Sheath-Core Pile Yarn Structure for Soft, Low-Fluff Towel Cloth
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Solution Overview
Problem
Existing pile yarns for towel cloths face issues of low strength, increased fluff, hard texture, and loss of puffiness due to uniform twisting or loose inner fibers, leading to poor durability and comfort.
Innovation Solution
A sheath-core spun yarn structure is used, where the core fiber is twisted in one direction and the sheath fiber is parallel to the yarn axis, with a water-soluble fiber wound in the reverse direction, allowing the core fiber to be tightened and the sheath fiber to be loose, enhancing durability and softness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If inner fibers and outer fibers are uniformly twisted in a ring spun yarn, then the yarn structure is uniform, but the yarn has low strength and increased fluff after untwisting
Solution Approach 1:
The patent applies local quality by creating different structural characteristics in different regions of the yarn. The core fibers are twisted in one direction while the sheath fibers are arranged parallel to the yarn axis, creating a non-uniform structure where the core provides strength through twisting and the sheath provides a loose, fluffy texture without the weakness associated with uniform twisting throughout the entire yarn.
2Ease of operation
If inner fibers are loose and outer fibers are tightly wound in a fasciated spun yarn, then the yarn has a soft texture, but the yarn becomes hard after washing
Solution Approach 1:
The patent resolves this contradiction by assigning different functions to different yarn regions. The core fibers are twisted to maintain structural integrity and prevent hardening after washing, while the sheath fibers are arranged parallel to the yarn axis to provide the desired soft texture. This local differentiation allows the yarn to maintain both softness and washing stability.
Solution Approach 2:
The patent segments the yarn into two distinct functional components: core fibers that provide structural stability through twisting, and sheath fibers that provide soft texture through parallel arrangement. This segmentation allows each component to fulfill its specific function without compromising the other, resolving the contradiction between softness and washing stability.
3Quantity of substance
If thick yarns with high fineness are used to increase basis weight for improved water absorbency, then water absorbency is improved, but the towel cloth becomes heavy and bulky
Solution Approach 1:
The patent utilizes the porous, fluffy structure created by the parallel-arranged sheath fibers to enhance water absorbency. The loose arrangement of sheath fibers creates air pockets and increased surface area that can hold more water, improving absorbency without requiring increased basis weight. This allows the towel to maintain lightness while achieving high water absorbency through structural design rather than mass increase.
Data Source
AI summary
A warp pile yarn 14 to be used for a towel cloth including a pile yarn, a warp ground yarn, and a weft ground yarn is a sheath-core spun yarn 10 in which a core fiber is twisted in one direction, while a sheath fiber is arranged parallel to a yarn axis. The sheath-core spun yarn 10 is twisted together with a water-soluble fiber yarn 13, and a direction in which the water-soluble fiber yarn 13 is wound is reverse to a direction in which the core fiber is twisted. By way of example, the pile yarn 14 is an air-spun yarn.