Twisted Union Towel Yarn Structure for Fluff Resistance and Absorbency
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Solution Overview
Problem
Existing towel fabrics lack a bulky and fluffy texture while maintaining effective water absorbency, and often suffer from fluff dropping during use.
Innovation Solution
A towel cloth with a ground weave and pile yarns formed from twisted union finished yarns, where two or more rovings are primarily twisted and then partially untwisted to create a distorted structure with irregular twists, enhancing fluff resistance and water absorbency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a terry cloth underlayer and loop-pile upperlayer are combined in conventional layers, then the fabric provides basic absorption, but the absorption speed is slow and water remains on the surface
Solution Approach 1:
The patent transforms the conventional two-dimensional layered structure into a three-dimensional integrated structure by forming the underlayer and upperlayer in the same plane through simultaneous knitting. This dimensional integration allows water to be absorbed immediately upon contact with the fabric surface, eliminating the slow sequential absorption process of traditional layered towels while maintaining effective water retention through the combined capillary networks of both layers.
Solution Approach 2:
The patent merges the underlayer and upperlayer into a single integrated fabric structure formed in the same plane through double knitting. This merging eliminates the interface between layers that causes water to pool in conventional towels, allowing continuous and rapid water absorption throughout the fabric while maintaining structural integrity and drying performance.
2Stability of the object's composition
If conventional layered towel structures are used, then manufacturing is simple, but the fabric lacks elasticity and becomes hard when wet
Solution Approach 1:
The patent combines the underlayer and upperlayer into a single integrated knitted structure formed simultaneously in the same plane. This merging creates inherent structural elasticity through the interconnected knit patterns while maintaining manufacturing simplicity through a single-knitting-process approach that produces both layers together without requiring separate assembly operations.
3Productivity
If highly absorbent materials are used, then water absorption is fast, but the fabric takes a long time to dry
Solution Approach 1:
The patent applies different knit structures to different regions of the fabric - the underlayer uses a terry cloth structure with deep piles for rapid water absorption, while the upperlayer uses a loop-pile structure with smaller loops for controlled water release and faster evaporation. This local differentiation of structural properties enables the fabric to absorb water quickly while drying efficiently, resolving the contradiction between absorption speed and drying time.
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 towel cloth achieves a bulky and fluffy texture with reduced fluff dropping and improved water absorbency, while maintaining a balanced mix of cotton and synthetic fibers for quick dryability and dimensional stability.
Implementation Method 1
a yarn is knitted to form a terry cloth underlayer (122) and a loop-pile upperlayer (124) in substantially the same plane
Data Source
AI summary
There are provided a towel cloth which has a bulky and fluffy texture, is less likely to undergo fluff dropping, and is excellent in water absorbency, and a manufacturing method thereof. For a towel cloth including a ground weave including a warp ground yarn and a weft ground yarn crossing each other therein, and a pile yarn locked to the ground weave, at least one of the warp ground yarn, the weft ground yarn, and the pile yarn is formed of a twisted union finished yarn, and the twisted union finished yarn includes a twisted union yarn including two or more rovings twisted in a primary twisting direction as a single yarn, one of the rovings having an even twist, and at least another of the rovings partially having a twist with irregular strand length and twisting angle, the twisted union yarn undergoing fiber opening and being puffy.