JP7553171B1 - Towel fabric and its manufacturing method - Google Patents

Abstract

[Problem] To provide a towel fabric with little yarn unevenness, which retains the pile nap of the finished towel fabric, soft and fluffy texture, water absorbency, etc., and a manufacturing method thereof. [Solution] Comprised of pile yarn, warp yarn, and weft yarn, the fiber material of the pile yarn is medium-fiber cotton or long-fiber cotton with an average fiber length of 28.6 to 34.7 mm and a micronaire of 4.1 to 5.8 μg/inch, with a short fiber content of 10 mass% or less with an average fiber length of 17 mm or less, and is a single yarn of untwisted or loosely twisted sirospun yarn, and the pile yarn, warp yarn, and weft yarn are yarn-bleached. [Selected Figure] Figure 1

Description

The present invention relates to a towel fabric that uses siro spun pile yarn and a method for manufacturing the same.

Traditionally, towel fabrics have been made by weaving pile yarns, warp yarns, and weft yarns into a pile fabric. To improve water absorption, towel fabrics have a relatively high basis weight (mass per unit area) and are made of thick, fine yarns.
Patent Document 1 proposes using synthetic sirospun yarn to make a heathered pile yarn. Patent Documents 2 and 3 propose using loosely twisted sirospun yarn to make a pile knitted fabric. In Patent Document 4, the present inventor proposes a towel fabric using untwisted or loosely twisted sirospun yarn as the pile yarn.

Japanese Patent Application Publication No. 10-088440 JP 2019-137941 A JP 2019-137942 A Patent No. 7372718

However, the above-mentioned conventional technology had problems with pile standability and soft, fluffy feel, and further improvements were required.

The present invention is the result of extensive research aimed at creating a high-quality towel fabric that has never been seen before. It provides a towel fabric with minimal unevenness in the threads, and which retains the pile nap, soft, fluffy texture, and absorbency of the finished towel fabric, as well as a method for producing the same.

One embodiment of the present invention relates to a towel fabric made of pile yarns, warp yarns, and weft yarns, in which the fiber material of the pile yarns is medium-fiber cotton or long-fiber cotton with an average fiber length of 28.6 to 34.7 mm and a micronaire of 4.1 to 5.8 μg/inch, and the content of short fibers with an average fiber length of 17 mm or less is 10 mass% or less, the pile yarns are untwisted or loosely twisted single yarns of silo spun yarn, and the pile yarns, warp yarns, and weft yarns are bleached.

Another embodiment of the present invention relates to a method for manufacturing a towel fabric, in which the fiber material of the pile yarn is medium-fiber cotton or long-fiber cotton with an average fiber length of 28.6 to 34.7 mm and a micronaire of 4.1 to 5.8 μg/inch, and the short fiber content with an average fiber length of 17 mm or less is reduced to 10 mass% or less by combing, the pile yarn is a spun yarn, the twist direction of the spun yarn is opposite to the primary twist direction of the three roving yarns, and a secondary twist equal to or greater than the number of twists in the primary twist is added to make a non-twisted or loosely twisted single yarn, the pile yarn, warp yarn, and weft yarn are bleached, and the pile yarn, warp yarn, and weft yarn are supplied to a jacquard loom to manufacture a towel woven fabric.

The fiber material of the pile yarn of the towel of the present invention is medium-fiber cotton or long-fiber cotton with an average fiber length of 28.6 to 34.7 mm and a micronaire of 4.1 to 5.8 μg/inch, and the content of short fibers with an average fiber length of 17 mm or less is 10% by mass or less. The pile yarn is a single yarn of untwisted or loosely twisted sirospun yarn, and the pile yarn, warp yarn, and weft yarn are bleached, so that there is little yarn unevenness, and a towel fabric and its manufacturing method can be provided that retains the pile standing property, soft and fluffy texture, water absorbency, etc. of the towel fabric in the woven state. In other words, by cutting the short fibers of medium-fiber cotton or long-fiber cotton at a specific ratio, it is possible to reduce yarn unevenness, and the towel fabric after weaving is made into a towel fabric product in a state after washing and drying without post-bleaching or post-dyeing. As a result, the quality of the towel fabric in the woven state becomes the quality of the product itself, resulting in a high-quality towel fabric.

FIG. 1 is a schematic perspective view of a triple sirospun spinning device according to one embodiment of the present invention. FIG. 2A is a schematic explanatory diagram of a towel fabric according to one embodiment of the present invention, and FIG. 2B is a woven fabric diagram of the same. FIG. 3A is a schematic explanatory diagram of a towel fabric according to another embodiment of the present invention, and FIG. 3B is a woven fabric diagram of the same. FIG. 4 is a staple diagram of a card sliver (fiber bundle) used in one embodiment of the present invention. FIG. 5 is a staple diagram of a sliver (fiber bundle) that has been combed once and is used in one embodiment of the present invention. FIG. 6 is a staple diagram of a sliver (fiber bundle) that has been combed twice for use in one embodiment of the present invention. FIG. 7 is a side photograph (magnification: 30 times) of the pile portion of the towel fabric in Example 1 of the present invention. FIG. 8 is a side photograph (magnification: 30 times) of the pile portion of the towel fabric of Comparative Example 1. FIG. 9 is a side photograph (magnification: 30 times) of the pile portion of the towel fabric of Comparative Example 2. FIG. 10 is a plan view (magnification: 10 times) of the towel fabric of Example 1 of the present invention. FIG. 11 is a plan view photograph (magnification: 10 times) of the towel fabric of Comparative Example 1. FIG. 12 is a plan view photograph (magnification: 10 times) of the towel fabric of Comparative Example 2.

The present invention is a towel fabric composed of pile yarn, warp yarn, and weft yarn. Pile yarn, which accounts for approximately 70% of the constituent yarns of towel fabric, is an important yarn that determines the pile standing property, the texture of the towel fabric, and functionality such as pilling. The fiber material of this pile yarn is medium-fiber cotton or long-fiber cotton with an average fiber length of 28.6 to 34.7 mm and a micronaire of 4.1 to 5.8 μg/inch, and the content of short fibers with an average fiber length of 17 mm or less is 10% by mass or less. This reduces unevenness in the spun yarn, resulting in a high-quality yarn. The pile yarn fiber material, medium-fiber cotton or long-fiber cotton, has an average fiber length of 28.6 to 34.7 mm and a fineness of 4.1 to 5.8 μg/inch micronaire, and has a high crimp and crimp strength. When applied to the spun spun yarn of the present invention, the twist tendency of the first twist and migration of the first twist (the phenomenon in which single fibers are twisted inward or outward) tend to remain, the fibers tend to entangle, and since it is a non-twisted yarn or a loosely twisted yarn, each constituent fiber exists in a free state. The "long-fiber cotton" mentioned above refers to the "long-fiber cotton" shown in Table 1 below, and is internationally recognized.

The pile yarn of the present invention is a single yarn of sirospun yarn with no twist or loose twist. That is, a secondary twist is added to the direction opposite to the primary twist of a plurality of roving yarns, the secondary twist being equal to or greater than the number of twists in the primary twist. This provides the following effects.
(1) Less shedding of fuzz.
(2) Bulky.
(3) It has a large amount of fluffiness and is very soft before washing.
(4) The fluffiness is less likely to be lost after washing, and deterioration due to washing is less likely to occur.
(5) There is little re-wetting, making wiping comfortable.
(6) Less likely to change dimensions when washed (less likely to shrink).
(7) It dries quickly.

The constituent yarns of the towel fabric of the present invention (pile yarns, warp yarns, and weft yarns) are bleached. This ensures that the quality of the towel fabric in the woven state is the quality of the finished product, resulting in a high-quality towel fabric.

The present invention uses sirospun yarn as the pile yarn. Sirospun yarn is a yarn in a state similar to a two-ply yarn or a three-ply yarn, which is made by drafting two or three roving yarns separately at a fixed interval and then twisting them together. Compared to two-ply yarns or three-ply yarns made by twisting multiple yarns together, the fibers of sirospun yarn are arranged regularly on the yarn surface and have less fuzz. For this reason, it can be used as a pile yarn as a single yarn. In addition, due to the yarn structure unique to sirospun yarn, even if it is a non-twisted yarn or a loosely twisted yarn, the fibers are entangled with each other, which makes it easy to wind, and it is less likely to break during weaving, and it also has good passability through the weaving process.

The count of the sirospun yarn is preferably 5 to 100 in English cotton count. For thin fabrics, a thin count of 100 to 40 is suitable, for medium-weight fabrics, a count of 30 to 16 is suitable, and for heavy fabrics, a thick count of 12 to 5 is suitable.

但し、t：撚回数(回／25.4ｍｍ)、Ｓ:綿番手（英式綿番手）
これにより、パイル糸は無撚り糸か又は甘撚り糸となる。 The spun spun yarn of the present invention preferably has a twist coefficient K of 0 to 3.5, more preferably 0 to 3.3, and even more preferably 0 to 3.0. The twist coefficient K is calculated by the following formula (Math 1).

Where, t: number of twists (twists/25.4mm), S: cotton count (British cotton count)
This results in the pile yarn being either a no twist yarn or a loosely twisted yarn.

It is preferable that the sirospun yarn is untwisted or loosely twisted by adding a secondary twist equal to or greater than the number of twists in the primary twist in the opposite direction to the primary twist direction of multiple rovings. For example, if the primary twist directions of two or three rovings are both Z-direction, the secondary twist is S-direction, and the number of secondary twists is equal to or greater than the number of twists in the primary twist. This allows each constituent fiber to exist in a more free state, resulting in a pile yarn with good nap standing and a soft, fluffy texture. Here, untwisted refers to a case where the twist coefficient K is zero, and loosely twisted refers to a case where the twist coefficient K is greater than zero and is 3.3 or less.

The silospun yarn is preferably a two-strand silospun yarn or a three-strand (triple) silospun yarn, more preferably a three-strand (triple) silospun yarn with a round cross section. The silospun yarn is preferably 100% cotton. 100% cotton provides a soft, fluffy texture and is also absorbent.

The warp and weft yarns are preferably ring-spun yarns using extra-long staple cotton with an average fiber length of 34.8-44.5 mm and a fineness of 3.0-4.1 μg/inch micronaire. The warp and weft yarns are preferably fine with an English cotton count of 10-50. The pile yarns form loop pile while being held in place by the ground structure made up of the warp and weft yarns, so if the warp and weft yarns are made of extra-long staple cotton and have a fine count, the pile yarns can be held in place with a high force and pile slippage can be prevented. Furthermore, the texture is good. The above-mentioned "extra-long staple cotton" is as shown in Table 1 below and is internationally recognized.

The twist coefficient K of the warp and weft yarns is preferably 3.5 to 4.5, more preferably 3.7 to 4.2, and even more preferably 3.8 to 4.0. The twist coefficient (K) is calculated using the above formula (Number 1). This increases the thread strength and extends the durability of the towel.

The pile yarn is preferably combed yarn. This allows the content of short fibers with an average fiber length of 17 mm or less to be 10% by mass or less, preferably 8% by mass or less, more preferably 6% by mass or less, and even more preferably 4% by mass or less. In addition, the pile yarn of the present invention can be used as both warp pile yarn and weft pile yarn, but it is preferable to use it as warp pile yarn.

The method for producing the towel fabric of the present invention includes the following steps.
(1) Combing process of pile yarn long staple cotton Medium staple cotton or long staple cotton with an average fiber length of 28.6 to 34.7 mm and micronaire of 4.1 to 5.8 μg/inch is used as the fiber material of the pile yarn, and the content of short fibers with an average fiber length of 17 mm or less is reduced to 10% by mass or less by combing. The combing process (combing process) is preferably performed twice, and the number of combing needles is increased, the lap width is adjusted as thin as possible, and the process is performed slowly at about 1/3 the normal speed. This allows the content of short fibers with an average fiber length of 17 mm or less to be reduced to 10% by mass or less, preferably 8% by mass or less, more preferably 6% by mass or less, and even more preferably 4% by mass or less.
(2) Pile yarn spinning process Using a sirospun spinning machine, two or three rovings are twisted in the opposite direction to the primary twist and with a secondary twist equal to or greater than the number of twists in the primary twist to produce a non-twisted or loosely twisted single yarn. The twist factor K of the sirospun yarn is preferably 0 to 3.5.
(3) Spinning process of warp yarn and weft yarn As the fiber material of the warp yarn and weft yarn, extra long staple cotton with an average fiber length of 34.8 to 44.5 mm and a micronaire fineness of 3.0 to 4.1 μg/inch is used, and spun into yarn by a ring spinning machine. The warp yarn and weft yarn are preferably fine with an English cotton count of 10 to 50.
(4) Yarn bleaching process for pile yarn, warp yarn, and weft yarn The pile yarn, warp yarn, and weft yarn are subjected to a yarn bleaching process. Yarn bleaching refers to scouring and bleaching the spun yarn. For white items, the yarn may be bleached alone, or may be dyed with a white dye and/or a fluorescent dye. For colored items, a dyeing process may be added after the yarn bleaching. Dyeing is preferably performed with reactive dyes at a temperature of 60 to 80°C for about 20 to 60 minutes.
(5) Weaving process of textiles Pile yarns, warp yarns and weft yarns are fed to a jacquard loom to weave a towel fabric, for example, with a three-pick terry motion weave or a four-pick terry motion weave. A four-pick terry motion weave is preferable. The four-pick terry motion weave has the advantage that the pile yarns are fixed to the ground weave compared to the three-pick terry motion weave, the pilling rate is lower, and the pile has good standing properties, so that the fabric is bulky, voluminous, and has good ventilation and dries quickly. After weaving, the fabric is washed and dried, and then hemmed to make a towel product. Scouring and bleaching after weaving is not preferable because the fabric is kneaded in water, causing the loops to be crushed or disordered.

The method for producing towel fabric of the present invention has the following effects and advantages.
(1) Although the secondary twist is applied, the twist tendency of the primary twist remains, migration from the primary twist also remains, there is entanglement between the fibers, and since the yarn is either untwisted or loosely twisted, each component fiber exists in a free state, the pile yarn has good nap standing, and has a soft, fluffy texture. Because of the soft, fluffy texture, it can be gently touched against the skin and can efficiently wipe away sweat and moisture (texture effect, wiping effect).
(2) Since the pile yarn is either untwisted or loosely twisted, the constituent fibers are more likely to absorb moisture, and at the same time, this swelling promotes air movement, improving breathability (water absorption effect, ventilation effect).
(3) The intertwining of the constituent fibers reduces pilling (impact of reduced pilling), reduces change in texture after washing, and maintains the original soft, fluffy texture (effect of durability of texture after washing).
(4) When producing spun yarn, there is no need to use water-soluble fibers (e.g., water-soluble vinylon), which reduces costs. Furthermore, if water-soluble fibers (e.g., water-soluble vinylon) are used and then removed after the fabric is made, the quality of the finished fabric is reduced.
(5) Since there is no need to use water-soluble fibers (such as water-soluble vinylon) when producing spun yarn, the environmental load caused by factory wastewater containing these can be reduced.

The towel of the present invention is suitable for bath towels (bath towels), bath towels, bedding skin towels, face towels, towel handkerchiefs (towel squares), hand towels, wash towels, hand towels, bath mats, sports towels, beach towels (body towels), etc. The fabric blend ratio, yarn type, yarn usage, mass per unit (bath weight), etc. are appropriately set according to the required properties such as fluffiness and water absorption. The basis weight can be controlled to be large or small by changing the pile length (long to short) of the pile yarn. Here, examples of preferable basis weights that can exert the effects of the present invention are 100 to 250 g/m ² for thin fabrics, 250 to 500 g/m ² for medium-weight fabrics, and 500 to 1000 g/m ² for heavy fabrics. In addition, a thickness of less than 100 g/m ² is thin and lacking in bulk, while a thickness of more than 1000 g/m ² is too thick and heavy, and neither is preferable.

The following description will be given with reference to the drawings. In the following drawings, the same reference numerals denote the same parts.
1 is a schematic perspective view of a triple sirospun spinning device according to an embodiment of the present invention. In this triple sirospun spinning device 10, three roving bobbins 11a, 11b, and 11c are hung from a creel (roving supplying device) per spindle, and rovings 12a, 12b, and 12c supplied from the three roving bobbins 11a, 11b, and 11c are sent in parallel to a draft device 15 through a three-mouth trumpet guide 13 provided upstream (roving bobbin side) of a back roller 14. The rovings 12a, 12b, and 12c are drafted at a predetermined interval between the back roller 14 and an apron 16, and between the apron 16 and a front roller 17, respectively, to form fleeces 18a, 18b, and 18c. The fleeces 18a, 18b, 18c are spun from the front roller 17, and twisted downstream of the front roller 17 by a twisting mechanism caused by the rotation of the spindle 21 to form one spun yarn 19, which is then taken up on a bobbin 22 via a snell wire 20 and a traveler 21. For example, the three rovings 12a, 12b, 12c are all twisted in the Z direction in the primary twist, and the twisting direction by the spindle 21 is the S direction, and they are twisted in the untwisting direction. In addition, the number of twists by the spindle 21 (secondary twist number) is set to be the same as or greater than the number of twists in the primary twist to form a non-twisted or loosely twisted yarn.

Figure 2A is a schematic diagram of a towel fabric 1 according to one embodiment of the present invention. This towel fabric 1 is composed of warp pile yarns 2a, 2b, weft yarn 3, and warp yarns 4a, 4b. The warp pile yarns 2a, 2b form loop piles while being engaged with the ground structure composed of the weft yarn 3 and the warp yarns 4a, 4b. The obtained towel fabric 1 is cut to a specified size, and the ends are processed to form a towel. Figure 2B is a weave diagram of the towel fabric. This weave structure is a three-pick terry motion weave. The warp pile yarns cross once for every three weft yarns. The warp yarns G and the warp pile yarns P are arranged alternately. The weft yarns 1 to 3 indicate the order. In Figure 2B, black and x indicate floating yarns, and white indicates sinking yarns, as viewed from the warp yarns.

Figure 3A is a schematic diagram of a towel fabric 1 according to another embodiment of the present invention. This towel fabric 1 is composed of warp pile yarns 2a, 2b, weft yarn 3, and warp yarns 4a, 4b, and the warp pile yarns 2a, 2b form loop pile while being engaged with the ground structure composed of the weft yarn 3 and the warp yarns 4a, 4b. The obtained towel fabric 1 is cut to a predetermined size, and the ends are processed to form a towel. Figure 3B is a weave diagram of the towel fabric. This weave structure is a four-pick terry motion weave. The warp pile yarns cross once for every four weft yarns. The warp yarns G and the warp pile yarns P are arranged alternately. Compared to a three-weft towel weave, a four-weft towel weave has pile yarns that are more firmly fixed to the ground weave, resulting in a lower rate of pilling and good pile standing, which gives it the advantage of being bulky, voluminous, and quick-drying due to better ventilation. Weft yarns 1 to 4 indicate the order. In Figure 3B, from the perspective of the warp yarns, black and x indicate floating yarns, and white indicates sinking yarns.

The present invention will be described in more detail below with reference to examples, but the present invention is not limited to the following examples.
<Evaluation of the texture of finished towel fabric>
(1) Evaluation of soft texture The softness of the texture is expressed as the volume per gram of towel fabric, and is calculated using the bulk height calculated using the following formula.
The higher the value, the softer the texture and the better the result. The thickness was measured according to JIS L 1096 (2010) 8.5 Bulkiness Test, and the basis weight was measured by precisely weighing the weight of a 1 m square. The measurements were taken at five points and expressed as the average value.
Bulk depth (cm ³ /g)=thickness (mm)/weight per unit area (g/m ² )×1000
(2) Evaluation of fluffy texture The towel fabric was compressed at a constant speed using a compression tester: KES-G5 (manufactured by Kato Tech Co., Ltd.) to determine the compression work: WC = ( ^gf.cm2 ). Measurements were taken at five points and the average value was expressed.
The WC value is the amount of energy required to compress the fabric; the higher the value, the better the towel is compressed, the more full it becomes, and the fluffier it is.
(3) Evaluation of Washing Durability of Texture The towel fabric was washed 30 times in a washing machine according to JIS L 0217 (1995), Method 103. After drying, the compression work (WC = ( ^gf.cm2 )) was measured at 5 locations and expressed as an average value. The smaller the difference in WC value before and after washing, the less the loss of fluffy texture due to washing, and the more durable and better the texture is.
(4) Evaluation of drainage during washing A 35 cm wide piece of towel fabric was cut to a length of 80 g, its weight was accurately measured to one decimal place, and it was soaked in water for 20 minutes. The wet towel fabric was then taken out and centrifuged in the spin tub of a washing machine for 4 minutes, its weight was accurately measured, and the residual moisture content (%) of the towel fabric was calculated using the following formula. The smaller the value, the better the drainage. Better drainage tends to lead to a faster subsequent drying speed. Three measurements were taken and the average value was used.
Residual moisture content of fabric (%)=(weight of fabric after soaking in water and dehydrating (W ₁ ))−(weight of fabric before soaking in water (W ₀ ))/(weight of fabric before soaking in water (W ₀ ))×100
(5) Evaluation of Drying Property The wet towel fabric after dehydration prepared in the above (4) evaluation of drainage property in washing was hung to dry, and the fabric weight was measured every 30 minutes as the drying time, and the time required for the fabric to reach a residual moisture content of 10% was calculated by dividing it by the time. The test environment was under standard conditions, with a temperature of 20±4°C and a relative humidity of 65±4% RH.
(6) Evaluation of shedding of fuzz in washing of towel fabric The shedding of fuzz in washing was measured according to JIS L0217 (1995), Method 103. The fuzz shedding rate (%) was calculated using the following formula, and the smaller the value, the less fuzz shedding and the better the result. The number of measurements was 5, and the average value was used.
Lint shedding rate (%) = (weight of lint that fell off after washing (g ₁ )) / (weight of towel before washing (g ₀ )) x 100
(7) Water absorption evaluation (modified Larose method)
The measurement was performed five times according to the modified Larose method of JIS L 1907 (2010), and the average value was calculated. The Larose index (water absorption index) was calculated according to the following formula.
Larose index (water absorption index) = 2545V x 1411W + 79
V: Maximum water absorption rate (ml/s), W: Water absorption amount at the maximum water absorption rate (ml)
The higher the value, the faster and larger the amount of moisture absorbed from the skin, which is preferable.
(8) Dimensional change rate This was carried out in accordance with JIS L 1096 (2010) 8,39,6 G method (method for a pulsator-type domestic electric washing machine). That is, the dimensional change rate was calculated using the following formula from the dimension (L1, mm) measured before washing and the dimension (L2, mm) measured after 30 washes and tumble drying.
Dimensional change rate (ΔL%)=[(L2−L1)/L1]×100
(9) Water absorption rate (dropping method)
The water absorption rate of the towel fabric was measured based on the Vuillet method of JIS L 1907 (2010). The test outline was to drop a drop of water onto the towel fabric from a height of 10 cm, measure the water absorption time (seconds) until the mirror-like surface of the drop disappeared three times, and calculate the average value. The shorter the time, the faster and better the water absorption.
<Rewetting rate test method>
The water-rewet rate is described in Patent Publication No. 6991633 proposed by the present applicant, and is a test method in which water droplets are dropped onto a test specimen of the fabric, the water is absorbed, and the fabric is evaluated as the property of not releasing the water, i.e., the water-rewet rate, which coincides with the evaluation of the water absorbency felt by people when using a fiber fabric such as a towel. The lower the water-rewet rate, the greater the water absorbency of the fabric, and the better it can be evaluated to be.
(1) Test environment and other conditions: The test environment was under standard conditions, with a temperature of 20±4°C and a relative humidity of 65±4% RH.
The filter paper used was stored for more than 24 hours under standard conditions of 20±4°C temperature and 65±4% RH.
The test specimens were stored for at least 24 hours under standard conditions at a temperature of 20±4°C and a relative humidity of 65±4% RH.
The water used for dripping was at a temperature of 20±15°C (5 to 35°C).
(2) Operating procedure: The size of the test specimen of the fiber towel fabric was 10 cm long and 10 cm wide. The test specimen was placed on the sample stand.
The filter paper used was made of α-cellulose, conforming to the JIS P 3801 (1976) Class 1 standard, with a diameter of 110 mm and a thickness of 0.22 mm, and the weight of the filter paper was measured. The filter paper used was Advantec Co., Ltd., product name "Circular Qualitative Filter Paper No. 1".
Measure 0.8 ml of water into a pipette and drop it onto the test specimen. Wait 5 seconds to allow the test specimen to absorb the water.
-A filter paper was placed on top and a load of 1.3 kg (1274 Pa) was placed on top of it.
- Wait 5 seconds and then release the load.
-The weight of the filter paper after absorbing water was measured.
(3) Calculation of Water Re-wetting Rate Calculation was performed using the following formula.
W=[(B-A)/A]×100
Where W: Water rewetting rate (%)
A: Weight of the filter paper before measurement (g)
B: Weight of filter paper after absorbing water (g)
<Pile standing property>
The pile portion of the towel fabric was observed by a side photograph (magnification 30x) using an optical microscope.
<Characteristics of sliver>
Measurement was performed in accordance with JIS L 1019 (2006).
<Other physical properties>
The measurements were made according to the methods used in the industry.

Example 1
(1) Warp pile yarn Cotton with an average fiber length of 30.5 mm and micronaire of 5.6 μg/inch was used as the fiber material for the warp pile yarn. After passing through a carding machine, the yarn was combed twice (combed process). The number of combing needles was increased, the lap width was adjusted as thin as possible, and the process was performed slowly at about 1/3 the normal speed. As a result, the content of short fibers with an average fiber length of 17 mm or less was set to 3.8% by mass. The effective fiber length, short fiber content, and cut rate after each process are shown in Table 2. Staple diagrams of each sliver (fiber bundle) are shown in Figures 4 to 6.

(2) Spinning of warp pile yarns Warp pile yarns were produced using a triple spun spinning machine shown in Figure 1. The three rovings 12a, 12b, and 12c were twisted in the Z direction for the primary twist, and the twisting direction by the spindle 21 was S direction, and they were twisted in the untwisting direction. The fineness of the roving was 5 g/6 yards (9113 decitex), and the Z direction twist number of the roving was 5 turns/inch (twist factor K=1 in terms of cotton count). The obtained spun yarn had a cotton count of 16.1 and a twist number of 11.5 turns/inch (twist factor K=2.875). The physical properties of the obtained warp pile yarns are shown in Table 3.
(3) Spinning of warp yarn and weft yarn Cotton (cotton extra-long staple cotton) with an average fiber length of 36.5 mm and a micronaire fineness of 3.5 μg/inch was used as the fiber material for the warp yarn and weft yarn, and spun yarn was produced using a ring spinning machine. The British cotton count was 20 and the twist factor K was 3.8.
(4) Bleaching process of pile yarn, warp yarn and weft yarn The pile yarn, warp yarn and weft yarn were bleached. According to a conventional method, the yarn was scoured in a dilute caustic soda and alcohol ethoxylate-added bath at 98°C for 50 minutes, then bleached in a hydrogen peroxide bath at 98°C for 50 minutes, then sized at 95°C at 100 m/min, and finished by drying at 120°C (off-white finish).
(5) Weaving process Pile yarns, warp yarns, and weft yarns were fed into a jacquard loom to weave a towel fabric with a four-pick terry motion weave as shown in Figures 3A-B. After weaving, the fabric was washed and dried, and then hemmed to produce a towel product. The pile length was 1.18 cm. Other physical properties are shown in Table 4.

(Comparative Example 1)
The same procedure as in Example 1 was carried out, except that card sliver was used as the warp pile yarn roving.

(Comparative Example 2)
The same procedure as in Example 1 was carried out, except that the warp pile yarns were not bleached, but were bleached after being woven into a fabric.
The results for the warp pile yarns are shown in Table 3, and the results for the towel fabric are shown in Table 4.

As is clear from Table 4, the following effects were confirmed for the towel fabric of Example 1 compared to Comparative Examples 1 and 2.
(1) Less shedding of fuzz.
(2) Bulky.
(3) It has a large amount of fluffiness and is very soft before washing.
(4) The fluffiness is less likely to be lost after washing, and deterioration due to washing is minimal.
(5) There is little re-wetting, making wiping comfortable.
(6) It is less likely to change dimensions or shrink when washed.
(7) It dries quickly and the residual moisture content drops to 10% or less in a short time.

The towel fabric of the present invention is also suitable for use in fabrics such as bath towels (towels for after a bath), bath towels, bedding skin towels, face towels, towel handkerchiefs, sports towels, bathrobes, towel blankets, clothing, socks, rugs, bedding, etc.

1 towel fabric 2a, 2b warp pile yarn 3 weft yarn 4a, 4b warp yarn 10 sirospun spinning device 11a, 11b, 11c roving bobbin 12a, 12b, 12c roving yarn 13 trumpet guide 14 back roller 15 draft device 16 apron 17 front roller 18a, 18b, 18c fleece 19 spun yarn 20 snell wire 21 spindle 22 bobbin

Claims (10)

A towel fabric composed of pile yarns, warp yarns and weft yarns,
The pile yarn fiber material is medium-fiber cotton or long-fiber cotton having an average fiber length of 28.6 to 34.7 mm and a micronaire of 4.1 to 5.8 μg/inch, and the content of short fibers having an average fiber length of 17 mm or less is 10 mass % or less;
The pile yarn is a single yarn of a sirospun yarn having no twist or a loose twist,
The warp yarn and the weft yarn are ring-spun yarns using extra-long staple cotton having an average fiber length of 34.8 to 44.5 mm and a micronaire of 3.0 to 4.1 μg/inch;
The towel fabric is characterized in that the pile yarns, warp yarns and weft yarns are bleached. The towel fabric according to claim 1, wherein the count of the silo spun yarn is 5 to 100 in English cotton count. The towel fabric according to claim 1, wherein the twist coefficient K of the silo spun yarn is 0 to 3.5.
The twist factor (K) is calculated using the following formula (1).

Where, t: number of twists (twists/25.4mm), S: British cotton count The towel fabric according to claim 1, in which the twist direction of the silo spun yarn is opposite to the primary twist direction of the multiple roving yarns, and a secondary twist is added with the same or more twists than the primary twist. The towel fabric according to claim 1, wherein the sirospun yarn is a two-strand sirospun yarn or a three-strand (triple) sirospun yarn. The towel fabric according to claim 1, wherein the warp yarns and weft yarns have a count of 10 to 50 in English cotton count. 2. The towel fabric according to claim 1, wherein the twist coefficient K of the warp yarns and the weft yarns is 3.5 to 4.5.
However, the twist factor (K) is calculated using the above formula (Math 1). The towel fabric according to claim 1, wherein the pile yarn is combed yarn. A method for producing a towel fabric according to any one of claims 1 to 8,
The pile yarn fiber material is medium-fiber cotton or long-fiber cotton having an average fiber length of 28.6 to 34.7 mm and a micronaire of 4.1 to 5.8 μg/inch, and the content of short fibers having an average fiber length of 17 mm or less is reduced to 10 mass% or less by combing treatment;
The pile yarn is a triple spun yarn, and the twist direction is opposite to the primary twist direction of the three rovings, and a secondary twist having the same or more twists as the primary twist is added to form a non-twisted or loosely twisted single yarn.
The pile yarns, warp yarns and weft yarns are subjected to a yarn bleaching treatment,
A method for producing a towel fabric, comprising the steps of: supplying the pile yarns, warp yarns and weft yarns to a jacquard loom to produce a woven towel fabric. The method for manufacturing towel fabric according to claim 9, in which the yarn is dyed after the bleaching process.

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