Pile fabric finishing process consisting of extra-long pile loops

Abstract

This provides a finishing process for pile fabrics with extra-long pile loops. [Solution] The finishing process for pile fabric involves compressing the wet pile fabric, untwisting the ropes, stretching, and drying. In the final pile fabric finishing process of the present invention, at least 99.5% of the pile loops can be stretched to their full height. The process of the present invention does not require the introduction of new equipment and can be performed with existing machinery.

Description

[Technical Field]

[0001] This invention relates to textile fabrics.

[0002] Definition of Terms The following terms used in this invention are intended to have the meanings defined below in general, unless otherwise specified in the context.

[0003] Water Absorption Rate: The term "water absorption rate" refers to a material's ability to absorb and retain liquids, usually water. The water absorption rate of fabrics can be measured using various test methods, such as water absorption tests, drop tests, and hydrostatic head tests. These tests measure the amount of liquid the fabric can absorb, the water absorption rate, and the time it takes for the fabric to become saturated with water.

[0004] Water absorption capacity: The term "water absorption capacity" refers to the mass of water absorbed when a textile fabric is saturated with water under specified conditions.

[0005] Droplet Absorption Capacity: The term "droplet absorption capacity" refers to the ability of a fabric to absorb a single drop of a test medium, such as water. It is measured as the time it takes for the fabric to lose its reflectivity the moment a single water droplet comes into contact with it. The droplet absorption time of pile fabric is very short.

[0006] High-speed air dryer: The term "high-speed air dryer" refers to an industrial dryer that moves the fabric "back and forth" at high speed for a predetermined period of time, exposing the fabric to hot air blown parallel to it during that time. Within the dryer, "forward motion" defines the forward movement of the fabric, and "reverse motion" defines the movement in the reverse direction. High-speed air dryers such as the Bianclani Airo 24 can be used.

[0007] Pile fabric, or terry cloth: The term "pile fabric," or terry cloth, refers to a type of fiber characterized by raised fibers or loops that create a soft, indistinct surface. These fibers are woven together with two warp threads, namely the base warp and the pile warp, and a set of weft threads to form the fabric. The base warp and weft threads form the base fabric (ground), and the pile warp threads woven with the weft threads form the pile loops that protrude from the surface of the fabric.

[0008] Extra-long pile loop: The term "extra-long pile loop" refers to a single loop formed by combining multiple pile loops (Z) whose length is twice or Z times the initial length of the pile loops in the woven fabric.

[0009] Warp threads: This term, also known as "warp threads," refers to the threads that run along the longitudinal direction of the fabric and are woven together with the weft threads.

[0010] Weft: The term "weft" refers to a thread that intersects the warp threads, which make up the base fabric (ground), at a right angle.

[0011] Pile warp: The term "pile warp" is also known as "pile" and refers to the threads that form the raised surface of a fabric, consisting of upright loops or bundles of threads.

[0012] Pile Ratio: The term "pile ratio" is calculated using the following formula: Pile ratio = (Weight of pile in grams × 2.2046 × 840 × Number of piles × 36) / (Number of pile ends per fabric × Fabric length × 1000)

[0013] Bulkiness: "Bulkiness" refers to a quality or condition where something is large in size.

[0014] Picks per centimeter: This term, also called "picks per centimeter" or "picks per cm," refers to the number of weft threads per centimeter of woven fabric, where one weft thread is called one pick. Generally, a higher pick count per centimeter results in less shrinkage of the fabric while wet. However, a very high pick count per centimeter will make the fabric stiff and rigid.

[0015] Polyvinyl alcohol (PVA) yarn: This term, also called "polyvinyl alcohol (PVA) yarn" or "soluble yarn," refers to a synthetic polymer yarn that does not require the addition of chemicals and readily dissolves in warm or hot water at temperatures between approximately 40°C and 110°C.

[0016] Rope unraveling: The term "rope unraveling" refers to a method of unraveling or releasing a tangled fabric.

[0017] USB Fiber Microscope: The term "USB fiber microscope" refers to a digital microscope that can be connected via a computer's USB port, and whose images can be visualized on a computer screen.

[0018] Material-to-Liquid Ratio: The term "material-to-liquid ratio" (ML ratio) refers to the weight-to-volume ratio between the volume of the textile being processed and the volume of the processing liquid bath. An ML ratio of 1:10 means that 10 liters of bath volume are needed to process 1 kg of textile material.

[0019] Dough moisture content: The term "dough moisture content," or "residual moisture," is calculated by dividing the weight of water in the dough by the weight of the completely dry dough and multiplying by 100. This value is expressed as a percentage of the total weight of the dough.

[0020] Padda: The term "padda" refers to a set of rollers traditionally used to squeeze water out of fabric or to impregnate it with dyes, chemicals, or other special high-performance finishing materials.

[0021] Standard pile fabric: The term "standard pile fabric" refers to a pile fabric that does not use soluble weft yarns and is finished by drying in a conventional manner.

[0022] Technical fabric: The term "technical fabric" means a fabric manufactured by applying special engineering to achieve functional purposes that surpass those of conventional apparel. This includes, for example, antistatic, delayed action by chemicals, flame retardants, solvent holding members, and holding functional characteristics such as the like. Technical styles are mainly classified into five groups for protective, sports, transportation, medical, industrial, and similar purposes.

Background Art

[0023] The following background information pertains to the present invention and is not necessarily related to prior art.

[0024] Pile fabric, i.e., terry cloth, is mainly used to remove excess moisture from the surface. A distinct feature that differentiates flat cloth from terry cloth is the use of an additional type of yarn called pile warp in the structure. In contrast to the base cloth warp and weft woven together with high tension, the pile warp is woven with the weft with much lower tension to produce pile loops. This is achieved by releasing the base cloth pile warp from the pile beam at a higher speed than the warp is released from the base cloth beam. As the released yarns are spun and combined with the weft and condensed, a larger amount of yarn released from the pile beam forms loops that protrude outward from between the base cloth warp and weft.

[0025] The pile loops protruding on both sides of the fabric greatly increase the surface area of the fabric, making it an excellent water-absorbing material. At the same time, the protruding pile loops impart a soft touch to the fabric, making it optimal for use as a towel. Furthermore, the protruding pile loops also produce a kind of elegance aesthetically, which is more appealing to consumers. The water absorbency of a towel is mainly related to the type of fiber used and the loop structure. It is known that increasing the loop height and the property of the pile loop having a low degree of twist increases the water absorbency while maintaining the characteristics usually possessed by a terry towel.

[0026] However, most terry fabrics often suffer from a common problem. That is, it takes longer to dry than non-terry fabrics. The moisture contained in the towel may lead to the generation of bacteria and mold, and furthermore, it may lead to the generation of an unpleasant odor.

[0027] Many changes have been made to dry terry towels more quickly, but most of them focus on using synthetic fibers such as polyester in a part of the base fabric warp. Polyester has little water absorbency. Therefore, a towel made of polyester fibers is less likely to retain moisture than a towel made of natural fibers, so a towel made of polyester yarns has faster drying properties. As an antagonistic effect, it affects the water absorbency and bulkiness of the towel. Another option for manufacturing a towel that can be quickly dried while having a high water absorption rate is to manufacture pile yarns with hollow cores. In this case, the core of the pile yarn is made of a water-soluble yarn with a cotton yarn covering the core. When heated, the core material decomposes, gaps are generated inside the cotton yarn, the bulkiness is maintained, the water absorbency increases, and the towel dries quickly and easily.

[0028] The manufacturing process for creating fabrics with extra-long pile loops through a unique weaving process is known. While the final product exhibits impressive performance, a significant drawback is that approximately 5% to 10% of the extra-long pile loops tend to become trapped within the warp and weft threads of the base fabric due to their length during processing, remaining trapped even after the towel dries. Therefore, a large portion of the final towels need to be tumble-dried again to release the trapped pile loops. Modifications to the processing, particularly a unique finishing method that helps release the condensed and deformed extra-long pile loops, are necessary.

[0029] Therefore, there is a real need to provide a finishing process for pile fabrics consisting of extra-long pile loops that mitigates the aforementioned disadvantages or at least provides a useful alternative method.

[0030] Some of the objectives of the present invention can be adequately represented by at least one example described herein, which is as follows:

[0031] The object of the present invention is to improve one or more of the underlying problems or to provide at least a useful alternative.

[0032] One objective of the present invention is to provide a finishing process for pile fabrics having extra-long pile loops.

[0033] Another objective of the present invention is to provide a simple and economical finishing process for pile fabrics having extra-long pile loops.

[0034] Another object of the present invention is to provide a finishing process for pile fabrics having extra-long pile loops that provides a fabric with improved aesthetics, elegance, and a more uniform appearance.

[0035] Another object of the present invention is to provide a final pile fabric having extra-long pile loops that is extremely soft, highly absorbent, and dries quickly.

[0036] Another object of the present invention is to provide a final pile fabric having extra-long pile loops with air pockets built into and around the pile loops.

[0037] Another object of the present invention is to provide a final pile fabric in which the pile loops extend to the total height of the pile.

[0038] Other objectives and advantages of the present invention will become even clearer from the following description, which is not intended to limit the scope of the invention. [Overview of the project]

[0039] The present invention provides a finishing process for pile fabric having extra-long pile loops in order to obtain a finished pile fabric.

[0040] This process consists of the following steps: (a) Obtain a wet pile fabric having extra-long pile loops containing moisture in the range of 150% to 500% (w / w), (b) Keep the wet pile fabric in a relaxed state for a predetermined time, thereby obtaining a wet relaxed pile fabric in which the relaxed pile fabric has a disordered shape. (c) The messy, wet, loose pile fabric is fed to the rope compression device by the first guide roller set at a first predetermined speed, passed through the rope compression process through at least one pair of water-squeezing cylinders, a first predetermined pressure is applied, and a compressed fabric containing 80% to 250% moisture is obtained. (d) The compressed dough is passed through a second set of guide rollers at a second predetermined speed and processed in the rope untwisting process to obtain the untwisted dough. (e) The open dough is stretched longitudinally on at least one set of sawtooth feed-in rollers, then fed to a third set of guide rollers at a third predetermined speed to obtain the first stretched dough, then the first stretched dough is fed onto a fourth set of guide rollers rotating at a fourth predetermined speed alternately, and fed to a first pad and a rotating water-squeezing cylinder of the first pad at a fifth predetermined speed, and a second predetermined pressure is applied to obtain a second stretched dough with a moisture content of 60% to 90%, (f) Alternatively, the second stretched fabric is fed to the fifth set of guide rollers at the sixth predetermined speed, and the third stretched fabric is obtained while keeping the second stretched fabric in a stretched state. (g) Alternatively, the third stretched dough is sent to the processing device at a seventh predetermined speed via a sixth set of guide rollers, where the processing device is filled with at least one type of finishing liquid and processes the third stretched dough while simultaneously maintaining it in a state of being stretched longitudinally for a second predetermined time to obtain a fourth stretched processed dough, the fourth stretched processed dough is passed through a second pad having a water-squeezing cylinder that rotates at an eighth predetermined speed and a ninth predetermined speed, a third predetermined pressure is applied to obtain a fifth stretched dough with a moisture content of 60% to 90%, and further (h) The second stretched fabric or the fifth stretched fabric is held in a relaxed state for a third predetermined time to obtain a relaxed fabric, and then the relaxed fabric is passed through a high-speed air dryer at a predetermined temperature, and the fabric is moved "back and forth" to alternately create tension and relaxation in the fabric to obtain the final pile fabric.

[0041] According to the present invention, a wet pile fabric is prepared by the following steps: (i) Provide multiple warp threads for the base fabric, multiple warp threads for the pile, and multiple weft threads. (ii) The base fabric warp threads are woven together with the weft threads under high tension to form the fabric matrix, wherein at least one of the weft threads is a soluble weft thread. (iii) Pile warp threads woven with weft threads under low tension, resulting in a weight of 300 g / m 2 From 700 g / m 2 The method involves obtaining a pile fabric having multiple pile loops on at least one surface of the pile fabric, (iv) Water is added to a pile fabric having multiple pile loops so that the material-to-liquid ratio is 1:5 to 1:7, and the fabric is heated at 90°C to 100°C for 25 to 35 minutes to bond the multiple pile loops and obtain a pile fabric having extra-long pile loops, and further, (v) The pile fabric having extra-long pile loops is sequentially washed with water, dyed, treated with soap, and washed to obtain wet pile fabric.

[0042] According to the present invention, the rope untwisting process involves passing the compressed fabric through an untwisting machine at a speed range of 10 m / min to 14 m / min to obtain the untwisted fabric.

[0043] According to the present invention, the first predetermined time in step (b) is 20 to 30 minutes.

[0044] In accordance with the present invention, in step (c), the first predetermined speed of the first set of guide rollers is in the range of 14 m / min to 18 m / min, and the first predetermined pressure by the compression cylinder is in the range of 2 bar to 4 bar.

[0045] In accordance with the present invention, in step (d), the second predetermined speed of the second set of guide rollers is in the range of 10 m / min to 15 m / min.

[0046] In accordance with the present invention, in step (e), the third predetermined speed of the third set of guide rollers and the fourth predetermined speed of the fourth set of guide rollers are in the range of 11 m / min to 15 m / min, and the fifth predetermined speed of the first padder is in the range of 2 rounds / min to 8 rounds / min.

[0047] In accordance with the present invention, in step (e), the second predetermined pressure by the first padder is in the range of 2 bar to 8 bar.

[0048] In accordance with the present invention, in step (f), the sixth predetermined speed of the fifth set of guide rollers is in the range of 12 m / min to 16 m / min.

[0049] In accordance with the present invention, in step (g), the seventh predetermined speed of the sixth set of guide rollers and the eighth predetermined speed for supplying the fourth stretched fabric are each independently in the range of 12 m / min to 16 m / min.

[0050] The second predetermined time ranges from 10 to 16 seconds, and the ninth predetermined speed of the second pad is in the range of 3 rounds / minute to 8 rounds / minute.

[0051] In accordance with the present invention, in step (h), the third predetermined time is in the range of 6 to 12 minutes, and the predetermined temperature is in the range of 150 °C to 165 °C.

[0052] According to the present invention, in step (h), the forward travel speed is in the range of 40 m / s to 50 m / s for 2 to 3 seconds, and the return travel speed is in the range of 30 m / s to 40 m / s for 2 to 3 seconds.

[0053] In accordance with the present invention, in the second or fifth stretched fabric, more than 95% of its ultra-long pile loops, up to a maximum of 99.5%, are extended to the total height.

[0054] In accordance with the present invention, in the final pile fabric obtained in step (h), 99.5% to 100% of the ultra-long pile loops are expanded to the total height.

[0055] According to embodiments of the present invention, the final pile fabric obtained using the process of the present invention is characterized by at least one of the following: • 55% to 65% increase in bulk • 65% to 75% increase in water absorption • The percentage reduction in drop-by-drop absorption capacity is 62% to 72%. • Absorption capacity increase rate from 24% to 62% • 25% to 40% reduction in drying time

[0056] According to embodiments of the present invention, the final pile fabric has a base fabric warp thread in the range of 20 end threads / cm to 28 end threads / cm and a weft thread in the range of 12 threads / cm to 30 threads / cm and a pile ratio of 1:4 to 1:8.

[0057] According to embodiments of the present invention, the final pile fabric has 99.5% to 99.9% of its ultra-long pile loops extended to the total height. [Brief explanation of the drawing]

[0058] The present invention will be described with reference to the accompanying drawings. The drawings are as follows: [Figure 1(a)] Figure 1(a) shows a 20x microscope image of an ultra-long pile loop containing an air pocket generated within the loop (internal loop) by the decomposition of soluble yarn in the final pile fabric prepared according to the present invention. [Figure 1(b)] Figure 1(b) shows a microscopic image at 20x magnification of an ultra-long pile loop containing an air pocket created between two loops (internal loops) by the decomposition of soluble yarn in the final pile fabric prepared according to the present invention. [Figure 2(a)] Figure 2(a) illustrates a comparison image of a towel with extra-long pile loops finished according to the present invention (final pile fabric) (right image) and a towel (pile fabric) finished by a standard finishing process (left image). It shows that the towel finished according to the present invention (final pile fabric) has a larger volume than the towel prepared using the standard method. [Figure 2(b)] Figure 2(b) illustrates a comparison image of a towel with extra-long pile loops finished according to the present invention (final pile fabric) (right image) and a towel (pile fabric) finished by a standard finishing process (left image). It shows that the towel (pile fabric) finished according to the present invention is aesthetically superior to the towel prepared using the standard method and exhibits a more uniform appearance. [Figure 2(c)]Figure 2(c) illustrates a comparison of a towel with extra-long pile loops finished according to the present invention (final pile fabric) (right image) and a towel finished by a standard finishing process (pile fabric) (left image), showing the final appearance of the finished towel when comparing the side view of the weft threads (towel width side image). [Figure 2(d)] Figure 2(d) illustrates a comparison of a towel with extra-long pile loops finished according to the present invention (final pile fabric) (right image) and a towel finished by a standard finishing process (pile fabric) (left image), showing the final appearance of the finished towel when comparing the warp side (long side image of the towel). [Figure 2(e)] Figure 2(e) is an enlarged view of the loop structure of a towel (pile fabric) finished using the standard method, in which the central pile loop remains sealed and not released. [Figure 2(f)] Figure 2(f) is an enlarged view of the loop structure of a towel (final pile fabric) finished according to the present invention, and was photographed at 20x magnification using a USB fiber microscope. [Figure 3(a)] Figure 3(a) is a comparative image of the ultra-long pile loops of a towel (final pile fabric) finished according to the present invention, photographed at 20x magnification using a USB fiber microscope. This image shows the ultra-long pile loops according to the present invention and the internal loops / air pockets (double arrows) within the ultra-long pile loops. [Figure 3(b)] Figure 3(b) is a comparative image showing a control towel fabric without a soluble pick. Detailed description of the invention

[0059] This invention relates to textile fabrics.

[0060] Embodiments of the present invention will be described below with reference to the accompanying drawings.

[0061] The embodiments described herein will allow a person skilled in the art to fully and completely grasp the scope of the present invention. Numerous details relating to individual components will allow for a complete understanding of the embodiments of the present invention. It will be clear to a person skilled in the art that the details described in the embodiments cannot be interpreted as limiting the scope of the present invention. Some embodiments do not describe in detail known processes, well-known apparatus or structures, or well-known techniques.

[0062] In this invention, the terms used herein are used solely to describe specific embodiments and should not be considered to limit the scope of the invention. Nouns used herein include multiple things unless the context requires them to be treated as singular. Terms such as "consisting of," "including," "composed of," and "consisting of" are transitional phrases that may include other things and thus define the existence of functions, features, integers, procedures, operations, elements, modules, units, or components described herein, but do not exclude the existence or addition of other functions, integers, procedures, operations, elements, components, or groups of components. The order of specific procedures disclosed in the methods and processes of this invention should be interpreted as meaning that the performance described or illustrated is not necessarily an essential element. It should also be understood that additional or alternative procedures may be used.

[0063] The terms "first," "second," "third," etc., can only be used to distinguish one element or component, region, layer, or section from other components, regions, layers, or sections, and therefore cannot be construed as limiting the scope of the invention. Unless expressly indicated in the invention, the terms "first," "second," "third," etc., do not imply any particular permutation or order.

[0064] As used herein, the term "or" includes one or any combination of the relevant list elements.

[0065] Pile fabric, or terry cloth, is primarily used to remove excess moisture from the surface. Numerous modifications have been made to make terry towels dry faster, but most of these focus on using synthetic fibers such as polyester in part of the warp threads of the base fabric. Polyester has very little absorbency, and for this reason, polyester towels do not retain moisture as well as towels made of natural fibers. Polyester towels dry faster. Counteracting this is the effect on the towel's absorbency and bulkiness. Another option for producing towels that are highly absorbent yet can dry quickly is to manufacture pile yarn with an empty core, in which case the core of the pile yarn is made from water-soluble yarn with cotton yarn surrounding the core. When heated, the core material decomposes, creating gaps within the cotton yarn, which maintains bulkiness, increases absorbency, and makes the towel dry faster.

[0066] The manufacturing process for creating fabrics with extra-long pile loops through a unique weaving process is known. While the final product has impressive performance, approximately 5% to 10% of the extra-long pile loops suffer a significant disadvantage during fabric processing, as their length makes them prone to becoming trapped within the warp and weft threads of the base fabric, remaining in this state even after the towel dries. Therefore, a large portion of the final towels need to be tumble-dried again to release the trapped pile loops.

[0067] This invention provides a process for obtaining a final pile fabric by a finishing process for a pile fabric having extra-long pile loops.

[0068] A process to prepare a wet pile fabric containing 150% to 500% (w / w) moisture. The wet pile fabric has extra-long pile loops. The wet pile fabric is held in a relaxed state for a first predetermined time to obtain a wet relaxed fabric. The wet relaxed fabric takes the form of a messy fabric. The messy wet relaxed fabric is fed at a first predetermined speed by a first set of guide rollers to a rope compressing device and subjected to a rope compressing process through at least one pair of compressing cylinders, applying a first predetermined pressure to obtain a compressed fabric containing 80% to 250% moisture. The compressed fabric is processed at a second predetermined speed by a second set of guide rollers in a rope untwisting process to obtain a released fabric. The released dough is stretched longitudinally over at least one set of serrated feed-in rollers, then passed through a third set of guide rollers at a third predetermined speed to obtain a first stretched dough, then alternately placed on a fourth set of guide rollers rotating at a fourth predetermined speed, and sent to a first padder and a first padder rotating at a fifth predetermined speed, where a second predetermined pressure is applied to obtain a second stretched dough containing 60% to 90% moisture. Alternatively, the second stretched dough is sent to a fifth set of guide rollers at a sixth predetermined speed, maintaining the second stretched dough in a stretched state to obtain a third stretched dough. Alternatively, the third stretched fabric is sent to a processing device at a seventh predetermined speed via a sixth set of guide rollers, where the processing device is filled with at least one type of finishing agent to process the third stretched fabric, while simultaneously maintaining the stretched state in the longitudinal direction of the fabric for a second predetermined time to obtain a processed fourth stretched fabric. This fourth stretched fabric is then passed through a second pad having a water-squeezing cylinder that rotates at an eighth predetermined speed and a ninth predetermined speed, and a third predetermined pressure is applied to obtain a fifth stretched fabric with a moisture content of 60% to 90%. The second or fifth stretched fabric is kept in a relaxed state for a third predetermined time to obtain a relaxed fabric, and then the relaxed fabric is put into a high-speed air dryer at a predetermined temperature, during which the fabric is moved "back and forth" at high speed to alternately create a taut and relaxed state to obtain a final pile fabric.

[0069] According to the present invention, the pile fabric is a woven fabric in which at least one of the weft threads is a soluble weft thread.

[0070] According to the present invention, multiple pile loops (Z) of the woven fabric combine to form a single pile loop that is Z times higher than the original woven fabric as the soluble weft dissolves. According to embodiments of the present invention, the pile fabric has a large number of extra-long pile loops. According to several embodiments of the present invention, it is possible to manufacture extra-long pile loops by combining 2 to 6 loops.

[0071] In the first step, prepare a wet pile fabric with extra-long pile loops, containing moisture in the range of 150% to 500% (w / w).

[0072] The following describes the preparation process for wet pile fabric: According to the present invention, multiple base fabric warp threads, multiple pile warp threads, and further multiple weft threads are obtained.

[0073] In accordance with the present invention, the warp threads of the base fabric are knitted together with the weft threads under high tension to form the base fabric of the material, and at least one of the weft threads is a soluble weft thread.

[0074] According to the present invention, the pile warp threads are knitted with the weft threads at low tension, with a weight range of 300 g / m². 2 From 700 g / m 2 Obtain a pile fabric having multiple pile loops on at least one surface of the pile fabric.

[0075] According to one embodiment of the present invention, the pile loops are created using a multi-pick terry method, and the terry loops protrude from one or both sides of the fabric.

[0076] In accordance with the present invention, the usable weft yarn in a fabric material having multiple pile loops is dissolved by adding water in a material-to-liquid ratio (MLR) range of 1:5 to 1:7, and then heated at a temperature range of 90°C to 100°C for a time range of 25 to 35 minutes to bond the multiple pile loops (Z) and obtain a pile fabric having extra-long pile loops.

[0077] The insoluble pile yarns are arranged such that, as the soluble yarns decompose, two loops adjacent to each side of the soluble yarns combine to form longer loops, and then even larger pile loops are generated. The usable weft yarns are solubilized so that at least two adjacent pile loops combine to form one long pile loop, i.e., an extra-long pile loop.

[0078] In accordance with the present invention, the fabric having extra-long pile loops is then washed with water, dyed, and washed with soap according to a standard processing method to obtain a wet pile fabric containing 150% to 500% (w / w) moisture. The weight of the wet pile fabric is 300 g / m 3 From 700 g / m 3 That is the case.

[0079] In one embodiment, the weight of the wet pile fabric was 450 g / m². 3 In one embodiment, the wet pile fabric contains 380% (w / w) moisture.

[0080] During the preparation of pile fabric containing 150% to 500% moisture, the length of the fabric decreases by approximately 7% to 11% due to shrinkage during the wetting process.

[0081] According to the same embodiment of the present invention, the wet pile fabric has extra-long pile loops that extend to the full height, with 90% to 95% of them.

[0082] In the second step, the wet pile fabric is kept in a relaxed state for a predetermined time, resulting in a wet, relaxed fabric, which then takes on the shape of a messy fabric.

[0083] In embodiments of the present invention, the first predetermined time is 20 to 30 minutes. In one embodiment, the first predetermined time is 25 minutes.

[0084] In the third step, the messy, wet, loose fabric is fed to the rope compression device at a predetermined speed by a first set of guide rollers and subjected to the rope compression process.

[0085] According to one embodiment of the present invention, the first predetermined speed of the first set of guide rollers is 14 m / min to 18 m / min. In one embodiment, the first predetermined speed of the first set of guide rollers is 16 m / min.

[0086] According to the present invention, the rope pressing process comprises the steps of feeding a messy, wet, loose pile fabric through at least one pair of pressing cylinders to a rope pressing device, applying a first predetermined pressure, and obtaining a pressed fabric with a moisture content of 80% to 250%.

[0087] According to embodiments of the present invention, the first predetermined pressure achieved by the compression cylinder as described above is in the range of 2 bar to 4 bar. In one embodiment, the first predetermined pressure is 3 bar.

[0088] According to the present invention, the pressed dough contains 80% to 250% moisture. In one example, the pressed dough has a moisture content of 190%.

[0089] According to the same embodiment of the present invention, wet, loose dough in the form of a messy dough is collected in a trolley. The trolley carrying the messy dough is placed on a rotatable turntable, and the dough is pushed into an opening and passed through suspended guide rollers (first set of guide rollers) into a rope press. This rope press consists of two stainless steel rollers that squeeze out water as the dough is pressed and passes through. The pressure applied to the rollers is between 2 and 4 bar.

[0090] In the fourth step, the compressed dough is passed through a second set of guide rollers at a second predetermined speed to obtain the dough that has been processed and released in the rope untwisting process.

[0091] According to one embodiment of the present invention, the rope release step involves passing the compressed fabric through a detangler at a speed range of 10 m / min to 14 m / min to obtain the released fabric. In one embodiment, the compressed fabric is passed through a detangler at a speed of 12 m / min.

[0092] According to an embodiment of the present invention, the compressed fabric passes over guide rollers and falls into a J-box. The fabric obtained from the J-box is lifted vertically about 4 to 5 m and placed on a stainless steel untwisting machine AP06 measuring 60 cm x 50 cm. The function of the untwisting machine is to perform a "rope unraveling" function to release the twist from the fabric. The untwisting machine consists of a circular path with an entrance equipped with multiple smooth curved projections that extend radially inward and make tight contact with the rope-like bundle as the pile rope enters the path. Two sensors are positioned at each end of the untwisting machine, and based on these sensors, the untwisting machine detects the twist in the fabric and rotates the circular path in the opposite direction to counteract the twist.

[0093] In the fifth step, the loosened dough is stretched longitudinally on at least one pair of sawtooth feed-in rollers, then fed to a third pair of guide rollers at a third predetermined speed to obtain the first stretched dough, then fed onto a fourth pair of guide rollers rotating at a fourth predetermined speed alternately to feed the first stretched dough onto the first padder and the rotating water-squeezing cylinder of the first padder at a fifth predetermined speed, and a second predetermined pressure is applied to obtain a second stretched dough with a moisture content of 60% to 90%.

[0094] According to an embodiment of the present invention, after passing through a twisting machine, the dough is processed by a beater that assists in spreading the dough on the roller surface. The dough, which is spread in stages, enters a stainless steel sawtooth feed-in roller that is 310 cm to 330 cm long and 20 cm to 25 cm in diameter. The grooves on the roller surface securely grip the dough so that it is spread into a flat, single-layer shape, and in this process the dough expands laterally across its entire width.

[0095] According to the present invention, the third predetermined speed of the third set of guide rollers and the fourth predetermined speed of the fourth set of guide rollers are independently between 11 m / min and 15 m / min. In one embodiment, the third predetermined speed of the third set of guide rollers is 12 m / min. In one embodiment, the fourth predetermined speed of the fourth set of guide rollers is 14 m / min.

[0096] According to the present invention, the fifth predetermined speed for rotating the water-draining cylinder of the first pad is from 2 rounds / min to 8 rounds / min. In one embodiment, the third predetermined rotational speed of the water-draining cylinder of the first pad is 5 rpm.

[0097] According to embodiments of the present invention, the second predetermined pressure achieved by the first padder as described above is between 2 bar and 8 bar. In one embodiment, the second predetermined pressure is 4 bar.

[0098] According to an embodiment of the present invention, the second stretched fabric is sent to the fifth set of guide rollers at a sixth predetermined speed as an alternative method, the second stretched fabric is held in a stretched state, and the third stretched fabric is obtained.

[0099] According to the present invention, the sixth predetermined speed of the fifth set of guide rollers is 12 m / min to 16 m / min. In one embodiment, the sixth predetermined speed is 14 m / min.

[0100] Furthermore, as an alternative method, the third stretched dough is sent to the processing device at a seventh predetermined speed through a sixth set of guide rollers, where at least one type of finishing agent is filled into the processing device to process the third stretched dough, while simultaneously maintaining a longitudinally stretched state for a second predetermined time to obtain a fourth processed stretched dough. The fourth processed stretched dough is passed through a second pad equipped with a water-squeezing cylinder that rotates at a ninth predetermined speed and fed in at an eighth predetermined speed, and a third predetermined pressure is applied to obtain a fifth stretched dough with a moisture content of 60% to 90%.

[0101] According to an embodiment of the present invention, a third stretched fabric is fed into the processing device through a sixth set of guide rollers. The processed fabric is fed into a second padder via a system consisting of three guide rollers, each having a diameter of 10 to 12 cm and a length of 290 to 310 cm. The second padder consists of two longitudinally mounted stainless steel cylinders coated with acrylonitrile butadiene rubber (NBR) to provide resistance to oil, fuel, and chemicals. This coating also allows for the application of uniform force without tearing any fabric passing through. Each cylinder has a diameter of 34 to 36 cm and a length of 290 to 310 cms. The distance between the rollers in the squeezing cylinder (which contains the rollers) and the rotation of this cylinder (i.e., the rollers) are variable by a hydraulic control unit consisting of an oil pump and a diaphragm. In one embodiment, the first padder is rotated at a speed of 5 rpm so that the fabric passes through in a stretched state. The applied pressure is 5 bar, which causes the fabric to be fully stretched to its longitudinal limit.

[0102] By stretching the fabric through the pad, the altered, grasped, and contained pile threads are more easily extruded to their actual height. The stretched, padded fabric is then removed from the pad by a series of four guide rollers.

[0103] According to embodiments of the present invention, the second predetermined time is 10 to 16 seconds. In one embodiment, the second predetermined time is 14 seconds.

[0104] In embodiments of the present invention, the seventh predetermined speed of the sixth set of guide rollers and the eighth predetermined speed for feeding the fourth processed stretched fabric are independently 12 m / min to 16 m / min. In one embodiment, the seventh predetermined speed is 13 m / min and the eighth predetermined speed is 12 m / min.

[0105] According to embodiments of the present invention, the ninth predetermined rotational speed of the second padder is 3 rounds / minute to 8 rounds / minute. In one embodiment, the ninth predetermined rotational speed of the second padder is 5 rpm.

[0106] According to embodiments of the present invention, the third predetermined pressure is between 2 bar and 8 bar. In one embodiment, the third predetermined pressure is 5 bar.

[0107] In these cases, the dough coming out of the four guide rollers is passed through a duct filled with additive solution. One of the three sets of guide rollers is placed at the bottom of the duct, keeping the dough stretched longitudinally and immersed for the required time. After immersion in the additive, the stretched dough is passed again through a second padder with the same parameters as before. Overall, the dough remains stretched, and any deformed loops are ensured to be released. However, this step is only necessary if the customer requests additional finishing agents. The stretched and compressed dough is then removed from the padder by a set of four guide rollers.

[0108] According to embodiments of the present invention, the finishing agent is selected from the group consisting of softeners, antibacterial agents, insecticides, and fragrances.

[0109] The stretching in this step increases the overall length of the fabric by approximately 8% to 12%, which will be returned to its original length in the next step.

[0110] In the sixth step, the second stretched fabric or the fifth stretched fabric is kept in a relaxed state for a third predetermined time to obtain a relaxed fabric.

[0111] In the same embodiment of the present invention, the third predetermined time is 6 to 12 minutes. In one embodiment, the third predetermined time is 8 minutes.

[0112] In the final step, the relaxed fabric obtained from the second or fifth stretched fabric is exposed to a high-speed airflow at a predetermined temperature in a dryer. Here, the fabric undergoes a "back-and-forth" motion, alternating between tension and relaxation, to obtain the final pile fabric.

[0113] According to each embodiment of the present invention, the predetermined temperature here is from 150 °C to 165 °C. In one example, the predetermined temperature is 155 °C.

[0114] According to an embodiment of the present invention, the state where the tension and relaxation of the fabric alternate is maintained in the dryer by a pulling and pushing mechanism.

[0115] According to an embodiment of the present invention, the high-speed air dryer pulls a part of the fabric within a speed range of 40 m / s to 50 m / s and a time range of 2 seconds to 3 seconds, maintaining the fabric in a tense state. Immediately, a part of the fabric is pulled away by an air flow in the reverse direction passing through the tunnel at a speed of 30 m / s to 40 m / s for 2 seconds to 3 seconds, maintaining the relaxed state of the fabric. In one example, the speed at which the fabric is pulled is 45 m / s, and the speed at which the fabric is pushed out is 35 m / s.

[0116] This alternating pulling and pushing operation is continued to alternately maintain the fabric in a tense state and a relaxed state until the entire fabric passes through the high-speed air dryer.

[0117] After the finishing process according to the present invention, more than 99% to 100% of the final pile fabric has the ultra-long pile loops expanded to the full height. In one example, 99.9% of the pile fabric is ultra-long pile loops stretched to the full height.

[0118] According to an embodiment of the present invention, the final pile fabric is based on a standard pile fabric with a weight in the range of 300 g / m 2 to 700 g / m 2 and is characterized by at least one of the following: a percentage increase in bulk capacity in the range of 55% to 65%, a percentage increase in water absorption rate in the range of 65% to 75%, a percentage decrease in dripping absorption capacity in the range of 62% to 72%, a percentage increase in water absorption capacity in the range of 24% to 62%, or a percentage decrease in drying time in the range of 25% to 40%.

[0119] In one embodiment, the ultra-long pile fabric is from 300 g / m 2 to 700 g / m2 This fabric is characterized by a 62% increase in bulk, a 72% increase in water absorption rate, a 67% decrease in water droplet absorption time, a 42.2% increase in water absorption capacity, and a 32% reduction in drying time compared to standard pile fabric within the same weight range.

[0120] According to embodiments of the present invention, the final pile fabric has 99.9% of the ultra-long pile loops extended to the total height.

[0121] The final pile fabric having extra-long pile loops has a large number of warp threads ranging from 20 ends / cm to 28 ends / cm and a large number of weft threads ranging from 12 threads / cm to 30 threads / cm, with a pile ratio ranging from 1:4 to 1:8. In one embodiment, the final pile fabric having extra-long pile loops has a warp thread ratio of 26 ends / cm, a weft thread ratio of 16.5, and a pile ratio of 1:5.

[0122] According to the present invention, the final pile fabric contains 4% to 8% moisture. In one embodiment, the final pile fabric contains 5% moisture.

[0123] The final pile fabric having extra-long pile loops according to the present invention has enclosed air pockets within and around the pile loops, resulting in higher water absorption, faster absorption rate, faster wicking, and quicker drying without compromising the aesthetics and feel of the towel. These air pockets are also created between two piles and within a single pile loop by removing the bonds between two or more consequent piles during the fabric processing. The resulting bonds between two or more piles are heated in a solvent to solubilize the usable weft, completely dissolving the usable weft.

[0124] According to embodiments of the present invention, the pile loop height in the final pile fabric is 6 mm to 12 mm. In one embodiment, the pile loop height in the final pile fabric is 9 mm.

[0125] The final pile fabric according to the present invention can be woven in various combinations to create different designs and patterns, and can be used for towels, bathrobes, clothing, finishing fabrics, industrial fabrics, and technical fabrics.

[0126] The final pile fabric with extra-long pile loops can be blended with fabrics woven using the same method as the present invention and regular pile fabrics in a variety of possible combinations, allowing for the creation of various design patterns. The extra-long pile loops can be used to produce towels, blankets, rugs, carpets, and similar products.

[0127] The final pile fabric having the ultra-long pile loops of the present invention is homogeneous, has high bulkiness, and high water absorption.

[0128] In the process of the present invention, the repeated drying process of a standard fabric having extra-long pile loops is insoluble.

[0129] The foregoing description of embodiments is for illustrative purposes only and is not intended to limit the scope of the present invention to that description alone. The individual components of a particular embodiment are generally not limited to that particular embodiment and are interchangeable. Such variations cannot be considered different from the present invention, and all such variations are considered to be included within the scope of the present invention.

[0130] The present invention is further described below with the following experiments as an aid. The experiments used in the present invention are solely intended to facilitate understanding how to make the embodiments of the present invention practical and to enable those with skills in this field to carry out the embodiments of the present invention. Therefore, the experiments described herein should not be interpreted as limiting the scope of the embodiments of the present invention. The above laboratory-scale experiments can be scaled up to an industrial / commercial scale, and the results obtained can be extrapolated to the industrial / commercial scale.

[0131] Experiment details Finishing process for pile having extra-long pile loops according to the present invention Example 1 In accordance with the present invention, a wet pile fabric was dried in a manner that increased the bulkiness and aesthetic appeal of the towel fabric by releasing the deformed and trapped pile. In this example, the final finishing process of the pile fabric was carried out in the following steps:

[0132] (a) 450 g / m² containing 380% moisture 2 The terry cloth (pile fabric) was acquired as wet pile fabric.

[0133] (b) The wet pile fabric was kept in a relaxed state for 25 minutes to obtain a wet relaxed pile fabric with a disordered fabric shape.

[0134] (c) The wet, relaxed dough was subjected to a rope compression process using a rope compression device to obtain compressed dough containing 190% moisture. The wet, loose pile fabric, which had taken on a haphazard shape, was collected on a trolley. The trolley carrying the haphazard fabric was placed on a rotatable turntable, and the fabric was pushed into an opening and passed through suspended guide rollers into a rope press at a speed of 16 m / min. This rope press consists of two stainless steel rollers that compress the fabric as it passes through. The pressure applied to the rollers was 3 bar.

[0135] (d) The compressed fabric is processed in a rope untwisting process to obtain the untwisted fabric. The compressed dough was passed over guide rollers and dropped into a J-box. The dough obtained from the J-box was lifted vertically about 4 to 5 meters and placed on a 60 cm x 50 cm stainless steel untwisting machine AP06. The function of the untwisting machine is to perform a "rope unraveling" function to release the twist in the dough. The untwisting machine consists of a circular path with an entrance equipped with multiple smooth curved projections that extend radially inward and make tight contact with the rope-like bundle as it enters the path. Two sensors are placed at each end of the untwisting machine, and when the untwisting machine detects the twist in the dough using these sensors, it rotates the circular path in the opposite direction to counteract the twist. The dough passing through the untwisting machine moves at a speed of 12 m / min, and the untwisted, i.e., released, dough is obtained.

[0136] (e) After passing through the untwisting machine, the released dough was treated with a beater to help spread the dough on the roller surface. The dough, which was being unfolded in stages, was fed into a stainless steel sawtooth feed-in roller that was 320 cm long and 22 cm in diameter. The grooves on the roller surface securely gripped the dough, so the dough was unfolded into a flat single layer, and then the dough expanded laterally across its entire width to obtain the first stretched dough. Next, the first stretched dough was stretched longitudinally onto a set of alternately arranged rollers, fed at a speed of 12 m / min, and then sent in its stretched state to the first padder, where it was pressurized at 4.5 bar to obtain a second stretched dough containing 82% moisture. The fabric length increased by approximately 8% to 10% due to the pressure applied while the fabric was wet and stretched. That is, the fabric, which had a pile-to-pile length of 111 cm after treatment, was stretched to approximately 120 cm. As a result of this lengthening, the pick count / cm of the padded fabric decreased by approximately 7% to 9%, from 14 to 16 picks / cm. The decrease in pick count / cm increased the distance between two picks. This additional space allowed 5% to 10% of the deformed or trapped extra-long pile loops to be released and stretched to their actual length. The wet, unwound fabric was stretched with 99.2% to 99.5% of its pile stretched to obtain a second stretched fabric.

[0137] (g) The second stretched dough was passed over multiple rollers at a speed of 13 m / min, and the second stretched dough was maintained in a stretched state to obtain a third stretched dough.

[0138] (h) Next, keep the third stretched dough relaxed for 9 minutes, BIANCLANI AIRO 24 TM The dough was dried in a dryer, alternating between periods of tension and relaxation, under continuous stirring conditions at 155°C, until the entire dough had passed through the dryer and was dry. The dryer was designed so that the dough would pass through a narrow, tunnel-shaped structure equipped with stainless steel grills at approximately 45 m / s for about 2.5 seconds, maintaining tension throughout. Immediately afterward, the dough was loosened and pushed away by an airflow passing in the opposite direction through the narrow tunnel-shaped structure at a speed of approximately 35 m / s. The alternating brushing action against the metal grill during this "back-and-forth" motion instantaneously loosened the base fabric structure, releasing any remaining trapped large pile loops. The final pile fabric was obtained by maintaining the dryer temperature at 155°C and alternating evaporation rates of 700 kg / h to 1100 kg / h. Next, the final pile fabric was passed through a stent to spread it out and correct any distortion in the width direction.

[0139] Example 2: Preparation process for pile fabric The preparation process for pile fabric consists of weaving and processing, and similar processes. This process is disclosed below:

[0140] Preparation of sized yarn: The pile warp and base fabric warp were twisted on a sizing beam by chemically sizing the beam. This sizing was carried out by applying a sizing paste to the warp, resulting in increased tensile strength during knitting. Furthermore, sizing allows the protruding fibers to be enclosed within the yarn, reducing the risk of entanglement with adjacent ends and breakage during weaving. Sizing also improved the abrasion resistance of the yarn.

[0141] The size and weight in pounds (A) were calculated as follows: JPEG2026073910000001.jpg17115 How to calculate the size percentage in warp (B): JPEG2026073910000002.jpg15115

[0142] Drying of sized yarn: The sized yarn was passed over a drying cylinder for drying and fixing of the size. The drying tumbler had a diameter of approximately 80 ± 10 cm and a width of 200 ± 40 cm. The warp speed on the slasher was approximately 115 ± 25 m / min, and the creep speed was 1.9 ± 0.1 m / min. The winding tension was 1050 ± 150 kg, and the roller compression pressure was 875 ± 75 kg. The drying temperature was maintained at 90 ± 5 °C, and the water evaporation rate was approximately 475 kg / hour. After drying, the sized yarn was wound onto the loom beam.

[0143] Preparing the yarn for the weft feeder: The sizing warp beams of the base fabric were mounted on the terry loom alongside the pile beams. As the weft yarn was loaded into the weft feeder, cotton yarns ranging from 6' to 30' and PVA yarns ranging from 30' to 80' were wound into cones.

[0144] Fabric Weaving: The weaving of the terry cloth was carried out using either a lapia or air-jet loom, which was operated according to a specified program. To understand when the weaving pattern had changed, it was essential to visualize the weaving patterns prevalent for standard terry cloth. The terry cloth consisted of two sides representing the top and bottom directions. The terry cloth matrix was woven by drawing in three threads: a large number of warp threads that create the length of the fabric were released at a constant rate from the warp beams, a large number of pile threads that create the length of the fabric were released from the pile beams faster, and a large number of weft threads that cross the fabric. The loom wove the three threads into a compact fabric according to the following three steps: In shedding, the warp threads of the base fabric and the warp threads of the pile were separated separately on the loom. In the picking process, the weft threads are woven in across the entire width of the fabric, and furthermore, In the beating process, the newly woven weft threads were pushed back against the fabric and compressed.

[0145] Because the pile warp threads are released at a higher speed than the base fabric warp threads, and the pile warp threads are longer, they form terry loops together with the weft threads, which "lock" them in place. This process was continued until the entire length of the fabric was woven.

[0146] In this example, we selected a 3-pick terry with terry loops on both sides. 3-pick terry means that the pile threads cross under / over the weft thread indicated by "a," move over the two weft threads, and change direction at the "a+3"th weft thread. The meaning of "on both sides" is based on the fact that the fabric is composed of two pile threads, and each thread runs on one side of the fabric.

[0147] Polyvinyl alcohol yarn, a synthetic polymer with a molecular weight of approximately 100,000 Daltons, was preferred as the soluble yarn. Hot water was chosen as the solvent because PVA is highly soluble in hot water. However, it would have been possible to use other yarns that are soluble in different solvents. Furthermore, the two types of soluble yarns were both soluble in different solvents and could have been used in the production of this fabric. In the example described herein, Y = PVA yarn and S = water.

[0148] To weave the fabric, numerous base fabric warp threads, spun from pure cotton, recycled cotton, bast fibers such as flax, bamboo, or hemp, or combinations of these fibers with a count of 8' to 30', were released from the base fabric warp beam at a constant speed. Numerous pile warp threads, spun from pure cotton, recycled cotton, bast fibers such as flax, bamboo, or hemp, or combinations of these fibers with a count of 8' to 30', were released from the pile beam at a pile ratio range of 10:42 to 10:80. The base fabric warp and pile warp threads were shedged, during which they were pulled separately on the loom, and then picking was performed to weave the weft threads throughout the entire width of the fabric.

[0149] Two types of weft yarns were loaded onto the weft feeder reel. The insoluble weft yarn consisted of yarn made from pure cotton, recycled cotton, bast fibers such as flax, bamboo, or hemp, or combinations of these fibers with British counts ranging from 6' to 30'. The soluble weft yarn consisted of PVA yarn with a count ranging from 30' to 80'. The loom was programmed to release the soluble weft yarn after a constant amount of the insoluble weft yarn had been released. In this example, using a 3-pick terry, the soluble yarn was released in multiples of 6. That is, for two sets of three, n-1 picks and 5 weft yarns were replaced with soluble yarn after n-1 picks and 5 weft yarns.

[0150] Once the weft threads are twisted, the loom performs a beating process, pressing the newly woven rows against the fabric and compressing them. The pile weight was determined by the post-beating length setting for the loosened pile on the terry loom. The pile height of the fabric during weaving was at least 1 mm, and it was woven to a maximum height comparable to the technical capabilities of the terry loom.

[0151] Other details for weaving the extra-long pile loops are as follows: number of terminals / cm = 20-28, number of weft threads / cm = 12-24, pile ratio = 10:42-10:80. The pile height was fixed at 3 mm to 7 mm during weaving, and after the removal of soluble yarns, the pile height increased in the range of 6 to 14 mm. In this example, the selected number of picks / cm was 17 to 19 picks / cm.

[0152] As the fabric was woven using soluble yarn as the weft at specific predetermined positions, the pile was released and subjected to a desizing process, where the soluble yarn and sizing material were dissolved. The fabric was added to water at an MLR (material-to-liquid ratio) of 1:5 to 1:7 and heated at 95°C to 100°C for 30 minutes. The soluble yarn Y was dissolved during this step, resulting in the release of the bonds between two consecutive piles. Next, if every sixth weft yarn, designated (n-1), was soluble, the pile formed between the first triple yarn (n-1) and the second triple yarn (n-1) was free. Similarly, the pile formed between the second (n-1) and the third (n-1) was also released. Thus, these two bonded pile yarns formed one large continuous loop, which extended from the (n-1)th weft yarn of the first triple yarn to the (n-1)th weft yarn of the third triple yarn.

[0153] A cross-section of the pile revealed that the soluble yarn Y was alternately decomposed at the (n-1)th position. As a result, two pile series held by the soluble yarn merged into a single pile, and the height of this resulting pile is represented by Z × H. The height of this single, long pile was Z times the height of the original woven fabric. This created large air pockets within the loops and between the two loops.

[0154] The first boiled cleaning solution was discarded.

[0155] Because a percentage of the loops were partially released or still trapped, the fabric was treated with a second pile untwisting process, for which the fabric was added to water at a material-to-liquid ratio (MLR) of 1:5 to 1:7 and heated at 95°C to 100°C for 30 minutes. The main challenge in the manufacturing technology of extra-long pile fabrics was that some of the long loops became entangled during processing. A further challenge was that approximately 5% to 10% of the loops remained entangled within the warp threads of the base fabric.

[0156] The washed pile was discarded.

[0157] The pile, consisting mostly of loosened piles, was bleached for 60 minutes at 93°C to 97°C with 10 g / L to 15 g / L concentrations of water peroxide and 2 to 3 g / L of NaOH (sodium hydroxide) solution at an MLR ratio of 1:5 to 1:7.

[0158] The washed and bleached fabric was rinsed in 80°C water for 10 minutes. The rinsed fabric was then neutralized by adding an organic acid.

[0159] The neutralized fabric was dyed with standard reactive or natural dyes along with varying amounts of sodium carbonate or sodium sulfate depending on the desired degree of shading of the fabric.

[0160] The dyed fabric was washed with soap and then finished to obtain pile fabric. Generally, the shrinkage rate after the wetting process for ordinary fabrics was 5% to 10% of the dimensions, resulting in a similar 5% to 10% increase in picks / cm. However, this effect was partially compensated for by the loss of several weft threads, resulting in a 4% to 8% decrease in picks / cm. The picks / cm of the wet-treated fabric were calculated to be 15 to 17 picks / cm, which was approximately 8% to 8.5% less than that of the woven fabric. The pile fabric obtained in this step can also be used as the pile fabric in Example 1.

[0161] Example 3 (Comparative Example): Conventional pile fabric finishing process The pile fabric, containing up to 300% moisture after boiling, was removed from the soft-flow fabric dyeing machine and placed in a dehydrator (centrifuge) where the residual moisture was reduced to 60% to 80% to obtain standard terry fabric.

[0162] At this stage, the pile fabric was put through a rope untwisting machine and then dried in a tumbler. This fabric was then fed into the machine from one end via rollers, while maintaining its relaxed state. Drying was started at a temperature of 100°C to 160°C, and the dried fabric was dropped onto a trolley via rollers, while still maintaining its relaxed state. Length correction was performed by passing the fabric through a stent at high temperature. However, the drying technique did not help to release the extra-long pile loops (5% to 10% of the total pile) that were still entangled in the warp structure of the base fabric. Although the dimensions were corrected by passing it through the stent, this process could not pull out the trapped / entrapped pile loops.

[0163] Characteristics of towel fabric with extra-long pile loops: The final moisture content of the fabric finished using the process in Example 1 was 3% to 7% by weight, and a total of 99.9% of the pile was released.

[0164] Table 1 shows the average changes in dimensions and pick count / cm of finished pile fabrics with extra-long pile loops dried according to the present invention, which may be called towel fabrics, compared to towels of similar GSM (grams per square meter) with extra-long pile loops dried by conventional methods and standard towels / standard pile fabrics of similar GSM dried by conventional methods. TIFF2026073910000003.tif125166

[0165] As is clear from the table, both the pile fabric with the ultra-long pile loops of the present invention and the standard towel treated in the wetting process showed a length reduction of approximately 8% to 10%. This reduction is a common phenomenon in the wetting process of fibers, due to the change in fiber properties upon contact with water. The reduction in towel length resulted in an increase in pick count / cm. However, for towels finished according to the present invention, approximately 393 weft threads were lost as a result of removing every 6th weft thread during the wetting process, ultimately reducing the total pick count to 1965. That is, the pick count / cm decreased by 8.3% to 16.5. In contrast, for the standard towel fabric, the pick count / cm increased by 10.1% to 19.8% because the length decreased while the pick count remained unchanged. Furthermore, visual inspection revealed that in towels with extra-long pile loops dried using standard methods, 5% to 10% of the loops were deformed or trapped within the fabric's base structure, with only 92.5 ± 2.5% of the loops being fully stretched.

[0166] Towels with extra-long pile loops dried using the standard method in a tumbler or stent returned to a length of 129 cm (an 8.4% increase), and the number of picks / cm decreased to 15.2, but no improvement was observed in the fragments of fully stretched loops. From this, it was demonstrated that towels dried using the standard method still retained 5% to 10% of the deformed and trapped loops, resulting in an uneven appearance. Further tumble drying and loosening were necessary, resulting in a loop stretching degree of 96 ± 1.5% of the total loops.

[0167] The towels subjected to the finishing process of the present invention, i.e., wet-stretch-dry, yielded different results. As visualized in the table, wetting and stretching the towels with a water wringer restored their length to 131 cm, while simultaneously reducing the number of picks to 15 (a 9.2% decrease from the previous step). Thus, the wet-stretch step offsets the reduction caused by wetting. The low number of picks / cm indicates that the space between picks was stretched considerably to its upper limit, thereby creating space for entangled and contained loops to form. It is noteworthy that the percentage of fully stretched loops visible on the surface of the towel increased from 95% to 99.5%. This increase was only possible under the conditions described above. In the drying step, a "back-and-forth" motion of the fabric within the contained space was induced, further releasing 0.4% of the pile, and stretching 99.9% of the pile loops to their maximum height. This step eliminates the need for re-drying.

[0168] The standard towel used for comparison, after being dried in a tumble dryer and then dimensionally corrected in a stent, increased in length by 7.6% and decreased in picks per cm by 7% compared to the previous stage.

[0169] In summary, both the towel with extra-long pile loops and the standard towel used as a comparative example showed a similar 2% to 3% increase in length in the final product. However, the towel finished according to the present invention had a 16.7% reduction in the number of weft picks, resulting in a 14.7% reduction in the final pick count / cm, so that 99.9% of the loops were extended to the full height.

[0170] Performance verification test of the finished fabric of the present invention Towels finished according to the present invention were tested using various standard tests, and the data were compared with two control towels of the same dimensions and GSM: control sample 1 was a towel with extra-long pile loops dried using the standard tumbler / stenter method, and control sample 2 was a standard towel dried using the standard tumbler / stenter method. The pile structure was recorded using a USB microscope. Bulkiness was confirmed using the ASTM D 1777 method. The water absorption rate of the towels was confirmed using the AATCC-79 drop sink method and the ASTM D-7242 method, while the vertical wicking characteristics of the towels in both the warp and weft directions were measured using AATCC 197. Drying time was tested using internal standard procedures. The dimensional stability of the towels against washing and measurement of lint generated during washing was measured using AATCC 135 / 150-2018.

[0171] Performance test results Figure 1(ab) is a 20x microscope image showing an ultra-long pile loop with air pockets. Figure 1(a) shows an air pocket within a single loop, i.e., an intraloop air pocket. Figure 1(b) is an illustration of an air pocket between two loops, i.e., an interloop air pocket. These air pockets were generated by the decomposition of soluble yarns in a pile fabric having ultra-long pile loops prepared according to the present invention.

[0172] Figure 2 shows comparative images of a final pile fabric with extra-long pile loops finished according to the present invention and a towel with extra-long pile loops finished using a standard drying process. Here, Figure 2(a) shows that the towel finished according to the present invention (right image) has a greater bulk than the towel finished / dried using the standard method (left image). Figure 2(b) shows that the towel finished according to the present invention (right image) has a more beautiful and uniform appearance than the towel finished using the standard method (left image). Figure 2(c) is an illustration of the finished appearance of the towel finished according to the present invention when comparing the weft side (width) with a towel finished using the standard method (right image). Figure 2(d) shows the final appearance of the towel finished according to the present invention (right image), comparing the warp side (towel length) with a towel finished using the conventional method (left image). Figure 2(e) is a magnified view of the loop structure of a towel finished using the standard method, where the central pile loop remains unreleased, and Figure 2(f) is a magnified view of the loop structure of a towel finished according to the present invention, where no trapped loops are observed. The images were taken at 20x magnification using a USB fiber microscope.

[0173] Figure 3 shows comparative images of extra-long pile fabrics taken at 20x magnification using a USB fiber microscope, where Figure 3(a) shows the extra-long pile loops and internal / inter-loop air pockets (double arrows) of a towel finished according to the present invention, and Figure 3(b) illustrates a control fabric manufactured without soluble loops.

[0174] The observations from Figures 2 and 3 are listed below: 1. The pile loops on the surface of the terry towel were prime number multiples of the pile loops in the control towel, thus resulting in "extra-long" pile loops. The pile fabric finished according to the present invention was fully stretched to the surface, providing a uniform surface undulation. 2. These extra-long pile loops had gaps within them, creating air pockets. These gaps were a direct result of the weaving process, as well as a consequence of two or more loops connecting to the area beneath the long pile that created the air pockets within the loops. 3. Gaps also formed between these pile loops, with extra-long loops creating large gaps between two piles. The surface of homogeneous pile loops created gaps between loops in repeating sequences.

[0175] The combination of these three characteristics resulted in two phenomena: the towel's bulk was greater than that of a standard pile loop towel, and the surface area of ​​the pile loop was significantly increased. This increased surface area allowed for a much larger volume of moisture exchange with the surrounding medium, leading to the following phenomena: 1. Due to faster water absorption, the wicking properties of towels with extra-long pile loops finished according to the present invention are increased compared to standard towels / standard pile fabrics. 2. Compared to standard towels / standard terry cloth, it retains more moisture after absorbing water. 3. Compared to standard towels / standard terry cloth, the drying rate was increased.

[0176] The above phenomenon can be seen more clearly in Table 2.

[0177] Table 2. Absorbency characteristics of a standard towel / standard pile fabric compared to a towel with extra-long pile loops finished according to the present invention and a towel with extra-long pile loops finished by the standard method. TIFF2026073910000004.tif122166

[0178] Comparative test of towels finished according to the present invention and towels finished by the standard method (control sample 1) As shown in Table 2, this towel had a loft increase of only 5.5% compared to a towel finished using the standard method. This phenomenon was due to a uniform pile density in which 99.9% of the pile was exposed to its limit length. On the other hand, when control sample 1 was dried using the standard method, 5% to 10% of the loops remained unreleased, resulting in an uneven appearance and reduced loft. However, it should be noted that this increase was not statistically significant based on the number of samples tested.

[0179] The effect of increasing uniform pile density is increased water absorption. As shown in Table 2, towels finished according to the present invention exhibited 16.7 ± 2.9% higher water absorption compared to towels with extra-long pile loops finished by the standard method. Similar results were obtained from drip absorption capacity and sink tests. Furthermore, wicking is unrelated to terry pile, and therefore the wicking rate of the towels of the present invention was not improved. However, the total water absorption capacity of the towels finished according to the present invention increased significantly by 7.8 ± 0.7%. This was a direct consequence of 99.9% fully expanded pile compared to 92% to 95% fully expanded pile loops in control sample 1. The drying time of the towels finished according to the present invention was slightly shorter than that of control sample 1.

[0180] Comparative test of towels finished according to the present invention and standard towels / standard pile fabrics (control sample 2) finished by the standard method. The towel of the present invention exhibited a loft 61.8 ± 1.5% higher than a control towel (control sample 2) with a similar GSM. This fabric exhibited 71.8 ± 6.1% higher water absorption, a rapid drip absorption capacity exceeding 67%, a water absorption rate exceeding 75%, and a water absorption capacity 60.1 ± 18.2% higher. These increases in parameters were due to the phenomena described in the preceding paragraphs. As before, the wicking value did not increase significantly because wicking is not related to the pile loops. Nevertheless, the towel of the present invention dries 31.6 ± 6.2% faster than a standard towel / standard pile fabric dried by the standard method.

[0181] Table 3 shows the dimensional stability of the ultra-long pile loop of the present invention. Table 3: Dimensional stability of the ultra-long pile loop of the present invention during washing As shown in Table 3 of TIFF2026073910000005.tif41166, the changes in width and length after three washes in a residential washing machine were approximately 2.5 ± 0.03% and 4.2 ± 0.22%, respectively, which were within the acceptable limits. The lint generation rate after three washes in a residential washing machine was 0.34 ± 0.02%, which was also within the acceptable limits.

[0182] Color fastness Colorfastness is defined as the fabric's resistance to changes in color properties caused by chemicals or physical processes. Colorfastness to washing and polishing was confirmed by AATCC 61-2A and AATCC 8, respectively. In summary, towels were placed in close contact with chemicals or physical materials for a predetermined time, and then the discoloration before and after treatment was measured using a grayscale. This scale ranges from 1 to 5, with median values ​​of 1 to 2, 2 to 3, 3, 3 to 4, 4, 4 to 5, and 5, where 1 represents a very high difference (poor performance) and 5 represents no difference after treatment (optimal performance). Towels with a score of 3 or higher are generally desirable.

[0183] Table 4 shows the colorfastness of the ultra-long pile fabric of the present invention to washing and polishing. Table 4: Color fastness of the ultra-long pile loop of the present invention to washing and polishing. As shown in Table 4 of TIFF2026073910000006.tif50156, the ultra-long pile fabric of the present invention exhibited acceptable colorfastness in shades after all tests.

[0184] Technological advancements The present invention described above has several technical advantages, including but not limited to achieving the following: The finishing process for pile fabric having extra-long pile loops: • Simple and economical, • It can be run on available machinery and requires no new investment. • The finished fabric does not shrink. moreover The final pile fabric is It has extra-long pile loops that fully extend from the towel base fabric, resulting in a uniform and aesthetically pleasing appearance while also increasing the towel's bulk. • Due to the presence of a Terry Loop that generates an air pocket within the structure, solvent / gas exchange is accelerated. • Increased water absorption capacity allows for the production of towels with a larger water-holding capacity and faster drying properties.

[0185] The embodiments of the present invention will be described below by reference to examples that do not limit the details of various features and advantages. Descriptions of established existing components and processing techniques are omitted to avoid unnecessarily complicating the understanding of the embodiments of the present invention. The experiments used in the present invention are solely intended to facilitate understanding how to make the embodiments of the present invention practical and to enable those skilled in the art to carry out the embodiments of the present invention. Therefore, they should not be construed as limiting the scope of the embodiments of the present invention by example.

[0186] The descriptions of the above-mentioned specific embodiments sufficiently clarify the general nature of the embodiments of the present invention. Therefore, by applying the existing knowledge, the above-mentioned specific embodiments can be modified or adapted for different uses without deviating from the above-mentioned general concepts. Accordingly, the adaptation / modification should and is intended to be understood in the sense and scope of being equivalent to the embodiments of the present invention. The usage of phrases and terms used herein is for illustrative purposes only and not for limitation. Accordingly, the embodiments described herein are based on preferred embodiments, and it is recognized that the embodiments described herein can be practiced even if they are modified in the intent and scope of the embodiments described herein.

[0187] The use of the expressions "at least" or "at least one" implies the use of one or more elements, components, or quantities, as they may be used in the embodiments of the invention to obtain one or more target substances or results. Although several embodiments of the invention have been described, these embodiments are provided only as examples and are not intended to limit the scope of the invention. Formulations or modifications relating to the preparation of the invention may be immediately possible for a person skilled in the art upon consideration of the invention, as long as they remain within the scope of the invention. Such variations and modifications are within the intended scope of the invention.

[0188] Numerical values ​​representing different physical parameters, dimensions, or quantities are approximate, and values ​​higher than those substituted for these physical parameters, dimensions, or quantities are intended to fall within the scope of the present invention. However, this does not apply if the specification makes a statement to the contrary.

[0189] Any discussion of documents, acts, materials, devices, products or similar items included herein is provided solely for the purpose of creating the context for the disclosure of the present invention. Nothing or all of the above shall be construed as an endorsement that any or all of the above constitutes part of the basis of known inventive art or is common knowledge in the art relevant to the present invention that existed anywhere prior to the priority date of this application.

[0190] While certain features of the present invention have been considerably emphasized, different modifications are possible, and many additions can be made to the preferred embodiments without deviating from the principles of the invention. It will be obvious to those with expertise in the art that the features of the present invention or the preferred embodiments can be modified, and it is important to understand that the above description is merely for illustrative purposes and should not be interpreted as limiting.

Claims

1. The finishing process for pile fabric, consisting of extra-long pile loops to obtain the final pile fabric, consists of the following steps: a) Obtain a wet pile fabric having extra-long pile loops containing moisture in the range of 150% to 500% (w / w), b) Keep the wet pile fabric in a relaxed state for a predetermined time, and obtain a wet relaxed pile fabric that takes the form of a disordered fabric. c) The messy, wet, loose pile fabric is fed to the rope compression device by a first guide roller set at a first predetermined speed, passed through at least one pair of compression cylinders in the rope compression process, a first predetermined pressure is applied, and a compressed fabric containing 80% to 250% moisture is obtained. d) The compressed fabric is passed through a second set of guide rollers at a second predetermined speed, processed in the rope untwisting process, and the untwisted fabric is obtained. e) The open dough is stretched longitudinally on at least one set of sawtooth feed-in rollers, then fed to a third set of guide rollers at a third predetermined speed to obtain the first stretched dough, then the first stretched dough is fed onto a fourth set of guide rollers that rotate at a fourth constant speed, alternately, and fed to a first pad and the rotating water-squeezing cylinder of the first pad at a fifth predetermined speed, and a second predetermined pressure is applied to obtain a second stretched dough with a moisture content of 60% to 90%. f) Alternatively, the second stretched fabric may be fed to the fifth set of guide rollers at a sixth predetermined speed, and the third stretched fabric may be obtained while keeping the second stretched fabric in a stretched state. g) Alternatively, the third stretched dough is sent to a processing device at a seventh predetermined speed via a sixth set of guide rollers, the processing device being filled with at least one type of finishing liquid, and while processing the third stretched dough, it is kept stretched longitudinally for a second predetermined time to obtain a fourth stretched dough, the fourth stretched dough is passed through a second pad having a water-squeezing cylinder that rotates at an eighth predetermined speed and a ninth predetermined speed, and a third predetermined pressure is applied to obtain a fifth stretched dough with a moisture content of 60% to 90%, h) The second stretched fabric or the fifth stretched fabric is held in a relaxed state for a third predetermined time to obtain a relaxed fabric, and then the relaxed fabric is passed through a high-speed air dryer at a predetermined temperature, and the fabric is moved "back and forth" to alternately create tension and relaxation in the fabric to obtain a final pile fabric.

2. A process according to claim 1, wherein the wet pile fabric is prepared by the following substeps: i. Provide multiple base fabric warp threads, multiple pile warp threads, and multiple weft threads, ii. The weft threads and the warp threads of the base fabric are woven together under high tension to form the base fabric of the fabric, and in this process, at least one of the weft threads is a soluble weft thread. iii. The aforementioned pile warp threads are knitted together with the aforementioned weft threads at low tension, resulting in a weight range of 300 g / m 2 From 700 g / m 2 The method involves obtaining a pile fabric having a plurality of pile loops on at least one surface of the pile fabric, iv. Water is added to the pile fabric having multiple pile loops so that the material-to-liquid ratio is 1:5 to 1:7, and the fabric is heated at 90°C to 100°C for 25 to 35 minutes to bond the multiple pile loops and obtain a pile fabric having extra-long pile loops, and further, v. The pile fabric having the extra-long pile loops was successively washed, dyed, washed with soap, and cleaned to obtain a wet pile fabric.

3. A process according to claim 1, wherein step (d) is a rope untwisting step, which passes the compressed fabric through an untwisting machine at a speed of 10 m / min to 14 m / min to obtain untwisted fabric.

4. A process according to claim 1, wherein in step (b), the first predetermined time is in the range of 20 to 30 minutes.

5. A process as claimed in claim 1, wherein in step (c), The first predetermined speed of the first set of guide rollers is between 14 m / min and 18 m / min. The first predetermined pressure applied by the compression cylinder is between 2 bar and 4 bar.

6. A process according to claim 1, wherein in step (d), the second predetermined speed of the set of guide rollers is in the range of 10 m / min to 15 m / min.

7. A process as claimed in claim 1, wherein in step (e), The third predetermined speed of the third set of guide rollers and the fourth predetermined speed of the fourth set of guide rollers are independently between 11 m / min and 15 m / min. - The fifth predetermined speed of the first pad is between 2 rounds / minute and 8 rounds / minute. The second predetermined pressure applied by the first padder is between 2 bar and 8 bar.

8. A process according to claim 1, wherein in step (f), the sixth predetermined speed of the fifth set of guide rollers is in the range of 12 m / min to 16 m / min.

9. A process as claimed in claim 1, wherein in step (g), - The seventh predetermined speed of the sixth set of guide rollers and the eighth predetermined speed for feeding the fourth stretched fabric are independently between 12 m / min and 16 m / min. The aforementioned second predetermined time is between 10 and 16 seconds. The aforementioned ninth predetermined speed of the second pad is 3 rounds / minute to 8 rounds / minute. The aforementioned third predetermined pressure is between 2 bar and 8 bar.

10. A process as claimed in claim 1, wherein in step (h), The aforementioned third predetermined time is between 6 and 12 minutes. The aforementioned predetermined temperature is between 150°C and 165°C. The previously mentioned "outbound" travel speed is in the range of 40 m / s to 50 m / s over 2 to 3 seconds, and the previously mentioned "return" travel speed is in the range of 30 m / s to 40 m / s over 2 to 3 seconds.

11. A process according to claim 1, wherein the stretched fabric or the fifth stretched fabric is stretched to its full height by 95% to 99.5% of its extra-long pile loops.

12. A process according to claim 1, wherein in step (h), the final pile fabric is stretched to its full height by 99.5% to 100% of the extra-long pile loops.

13. The final pile fabric obtained by the process claimed in claim 1 is characterized by at least one of the following: - 55% to 65% increase in bulk - 65% to 75% increase in water absorption The percentage reduction in drop-by-drop absorption capacity is 62% to 72%. - Absorption capacity increase rate from 24% to 62% - 25% to 40% reduction in drying time

14. The final pile fabric claimed in claim 13 consists of warp threads in the range of 20 end-to-cm to 28 end-to-cm and weft threads in the range of 12 threads / cm to 30 threads / cm, with a pile ratio of 1:4 to 1:

8.

15. The final pile fabric claimed in claim 13 has 99.5% to 99.9% extra-long pile loops extended to its total height.

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