Terry Fabric Differential Pick Density Weight Reduction
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Solution Overview
Problem
Conventional woven terry fabrics have uniform pick density, leading to inefficient resource usage and higher weight, which results in increased laundry costs and reduced absorbency, making them less luxurious and less preferred in the hospitality industry.
Innovation Solution
A woven terry fabric with differential pick density, featuring zones with varying picks per centimeter, achieved through a three-pick terry weave construction that includes zones of lowest, highest, and intermediate pick densities, allowing for controlled weight distribution and reduced unit weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform pick density is used throughout the fabric, then manufacturing is simplified, but weight and resource consumption increase
Solution Approach 1:
The patent applies local quality by varying the pick density in different zones of the fabric. The central zone has higher pick density (20-30 picks/cm) for enhanced absorbency where it is most needed, while edge zones have lower pick density (10-20 picks/cm) to reduce weight. This localized differentiation resolves the contradiction by optimizing each region according to its functional requirements rather than applying uniform density throughout.
Solution Approach 2:
The fabric is segmented into multiple zones with distinct pick density characteristics. The patent divides the fabric into a central zone and edge zones, each with different pick density ranges. This segmentation allows independent optimization of weight and absorbency properties in different regions, resolving the contradiction between manufacturing simplicity and weight reduction.
2Weight of moving object
If picks per centimeter is reduced to lower weight, then resource consumption decreases, but absorbency and luxury feel deteriorate
Solution Approach 1:
The patent resolves this contradiction by applying local quality through zone-specific pick density. The central zone maintains high pick density (20-30 picks/cm) to ensure adequate absorbency and luxury feel in the primary usage area, while edge zones use lower pick density (10-20 picks/cm) to reduce overall weight. This localized approach ensures absorbency is maintained where needed without unnecessarily increasing weight throughout the entire fabric.
3Quantity of substance
If higher picks per centimeter are used to increase absorbency, then luxury feel improves, but weight and laundry resource consumption increase
Solution Approach 1:
The patent applies local quality by concentrating higher pick density (20-30 picks/cm) in the central zone where absorbency is most critical, while using lower pick density (10-20 picks/cm) in edge zones. This resolves the contradiction by providing luxury feel and absorbency where needed without uniformly increasing weight across the entire fabric, thereby reducing overall resource consumption.
4Device complexity
If uniform pick density is used, then construction is simplified, but resource consumption for laundry increases
Solution Approach 1:
The patent resolves this contradiction by implementing local quality through zone-specific pick density. The central zone uses higher pick density (20-30 picks/cm) for enhanced absorbency, while edge zones use lower pick density (10-20 picks/cm) to reduce weight and resource consumption. This differentiated construction, while slightly more complex than uniform density, significantly reduces laundry resource consumption by lowering overall fabric weight.
Data Source
AI summary
The present invention generally relates to the field of textiles. More particularly, it relates to A woven terry cloth with differential or non uniform pick density having different picks per centimeter and method for producing the same with controlled weight distribution. The terry fabric with differential pick density, having: a body comprising of one or more ends of first end (L1) and second end (L2), one or more edges of first side edge (W1) and second side edge (W2), and a plurality of zones (Z1, Z2, Z3); a plurality of ground warp ends (G1, G2); a plurality of terry pile loop yarn (P1, P2); and a plurality of ground fill picks (f1, f2, f3, f4, f5, f6, f7, f8). Additionally the woven terry cloth includes variable density of picks in different zones of the fabric.