A terry article with elegant look, enhanced properties and low carbon footprint during use

Abstract

The present invention relates to a terry article having a ground component and a pile component. The ground component comprises a plurality of ground warp yarns (G1, G2) and a plurality of weft yarns (W), wherein each of ground warp yarn is interlaced on the plurality of weft yarns (W) to form a ground. The pile component comprises of a pile warp yarn (P) looped over the plurality of weft yarns (W) on the upper side (US) or the lower side (LS), thereby forming a plurality of pile loops extending away from the ground component along the vertical direction, wherein the plurality of pile loops formed in the second block (B2) complements the plurality of pile loops formed in the first block (B1).

Description

TITLE OF THE INVENTIONA TERRY ARTICLE WITH ELEGANT LOOK, ENHANCED PROPERTIES AND LOWCARBON FOOTPRINT DURING USETECHNICAL FIELD

[0001] The present invention relates to the field of textile engineering. Particularly, it relates to a quick drying terry article with reduced pile content. The terry article has an elegant look, enhanced properties and low carbon footprint in use.BACKGROUND OF THE INVENTION

[0002] Fabric products used in various applications, such as towelling, rugs, bedding, and leisure fabrics, are preferred to have high moisture absorbency, high bulk and soft hand feel. These fabrics are usually made with cellulosic fibres and are often designed to maximize the absorptive properties of the fabric.

[0003] Towels are generally thick textile articles with a piled surface (i.e., looped surface) on the front and / or back of the fabric. Thicker towels typically have a deeper pile with a greater surface area. This increased surface area generally increases the absorption properties of the fabric. For example, when a terry towel fabric contacts a water droplet, the pile loops first remove the droplet by drawing the droplet into the spaces between the fibres in the yam. Water is then wicked throughout the length of the pile and into the ground weave of the fabric. Further, once water is drawn into the yam, it may be absorbed into the lumen of the cotton fibre. The density of the fibres in the yam impacts the yarn’s ability to dry; this in turn impacts the yarn’s ability to absorb more water.

[0004] Generally, woven fabrics are made with two sets of yams: the warp and the weft; however, terry fabrics are generally formed with three sets of yarns. The first set is a ground warp which is a longitudinal set of yams forming the ground fabric. The second set, a pile warp, is a set of longitudinal warp yarns that are used to form the loop piles on the fabric surface. The third set, a weft yam, forms the transverse yam that interlaces with the ground and the pile warps to form the fabric. Any of these two (or three) sets of yarns, and the resulting fabric, may be designed to absorb water.

[0005] A conventional weaving is carried out by employing warp threads interweaved with weft threads to form a ground fabric and one or more loop pile made up of independent warp thread fastened to this fabric where the interweaving of ground warp with weft threads is done at a high tension and loop pile warps are woven at a relatively lower tension. The final structure and use of the fabric depend predominantly on the feature of the loop pile.

[0006] The desirous variation in form, look and properties can be achieved by employing various kinds of yam in different fastening ways. The amount of twist in the yam also affects the properties of the towel products. The pile yam is generally a low-twist yam. Pile loops provide maximum surface area for the absorption of water, and the low twist aids in the absorption by imparting wicking properties to the yam. Ground warp and weft are generally hard twisted compared to the pile yarn. The ground and weft yam twist factors generally range from about 3.8 to about 6, depending upon the towel construction. In contrast, the twist factor in the pile yam generally ranges from about 0.5 to about 6. Yarns like low twist, zero twist, hygro-yarn etc. as loop piles are specially used to obtain luxurious soft feel and high absorbance in the resultant towel / fabric.

[0007] In the conventional weaving techniques, the loop pile yams are used in high amounts (60 to 65% pile content by weight) and contribute majorly to the cost of the fabric.

[0008] Cellulose, and more specifically cotton fibres are generally preferred since these fibres are highly hygroscopic and can absorb many multiple times their weight in water. However, cotton terry fabrics have several disadvantages. While cotton terry fabrics have good moisture absorption, cotton fabrics do not dry out very quickly. A wet or soaked cotton terry fabric will not absorb additional moisture and usually takes a long time to dry out for subsequent use since these fibres are slow to shed water and take a long time to dry, especially in humid conditions. Further, use of only cellulosic fibre yarns results in lower durability with noticeable fraying after only a few rounds of machine washing. It is widely known that cotton terry fabrics can have low durability and may not withstand repeated laundering, which is required for towels and other such articles.

[0009] Since towels are used for the purpose of absorbing water and then dried, each article is subjected to countless wetting and drying cycles over its useable lifetime. Accordingly, there is a need in the art for terry fabric weaving methods which are cost-effective and result in improved properties such as but not limited to durability, quick drying properties along-with desired look, and softness to maintain the aesthetic of the fabric. Reducing weight of the fabric may be effective in reducing manufacturing and maintenance costs, however it results in the reduction of the fabric strength, thereby impacting the durability of the fabric to withstand repeated laundering.

[0010] Several approaches have been tried to produce quick drying terry towels. One common approach is to reduce the pile content by having pile loops on only one side of terry fabric. However, this reduces absorptive properties of one side of the fabric and reduce the look and elegance of the resultant towel for industrial purposes. Other approaches involve weaving using a combination of cotton pile yam of finer counts with the ground and weft yarn having a proportion of synthetic fibre (10-100%) creating double density loop stripes to produce a low weight, high absorbent terry towel. However, this reduces the overall GSM of the towel cloth, thereby reducing the hand feel and bulk of the finished fabric.[Oi l] Another method is to incorporate a combination of blended yarns having a combination of open structured cotton and synthetic fibres. Replacing cotton fibres with polyester addresses a number of disadvantages of associated with cotton terry fabrics. However, polyester terry fabrics are less absorbent than cotton fabrics. Polyester terry fabrics also have less loft, cushion, and bulk compared to cotton terry fabrics. Although polyester terry fabrics have a smooth hand, they tend to feel "plastic like" to the user. Presence of synthetic fibres in the contacting portion of the towel reduces the absorptive properties and skin feel of the fabric.

[0012] Therefore, there is a need in the art for a terry article which solves one or more of the above-mentioned problems.SUMMARY OF THE INVENTION

[0013] An aspect of the present invention is directed to a terry article with reduced pile content. The terry article comprises alternating sequence of a first block and a second block. Each of the first block and the second block comprise of a ground component and a pile component. The ground component comprises of a plurality of ground warp yarns and a plurality of weft yarns, the plurality of weft yams interwoven with the plurality of ground warp yams. Further, the ground component has a lower side, and an upper side opposed to the lower side along a vertical direction. Each of the ground warp yarn is interlaced on the plurality of weft yarns to form a ground. The interlaces of the ground warp yarn (Gl) complements the interlaces of the ground warp yarn (G2). The pile component comprises of a pile warp yarn having a pile base located at the ground component. The pile warp yarn is looped over the plurality of weft yarns on the upper side or the lower side, thereby forming a plurality of pile loops extending away from the ground component along the vertical direction. Further, the plurality of pile loops formed in the second block complements the plurality of pile loops formed in the first block.

[0014] In an embodiment, each of the ground warp yarn in the plurality of ground warp yarns are same or different and can be selected from natural cotton, man-made cellulose fibre, synthetic polymers, recycled fibres, low-absorbent fibres, and blends thereof.

[0015] In another embodiment, the pile warp yam is selected from natural cotton, man-made cellulosic fibres, hygroscopic - high absorbent low twist fibres, and combinations or blends thereof.

[0016] In yet another embodiment, the weft yarn is selected from natural cotton, man-made cellulose fibre, synthetic polymers, recycled fibres, low-absorbent fibres, and blends thereof.

[0017] In another embodiment, the pile content in the terry article ranges between 30 wt.% to 55 wt.% based on the total weight of the article.

[0018] In still another embodiment, each ground interlace of the ground warp yam on the upperside or the lower side has a corresponding ground interlace of the ground warp yam on the lower side or the upper side, thereby each ground interlace of the ground warp yarn complementing each ground interlace of the ground warp yam.

[0019] In another embodiment, each pile loop of the first block on the upper side or the lower side has a corresponding pile loop of the second block on the lower side or the upper side, thereby each pile loop of the first block complementing each pile loop of the second block.

[0020] In yet another embodiment, the terry article is selected from 3-pick terry article, 4-pick terry article, 5-pick terry article, 6-pick terry article, 7-pick terry article, 8-pick terry article, 9-pick terry article, and any combination thereof.

[0021] In still another embodiment, the terry article has a GSM ranging between 200 to 900, a pick density ranging between 33 to 62 picks per inch, a pile loop count ranging from 6’s to 30’s and a pile height ranging from2 mm to 7.5 mm.

[0022] In yet another embodiment, the terry article further comprises: (i) one or more pile warp yams in the first block (Bl) and / or the second block (B2), and / or (ii) one or more ground warp yams between the first block (Bl) and the second block (B2).

[0023] Another aspect of the present invention relates to a method for producing the terry article as described above. The method comprises at least the step of weaving the ground component and the pile component followed by optionally subjecting the terry article to wet processing.

[0024] In an embodiment, the wet processing comprises treating the terry article with one or more of the following: wetting agent, desizing agent, hydrogen peroxide stabilizer, lubricant, core alkali neutralizer / buffer, and levelling agent.BRIEF DESCRIPTION OF FIGURES

[0025] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.Figure la illustrates a weaving structure of a conventional terry article.Figure lb illustrates a weaving structure of a terry article in accordance with an embodiment of the present invention.Figure 1c illustrates another weaving structure of a terry article in accordance with an embodiment of the present invention.Figure 2a represents a weaving drawdown of the terry article of Figure 1c.Figures 2b to 2f represent weaving drawdowns of a terry article in accordance with various embodiments of the present invention.DETAILED DESCRIPTION OF THE INVENTION

[0026] Various features and embodiments of the present invention here will be discernible from the following further description thereof, set out hereunder.

[0027] The present invention relates to the field of textile engineering, more specifically to a quick drying terry article with reduced pile content having an elegant look, enhanced properties and low carbon footprint in use. Embodiments of the present invention are directed towards the terry article and a method for producing the same.

[0028] In the present context, “absorbency” refers to the propensity of a fabric to take in and retain liquid, usually water.

[0029] Herein, “blend” refers to a textile containing two or more different fibres, variants of the same fibre or different colours and grades of the same fibre.

[0030] “GSM” stands for grams per square meter (g / m2). It is the weight of 1 meter square of fabric in grams.

[0031] “Pile” is the surface effect on a fabric formed by tufts or loops of yarn that stand up from the body of the fabric.

[0032] “Pile height” refers to the height of the pile loop protruding above the surface of the ground weave. For looped piles, pile height is taken to be roughly half of the loop length.

[0033] “Picking” refers to the passing of the pile yarn through the ground cloth. Terry can be classified based on the number of weft yarns passed by a single pile loop. Common examples of terry weave are 3-pick, 4-pick, 5-pick, 6-pick, 7-pick, 8-pick and 9-pick weaves. Combinations of such weaves are also possible based on the desired qualities in the terry material being produced.

[0034] “Pick density or picks per inch (PPI)” refers to the number of weft threads in one inch of woven fabric. A pick is a single weft thread, and in general, the higher the PPI, the finer the fabric.

[0035] “Warp” are yams, in woven fabric, that run lengthwise and are interwoven with the fill (weft) yarns.

[0036] “Weft” is filling yarns, in woven fabric, that run perpendicular to the warp yarns.

[0037] Yam” refers to a continuous strand of textile fibre created when a cluster of individual fibres are twisted around one another.

[0038] An aspect of the present invention is directed towards a terry article with reduced pile content.

[0039] “Ground base” refers to the foundational structure of a terry fabric that supports the pile loops or tufts. It is formed by the interlacing of warp and weft yarns, creating a stable woven ground onto which pile yarns are inserted. The characteristics of the ground base, such as weave tightness and yam type, influence the durability, absorbency, and feel of the final terry article. Thepile warp yarns form pile loops having a base (Pile Base) located at the ground base, and a peak (Pile End) that is vertically separated from the pile base. The distance between the base and peak is the pile height. “Ground” also refers to plurality of ground interlaces.

[0040] In an embodiment, the terry article comprises an alternating sequence of a first block (Bl) and a second block (B2). Each of the first block (Bl) and the second block (B2) comprise a ground component and a pile component. The ground component comprises of a plurality of ground warp yams (Gl, G2) and a plurality of weft yarns (W), the plurality of weft yarns (W) interwoven with the plurality of ground warp yarns (Gl, G2), the ground component having a lower side (LS) and an upper side (US) opposed to the lower side (LS) along a vertical direction, wherein each of ground warp yarn is interlaced on the plurality of weft yarns (W) to form a ground, the interlaces of the ground warp yam (Gl) complementing the interlaces of the ground warp yam (G2). The pile component comprises of a pile warp yarn (P) having a pile base (PB) located at the ground component, the pile warp yarn (P) looped over the plurality of weft yarns (W) on the upper side (US) or the lower side (LS), thereby forming a plurality of pile loops extending away from the ground component along the vertical direction, wherein the plurality of pile loops formed in the second block (B2) complements the plurality of pile loops formed in the first block (Bl).

[0041] Referring to Figures la, lb and 1c, the ground component is shown comprising the plurality of ground warp yarns (Gl, G2) and the plurality of weft yarns (W). The plurality of ground warp yams is interwoven with the plurality of weft yarns. As shown in Figure 1c, the ground component has the lower side (LS), and the upper side (US) opposed to the lower side along the vertical direction. Further, the pile component comprising the pile warp yam (P) is also shown in Figures lb and 1c.

[0042] Figure la depicts a conventional terry weave having two pile yarns (Pl and P2), along with two ground warp yams (Gl and G2). Figures lb and 1c show a weaving structure of terry articles of the present invention, i.e., with reduced pile content. Additionally, the pile component in the terry article of the present invention consists of a single pile warp yarn (P).

[0043] Accordingly, in an embodiment, the terry article comprises the alternating sequence of the first block (Bl) and the second block (B2), each of the first block (Bl) and the second block (B2) comprising: the ground component comprising of the plurality of ground warp yarns (Gl, G2) and the plurality of weft yams (W), the plurality of weft yarns (W) interwoven with the plurality of ground warp yarns (Gl, G2), the ground component having the lower side (LS) and the upper side (US) opposed to the lower side (LS) along the vertical direction, wherein each of ground warp yam is interlaced on the plurality of weft yarns (W) to form the ground, the interlaces of the ground warp yarn (Gl) complementing the interlaces of the ground warp yarn (G2); the pile component consisting of the pile warp yarn (P) having the pile base (PB) located at the ground component,the pile warp yarn (P) looped over the plurality of weft yarns (W) on the upper side (US) or the lower side (LS), thereby forming the plurality of pile loops extending away from the ground component along the vertical direction, wherein the plurality of pile loops formed in the second block (B2) complements the plurality of pile loops formed in the first block (Bl).

[0044] In another embodiment, the ground components, the pile components, and the weft yarns are weaved to form arrangements and / or patterns. The present invention provides several unique weaving patterns for making the terry article. Each of these unique loom arrangements for weaving the terry article have been covered in Figures 2a to 2f which show the weaving drawdowns of the terry article having one pile yam and two ground yarns in repeating sequence.

[0045] Herein, Wl, W2, W3 and so on refers to first weft yam, second weft yam, third weft yarn and the like. Further, with reference to Figures 2a to 2f ‘x’ represents the warp yarns crossing over the weft yarns on the upper side, whereas a blank represents the warp yarns crossing under the weft yarns on the lower side.

[0046] Reference is made to Figure 2a (and corresponding to Figure 1c) and a block PG1G2 (refer dotted lines showing Block Bl in Figure 2a). As shown, the pile warp yarn has the pile base (PB) located at the ground component and at the first weft yarn (Wl). The pile warp yarn has a pile end (PE) spaced apart from the pile base, and a pile height (PH) extending from the pile base to the pile end along the vertical direction, thereby forming a first pile loop over the second weft yarn (W2) as represented by ‘x’ in Figure 2a (see column ‘P’). The first pile loop is formed on the upper side along the vertical direction. The pile warp yarn is looped around the third weft yarn (W3) on the lower side to form a second pile loop, represented by a blank in Figure 2a (see column ‘P’). The second pile loop is interlaced around the third weft yarn (W3) such that no pile height on the lower side is formed. The pile warp yarn is then looped around the fourth weft yarn (W4) on the upper side to form a third pile loop, represented by ‘x’ in Figure 2a (see column ‘P’). The pile warp yarn is then looped around the fifth weft yarn (W5) on the lower side to form a fourth pile loop. The pile warp yarn has the pile end spaced apart from the pile base, and the pile height extending from the pile base to the pile end along the vertical direction, thereby forming the fifth pile loop over the fifth weft yarn (W5) as represented by a blank in Figure 2a (see column ‘P’).

[0047] In an embodiment, the pile height of the first pile loop is greater than the pile height of the subsequent pile loop, or vice versa.

[0048] The plurality of ground warp yarns (Gl, G2) has a ground base located on the plurality of weft yams (Wl, W2, W3. . .). In an embodiment, the first ground warp yam (Gl) interlaces around the first weft yarn (Wl) and the second weft yarn (W2) on the upper side to form the first ground interlace, as represented by two consecutive ‘x’ in Figure 2a (see column ‘Gl’). The first ground warp yam (Gl) is interlaced around the third weft yarn (W3) on the lower side to form the secondground interlace, as represented by a blank in Figure 2a (see column ‘Gl’). The first ground warp yam is further interlaced around each of the fourth weft yarn (W4) and the fifth weft yarn (W5) on the upper side to form the third ground interlace, as represented by two consecutive ‘x’ in Figure 2a (see column ‘Gl’).

[0049] In another embodiment, as shown in Figures 2a to 2f, the ground formed by the ground warp yarn (Gl) on the upper side (US) corresponds to the ground formed by the ground warp yarn (G2) on the lower side (LS), and vice versa, such that the ground structures of Gl and G2 complement each other across the two sides.

[0050] This is evident, for instance, in Figure 2a where the second ground warp yarn (G2) complements the first ground warp yarn (Gl) such that each of the weft yarns where the first ground warp yarn (Gl) loops on the upper side, the second ground warp yarn (G2) is on the lower side, and vice versa. Said otherwise, the weft yarns where the first ground warp yarn (Gl) is on the upper side, the second ground warp yarn (G2) on the same weft yarn is on the lower side, thereby forming a strong foundation or base structure of the terry article.

[0051] In another embodiment, as shown in Figures 2a to 2f, each pile loop of the first block (Bl) on the upper side (US) or the lower side (LS) has a corresponding pile loop of the second block (B2) on the lower side (LS) or the upper side (US), thereby each pile loop of the first block (Bl) complementing each pile loop of the second block (B2).

[0052] As shown, in Figure 2a and 1c the blocks PG1G2 are repeated multiple times. For example, first block may be denoted as Bl, second block may be denoted as B2, third block is identical to Bl, fourth block identical to B2, and so on to form the terry article in accordance with the present invention. In such case, the pile warp yam of the second block B2 complements the pile warp yarn of the first block Bl. Said otherwise, the pile warp yarn of the second block loops around a weft yam on the lower side or upper side where the pile warp yarn of the first block on the same weft yam is on the upper side or lower side.

[0053] Reference is now made to Figure 2b and the block PG1G2 (refer dotted lines showing block Bl in Figure 2b). As shown in this illustrated embodiment, the pile yarn has the pile base (PB) located at the ground component and at the first weft yam (Wl). The pile warp yarn has the pile end (PE) spaced apart from the pile base, and the pile height (PH) extending from the pile base to the pile end along the vertical direction, thereby forming a first pile loop over the second weft yarn (W2), as represented by ‘x’ in Figure 2b (see column ‘P’). The first pile loop is formed on the upper side along the vertical direction. The pile warp yarn is then looped around the third and fourth weft yarns (W3 and W4) on the lower side to form a second pile loop, represented by two consecutive blanks in Figure 2b (see column ‘P’). The pile warp yarn is subsequently looped around the fifth weft yam (W5) on the upper side to form a third pile loop, represented by ‘x’ inFigure 2b (see column ‘P’). The pile warp yarn is then looped around the sixth weft yam (W6) on the lower side to form a fourth pile loop, as indicated by one blank in Figure 2b (see column ‘P’). The pile warp yarn is thereafter looped around the seventh weft yam (W7) on the upper side and eighth weft yarn (W8) on the lower side to form alternating tight loops. The pile warp yarn is then looped around the ninth and tenth weft yams (W9 and W10) to form a loop on the upper side, indicated by two consecutive ‘x’ in Figure 2b (see column ‘P’). Thereafter, the pile warp yam is looped around the eleventh weft yarn (W11) on the lower side as indicated by blank in Figure 2b (see column ‘P’) and on the upper side around the twelfth weft yam (W12), as indicated by ‘x’ in Figure 2b (see column ‘P’).

[0054] The plurality of ground warp yams (Gl, G2), as shown in Figure 2b, has the ground base located on first weft yam (Wl). In an embodiment, the first ground warp yarn (Gl) interlaces around the first weft yam (Wl) and the second weft yam (W2) on the upper side to form the first ground interlace, as represented by two consecutive ‘x’ in Figure 2b (see column ‘Gl’). The first ground warp yam (Gl) is interlaced around the third weft yarn (W3) on the lower side to form the second ground interlace, as represented by a blank in Figure 2b (see column ‘Gl’). The first ground warp yam is further interlaced around each of the fourth weft yarn (W4) and the fifth weft yarn (W5) on the upper side to form the third ground interlace, as represented by two consecutive ‘x’ in Figure 2b (see column ‘Gl’). The first ground warp yarn (Gl) is interlaced around the sixth weft yam (W6) on the lower side to form the fourth ground interlace, as represented by a blank in Figure 2b (see column ‘Gl’). The first ground warp yarn is further interlaced around each of the seventh weft yarn (W7) and the eighth weft yarn (W8) on the upper side to form the fifth ground interlace, as represented by two consecutive ‘x’ in Figure 2b (see column ‘Gl’). The first ground warp yarn (Gl) is interlaced around the ninth weft yarn (W9) on the lower side to form the sixth ground interlace, as represented by a blank in Figure 2b (see column ‘Gl’). The first ground warp yam is further interlaced around each of the tenth weft yarn (W10) and the eleventh weft yarn (Wl 1) on the upper side to form the seventh ground interlace, as represented by two consecutive ‘x’ in Figure 2b (see column ‘Gl’).

[0055] In another embodiment, the second ground warp yam (G2) complements the first ground warp yarn (Gl) such that each of the weft yarns where the first ground warp yarn (Gl) loops on the upper side the second ground warp yarn (G2) is on the lower side, and vice versa. Said otherwise, the weft yarns where the first ground warp yam (Gl) is on the upper side, the second ground warp yarn (G2) on the same weft yarn is on the lower side, thereby forming a strong foundation or base structure of the terry article.

[0056] In an embodiment, the block PG1G2 is repeated multiple times (first block is denoted as Bl, second block is denoted as B2, third block is identical to Bl, fourth block identical to B2, andso on) to form the terry article. In such case, the pile warp yarn of the second block B2 complements the pile warp yarn of the first block Bl. Said otherwise, the pile warp yarn of the second block loops around the weft yarn on the lower side or upper side where the pile warp yarn of the first block on the same weft yarn is on the upper side or lower side.

[0057] Reference is now made to Figure 2c and the block PG1G2 (refer dotted lines showing Block Bl in Figure 2c). As shown, the pile yam has the pile base (PB) located at the ground component and at the first weft yarn (W 1). The pile warp yarn has the pile end (PE) spaced apart from the pile base, and the pile height (PH) extending from the pile base to the pile end along the vertical direction, thereby forming a first pile loop over the first weft yarn (Wl), as represented by ‘x’ in Figure 2c (see column ‘P’). The first pile loop is formed on the upper side along the vertical direction. The pile warp yarn is then looped around the second weft yam (W2) on the lower side to form a second pile loop, represented by a blank in Figure 2c (see column ‘P’). The pile warp yam is subsequently looped around the third and fourth weft yarn (W3 and W4) on the upper side to form a third pile loop, represented by two consecutive ‘x’ in Figure 2c (see column ‘P’). Subsequently, the pile warp yarn is looped around the fifth weft yarn (W5) on the lower side to form a fourth pile loop, represented by a blank in Figure 2c (see column ‘P’). The pile warp yarn is then looped around the sixth weft yarn (W6) on the upper side to form a fifth pile loop, represented by ‘x’ in Figure 2c (see column ‘P’). Finally, the pile warp yarn is looped around the seventh and eighth weft yarn (W7 and W8) on the lower side to form a sixth pile loop, represented by two consecutive blanks in Figure 2c (see column ‘P’)

[0058] The plurality of ground warp yarns (Gl, G2), as shown in Figure 2c, has the ground base located on first weft yam (Wl). In an embodiment, the first ground warp yarn (Gl) interlaces around the first weft yam (Wl) and the second weft yam (W2) on the upper side to form the first ground interlace, as represented by two consecutive ‘x’ in Figure 2c (see column ‘Gl’). The first ground warp yam (Gl) is interlaced around each of the third and fourth weft yams (W3 and W4) on the lower side to form the second ground interlace, as represented by two consecutive blanks in Figure 2c (see column ‘Gl’). The first ground warp yarn is further interlaced around each of the fifth and sixth weft yarns (W5 and W6) on the upper side to form the third ground interlace, as represented by two consecutive ‘x’ in Figure 2c (see column ‘Gl’). The first ground warp yarn (Gl) is interlaced around each of the seventh and eighth weft yarns (W7 and W8) on the lower side to form the fourth ground interlace, as represented by two consecutive blanks in Figure 2c (see column ‘Gl’).

[0059] In another embodiment, the second ground warp yam (G2) complements the first ground warp yarn (Gl) such that each of the weft yarns where the first ground warp yam (Gl) interlaces on the upper side the second ground warp yarn (G2) is on the lower side, and vice versa. Saidotherwise, the weft yarns where the first ground warp yam (Gl) is on the upper side, the second ground warp yarn (G2) on the same weft yarn is on the lower side, thereby forming a strong foundation or base structure of the terry article.

[0060] In an embodiment, the block PG1G2 is repeated multiple times (first block is denoted as Bl, second block is denoted as B2, third block is identical to Bl, fourth block identical to B2, and so on) to form the terry article. In such case, the pile warp yarn of the second block B2 complements the pile warp yarn of the first block Bl. Said otherwise, the pile warp yarn of the second block loops around the weft yarn on the lower side or upper side where the pile warp yarn of the first block on the same weft yarn is on the upper side or lower side.

[0061] Reference is now made to Figure 2d and the block PG1G2 (refer dotted lines showing Block Bl in Figure 2d). As shown in this illustrated embodiment, the pile yam has the pile base (PB) located at the ground component and at the first weft yam (Wl). The pile warp yam has the pile end (PE) spaced apart from the pile base (PB), and the pile height (PH) extending from the pile base to the pile end along the vertical direction, thereby forming a first pile loop over the first weft yarn (Wl), as represented by ‘x’ in Figure 2d (see column ‘P’). The first pile loop is formed on the upper side along the vertical direction. The pile warp yam is then looped around the second weft yarn (W2) on the lower side to form a second pile loop, represented by a blank in Figure 2d (see column ‘P’). The pile warp yarn is subsequently looped around each of the third, fourth and fifth weft yarns (W3, W4 and W5) on the upper side to form a third pile loop, represented by three consecutive ‘x’ in Figure 2d (see column ‘P’). Subsequently, the pile warp yarn is looped around the sixth weft yarn (W6) on the lower side to form a fourth pile loop, represented by a blank in Figure 2d (see column ‘P’). The pile warp yam is then looped around the each of the seventh and eighth weft yarn (W7 and W8) on the upper side to form a fifth pile loop, represented by two consecutive ‘x’ in Figure 2d (see column ‘P’). Thereafter, the pile warp yam is looped around the ninth weft yam (W9) on the lower side to form a sixth pile loop, represented by a blank in Figure 2d (see column ‘P’). Subsequently, the pile warp yam is looped around the tenth weft yarn (W10) on the upper side to form a seventh pile loop, represented by ‘x’ in Figure 2d (see column ‘P’). Thereafter, the pile warp yarn is looped around each of the eleventh, twelfth and thirteenth weft yams (Wi l, W12 and W13) on the lower side to form an eighth pile loop, represented by three consecutive blanks in Figure 2d (see column ‘P’). The pile warp yarn is then looped around the fourteenth weft yarn (W14) on the upper side to form a ninth pile loop, represented by ‘x’ in Figure 2d (see column ‘P’). Finally, the pile warp yarn is looped around each of the fifteenth and sixteenth weft yarns (W15 and W16) on the lower side to form a tenth pile loop, represented by two consecutive blanks in Figure 2d (see column ‘P’).

[0062] The plurality of ground warp yams (Gl, G2), as shown in Figure 2d, has the ground baselocated on the first and second weft yarns (W 1 and W2). In an embodiment, the first ground warp yam (Gl) interlaces around the third weft yarn (W3) and the fourth weft yarn (W4) on the upper side to form the first ground interlace, as represented by two consecutive ‘x’ in Figure 2d (see column ‘Gl’). The first ground warp yam (Gl) is interlaced around each of the fifth and sixth weft yams (W5 and W6) on the lower side to form the second ground interlace, as represented by two consecutive blanks in Figure 2d (see column ‘Gl’). The first ground warp yarn (Gl) is further interlaced around each of the seventh and eighth weft yarns (W7 and W8) on the upper side to form the third ground interlace, as represented by two consecutive ‘x’ in Figure 2d (see column ‘Gl’). The first ground warp yarn (Gl) is interlaced around each of the ninth and tenth weft yams (W9 and W10) on the lower side to form the fourth ground interlace, as represented by two consecutive blanks in Figure 2d (see column ‘Gl’). The first ground warp yam (Gl) is interlaced around each of the eleventh and twelfth weft yams (W11 and W12) on the upper side to form the fifth ground interlace, as represented by two consecutive ‘x’ in Figure 2d (see column ‘Gl’). Subsequently, the first ground warp yarn (Gl) is interlaced around each of the thirteenth and fourteenth weft yams (W13 and W14) on the lower side to form the sixth ground interlace, as represented by two consecutive blanks in Figure 2d (see column ‘Gl’). Finally, the first ground warp yarn (Gl) is interlaced around each of the fifteenth and sixteenth weft yarns (W15 and W16) on the upper side to form the seventh ground interlace, as represented by two consecutive ‘x’ in Figure 2d (see column ‘Gl’).

[0063] In another embodiment, the second ground warp yam (G2) complements the first ground warp yarn (Gl) such that each of the weft yarns where the first ground warp yam (Gl) interlaces on the upper side the second ground warp yarn (G2) is on the lower side, and vice versa. Said otherwise, the weft yarns where the first ground warp yam (Gl) is on the upper side, the second ground warp yarn (G2) on the same weft yarn is on the lower side, thereby forming a strong foundation or base structure of the terry article.

[0064] In an embodiment, the block PG1G2 is repeated multiple times (first block is denoted as Bl, second block is denoted as B2, third block is identical to Bl, fourth block identical to B2, and so on) to form the terry article. In such case, the pile warp yarn of the second block B2 complements the pile warp yarn of the first block Bl. Said otherwise, the pile warp yarn of the second block loops around the weft yarn on the lower side or upper side where the pile warp yarn of the first block on the same weft yarn is on the upper side or lower side.

[0065] Reference is now made to Figure 2e and the block PG1G2 (refer dotted lines showing block Bl in Figure 2e). As shown, the pile warp yam has the pile base (PB) located at the ground component and at the first weft yarn (W 1). The pile warp yarn has the pile end (PE) spaced apart from the pile base, and the pile height (PH) extending from the pile base to the pile end along thevertical direction, thereby forming a first pile loop over the second weft yarn (Wl) as represented by ‘x’ in Figure 2e (see column ‘P’). The first pile loop is formed on the upper side along the vertical direction. The pile warp yam is looped around the second weft yam (W2) on the lower side to form a second pile loop, represented by a blank in Figure 2e (see column ‘P’). The pile warp yarn is then looped around the third weft yam (W3) on the upper side to form a third pile loop, represented by ‘x’ in Figure 2e (see column ‘P’).

[0066] The plurality of ground warp yarns (Gl, G2), as shown in Figure 2e, has the ground base located on the first and second weft yarns (W 1 and W2). In an embodiment, the first ground warp yam (Gl) interlaces around the third weft yarn (W3) and the fourth weft yarn (W4) on the upper side to form the first ground interlace, as represented by two consecutive ‘x’ in Figure 2e (see column ‘Gl’).

[0067] In another embodiment, in accordance with Figure 2e, the ground yams Gl and G2 are woven across the weft yarns as depicted in the columns Gl and G2 respectively. Unlike the pile yam P, yarns Gl and G2 are interlaced across the weft such that there is no loop formed extending away from the plane of the fabric. Further, the ground yams Gl and G2 are woven on alternating sides of the weft yarn; such that each of the weft yarns where the first ground warp yarn (Gl) interlaces on the upper side the second ground warp yarn (G2) is on the lower side, and vice versa. Said otherwise, the weft yarns where the first ground warp yarn (Gl) is on the upper side, the second ground warp yam (G2) on the same weft yarn is on the lower side, thereby forming a strong foundation or base structure of the terry article.

[0068] In an embodiment, the block PG1G2 is repeated multiple times (first block is denoted as Bl, second block is denoted as B2, third block is identical to Bl, fourth block identical to B2, and so on) to form the terry article. In such case, the pile warp yarn of the second block B2 complements the pile warp yarn of the first block Bl. Said otherwise, the pile warp yarn of the second block loops around the weft yarn on the lower side or upper side where the pile warp yarn of the first block on the same weft yarn is on the upper side or lower side respectively thereby resulting in an alternate piling arrangement across the surface of the fabric.

[0069] Reference is now made to Figure 2f and the block PG1G2 (refer dotted lines showing block Bl in Figure 2f). As shown, the pile yarn has the pile base (PB) located at the ground component and at the first weft yam (Wl). The pile warp yarn has the pile end (PE) spaced apart from the pile base, and the pile height (PH) extending from the pile base to the pile end along the vertical direction, thereby forming a first pile loop over the first weft yarn (Wl), as represented by ‘x’ in Figure 2f (see column ‘P’). The first pile loop is formed on the upper side along the vertical direction. The pile warp yarn is then looped around the second weft yam (W2) on the lower side to form a second pile loop, represented by the blank in Figure 2f (see column ‘P’). The pile warpyam is subsequently looped around the third and fourth weft yarns (W3 and W4) on the upper side to form a third pile loop, represented by two consecutive ‘x’ in Figure 2f (see column ‘P’).

[0070] The plurality of ground warp yarns (Gl, G2), as shown in Figure 2f, has the ground base located on the first and second weft yarns (W 1 and W2). In an embodiment, the first ground warp yam (Gl) interlaces around the third and fourth weft yarn (W3 and W4) on the upper side to form the first ground interlace, as represented by two consecutive ‘x’ in Figure 2f (see column ‘Gl’).

[0071] In a further embodiment, in accordance with Figure 2f, the second ground warp yarn (G2) complements the first ground warp yarn (Gl) such that each of the weft yarns where the first ground warp yarn (Gl) interlaces on the upper side the second ground warp yarn (G2) is on the lower side, and vice versa. Said otherwise, the weft yarns where the first ground warp yam (Gl) is on the upper side, the second ground warp yam (G2) on the same weft yarn is on the lower side, thereby forming a strong foundation or base structure of the terry article.

[0072] In an embodiment, the block PG1G2 is repeated multiple times (first block is denoted as Bl, second block is denoted as B2, third block is identical to Bl, fourth block identical to B2, and so on) to form the terry article. In such case, the pile warp yarn of the second block B2 complements the pile warp yarn of the first block Bl. Said otherwise, the pile warp yarn of the second block loops around the weft yarn on the lower side or upper side where the pile warp yarn of the first block on the same weft yarn is on the upper side or lower side.

[0073] In an embodiment, each of the ground yarns in the plurality of ground warp yarns (Gl, G2) are same or different and can be selected from natural cotton, man-made cellulose fibre, synthetic polymers, recycled fibres, low-absorbent fibres, and blends thereof. Exemplary ground warp yarns include, but are not limited to, Dryion, PET, and

[0074] In another embodiment, the pile warp yarn (P) is selected from natural cotton, man-made cellulosic fibres, hygroscopic - high absorbent low twist fibres, and combinations or blends thereof. Exemplary pile warp yarns include Hygrocotton, low twist, and natural cotton.

[0075] In still another embodiment, the weft yarn is selected from natural cotton, man-made cellulose fibre, synthetic polymers, recycled fibres, low-absorbent fibres, and blends thereof.

[0076] In a further embodiment, the terry article is selected from 3-pick terry article, 4-pick terry article, 5-pick terry article, 6-pick terry article, 7-pick terry article, 8-pick terry article, 9-pick terry article, and any combination thereof. Further, the terry article may include alternating double side piling as illustrated in Figures 2a to 2f.

[0077] In yet another embodiment, the terry article further comprises one or more pile warp yarns in the first block (Bl) and / or the second block (B2), and / or (ii) one or more ground warp yarns between the first block (Bl) and the second block (B2). The addition of further ground warp yarns further increases the ground component in comparison to the pile component, such that variouscombinations are possible, such as 3 ground warp yarns for each pile warp yarn, 4 ground warp yams for every pile warp yarn, 3 ground warp yarns for two pile warp yarns and the like, wherein in each combination, the number of pile yams is always fewer than the number of ground yarns.

[0078] In various embodiments as illustrated in figures 2a to 2f, the pile component consists of one pile yarn (P) in each of the blocks Bl and B2. Advantageously, this unique weaving of the yam, as discussed hereinabove in reference to Figures 2a to 2f, result in a reduced pile content in the terry article. In fact, the pile content is reduced to between 30-55% by weight of the article as opposed to 60 to 65% pile component by weight in conventionally woven terry (illustrated in Figure la). The reduction in the pile content is compensated with the increase in the ground component. This reduction in the pile component results in the present invention terry article having elegant look, enhanced properties like high durability and quick drying while not degrading the absorptive nature and hand feel of the finished article.

[0079] In another embodiment, the terry article has a GSM ranging between 200 to 900, a pick density ranging between 33 to 62 picks per inch, a pile loop count ranging from 6’s to 30’s and a pile height ranging from 2 mm to 7.5 mm. The terry article of the present invention finds application in home textiles such as, but not limited to, towels and bathrobes.

[0080] Advantageously, selection of a low absorbent yarn as at least one of the two ground warp yams (G1 and G2) results in the terry article having low absorbency in the ground component. Further, selection of a hygroscopic yarn as the pile warp yarn (P) results in the terry article having high absorbency in the pile component.

[0081] Further, during use, the terry article contacts a user’s skin by means of the pile component. High absorbency in the pile component enables quick wicking away of moisture from the skin. This results in an enhanced experience for the user. Correspondingly, once the terry article has absorbed the moisture away from the user, this moisture is not retained in the ground component due to the low absorbency of the ground component. The moisture is rapidly evaporated away from the pile component when the terry article is put in the clothes dryer. This is essential for terry products such as towels and bathrobes which undergo repeated cycles of wetting (for example when the user dries themselves using the towel) and drying (when the towel or bathrobe is dried after use). Over the lifecycle of the terry article, it undergoes several hundreds or thousands of wettings and drying. Advantageously, the quick drying nature of the terry article as achieved in the present invention results in significant cumulative energy savings in the form of reduced use of the clothes dryer, thereby contributing to a low carbon footprint of the product in use.

[0082] Another aspect of the present invention relates to a method for producing the terry article as described above. Accordingly, the embodiments pertaining to the terry article are applicable here as well.

[0083] In an embodiment, the method comprises at least the step of weaving the ground component and the pile component followed by optionally subjecting the terry article to wet processing.

[0084] The term "weaving" as used herein refers to a process of fabric or terry article production that involves interlacing two sets of yarn - the warp, and the weft, to create the terry article. The warp yams run lengthwise, and the weft yarns run crosswise, forming a stable and structured textile. In this regard, the yarn obtained from the spinning process is subjected to weaving, where the yarn is threaded onto a loom. The loom facilitates the interlacing of the warp and the weft yams, thereby creating the terry article. The weaving imparts strength, structure, and durability to the terry article. The interlacing of the yarns creates a cohesive textile that can be used for a wide range of applications.

[0085] In an embodiment, the method includes at least weaving the ground component and the pile component in accordance with the weaving drawdowns illustrated in Figures 2a to 2f.

[0086] Further, the terry article of the present invention may be subjected to wet processing post weaving. For this, the terry article may be treated with suitable chemicals known to a person skilled in the art. In an embodiment, the wet processing comprises treating the terry article with one or more of the following: wetting agent, desizing agent, hydrogen peroxide stabilizer, lubricant, core alkali neutralizer / buffer, and levelling agent.

[0087] Wet processing refers to a series of steps that treat textiles with various chemicals and colorants to improve their performance and appearance. Textile wet processing, which includes but is not limited to pretreatment, desizing, scouring, bleaching, dyeing, or printing, and finishing, is of crucial importance for improving the performance and serviceability of textile materials. Herein, desizing includes removal of sizing agents applied during weaving for smoother fabric. Scouring includes cleaning to eliminate impurities, waxes, and natural oils from the fabric. Bleaching includes whitening the fabric by removing colour impurities. Dyeing includes applying colour to the fabric for desired aesthetics. Printing includes adding patterns or designs onto the fabric. Finishing includes final treatments to improve texture, feel, and durability. Wet processing imparts textiles the desired characteristics, such as colour, softness, water repellence, wrinkle resistance, and durability.

[0088] In an embodiment, the wet processing for obtaining the terry article is carried out through continuous or exhaust process in long length fabric form. However, in case of bath rugs, wet processing may be carried out in in rope form using exhaust process and / or one-piece using paddle dyeing machine.

[0089] The terry article of the present invention has several advantages, including but not limited to the following:Cost reduction due to reduced consumption of pile yam (10 to 30% reduction). Slightly increased ground content - ranging between 15 to 20% over conventional terry.Soft hand feel comparable to or better than natural cotton terry towel due to specific yarn selection of pile and ground yarns.- Extended life of terry article as overall strength is increased, thereby enhancing the durability of the article.Quick drying time and reduced energy consumption during machine drying.- Physical fabric properties per unit weight of fabric remains intact and / or not compromised.EXAMPLES

[0090] The following examples are illustrative of the invention but not limitative of the scope thereof.

[0091] Material Analysis Test

[0092] Two terry towels having dimensions 30-inch x 54 inch (1.045 m2) and fabric densities of 350 GSM and 400 GSM were prepared according to an embodiment of the present invention, wherein one ground warp yam (Gl) was Dryion (polyester based) and natural cotton was used as the other ground warp yarn (G2), pile warp yarn (P), and weft yarn (W). The pile density for both the terry towels ranged between 10 picks to 50 picks with the pile height \ranging between 2mm to 9mm. The samples are labelled as Sample A and Sample B respectively.

[0093] The overall material of the towel was analysed according to AATCC test method for qualitative fibre analysis, with ASTM DI 909 moisture regains applied. The results are summarized in Table 1 below.

[0094] Table 1 : Material Analysis Test

[0095] Fabric Drying Time

[0096] The samples were tested for drying time according to CPSD-SL-31081-MTHD standardised testing methodology where sample drying time after 1stwash and 3rdwash were observed. The results are summarized in Table 2 below.

[0097] Table 2: Fabric Drying Time098] As illustrated above, both samples have drying times of roughly 20 mins. Further, several conventional / comparative terry articles woven with a single natural cotton pile warp yam and a single natural cotton ground warp yam were also prepared. These articles exhibited a drying time of 35 mins for articles below 700 GSM and greater than 40 mins for articles greater than 700 GSM. Clearly, the terry article of the present invention exhibits significantly reduced drying time over conventional terry articles.

[0099] Surface Water Absorption of Terry Fabric

[0100] Surface water absorbency of the prepared samples was tested according to ASTM D4772- 14 standardized testing methodology. The results are summarised in Table 3 below.

[0101] Table 3: Absorbency test

[0102] As noted from Table 3, the terry article of the present invention has enhanced absorbency.

[0103] The foregoing description of the invention has been set merely to illustrate the invention and is not intended to be limiting. While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.

Claims

WE CLAIM:

1. A terry article with a reduced pile content, comprising: an alternating sequence of a first block (Bl) and a second block (B2), each of the first block (Bl) and the second block (B2) comprising: a ground component comprising a plurality of ground warp yarns (Gl, G2) and a plurality of weft yarns (W), the plurality of weft yarns (W) interwoven with the plurality of ground warp yarns (Gl, G2), the ground component having a lower side (LS) and an upper side (US) opposed to the lower side (LS) along a vertical direction; wherein each of ground warp yarn is interlaced on the plurality of weft yams (W) to form a ground, the interlaces of the ground warp yarn (Gl) complementing the interlaces of the ground warp yarn (G2); and a pile component comprising a pile warp yarn (P) having a pile base (PB) located at the ground component, the pile warp yam (P) looped over the plurality of weft yarns (W) on the upper side (US) or the lower side (LS), thereby forming a plurality of pile loops extending away from the ground component along the vertical direction; wherein the plurality of pile loops formed in the second block (B2) complements the plurality of pile loops formed in the first block (Bl).

2. The terry article as claimed in claim 1, wherein each of ground warp yam in the plurality of ground warp yarns (Gl, G2) are same or different yarns and can be selected from natural cotton, manmade cellulose fibre, synthetic polymers, recycled fibres, low-absorbent fibres, and blends thereof.

3. The terry article as claimed in claim 1, wherein the pile warp yarn (P) is selected from natural cotton, man-made cellulosic fibres, hygroscopic - high absorbent low twist fibres, and combinations or blends thereof.

4. The terry article as claimed in claim 1, wherein the weft yam is selected from natural cotton, manmade cellulose fibre, synthetic polymers, recycled fibres, low-absorbent fibres, and blends thereof.

5. The terry article as claimed in claim 1, wherein the pile content in the terry article ranges between 30 wt.% to 55 wt.% based on the total weight of the article.

6. The terry article as claimed in claim 1, wherein each ground interlace of the ground warp yarn (Gl) on the upper side (US) or the lower side (LS) has a corresponding ground interlace of theground warp yarn (G2) on the lower side (LS) or the upper side (US), thereby each ground interlace of the ground warp yam (Gl) complementing each ground interlace of the ground warp yam (G2).

7. The terry article as claimed in claim 1, wherein each pile loop of the first block (Bl) on the upper side (US) or the lower side (LS) has a corresponding pile loop of the second block (B2) on the lower side (LS) or the upper side (US), thereby each pile loop of the first block (Bl) complementing each pile loop of the second block (B2).

8. The terry article as claimed in claim 1, wherein the terry article is selected from 3-pickterry article, 4-pick terry article, 5-pick terry article, 6-pick terry article, 7-pick terry article, 8-pick terry article, 9-pick terry article, and any combination thereof.

9. The terry article as claimed in one or more of claims 1 to 8, wherein the terry article has a GSM ranging between200 to 900, a pick density ranging between 33 to 62 picks per inch, a pile loop count ranging from 6’s to 30’s and a pile height ranging from 2 mm to 7.5 mm.

10. The terry article as claimed in one or more of claims 1 to 9, wherein the terry article further comprises: (i) one or more pile warp yarns in the first block (Bl) and / or the second block (B2), and / or (ii) one or more ground warp yarns between the first block (Bl) and the second block (B2).

11. A method for producing the terry article with reduced pile content as claimed in one or more of claims 1 to 10, comprising at least the step of weaving the ground component and the pile component followed by optionally subjecting the terry article to wet processing.

12. The method as claimed in claim 11, wherein the wet processing comprises treating the terry article with one or more of the following: wetting agent, desizing agent, hydrogen peroxide stabilizer, lubricant, core alkali neutralizer / buffer, and levelling agent.

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