CN105531411A - Terry fabric and method of manufacture - Google Patents

Abstract

The invention provides a loop fabric which is light and thin as common clothes and has the same water absorption, heat preservation, air permeability, skin touch feeling and the like as towel tissues. The loop height is low compared to the general towel stitch, i.e., the comparative example, which is the first structure. A loop was formed from cotton yarn having a finer count than the comparative example, which is the second structure. The loop density is high compared to the comparative example, which is the third configuration. The fourth structure is that the water-soluble yarn is reversely twisted in the cotton yarn, and the water-soluble yarn is removed after weaving, so that the cotton yarn is untwisted.

Description

Terry fabric and method of manufacture

technical field

The invention relates to a terry fabric and a method for manufacturing the terry fabric.

Background technique

As the fabric having loops, there is, for example, a towel. The warp yarns of the fabric organization are divided into two systems, one system is tensioned, and the other system is loosened, and the warp yarns of the loosened system are looped and relaxed, thereby forming piles. Because the loop is in the shape of a loop and there are gaps between the yarns, it contains a lot of air and has moderate elasticity. By having loops, the towel has excellent water absorption, heat retention, air permeability, skin touch, and the like.

Conventionally, there is disclosed a towel which has the above-mentioned pile characteristics and is soft and excellent in volume (for example, Patent Document 1).

However, the present inventor has made great efforts for the innovative development of the towel industry. One aspect of the efforts is that the towel weave has both water absorption, heat retention, breathability and skin touch, and thus the use of the towel weave for clothes has been studied. About the clothes of towel structure, although bathrobe has been commercially available, the present inventor also hopes to be used in clothes such as shirts.

Generally speaking, the fabrics of shirts, underwear, home clothes, and pajamas are slub weaving, circular rib weaving, knitting, flute cotton, etc., or cloth, yarn, Oxford cloth, twill, satin, flannel, etc. and other fabrics.

When the pile fabric is used as clothing, it needs to be as light and thin as general clothing fabrics.

However, general towel tissue is 2 to 3 times heavier and 5 to 10 times thicker than general cloth for clothing (described later). Clothes are for everyday wear. If the clothes are heavy, the burden is heavy, and comfort and wearing comfort cannot be maintained. In addition, when used as clothes, it is required to be easy to sew. When the fabric is thick, it is difficult to sew.

As a means to solve the problem of the heavy and thick towel weave, it is proposed to lower the pile height (the pile length is short, the meaning of which will be described later). Examples of towels with short (low) piles include sports towels. The purpose of sports towels is to absorb sweat, and therefore, the water absorbency of bath towels for the purpose of absorbing water during bathing is not required. On the other hand, since it is thin and light, it is suitable for situations requiring portability such as sports.

Patent Document 1: Japanese Patent Application Laid-Open No. 8-013283

Contents of the invention

If a thin sports towel tissue is used for clothing with emphasis on portability, the skin feel of the towel will be lost. Although skin touch is subjective, it can be approximated by the ratio of loop height to loop yarn diameter. That is, if the pile height is low, the rigidity of the pile is too strong, and a stiff feeling is produced. Sports towels do not care about the touch when wiping sweat, and this level of touch is not suitable for clothing that is always in contact with the skin.

The present invention was made in order to solve the above problems, and its object is to provide a terry fabric that can maintain the same lightness and thinness as general clothing fabrics, and has the same water absorption, heat retention, and air permeability as towel tissue. and skin feel.

In order to solve the above problems, the present invention provides a terry fabric having loops formed using cotton yarns with a count of 50 to 100 and a pile height of less than 5 mm.

Preferably, the cotton yarn is cotton yarn with a count above 60 inch and below 90 inch.

Thinness and lightness can be achieved by having a low pile height and using a fine count cotton yarn.

Preferably, the loop density of the loops is not less than 40 and not more than 60 per inch in the weft direction, and not less than 18 and not more than 22 per inch in the warp direction.

Thereby, the feature of a pile is not impaired.

Preferably, the water-soluble yarn is reverse twisted in the cotton yarn of the terry. That is, it is an intermediate product having a water-soluble yarn.

Preferably, the loops are formed by removing water-soluble yarn reversely twisted in the cotton yarn.

Preferably, the water-soluble yarn is twisted with the cotton yarn in a range of not less than 30% and not more than 170% of the twisting direction relative to the cotton yarn.

Water-soluble yarns become reinforcements when woven. After removal of the water soluble yarn, untwisting occurs.

In order to solve the above problems, the present invention also provides a method for manufacturing terry fabrics, comprising: reversely twisting water-soluble yarns in cotton yarns with a count above 50 inches and below 100 inches to form a plied yarn; forming a fabric having loops having a loop height of less than 5 mm from the plied yarn; and removing the water-soluble yarn from the fabric.

The terry fabric of the present invention can maintain the same lightness and thinness as general clothing fabrics, and has the same water absorption, heat retention, breathability, and skin feel like towel tissue. As a result, the terry fabric of the present invention can be used for clothing.

Description of drawings

FIG. 1 is a comparison between a comparative example and an embodiment of the present invention.

detailed description

Structure Summary

In the present embodiment, the pile height is lower than that of a general towel structure (comparative example 1, which will be described in detail later) (first structure). Compared with Comparative Example 1, loops were formed from a finer count cotton yarn (second structure). Compared with Comparative Example 1, the pile density is high (third structure). The water-soluble yarn is reversely twisted with the cotton yarn, and after weaving, the water-soluble yarn is removed, whereby the cotton yarn is untwisted (fourth structure).

The first structure (low pile) and its function

The pile height of a general towel structure (comparative example 1) is about 5 to 12 mm, for example, often about 5 to 7 mm. This is because the high loop height improves water absorption and skin feel.

On the other hand, in Comparative Example 1, when the pile height was less than 5 mm, the rigidity was high, and a soft touch on the skin could not be obtained.

On the other hand, in this embodiment, the pile height is 0.8 mm or more and less than 5 mm.

If it exceeds 5 mm, it is the same as the comparative example, and the light and thin effect cannot be obtained. When it is less than 0.8 mm, the effects of the pile (water absorption, heat retention, air permeability, etc.) cannot be obtained.

Within the range described above, both the light and thin effect and the loop effect can be achieved. Moreover, the above-mentioned effect can be more reliably achieved if it is 1.5 mm or more and 3 mm or less.

By making the cloth light, a feeling of wearing as clothes can be obtained.

By making the fabric thin, it is easy to sew.

The second structure (fine count) and its function

In the pile yarn of Comparative Example 1, a cotton yarn having a coarse count of 20 to 30 imperial counts was used. In the case of using double yarn, it is 30-60 inch count. This is because the thicker the pile yarn, the higher the water absorption.

On the other hand, in this embodiment, the pile yarn uses the cotton yarn of 50 inch count or more and 100 inch count or less.

If the thread count is less than 50 inch (thicker than the 50 inch thread count), the skin feeling significantly different from that of Comparative Example 1 cannot be obtained. If the thread count exceeds 100 inch (thinner than 100 inch thread), sufficient heat retention and water absorption cannot be obtained. In addition, from the viewpoint of weaving ability, the thread count is preferably 100 inches or less.

Within the above range, the ratio of the pile yarn diameter to the pile height becomes small. Thereby, when the loops are in contact with the skin, they are moderately deformed, and a soft touch on the skin can be realized. On the other hand, sufficient heat retention and water absorbency can be maintained.

By thinning the count, it is possible to further reduce the weight.

And, if use the cotton yarn of more than 60 imperial counts more than 90 imperial counts, can realize above-mentioned effect more surely.

In the present embodiment, yarns (ground warp yarns, ground weft yarns) used in the ground weave are also 30 to 50% thinner than Comparative Example 1.

The third structure (high density) and its function

In Comparative Example 1, the number of piles per inch was 32 to 33 in the weft direction, and 16 to 17 in the warp direction. The density of the ground weave is 32-33 warp yarns per inch and 48-50 weft yarns per inch.

When the above-mentioned pile density is used for the above-mentioned second structure (fine count), it looks transparent, and the pile retention property is also weak. In addition, sufficient cloth strength cannot be obtained. Also in the case of sewing clothes, sufficient sewing strength cannot be obtained.

In contrast, in this embodiment, the number of loops per inch is 40 to 60 in the weft direction, and 18 to 22 in the warp direction, and the density of the ground weave is 40 to 60 per inch in the warp yarn. Weft yarns are 54 to 66 per inch.

By making the pile density and the ground texture density higher than those of Comparative Example 1, the ratio of the pile yarn weight to the cloth weight can be maintained within a predetermined range even with the first and second configurations described above. As a result, the characteristics of the pile fabric are not impaired.

On the other hand, although the weight increases when the density is high, since the above-mentioned first structure and the second structure have a large weight reduction effect, the overall weight reduction effect can be maintained.

In addition, the high density ensures sufficient loop retention, fabric strength, and sewing strength.

The fourth structure (water-soluble yarn and untwisting) and its function

Because the second structure (fine count) is adopted, high-speed weaving cannot be performed under the condition of using an automatic loom widely used at present. That is, since the yarn is thin, the strength of the yarn during weaving is not sufficient.

On the other hand, in the present embodiment, a water-soluble yarn is reversely twisted with a fine-count cotton yarn to form a plied yarn, and a woven fabric having loops is formed from the plied yarn. By reinforcing fine-count cotton yarns with water-soluble yarns, it is possible to weave at high speeds using automatic looms widely used today.

The water-soluble yarn is twisted with the cotton yarn in a reverse direction of 30% to 170%. After weaving, the water soluble yarn is removed from the fabric.

30% twisting of the water-soluble yarn means that the number of twists of the water-soluble yarn is 30 relative to 100 twists of the cotton yarn.

As a result, in the cotton yarn from which the water-soluble yarn was removed, untwisting occurred with respect to the twisting in the original cotton yarn, and the number of twists was -70% or more and 70% or less.

For example, when the water-soluble yarn is reversely twisted with the cotton yarn by 30%, the twist number of the cotton yarn from which the water-soluble yarn is removed is 70% (=100-30). When the water-soluble yarn was reversely twisted with the cotton yarn by 170%, the twist number of the cotton yarn from which the water-soluble yarn was removed was -70% (=100-170). A negative twist count indicates reverse twisting from the twist of the original cotton yarn.

When the yarn is untwisted, the twist is relaxed, which can improve the soft skin touch.

If the twist of the water-soluble yarn is less than 30%, a sufficient reinforcing effect cannot be obtained. When the water-soluble yarn is twisted more than 100%, the original cotton yarn is reverse twisted. Therefore, if the water-soluble yarn is twisted more than 170%, the effect of soft skin touch is insufficient.

Verification test

The effect of this embodiment was verified by comparing this embodiment with Comparative Example 1 (towel texture) and Comparative Example 2 (common clothing fabric).

FIG. 1 is a conceptual diagram of a comparison between Comparative Example 1 and the present embodiment. The upper figure shows Comparative Example 1, and the lower figure shows Examples.

As an example of this embodiment, Example 1 and Example 2 were tried. In embodiment 1 and embodiment 2, the loop height is 1.8mm, and the cotton yarn of count 80 is used for the loop, and the loop density is 47 loops/inch in the horizontal direction and 20 loops/inch in the vertical direction. The number of twists after untwisting in Example 1 was 70%, and the number of twists after untwisting in Example 2 was 0% (untwisted yarn).

Comparative Example 1 is a towel tissue for thin hand towels and the like. In Comparative Example 1-1, the pile height was 5.0 mm, cotton yarn with a count of 20 inches was used for the pile, the pile density was 32 loops/inch in the horizontal direction, and 16 loops/inch in the vertical direction, and it was a twisted yarn. In Comparative Example 1-2, the pile height was 7.0 mm, cotton yarn with a count of 30 inches was used for the pile, the pile density was 33 loops/inch in the horizontal direction, and 17 loops/inch in the vertical direction, and it was a non-twisted yarn.

Comparative example 2 is a general fabric for home clothes and pajamas.

Comparative Example 2-1 is slub cotton. Slub cotton is used as material for underwear and T-shirts. As a general clothing fabric, it has excellent air permeability and water absorption.

Comparative Example 2-2 is cotton cloth. Cotton is widely used as a material for spring and summer pajamas and spring and summer collared shirts. As a general clothing fabric, it is excellent in thinness and lightness.

Comparative Examples 2-3 are flannel. Flannel is widely used as a material for autumn and winter pajamas and autumn and winter collared shirts. As a general clothing fabric, it has excellent heat retention.

The comparison results are shown in Table 1, and the comparison results will be described with reference to Table 1.

Table 1

About Cloth Thickness

Comparing Comparative Example 1 and Comparative Example 2, Comparative Example 1 is 5 to 10 times thicker than Comparative Example 2. That is, Comparative Example 1 was not easy to sew. Comparative Example 1 could not be used for clothing.

On the other hand, in this embodiment, cloth can be thinned by the said 1st structure. The thickness is slightly thicker than that of Comparative Example 2, and it is thin enough to allow easy sewing.

About lightweight

Comparing Comparative Example 1 and Comparative Example 2, Comparative Example 1 is 2 to 3 times heavier than Comparative Example 2. That is, in Comparative Example 1, the weight borne was large, and wearability was insufficient.

On the other hand, in this embodiment, cloth can be made light by the said 1st structure and 2nd structure.

Comparing this embodiment with Comparative Example 1, it is about 50% or less lighter. The inventors of the present invention also conducted surveys on consumers who needed it, and as a result, it was confirmed that if the weight is reduced by 20% or more, the weight reduction can be felt reliably. Although Comparative Example 1 is also characterized by lightness due to its thinness, in this embodiment, lightness is remarkably improved. Therefore, this embodiment is not only light in weight, but lightness that can be felt reliably by the person who needs it. In particular, there is a significant difference in the lightness feeling for persons who require weak strength, such as children, the elderly, and women.

Comparing this embodiment with Comparative Example 2, it is about the same as the lightest Comparative Example 2-2. Therefore, even in comparison with Comparative Example 2, this embodiment can make the user feel lightness reliably.

Although the above-mentioned third structure has an effect of increasing the weight, since the above-mentioned first structure and the second structure have a large effect in terms of weight reduction, the effect of weight reduction can be maintained as a whole.

About hygroscopicity and water absorption

Generally speaking, the larger the volume of the towel, the higher the water absorption. Therefore, at the research stage of the present invention, since the count of the pile yarn is made thin and the pile height is low, the volume is small, and it seems that hygroscopicity and water absorbency should be lowered. However, when this embodiment is compared with Comparative Example 1, they are almost at the same level. Specifically, when compared with Comparative Example 1-1 for the purpose of exhibiting the water absorbing function, the hygroscopicity and water absorbability were slightly lower than those of Comparative Example 1-1. Considering that the weight ratio is 50% or less, hygroscopicity and water absorption are almost equal. When compared with Comparative Example 1-2, the hygroscopicity and water absorbency of the present embodiment are higher.

In the present embodiment, the ratio of the weight of the pile yarn to the weight of the cloth is maintained within a predetermined range by the above-mentioned third structure, thereby maintaining the characteristics of the pile fabric. As a result, it is hygroscopic and absorbent.

When this embodiment is compared with Comparative Example 2, it has remarkable water absorption of 1.8 times to 3 times that general clothes fabrics do not have.

About breathability

In this embodiment, the clearance between loops is large by the said 2nd structure and 4th structure. As a result, it is breathable.

Although the above-mentioned third structure makes the gap between loops small, because the effect of the above-mentioned second structure and fourth structure is large, air permeability is maintained as a whole.

Comparing the present embodiment with Comparative Example 1, the air permeability is better than that of Comparative Example 1-1, and has an air permeability close to that of Comparative Example 1-2. That is, the characteristics of the pile fabric are maintained.

Comparing this embodiment with Comparative Example 2, it has better air permeability than Comparative Example 2-1 which has the best air permeability.

About heat retention

Generally speaking, the larger the volume of the terry fabric, the higher the heat retention. Therefore, at the research stage of the present invention, since the count of the pile yarn is made thin and the pile height is low, the volume is small, and it seems that the heat retention should be sacrificed (reduced). However, comparing the present embodiment with Comparative Example 1, the heat retention property decreased by 15 to 35% with respect to the weight ratio of 50% or less. That is, the heat retention of the terry fabric is maintained.

In the present embodiment, the ratio of the weight of the pile yarn to the weight of the cloth is maintained within a predetermined range by the above-mentioned third structure, thereby maintaining the characteristics of the pile fabric. As a result, it has heat retention.

Comparing this embodiment with Comparative Example 2, it has the same or higher heat retention than Comparative Example 2-3 which has the best heat retention.

About contact cold

The so-called cold feeling is an index related to the temperature when the cloth touches the skin. The larger the value, the more heat moves from the skin to the fabric, and the user feels colder. Conversely, a small value means less heat transfer from the skin to the fabric, and it does not feel cold when in contact with the skin. In general, when the difference between the two samples is 0.03 W/cm ² or less, it is judged that there is no significant difference.

Comparing the present embodiment with Comparative Example 1, the cold feeling upon contact is at the same level as that of Comparative Example 1-1, and not much different from that of Comparative Example 1-2. That is, the characteristics of the pile fabric are maintained.

Comparing this embodiment with Comparative Example 2, the amount of heat transfer is reduced by 40 to 50%, and it does not feel cold when it comes into contact with the skin. This embodiment has a remarkable touch warm feeling.

About skin touch

In the present embodiment, soft skin feel can be obtained by the above-mentioned second structure and fourth structure.

Effect summary

In this embodiment, lightness and thinness equal to or higher than that of general clothing fabrics (Comparative Example 2) can be realized.

In this embodiment, it is possible to achieve hygroscopicity, water absorption, air permeability, heat retention, contact warmth, and skin touch that are equivalent to or higher than those of general towel tissue (Comparative Example 1).

That is, the present embodiment has balance in various functions required for clothing such as lightness, thinness, hygroscopicity, water absorption, air permeability, heat retention, contact warmth, and skin touch. In other words, there is no trade-off relationship between functions in order to improve one function at the expense of other functions.

When used in clothing, it has hitherto unseen comfort and wearability. That is, in summer, it has hygroscopicity, water absorption, and air permeability, and can maintain the environment inside the clothes against a rise in body temperature and perspiration. In addition, because it has loops, the contact area with the skin is small, so there is less sweat stickiness. In winter, it has heat retention and good contact warmth, and it does not feel cold when it contacts the skin, and maintains body temperature. In addition, it is lightweight regardless of the season.

In addition, it is thin enough to sew easily, and has sufficient loop retention, cloth strength, and sewing strength. That is, the practicality is high.

other structures

Because of the above-mentioned second structure and fourth structure, there is sometimes concern about hair loss.

However, when cotton is decomposed, fibers of various lengths are obtained. Generally speaking, if there is more long-staple cotton, there will be fewer joints during spinning and the strength will be higher.

Generally, cotton having an effective fiber length of 20 mm to 25 mm is mixed, and cotton yarn having an average effective fiber length of 22 mm to 23 mm is used.

On the other hand, in this embodiment, it forms by twisting the cotton whose effective fiber length is 30 mm or more and 42 mm or less. Preferably, it is formed by twisting cotton whose effective fiber length is not less than 34 mm and not more than 42 mm.

The present inventors have concluded through trial and error that if the effective fiber length is 30 mm or more, durable strength can be obtained and lint can be suppressed. Furthermore, if the effective fiber length is 34 mm or more, durable strength can be reliably obtained regardless of the type of cotton.

On the other hand, the effective fiber length of 42 mm is the upper limit of the fiber length of general cotton. Although there are individual differences, fibers longer than 42 mm cannot be obtained.

Thereby, even in the case where the said 2nd structure and 4th structure are employ|adopted, lint fall can be suppressed.

Supplementary matters

Supplement 1

Generally speaking, in the towel industry, towels with a sense of volume tend to be considered high-end. If the count is thick, there will be a sense of volume. Therefore, those skilled in the art pay attention to how to use the coarse count. In the process of towel trading, the price is also tended to be determined according to the weight of the towel. Therefore, those skilled in the art would not think of using fine count cotton yarns in pile loops.

However, the inventors of the present invention have studied the use of towel tissue not only for bathing articles such as bathrobes but also for everyday clothes such as shirts. In this process, focus on the fine count.

That is, the focus of the present inventors is opposite to the technical direction of those skilled in the art, so it is difficult for those skilled in the art to think about it.

In addition, towels are mostly used to wipe the body when taking a bath, and technical personnel in the clothing industry do not focus on the organization of towels. The present invention provides a completely new cloth for clothing in the clothing industry so far.

Supplement 2

The functions of light and looped are often opposite. This embodiment realizes both of them simultaneously by the above-mentioned structures 1-4.

The present inventors found the balance of the above-mentioned structures 1 to 4 by repeating a large number of experiments and examining the results of the experiments. That is, it is not easily conceivable by those skilled in the art.

Supplement 3

Both sides of the cloth have loops, and the cloth whose surface is covered by the loops, the cloth knitted by weaving, trolley, etc. is heavy. In order to make it light, the density must be thick, and in order to maintain strength, it is necessary to use polyester in weaves other than pile.

Moreover, the fabric with loops has stretchability, because the ground tissue lacks directionality, so the fabric is not stretched, and when worn, the fabric is in a sagging state due to weight, resulting in loss of shape. In addition, because it is easy to be in close contact with the skin, although it has a sense of fit, it sometimes lacks breathability or heat retention.

Therefore, the present inventors focused on towel tissue.

Supplement 4

In the present specification, "the pile height is low" is used to mean "the pile length is short".

However, the pile yarn rises from between the weft yarns and returns between the weft yarns via two weft yarns. Thus a ring is formed. Generally speaking, the length of each loop refers to the length of the yarn from the beginning (rising) to the end (return) of a loop.

Although "pile length" and "pile height" have the same meaning, "pile height" is used uniformly in this application because it may be confused with "length of each loop".

The loops may expand due to their loop shape, or shrink due to the twisting of the yarn, so the actual measurement of the loop height is not certain. On the other hand, the length of each pile is determined by the reed pitch (reedloose) at the time of weaving, and is accurately determined according to the setting of the loom. Therefore, let's take half of the length of each loop as the loop height.

industry availability

The present invention can be applied to clothes such as shirts, house clothes, pajamas, and baby clothes. For example, it can be used for collared shirts, crew neck shirts, pajamas, loungewear, underwear, etc. Especially, it is suitable for pajamas, home clothes, underwear, etc.

Although it can be widely used as a material of clothing, it is not limited to these uses, and can also be used for sewn products such as bedding and clothing.

Claims (7)

1. a knop cloth, that the cotton with below more than use 50 English count 100 English counts is formed, terry height is less than the looped pile of 5mm.

2. knop cloth according to claim 1, is characterized in that, described cotton is the cotton of below more than 60 English counts 90 English count.

3. knop cloth according to claim 1 and 2, is characterized in that, the pile density of described looped pile is broadwise per inch more than 40 less than 60, warp-wise per inch more than 18 less than 22.

4. the knop cloth according to any one of claims 1 to 3, is characterized in that, the water-soluble yarn of reverse twisted in the cotton of described looped pile.

5. the knop cloth according to any one of claims 1 to 3, is characterized in that, described looped pile is formed by the water-soluble yarn of removing reverse twisted in described cotton.

6. the knop cloth according to claim 4 or 5, is characterized in that, described water-soluble yarn with reverse relative to the twisting of described cotton more than 30% less than 170% scope and described cotton twisted.

7. a manufacture method for knop cloth, comprising:

The water-soluble yarn of reverse twisted in cotton more than 50 English counts below 100 English counts and form doubled yarn;

Formed by described doubled yarn and there is the fabric of terry height less than the looped pile of 5mm; And

From the described water-soluble yarn of described fabric removing.