Method for producing durable fluffy and soft loop fabric having embedded weft floats
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Solution Overview
Problem
Existing textile technologies face challenges in producing towels with durable softness and quick drying properties, as they often require high-energy dyeing processes and are prone to yarn breakage and uneven tension during weaving, leading to low-quality products.
Innovation Solution
A method involving yarn selection, winding, warping, sizing, weaving, and dyeing that uses a combination of natural and chemical fibers, with embedded weft floats forming a stacked stereoscopic structure to enhance moisture diffusion and drying, utilizing specific yarn ratios and twisting, and a unique dyeing and finishing process to maintain softness and hydrophilicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If microfiber filament yarns with fineness lower than 0.6 dtex are used to achieve durable softness and quick drying, then the softness and drying performance are improved, but yarn breakage occurs during warping and weaving, and weaving quality deteriorates
Solution Approach 1:
The patent changes the fineness parameter of the microfiber filament yarns to a specific range (0.6-1.5 dtex) and controls the twist factor within specific ranges. These parameter optimizations balance the softness and drying performance with weaving process stability, preventing yarn breakage while maintaining the desired tactile and functional properties.
Solution Approach 2:
The patent uses composite yarn structures combining natural fibers and chemical fibers in specific ratios. This composite approach leverages the softness and absorbency of natural fibers while incorporating the quick-drying properties of chemical fibers, achieving a balance between durability, softness, and manufacturability.
2Adaptability or versatility
If double-double pile structure is used to accommodate both microfiber yarns and natural fiber yarns, then both yarn types can be woven, but the weaving process becomes complex and production efficiency decreases
Solution Approach 1:
The patent designs a single pile structure that can accommodate both microfiber filament yarns and natural fiber yarns without requiring separate double-double pile configurations. This universal structure simplifies the weaving process while maintaining the ability to incorporate different yarn types, thereby improving production efficiency.
3Adaptability or versatility
If two bath and two step dyeing method is applied to dye both natural fiber yarns and microfiber filament yarns, then both yarn types are dyed, but energy consumption increases
Solution Approach 1:
The patent merges the dyeing processes for natural fibers and chemical fibers into a single bath and single step by selecting dyes and process conditions that can simultaneously dye both fiber types. This consolidation reduces the number of dyeing cycles, lowers energy consumption, and simplifies the dyeing workflow while maintaining colorfastness and quality.
4Reliability
If towels are washed frequently to maintain hygiene, then cleanliness is improved, but the towels become hard and take longer to dry
Solution Approach 1:
The patent employs composite yarns combining natural fibers (cotton, viscose) with quick-drying chemical fibers (polyester, polyacrylonitrile). This composite structure maintains softness and accelerates drying even after repeated washings, as the chemical fiber components provide rapid moisture evaporation while natural fibers retain absorbency and softness.
Solution Approach 2:
The patent optimizes the yarn fineness parameters (0.6-1.5 dtex for microfiber, 1.7-3.3 dtex for natural fibers) and twist factors to create a structure that resists hardening during washing. The controlled parameter ranges ensure the towel maintains its softness and drying performance throughout its service life.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in towels with durable softness and rapid drying capabilities, reducing energy consumption and yarn breakage, while maintaining softness after washing and enhancing moisture diffusion for efficient drying.
Implementation Method 1
the embedded floating weft yarns are small twisted or untwisted yarns with twist factor less than 260... the fluffy zero-twist yarns and interlaced yarn floats further form a stacked stereoscopic structure with other weft yarns fixedly connected to the loops, thereby facilitating the extension of the loops and enlarging moisture diffusion surfaces of the loops during baking and air-drying processes
Implementation Method 2
enlarging moisture diffusion surfaces of the loops during baking and air-drying processes to create a rapid drying condition for towels
Data Source
AI summary
A method for producing durable fluffy and soft loop fabric having embedded weft floats, including: 1) yarn selection; 2) winding; 3) warping; 4) sizing; 5) weaving; and 6) dyeing and finishing. During the weaving process, low-twist or zero-twist yarns or filament long floats are embedded into loops. During the dyeing and finishing process, due to weft-wise shrinkage, the embedded weft floats shrink and expand, thereby supporting the loops upright without lodging. In addition, the fluffy zero-twist yarns and interlaced yarn floats form a stacked stereoscopic structure with other weft yarns fixedly connected to the loops, thereby facilitating the extension of the loops and enlarging moisture diffusion surfaces of the loops during baking and air-drying processes to create a rapid drying condition for towels. Therefore, a loop fabric which has a special style and a fluffy and soft hand feeling and is still fluffy and soft after being washed is obtained.