Loop Pile Fabric Structure for Soft Touch and Pile Retention
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Solution Overview
Problem
Existing pile fabrics face challenges in achieving both a soft touch feeling and durability, with non-twisted yarns leading to fluff coming out and fine count yarns compromising water absorbency and rigidity, resulting in pile yarns easily coming out during use and washing.
Innovation Solution
The pile fabric features a base weave construction with loop piles formed of twisted yarns having a twisting coefficient of 2.0 or greater, where the loop piles have a height 40 times or greater than the diameter, and snarls are formed on neighboring loop piles that entwine together, enhancing pile retention properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If non-twisted yarn is used for pile yarn to achieve soft touch feeling, then the softness and lightness are improved, but fluff comes out easily and bundle formation is poor
Solution Approach 1:
The patent applies parameter changes by using non-twisted yarn (zero twist) instead of traditionally twisted yarn, fundamentally changing the twist parameter to achieve softness while accepting the fluff issue, which then requires additional structural solutions
Solution Approach 2:
The patent segments the pile structure by forming multiple snarls along the pile yarn length and creating entwinement between neighboring piles, dividing the single structural element into multiple interacting components that collectively prevent fluff loss
2Ease of operation
If fine count yarn is used for pile yarn to achieve soft touch feeling, then the rigidity decreases and softness increases, but water absorbency and other properties are lowered
Solution Approach 1:
The patent changes the yarn count parameter to fine count (higher number) to reduce rigidity and increase softness, while compensating for the reduced water absorbency through increased pile density and the snarl entwinement structure that maintains functional properties
3Ease of operation
If loop piles are made longer to achieve softer feel, then the rigidity of piles becomes lower, but the tendency of hooking and coming out of pile yarn becomes stronger
Solution Approach 1:
The patent segments the long pile structure by forming multiple snarls at different positions along the pile yarn, creating multiple anchoring points that prevent the entire long pile from hooking and coming out, thus enabling long piles to maintain both softness and retention
Solution Approach 2:
The patent merges neighboring loop piles through entwinement of their snarls, creating a interconnected network where piles support each other, reducing the tendency of individual long piles to hook and come out during use and washing
4Reliability
If twisted yarn is used for pile yarn to improve durability, then the bundle formation is good, but the soft touch feeling is reduced
Solution Approach 1:
The patent changes the twist parameter from traditional twisted yarn to non-twisted yarn (zero twist), fundamentally altering the yarn structure to achieve softness, while compensating for the resulting durability issues through the snarl entwinement structure that provides mechanical reinforcement
Data Source
AI summary
Provided is a pile fabric that can provide both a soft touch feel and durability (pile retention and/or suppression of pile loss). The pile fabric is provided with a base structure formed from a warp and weft and a loop pile formed from pile yarn. The pile yarn is twisted yarn with a twist factor of 2.0 or greater. When the pile yarn is untwisted yarn or weakly twisted yarn, insoluble yarn prior to water soluble yarn elimination is twisted yarn with a twist factor of 2.0 or greater. The proportion of pile height to pile yarn diameter is 40× or greater. The gap between adjacent pile yarn strands is 0.5 mm or less. The pile yarn is 50-120 English yarn count. The loop pile has snarling, and the snarling for adjacent piles is entangled.