Terry Fabric Weave Sequence for High Pick Density and Uniformity
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Solution Overview
Problem
Existing terry fabrics face limitations in achieving higher pick density, improved pull resistance, absorbency, softness, and uniformity of texture, as prior art weave sequences restrict these properties.
Innovation Solution
A terry fabric weave sequence with a repeated weave pattern that includes specific interlacing arrangements of ground warp and pile warp yarns with weft yarns, allowing for the formation of pile loops over varying numbers of weft yarns on different surfaces, enhancing pick density and texture uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional 3 pick sequence weave pattern is used, then manufacturing process is simple, but pick density is limited
Solution Approach 1:
The weave pattern is segmented into distinct zones: compression zones where pile loops are compressed between ground fabric layers, and formation zones where pile loops are allowed to extend. This segmentation enables higher pick density by efficiently organizing pile yarn placement without requiring complex continuous patterns throughout the entire fabric.
Solution Approach 2:
The invention utilizes the third dimension (vertical compression) by allowing pile loops to extend in one direction and then compressing them between ground fabric layers. This dimensional approach enables higher pick density by stacking multiple pile loops vertically rather than only horizontally, effectively increasing the number of piles per unit area without proportionally increasing weave complexity.
2Reliability
If more pile yarn is used to increase absorbency, then absorbency improves, but material efficiency decreases
Solution Approach 1:
The ground fabric is designed with controlled porosity and open spaces between ground warp and weft yarns. These porous regions allow moisture to penetrate through to the pile loops, enhancing absorbency without requiring excessive pile yarn. The compression zones create controlled void spaces that facilitate moisture transfer while maintaining efficient material usage.
Solution Approach 2:
The invention changes the physical state and arrangement parameters of pile yarn by compressing loops in specific zones and allowing extension in others. This parameter variation optimizes the moisture absorption capacity of the pile structure while minimizing the total amount of pile yarn required, achieving better absorbency per unit of material consumed.
3Reliability
If pile loops are formed frequently to improve softness, then softness improves, but pull resistance decreases
Solution Approach 1:
Different regions of the fabric are assigned different qualities: compression zones provide structural integrity and pull resistance where pile loops are tightly bound between ground layers, while extension zones provide softness where pile loops are allowed to extend freely. This local differentiation enables the fabric to simultaneously achieve both softness and durability without compromising either property.
4Manufacturing precision
If traditional weave patterns are used, then manufacturing is straightforward, but texture uniformity is poor
Solution Approach 1:
The weave pattern employs periodic alternation between compression zones and extension zones in a regular, repeating sequence. This periodic structure creates uniform texture across the fabric by ensuring consistent distribution of compressed and extended pile loops throughout the material, while the regular repetition maintains relative simplicity in the weaving process through predictable pattern cycles.
Data Source
AI summary
A terry fabric having a plurality of longitudinally oriented ground warp yarns pairs, a plurality of longitudinally oriented pile warp yarns, and a plurality of weft yarns oriented substantially perpendicular to the ground warp yarn pairs. The terry fabric includes a repeated weave sequence comprising first and second interlacing arrangements.