Terry Fabric with Variable Pile Height Zones
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Solution Overview
Problem
Woven terry fabrics, such as towels, have uniform weight distribution, leading to inefficient resource usage in manufacturing and laundering, as the entire fabric is treated equally despite only the central area being primarily used, resulting in higher material and energy consumption.
Innovation Solution
A terry fabric with controlled weight distribution is achieved by varying the pile height of individual rows or zones, reducing the weight of non-primary use areas while maintaining the appearance and absorbency of conventionally woven towels, by incrementally increasing pile height from the edges to the center.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If the pile height is reduced to decrease towel weight, then resource consumption in laundering is reduced, but the absorbency and perceived quality of the towel deteriorates
Solution Approach 1:
The patent applies local quality by creating different pile heights in different zones of the towel. The central zone (primary use area) maintains higher pile height for optimal absorbency and luxurious feel, while peripheral zones have reduced pile height to decrease overall weight. This spatial variation in pile height allows the towel to provide high performance where needed while reducing material consumption in less critical areas.
Solution Approach 2:
The towel is segmented into multiple zones with different pile height characteristics. The fabric is divided into a central zone with higher pile height and peripheral zones with lower pile height, allowing differential treatment of different functional areas. This segmentation enables the towel to optimize the balance between weight reduction and performance maintenance.
2Ease of manufacture
If uniform pile height is used across the entire towel, then manufacturing simplicity is maintained, but resource inefficiency occurs as non-primary areas have unnecessary weight
Solution Approach 1:
The patent implements local quality by varying pile height across different zones of the towel fabric. The central zone maintains higher pile height while peripheral zones have reduced pile height, creating a non-uniform weight distribution that reduces overall material consumption and laundering resources while maintaining manufacturing feasibility through controlled zone definitions.
3Weight of stationary object
If the towel weight is reduced by decreasing pile height, then laundering costs are reduced, but the luxurious feel and absorbency in the primary use area deteriorates
Solution Approach 1:
The patent applies local quality by concentrating higher pile height in the central zone where users primarily contact the towel, ensuring optimal absorbency and luxurious feel in the most important area. Peripheral zones with reduced pile height contribute to weight reduction without significantly impacting user experience, as they are less frequently used for drying purposes.
Data Source
AI summary
Described is a controlled weight distribution woven terry fabric that includes a body having a first end and a second end, wherein the first and second ends are opposite one another and a first side edge 34 and a second side edge, wherein the first and second side edges are opposite one another and generally perpendicular to the first and second opposite ends. The terry fabric further includes a plurality of zones extending across the fabric between one of the first and second opposite ends or the first and second opposite edges. Each zone of the plurality of zones has a pile with a pile height and the pile height in a zone differs from the pile height in an adjacent zone and the difference between the pile heights in adjacent zones is in a range between about 0.1 mm and about 2 mm. Also described are articles, such as towels, wash cloths, and bath mats, made from the controlled weight distribution woven terry fabric.