoing expression (Expression 1).

8. The towel cloth according to claim 1, wherein the pile yarn is a combed yarn.

9. A manufacturing method of the towel cloth according to any one of claims 1 to 8, wherein a fiber material of the pile yarn is cotton medium-staple cotton or long-fiber cotton having an average fiber length of 28.6 to 34.7 mm and a micronaire of 4.1 to 5.8 µg / inch, and a content of short fibers with an average fiber length of 17 mm or less therein is set to 10 mass% or less by combing treatment, the pile yarn is a triple siro spun yarn that is twisted in a direction opposite to a primary twisting direction of three roving yarns, and secondary twisting is applied thereto with the number of twists equal to or larger than the number of twists of primary twisting to provide a non-twisted or low twisted single yarn, each of the pile yarn, the warp ground yarn, and the weft ground yarn is subjected to bleaching treatment, and each of the pile yarn, the warp ground yarn, and the weft ground yarn is supplied to a Jacquard loom to manufacture a towel woven cloth.

10. The manufacturing method of the towel cloth according to claim 9, wherein, after being subjected to the bleaching treatment, the yarns are dyed.

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