Method for producing a quick-drying towel with an extremely long pile height

Abstract

To provide a method for producing a fast-drying towel having an ultra-long pile height.SOLUTION: A method for producing a fast-drying towel having an ultra-long pile height comprises the steps of: setting a reed in a loosening position with respect to a plurality of successive picks; setting a reed in a fast position with respect to an n-th pick, where n may be a number in the range of 4 to 7; inserting first picks of (n-4)-th successive picks into warp by a loose picking technique according to a predetermined design; creating a predetermined gap proximate to any point so that a fabric piece can be discharged from the end of the fabric; and sequentially inserting (n-3)-th, (n-2)-th, and (n-1)-th picks into warp following the insertion of the first picks by using the loose picking technique on each of the picks. Then, the method comprises the steps of: inserting the n-th pick into the warp by a tight picking technique so that all picks are aligned at the end of the fabric; and facilitating the formation of a void within a loop of the fabric by using a plain weaving for the ground warp.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to the textile industry. More specifically, the present disclosure relates to methods of weaving, treating, and finishing a fabric having super-long pile loops and quick-drying properties.

Background Art

[0002] Terry cloth is quite commonly used in several products such as, for example, towels, robes, etc. Terry cloth typically includes pile loops within the fabric that provide texture, absorbency, softness, and other desirable properties to the fabric. The pile loops are woven with "ground" yarns that act as a base for the entire fabric. The loops can be incorporated on one or both sides of the fabric. Also, the loops are of different heights and can provide a desired appearance or texture, and different colors, or types or sizes of yarns can also be utilized to affect the look and properties of the fabric.

[0003] Terry towels generally use a twist variation of the towel structure yarns. The ground yarns and the weft yarns are generally composed of high-twist yarns with a value of about 3.8 to 4.2 TM, providing strength to the towel and acting as a slow moisture absorption network. On the other hand, in many cases, the pile yarns are given a low twist, thereby making it possible to result in a greater exposure, and as a result, a high moisture exchange rate becomes possible.

[0004] Terry cloth is typically woven by utilizing two different types of warp threads that intermingle with the weft (also known as "picks"). The "ground warp" threads are woven with the weft at a relatively high tension to form the base or substrate of the cloth. The "pile" warp threads are woven at a considerably lower tension and advance, or are "released," from the loom beam at a higher speed than the ground warp threads, allowing them to "float" over two or more adjacent picks. At the end of the repeating weaving process when all the threads are "beaten in" (i.e., pushed together with a bar or the like), the pile threads form loops that extend away from the substrate. Common terry patterns include 3, 4, 5, 6, and 7 pick weaving processes. Often, higher pick patterns are avoided due to cost, and thus, most terry cloth is woven in a 3 pick repeating pattern.

[0005] This type of terry cloth pattern has been used for many years, but it may have some drawbacks. For example, the finished towel may exhibit twisting in the loop structure. This results in a reduction in softness and thickness. Additionally, the twisting may not be uniform across the entire pile area, which subsequently leads to an uneven pile height and ultimately impairs the aesthetic sense of the towel. At the same time, the reduction in pile height causes a reduction in thickness.

[0006] The main problem with most thick terry towels is their drying time. The increasing consumer demand for terry towels that not only absorb large amounts of water but also dry quickly has strongly compelled fiber companies to explore new ideas regarding quick drying. Recently, multiple trials have been conducted to create towels with short drying times while retaining all other desirable features of terry towels, including high absorbency, thickness, and aesthetic sense. However, all of these criteria are generally mutually exclusive, meaning that an increase in one parameter has an adverse effect on the other parameter.

[0007] In U.S. Patent No. 10,287,714, the concept of a high-absorbency towel is described, which enables the towel to dry quickly by using a water-soluble thread in the weaving process while maintaining the thickness and aesthetic sense of the towel. In the process, a water-soluble thread such as PVA is inserted into the core of the cotton sheath during drafting. As a result, during processing, the PVA dissolves, leaving behind cotton threads with a hollow core that allows for greater absorbency and a faster drying rate.

[0008] In U.S. Patent Application Publication No. 2016 / 0097151, it is described that coating the towel surface with a surfactant filled in the towel surface can lower the surface tension of water when it comes into contact with the towel surface, enabling the water to spread evenly. The surfactant contains molecules such as poly(N-isopropylacrylamide) and (2-methoxymethylethoxy)propanol. According to the claims of that patent document, the molecules do not affect the towel at room temperature, and after washing with warm water, the molecules behave hydrophobically, assisting in the rapid dissipation of moisture. As a result, the towel absorbs moisture with quick-drying properties. However, the biocompatibility or stability of these molecules for home laundering is not described.

[0009] Therefore, there is a need for a terry towel that dries faster than commercially available towels while maintaining high absorbency and a uniform and beautiful appearance.

Prior Art Documents

Patent Documents

[0010]

Patent Document 1

Patent Document 2

Non-Patent Documents

[0011]

Non-Patent Document 1

Non-Patent Document 2

[0012] In one aspect of the present disclosure, a method for processing an extra - long pile fabric is provided.

[0013] The method for processing a pile fabric includes using yarns having the same count or alternating counts as the weft that varies from 6 Ne to 40 Ne. The method further includes setting a lead at a slack position for a selected number of consecutive picks up to the (n - 1)th pick, called a loose pick, and setting a lead at a high - speed position for the nth pick, called a high - speed pick (where n can be a number that varies from 4 to 7). Further, by a loose driving technique, according to a predetermined design, inserting the first pick of the low consecutive picks into the warp, and further creating a predetermined gap close to a point where the fabric is released from the edge of the fabric. Also, for each of the picks, using the loose driving technique to continuously insert a selected number of slow consecutive picks following the insertion of the first pick until the (n - 1)th pick enters the warp. The method further includes inserting the nth pick into the warp by a strong driving technique so that all n picks are aligned at the edge of the fabric, and using plain weaving for the ground warp to facilitate the formation of voids within the loops of the fabric.

[0014] In some aspects of the present disclosure, the use of yarns having alternating coarse and fine properties enables the formation of pile loops having an ultra - high length of 7 - 11 mm.

[0015] In some aspects of the present disclosure, the method improves the drying efficiency of the towel by using a high - quality weaving system to facilitate the formation of gaps within the loops and between the loops.

[0016] In some aspects of the present disclosure, the increased absorbency and drying rate of the towel result from elongated low-twist (2.3 - 2.5 TM) terry loops or loosened terry loops formed by a high-quality weaving system.

[0017] In some aspects of the present disclosure, the uniform appearance and aesthetic look of the towel are achieved by the uniform arrangement of pile orientation within the weave structure.

[0018] In some aspects of the present disclosure, air pockets are created by the presence of ultra-long piles.

[0019] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate specific aspects of the subject matter disclosed herein and, together with the description, serve to explain some of the principles associated with the disclosed embodiments.

Brief Description of the Drawings

[0020]

Figure 1

Figure 2A

Figure 2B

Figure 3A

Figure 3B

Figure 3C

Figure 3D

Modes for Carrying Out the Invention

[0021] Various embodiments of the present disclosure are described in detail below. It should be understood that specific embodiments are described for illustrative purposes only. Those skilled in the art will recognize that other components and configurations may be used without departing from the spirit and scope of the present disclosure. As a result, the following description and drawings should be construed as illustrative and not limiting. Some specific details are described to provide a complete understanding of the present disclosure. However, in certain instances, well-known details are not described so as not to obscure the description.

[0022] Reference to an embodiment or one embodiment of the present disclosure can refer to the same embodiment or any of the embodiments. Such reference means at least one of a plurality of embodiments.

[0023] References to "one embodiment", "an embodiment", "one aspect", "some aspects", "an aspect" mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. The appearance of the phrase "in one embodiment" in various places throughout this specification does not necessarily refer to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Furthermore, various features are described, which may be shown by some embodiments and not by others.

[0024] The terms used herein generally have their ordinary meaning in the context of the art within the context of the present disclosure, and each term is used in a particular context. Alternative languages and synonyms may be used for any one or more of the terms described herein, and no special significance should be attributed to whether or not a term is elaborated or described herein. In some cases, synonyms for particular terms are provided.

[0025] The detailed description of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification, including examples of any terms described herein, is for illustrative purposes only and is not intended to further limit the scope and meaning of the present disclosure or any of the exemplary terms. Similarly, the present disclosure is not limited to the various embodiments given herein. Without intending to limit the scope of the present disclosure, examples of apparatuses, devices, methods, and their related results according to embodiments of the present disclosure are given below. Note that titles or subtitles may be used as examples for the convenience of the reader and are never intended to limit the scope of the present disclosure. Unless otherwise defined, all technical and scientific terms used herein have the meaning as commonly understood by one of ordinary skill in the art to which the present disclosure pertains. In case of conflict, the document of the present invention including the definitions shall prevail.

[0026] Additional features and advantages of the present disclosure will be described in the following description, and will be, in part, apparent from the description, or can be learned by practice of the principles disclosed herein. The features and advantages of the present disclosure can be realized and obtained by using the apparatuses and combinations particularly pointed out in the appended claims. These and other features of the present disclosure will become more fully apparent from the following description and appended claims, or can be learned by practice of the principles described herein.

[0027] According to the prior art, thick towels provide a large surface area and are able to absorb a large amount of water compared to plain-woven fabrics. When water droplets fall onto the terry loops, the water droplets are absorbed by the fibers present in the terry loops and subsequently the water is transferred to the warp and weft threads. Since there is no tension in the loops, they have an exposed surface and can absorb a large amount of water. However, due to its structure, terry towels take longer to dry compared to plain-woven fabrics.

[0028] Generally, most of the terry towels are made according to the 3-pick format with a higher peak weave and are rarely used due to their high production costs. Although standardized, the 3-pick format results in a higher loop density compared to the higher peak weave, which hinders the evaporation of water from the ground yarn and the weft yarn, leading to the towel remaining wet for a long time. A wet towel can become a breeding ground for unwanted microorganisms and may produce odors. The first technical problem that is desired to be noted in this patent is to use a high-quality weaving system to enable the formation of gaps within the loops and between the loops so that the towel can be woven and dried quickly.

[0029] In some fabrics, the loop geometry or loop profile of the finished towel remains unchanged after finishing, while in some fabrics, the loops are twisted and lose their original shape after finishing. The shape loss is essentially non-uniform, and due to the shape loss, variable-shaped loops are generated on the surface, reducing the aesthetic value of the towel.

[0030] In summary, there is a need for a method / process to produce towels with the characteristics of rapid drying, high absorbency, and an aesthetically pleasing uniform appearance of the terry loops. The present disclosure provides a way to address these problems by providing a higher-quality weaving method with either fine or thick yarns in the range of 6’s to 40’s, resulting in a product with an elegant appearance, higher absorbency, and ultra-high loops and air pockets between two loops that also provide rapid drying.

[0031] FIG. 1 shows a method for processing a pile fabric according to an aspect of the present disclosure. The method includes the following (102)-(114).

[0032] Set the reed to the slack position for a series of (n - 1) consecutive picks (102). Thereby, the reed is positioned in the slack configuration to start the weaving process. This reed is an essential component of the weaving machine and serves to separate the warp threads and maintain the desired space between them. During the initial stage, the reed processes a series of consecutive picks that are slackened and intentionally positioned.

[0033] Furthermore, set the reed to the fast position for the nth pick (104). Thereby, following the slack positions of the reeds for the previous picks (n - 1, n - 2, etc.), the position of the reed conveniently moves to the fast position. This transition to the fast reed position indicates the start of a new pick designated as the fast pick.

[0034] Furthermore, insert a determined number of the first picks of the consecutive picks into the warp threads according to a predefined design by a loose driving technique (106). Thereby, the method includes inserting the first picks from a series of consecutive picks into the warp threads. This insertion is carried out strictly in accordance with a predefined design that defines the arrangement and rows of the threads. During this insertion, a specific technique known as the "loose driving technique" is utilized. The loose driving technique involves gradually packing the inserted picks without applying excessive force, resulting in the appearance of texture processing.

[0035] Furthermore, create a predefined gap close to a certain point (108) and the fabric is released from the edge of the fabric. Thereby, a predefined gap is provided close to the point where the fabric is released from the edge of the fabric to enable subsequent adjustment and operation of the fabric structure. This gap serves as an important space that contributes to the improvement of the fabric characteristics during subsequent processing stages.

[0036] Furthermore, for each pick, a loose driving technique is utilized. Following the insertion of the first pick, slow consecutive picks are continuously inserted (110) until the (n - 1)-th pick enters the warp threads, such that after the insertion of the first pick, the method involves continuously introducing the next series of loose picks into the warp threads. Similar to the initial pick, each of these picks undergoes the loose driving technique. The application of this technique ensures the uniformity of the overall texture of the fabric and results in a uniform appearance.

[0037] Furthermore, the n-th pick is inserted into the warp threads (112) by a powerful driving technique, and all picks are aligned at the edge of the fabric. Thus, the n-th pick is introduced into the warp threads using an individual approach known as the "powerful driving technique". In contrast to the aforementioned loose driving technique, the powerful driving technique involves firmly packing the inserted picks. This powerful driving action causes all picks to be in a state of alignment at the edge of the fabric, contributing to a well-integrated fabric structure.

[0038] Plain weaving is utilized for the ground warp threads to facilitate the formation of voids within the loops of the fabric (114). Thus, the plain weaving pattern of the ground warp threads is utilized. This plain weaving configuration plays a crucial role in creating voids within the loops of the fabric. These voids improve the breathability, comfort, and ability of the fabric to efficiently release moisture.

[0039] Figure 2A shows the loop structure of a conventional terry cross-section, while on the other hand, Figure 2B shows the loop structure of a terry cross-section with increasing picks according to the present disclosure.

[0040] In some aspects of the present disclosure, the method of generating a terry towel overcomes the drawbacks initially mentioned in the following manner.

[0041] Creation of air pockets between loops: Figures 3A, 3B, and 3C show the loosened long loop structure of the towel filed in the present disclosure. It should be noted that the average pile height is about 11.5 ± 0.25 mm, the distance between loops is 1.25 ± 0.25 mm, while the in-loop gap (ground surface) is 1.6 ± 0.12 mm. Further, it is noted that the distances between loops and within loops are significantly larger than those of the control group towels. This size of the distance creates air pockets that allow the loops to be efficiently exposed, enabling fairly fast and effective moisture exchange. The loops with a large pile height generate two different types of air pockets. The in-loop air pocket ("A" type) occurs within the long loop structure, while the between-loop air pocket ("U" type) occurs between two adjacent loops.

[0042] Loosened loops: Since the loops are not twisted in large quantities (about 2.8 TM), the possibility of a decrease in pile height is fairly low. This ensures that the loops become straight so that they reach their maximum length, and as a result, the thickness of the towel is maintained. At the same time, the exposure of the loops to both water and air increases fairly significantly. As a result, the towel absorbs more water and releases water at an increased rate compared to a 3-pick terry towel.

[0043] Ultra-long pile height: The high-density weaving used during weaving makes it possible to confine a large proportion of the yarns as a uniform homogeneous layer of ultra-long loops. As a result, the towel exhibits a high moisture exchange ratio while looking elegant and aesthetically appealing.

[0044] In some aspects of the present disclosure, the loop structure created in this way results in a fairly fast drying speed compared to towels of similar dimensions and weight in GSM. This is generally due to the air pockets created by the large pick size and the ultra-long nature of the terry loops. The drying of the towel is determined by the transfer rate of the water absorbed from the ground warp and weft to the terry loops.

[0045] In Figure 3, it is noted that the distances between and within the loops are considerably larger than those of the towels in the control group. This greater distance creates air pockets that enable the efficient exposure of the loops, allowing for quite rapid and effective moisture exchange. In comparison, as seen in Figure 3d, the 3-pick towel has a higher loop density and no air pockets. This results in a slower drying rate and an increased drying time for the towel compared to the towel in the patent application. Consequently, as is also evident from the drying data shown in Table 1, the towel in the present disclosure dries quickly. This means that the towel does not remain wet for an extended period that would slow the growth of bacteria and other microorganisms, and as a result, it remains odorless.

[0046]

Table 1

Claims

【Claim 1】 A method (100) for processing an extra-long pile fabric, setting a lead at a slack position for a series of (n - 1) consecutive picks (102), wherein said "n" varies in the range of 4 to 7, the setting (102); setting the lead at a high-speed position for the nth pick (104); inserting a selected number of first picks of slow consecutive picks into the warp yarns according to a predetermined design by a slack driving technique (106); creating a predetermined gap close to a point (108), wherein the fabric is released from the edge of the fabric, the creating (108); continuously inserting the slow consecutive picks until the (n - 1)th pick enters the warp yarns following the insertion of the first pick, using a slack driving technique for each of the picks (110); inserting the nth pick into the warp yarns by a strong driving technique (112), wherein all the nth picks are aligned at the edge of the fabric, the inserting (112); using plain weave for the ground warp yarns to facilitate the formation of voids within the loops of the fabric (114); A method (100) comprising: The method utilizes a high-quality weaving system to facilitate the formation of gaps within loops and between loops, thereby improving the drying efficiency of the towel. The increase in the absorbency and drying speed of the towel results from the elongated and loosened terry loops with a twist multiple (TM) of 2.3 to 2.5 formed by the high-quality weaving system. The gap between loops is 1.25 ± 0.25 mm, and the gap within loops is 1.6 ± 0.12 mm. The uniform appearance and beautiful look of the towel are achieved by the dense arrangement of pile elements within the weaving structure. Air pockets are created using a large pick size.

Images