Composite low-twist yarn towel and production method thereof

Abstract

A composite low-twist towel that is formed of three parts: terry yarn, ground warp yarn and weft yarn. The ground warp yarn and the weft yarn are normal towel yarns and the terry yarn is a composite low-twist yarn. The composite low-twist yarn is composed of two yarns of different thickness, among them, the spun yarn is synthetic fiber spun yarn or filament yarn, and the thick yarn is the pure cotton yarn or the blended yarn of pure cotton and other fibers. The composite low-twist yarn is made into a warp beam through warping and sizing. Then, it interweaves with ground warp yarns and weft yarns through a towel loom or warp loom to form terry fabrics.

Claims

1. A composite low-twist yarn towel, comprising: a terry yarn; a ground warp yarn and a weft yarn; wherein the terry yarn comprises a composite low-twist yarn that is composed of first and second yarns of different thickness, the first yarn comprising a fine yarn that is a synthetic fiber spun yarn or a filament yarn with a weight not higher than 27.8 g/km, and the second yarn is a thick yarn that is a pure cotton yarn or a blended yarn with pure cotton and other fibers with a weight not less than 18.2 g/km, and the twist factor of the thick yarn is not higher than 295, and wherein a twist of the fine yarn is 130t/10 cm and twist directions of the fine yarn and the thick yarn are both Z-direction twist.

2. The composite low-twist yarn towel according to claim 1, wherein single yarn twist directions of the two yarns in the composite low-twist yarn are the same, and a twist direction of the composite low-twist yarn is opposite to the single yarn twist directions of the two yarns and twists of the composite low-twist yarn are not higher than 30 per decimeter.

3. The composite low-twist yarn towel according to claim 1, wherein the fine yarn comprises a synthetic yarn and the thick yarn comprises a natural fiber.

4. The composite low-twist yarn towel according to claim 3, wherein the fine yarn comprises 100% modal fiber and the thick yarn comprises 100% cotton fiber.

5. The composite low-twist yarn towel according to claim 1, wherein the fine yarn comprises 100% viscose fiber and the thick yarn comprises 100% cotton fiber.

6. The composite low-twist yarn towel according to claim 5, wherein the composite low-twist yarn has a thick count of 48.6 tex and a fine yarn count of the composite low-twist yarn is 7.3 tex.

7. The composite low-twist yarn towel according to claim 1, wherein a number of twists in the composite low-twist yarn is 26t/10 cm.

8. A composite low-twist yarn towel, comprising: a terry yarn; a ground warp yarn and a weft yarn; wherein the terry yarn comprises a composite low-twist yarn that is composed of first and second yarns of different thickness, the first yarn comprising a fine yarn that is a regenerated cellulose fiber yarn or a filament yarn, and a weight of the fine yarn is not higher than 14.5 g/km, and the second yarn is a thick yarn that is a pure cotton yarn, a weight of the thick yarn is not less than 36.4 g/km, and the twist factor of the thick yarn is not more than 258.

9. The composite low-twist yarn towel according to claim 8, wherein the fine yarn comprises one of a viscose yarn, a synthetic fiber yarn, and a spun yarn.

10. The composite low-twist yarn towel according to claim 8, wherein the fine yarn comprises spun yarn selected from the group consisting of terylene, nylon, and acrylic.

11. The composite low-twist yarn towel according to claim 8, wherein the fine yarn comprises filament yarn selected from the group consisting of modal, polynosic viscose, cuprammonium fiber and Lyocell.

12. A method of producing a composite low-twist yarn product comprising the steps of: forming a terry yarn that comprises a composite low-twist yarn that is composed of first and second yarns of different thickness, the first yarn comprising a fine count yarn that is a synthetic fiber spun yarn or a filament yarn with a weight not higher than 27.8 g/km, and the second yarn is a thick count yarn that is a pure cotton yarn or a blended yarn with pure cotton and other fibers with a weight not less than 18.2 g/km, and the twist factor of the thick count yarn is not higher than 295; and warping a ground warp yarn and the composite low-twist yarn that serves as a low-twist pile warp yarn; and weaving on a towel loom or a warp loom using the ground warp yarn, the composite low-twist yarn and a weft yarn to form the low-twist yarn product, and wherein a twist of the fine count yarn is 130t/10 cm and twist directions of the fine count yarn and the thick count yarn are both Z-direction twist.

13. The method of claim 12, wherein the step of forming the terry yarn comprises the steps of: spinning the fine-count yarn with a twist direction of the spun fine-count yarn being in the Z-direction; spinning the thick count yarn with a twist direction of the spun thick count yarn being the first Z direction; combining the spun fine count yarn and the spun thick count yarn on a doubling machine to form a combined yarn; and twisting the combined yarn in a second direction that is opposite to the first direction to form the twisted combined yarn that comprises the terry yarn.

14. The method of claim 13, further including the steps of: winding the twisted combined yarn and preparing the twisted combined yarn for dyeing or warping.

15. The method of claim 12, wherein the step of warping comprises the step of conducting warp sizing to a pile warp beam and a ground warp beam respectively.

16. The method of claim 12, further including the step of dying the composite low-twist yarn prior to the weaving step.

17. The method of claim 13, wherein the step of spinning the thick count yarn comprises the steps of: conducting a thick count yarn draft spinning for thick yarn slivers on a spinning frame to increase a strength of the thick count yarn and reduce hairiness of the thick count yarn, and improve the quality of the thick count yarn for a successful weaving, wherein the spinning frame includes at least one of the following modifications: (1) adding a thick yarn hanging frame to the spinning frame, and adding a coarse sliver cotton collector at an inlet of the thick yarn slivers entering a back roller of the spinning frame; (2) installing a negative pressure suction compact spinning device on the spinning frame under an output end of a front roller, so that the thick yarn slivers are bundled and a floating hairiness of the thick yarn sliver is concentrated on a yarn backbone to reduce hairiness and improve yarn strength; and (3) adding a tangential belt which is installed between an output roller and a guide hook or leaf plate on the spinning frame to produce a false twist effect on the thick yarn slivers output from the front roller, through a false twist device.

18. A method of producing a composite low-twist yarn product comprising the steps of: forming a terry yarn that comprises a composite low-twist yarn that is composed of first and second yarns of different thickness, the first yarn comprising a fine count yarn that is a synthetic fiber spun yarn or a filament yarn with a weight not higher than 27.8 g/km, and the second yarn is a thick count yarn that is a pure cotton yarn or a blended yarn with pure cotton and other fibers with a weight not less than 18.2 g/km, and the twist factor of the thick count yarn is not higher than 295; and warping a ground warp yarn and the composite low-twist yarn that serves as a low-twist pile warp yarn; and weaving on a towel loom or a warp loom using the ground warp yarn, the composite low-twist yarn and a weft yarn to form the low-twist yarn product; wherein the step of forming the terry yarn comprises the steps of: spinning the fine-count yarn with a twist direction of the spun fine-count yarn being in a first direction; spinning the thick count yarn with a twist direction of the spun thick count yarn being the first direction; combining the spun fine count yarn and the spun thick count yarn on a doubling machine to form a combined yarn; and twisting the combined yarn in a second direction that is opposite to the first direction to form the twisted combined yarn that comprises the terry yarn; winding the twisted combined yarn and preparing the twisted combined yarn for dyeing or warping; wherein the sliver twist from the false twist device to the output roller and from the false twist device and a wire ring of the spinning frame is substantially increased, a spinning triangle is eliminated, a speed of false twist device is separately controlled by a servo motor, wherein a sliver output from the front roller forms an included angle through the false twist device, showing arc-shaped contact; setting a specific linear speed ratio for the output linear speed of the false twist device and the front roller between 1.2-1.5.

19. The method according to claim 14, wherein the step of spinning the thick count includes the following step: changing a cotton assorting of the thick count yarn to improve the strength and hairiness of the thick count yarn.

20. The method according to claim 19, wherein the step of changing the cotton assorting comprises the step of selecting long staple cotton or mixing a synthetic fiber into cotton.

21. The method according to claim 12, wherein the synthetic fiber is a fiber selected from the group consisting of: terylene fiber, nylon fiber and regenerated cellulose fiber.

22. A method of producing a composite low-twist yarn towel, comprising the steps of: (i) using a spinning device to spin a fine-count yarn that comprises a synthetic staple fiber or a regenerated cellulose fiber or mixtures thereof, wherein a weight of the spun fine-count yarn is not more than 27.8 g/km, and a twisting direction of the spun fine-count yarn is not fixed; (ii) spinning a thick-count yarn using the spinning device to conduct opening, removing impurities, combing and drawing to a cotton fiber or a mixed fiber of cotton and other fibers to form a thick yarn sliver, wherein a weight of spun thick-count yarn is not less than 18.2 g/km, and the twist factor of the spun thick yarn spun is not higher than 295; and wherein a twist direction of the spun thick-count yarn is the same twist direction as the spun fine-count yarn of step (i); (iii) combining the spun fine-count and spun thick-count yarns formed in steps (i) and (ii) on a doubling machine; (iv) twisting the combined yarn of step (iii) in an opposite twist direction as that of the thick-count yarn and fine-count yarn spun in steps (i) and (ii) to form a terry yarn, wherein a number of twists of the composite low-twist yarn is no higher than 30 per decimeter; (v) conduct winding for the yarns made in step (iv), and prepare for dyeing or warping; and (vi) weaving on a towel loom or a warp loom the ground warp yarn, the terry yarn and a weft yarn to form the composite low-twist yarn towel.

Description

BRIEF DESCRIPTION OF THE DRAWING FIGURES

(1) FIG. 1 is a structural diagram of modifications that define an improved FA507 spinning frame adopted by this invention,

(2) FIG. 2 shows a siro spinning cotton collector that is part of an FA507 spinning frame added with a siro spinning device;

(3) FIG. 3A is a negative pressure suction pipe of the FA507 spinning frame added with a compact spinning device;

(4) FIG. 3B is an exploded view of the negative pressure suction pipe;

(5) FIG. 4 is a view of the FA507 spinning frame added with a false twist device; and

(6) FIG. 5 is a view of the FA507 spinning frame added with a siro spinning device, compact spinning device and false twist device in sequence.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

(7) The follow description sets forth exemplary composite low-twist yarn towels and production methods thereof. It will be appreciated that the following examples are exemplary and not limiting of the scope of the present invention.

Embodiment 1

(8) A composite low-twist yarn towel and production method thereof are described.

(9) Take woven terry fabrics as an example: the specific steps are as follows:

(10) (1) Fiber selection of the composite low-twist yarn: the fine-count yarn is 100% viscose fiber and the thick count yarn is 100% cotton, in which the viscose fiber produced by Sichuan Yibin Grace Group Company with the trade name of Gracell and the model of 1.1 dtexx38 mm is used here.

(11) (2) The thick yarn count of the composite low-twist yarn is 48.6 tex, and the fine yarn count of the composite low-twist yarn is 7.3 tex.

(12) (3) The twist of the thick count yarn of the composite low-twist yarn is: any twist not higher than the twist factor 295, the twist of fine-count yarn is 130t/10 cm, and the twist directions of thick count yarn and fine-count yarn are both Z-direction twist.

(13) (4). The thick count yarn of the composite low-twist yarn is spun on the improved spinning frame, using siro, compact, false twist or its composite improved device. According to the different modification modes of the spinning frame, the specific process is as follows:

(14) (A) The process parameters of spinning thick count yarn on the spinning frame added with siro spinning are as follows: the weight of the thick yarn is 8 g/10 m×2 pieces, and the number of spun yarns is 48.6 tex; total drafting multipliers: 36.4 times, the design twist is 39 twists/10 cm, the spindle speed is 7950 rpm (revolutions per minute), and the front roller speed is 256 rpm. Under the same technological conditions, compared with the thick count yarn obtained from the conventional ring spinning, the thick-count yarn obtained using this method has higher average strength: 5.3%, the number of roots of the hairiness with length 3 mm decreases by 8%, and the coefficient of strength variation decreases by 0.3%.

(15) (B) The process parameters of spinning the thick count yarn on the spinning frame added with compact spinning are as follows: the weight of the thick yarn is 8 g/10 m, and the number of spun yarns is 48.6 tex; total drafting multipliers: 18.2 times, the design twist is 39 twists/10 cm, the spindle speed is 7950 rpm (revolutions per minute), and the front roller speed is 256 rpm. Under the same technological conditions, compared with the thick count yarn obtained from the conventional ring spinning, the thick count yarn obtained using this method has higher average strength: 7.8%, the number of roots of the hairiness with length 3 mm decreases by 20%, and the coefficient of strength variation decreases by 0.8%.

(16) (C) The process parameters of spinning thick count yarns on the spinning frame equipped with siro spinning and compact spinning composite device are as follows: the weight of the thick yarn is 8 g/10 m×2 pieces, and the number of spun yarns is 48.6 tex; total drafting multipliers: 36.4 times, the design twist is 39 twists/10 cm, the spindle speed is 7950 rpm (revolutions per minute), and the front roller speed is 256 rpm. Under the same technological conditions, compared with the thick count yarn obtained from the conventional ring spinning, the thick count yarn obtained using this method has higher average strength: 12.2%, the number of roots of the hairiness with length 3 mm decreases by 24.5%, and the coefficient of strength variation decreases by 1.9%.

(17) (D) The process parameters of spinning thick count yarns on the spinning frame equipped with siro spinning, compact spinning and false twist composite device are as follows: the weight of the thick yarn is 8 g/10 m×2 pieces, and the number of spun yarns is 48.6 tex; total drafting multipliers: 36.4 times, the designed number of twists is 39 twists/10 cm, the spindle speed is 7950 rpm, the front roller speed is 256 rpm, and the ratio of the linear speed of the front roller to the linear speed of the false twist tangential belt is 1.33. Under the same technological conditions, compared with the thick count yarn obtained from the conventional ring spinning, the thick count yarn obtained using this method has higher average strength: 28.4%, the number of roots of the hairiness with length 3 mm decreases by 32.7%, and the coefficient of strength variation decreases by 2.7%.

(18) The following table shows the comparison of main indexes of thick count yarns obtained under the same environment, same cotton assorting and same process conditions:

(19) TABLE-US-00001 Siro compact Ordinary Siro false twist Spinning ring Siro Compact compact composite methods spinning spinning spinning spinning spinning Average 678 714.1 731.2 760.6 870.4 strength CN Number of 49 45 39 37 33 roots of the hairiness with length 3 mm Strength 7.5% 7.2% 6.7% 5.6% 4.8% coefficient of variability %

(20) It can be seen that the spinning frame equipped with siro, compact spinning and false twist composite devices is the optimal choice (see last column on the right in above table). Other modification methods can be selected or combined randomly according to weaving requirements.

(21) This embodiment uses method D, which is the combination of compact spinning, siro spinning and false twist technologies.

(22) (5) The thick count yarn and fine-count yarn of the composite low-twist yarn are combined and twisted to form the composite low-twist yarn. Its number of strand twists is 26 t/10 cm, and its twist direction is S-twist.

(23) (6) The ground warp yarn and the weft yarn of the composite low-twist towel fabric are 21s/2 and 16s respectively; conduct warping for the 21s/2 ground warp yarn of the composite low-twist towel fabric and the 48.6 tex/7.3 tex composite low-twist pile warp yarn separately to form the ground warp beam and the pile warp beam respectively.

(24) (7). Conduct sizing for the warp beams formed in step (6) separately to form the ground warp beam and the pile warp beam respectively. For the pile warp beam sizing, the sizing method of single immersion single compression should be used to reduce the number of pile warp breakages and ensure smooth weaving.

(25) (8). Using the pile warp and ground warp of step (7) and the 16s weft yarn to weave on a shuttle less towel loom to produce the low-twist composite semi-finished terry fabrics, or only use the pile warp and ground warp of step (7) to weave on the warp knitting towel loom to produce the warp knitting low-twist composite terry fabrics.

(26) (9). Conduct desizing, bleaching, dyeing, polishing, soaping, softening, dehydration, scutching, drying and setting for the low-twist composite terry fabrics woven in step (8) to form the low-twist composite terry fabrics. The above procedures are all conventional technical means.

(27) (10). Cutting and sewing the low-twist composite terry fabrics formed in step (9) to form a soft and fluffy low-twist composite terry fabric product.

(28) The low-twist composite terry fabric formed by the above technical scheme has the following benefits:

(29) (i) Compared with traditional water-soluble or alkali soluble twist less terry fabrics: low pollution, low energy consumption, high yield, low depilation rate, similar product hand feel and fluffy degree; compared with the twist less yarn towel produced using the 48.6 tex/80s PVA yarn, the benefits are as follows:

(30) TABLE-US-00002 AATCC (American Association of Textile COD Chemists (Chemical and Colorists) Water for Steam for Oxygen Weight Standard 135 pre- pre- Demand) loss Product treatment treatment index of rate of depilation (ton/ton (ton/ton pre- product rate % after Variety yarn) yarn) treatment % 5 washes 48.6 t cotton/ 10 1.37 8740 8 5.1 7.3 t composite low- twist towel 48.6 t cotton/ 21 2.89 21804 16.3 7.2 7.3 PVA twist less towel

(31) Note: This test data is obtained under the same cotton assorting, the same pre-treatment process conditions, the same dyeing and post-treatment conditions. This data may vary slightly with different colors and different cotton assorting.

(32) (ii). Compared with the terry fabric with patent No. U.S. Pat. No. 7,810,308B2 (which is hereby expressly incorporated herein by reference in its entirety): the thickness of the composite low-twist yarn towel in the present invention is 10% higher; the softness of hand feel is also obviously better than the prior patents, closer to the traditional PVA twist less yarn.

(33) All publications, patents and patent applications referred to herein are incorporated by reference in their entirety to the same extent as if each individual publication, patent or patent application was specifically and individually indicated to be incorporated by reference in its entirety

Embodiment 2

(34) A composite low-twist yarn towel and production method thereof are described below.

(35) Take woven terry fabrics as an example: the specific steps are as follows:

(36) (1) Fiber selection of the composite low-twist yarn: the fine-count yarn is 100% modal fiber. The modal fiber is a commodity of modal with the model of 1.3 dtex×38 mm produced by Austrian Lenzing Company with the trade name of LENZING™ Modal. The thick count yarn is 100% cotton.

(37) (2) The coarse yarn count of the composite low-twist yarn is 41.6 tex, and the fine yarn count of the composite low-twist yarn is 7.3 tex.

(38) (3) The twist of the thick count yarn of the composite low-twist yarn is: any twist not higher than the twist factor 295, the twist of fine-count yarn is 120t/10 cm, and the twist directions of thick count yarn and fine-count yarn are both Z-direction twist.

(39) (4). The thick count yarn of the composite low-twist yarn is spun on the improved or added spinning frame, using siro, compact, false twist or its composite improved device. In this embodiment, the method C in embodiment 1 is selected for improvement, and the final thick count yarn obtained is about 12% higher than the strength of the yarn not improved, and the hairiness with length 3 mm and above decreases by 25%.

(40) (5) The thick count yarn and fine-count yarn of the composite low-twist yarn are combined and twisted to form the composite low-twist yarn. Its number of strand twists is 20 t/10 cm, and its twist direction is S-twist.

(41) (6) The ground warp yarn and the weft yarn of the composite low-twist towel fabric are 48.6 tex and 36.4 tex respectively; conduct warping for the 48.6 tex ground warp yarn of the composite low-twist towel fabric and the 41.6 tex/7.3 tex composite low-twist pile warp yarn separately to form the ground warp beam and the pile warp beam respectively.

(42) (7). Conduct sizing for the warp beams formed in step (6) separately to form the ground warp beam and the pile warp beam respectively. For the pile warp beam sizing, the sizing method of single immersion single compression should be used to reduce the number of pile warp breakages and ensure smooth weaving.

(43) (8). Using the pile warp and ground warp of step (7) and the 36.4 tex weft yarn to weave on a shuttle less towel loom to produce the low-twist composite semi-finished terry fabrics, or only use the pile warp and ground warp of step (7) to weave on the warp knitting towel loom to produce the warp knitting low-twist composite terry fabrics.

(44) (9). Conduct desizing, bleaching, dyeing, polishing, soaping, softening, dehydration, scutching, drying and setting for the low-twist composite terry fabrics woven in step (8) to form the low-twist composite terry fabrics. The above procedures are all conventional technical means.

(45) (10). Cutting and sewing the low-twist composite terry fabrics formed in step (9) to form a soft and fluffy low-twist composite terry fabric product.

(46) The low-twist composite terry fabric formed by the above technical scheme has the following benefits:

(47) (i) Compared with traditional water-soluble or alkali soluble twist less terry fabrics: low pollution, low energy consumption, high yield, low depilation rate, similar product hand feel and fluffy degree; compared with the twist less yarn towel produced using the 48.6 tex/80s PVA yarn, the benefits are as follows:

(48) TABLE-US-00003 AATCC (American Association of Textile COD Chemists (Chemical and Colorists) Water for Steam for Oxygen Weight Standard 135 pre- pre- Demand) loss Product treatment treatment index of rate of depilation (ton/ton (ton/ton pre- product rate % after Variety yarn) yarn) treatment % 5 washes 48.6 t cotton/ 10 1.30 8364 7.5 4.9 7.3 t modal composite low-twist towel 48.6 t cotton/ 21 2.9 20962 15.7 7.2 7.3 PVA twist less towel

(49) Note: This test data is obtained under the same cotton assorting, the same pre-treatment process conditions, the same dyeing and post-treatment conditions. This data may vary slightly with different colors and different cotton assorting.

(50) (ii). Compared with the terry fabric with patent No. U.S. Pat. No. 7,810,308B2, it has the advantages of soft hand feel, low depilation rate, more stable yield efficiency.

Embodiment 3

(51) A composite low-twist yarn towel and production method thereof are described below.

(52) Take woven terry fabrics as an example: the specific steps are as follows:

(53) (1) Fiber selection of the composite low-twist yarn: the fine-count yarn is 100% Lyocell fiber, which is the brand of LENZING™ Lyocell A100 produced by Austrian Lenzing company, and the model is: 1.56 dtex×38 mm, the thick count yarn is 100% cotton.

(54) (2) The coarse yarn count of the composite low-twist yarn is 97.2 tex, and the fine yarn count of the composite low-twist yarn is 27.8 tex.

(55) (3) The twist of the thick count yarn of the composite low-twist yarn is: any twist not higher than the twist factor 295, the twist of fine-count yarn is 120t/10 cm, and the twist directions of thick count yarn and fine-count yarn are both Z-direction twist.

(56) (4) The thick count yarn of the composite low-twist yarn is spun on the improved or added spinning frame. In this embodiment, the 97.2 tex thick count yarn is spun on the spinning frame equipped with siro spinning. The specific process parameters are as follows: the weight of the thick yarn is 8 g/10 m×2 pieces, and the number of spun yarns is 97.2 tex; total drafting multipliers: 18.20 times, the design twist is 29.6 twists/10 cm, the spindle speed is 6190 rpm (revolutions per minute), and the front roller speed is 266 rpm. Compared with the conventional ring spinning under the same process conditions, the average strength of the thick count yarn obtained by this method increases by 4.7%, the number of roots of the hairiness with length 3 mm decreases by 3.2%, and the coefficient of strength variation decreases by 0.41%, meeting the weaving requirements.

(57) (5) The thick count yarn and fine-count yarn of the composite low-twist yarn are combined and twisted to form the composite low-twist yarn. Its number of strand twists is 26 t/10 cm, and its twist direction is S-twist.

(58) (6) The ground warp yarn of the composite low-twist towel fabric is 24.3 tex/2 stranded yarn, and the weft yarn is 36.4 tex; warping the 24.3 tex/2 stranded ground warp and 97.2 tex/27.8 tex composite low-twist pile warp of the composite low-twist towel separately to form the ground warp bean and the pile warp beam respectively.

(59) (7). Conduct sizing for the warp beams formed in step (6) separately to form the ground warp beam and the pile warp beam respectively. For the pile warp beam sizing, the sizing method of single immersion single compression should be used to reduce the number of pile warp breakages and ensure smooth weaving.

(60) (8). Using the pile warp and ground warp of step (7) and the 16s weft yarn to weave on a shuttle less towel loom to produce the low-twist composite semi-finished terry fabrics, or only use the pile warp and ground warp of step (7) to weave on the warp knitting towel loom to produce the warp knitting low-twist composite terry fabrics.

(61) (9). Conduct desizing, bleaching, dyeing, polishing, soaping, softening, dehydration, scutching, drying and setting for the low-twist composite terry fabrics woven in step (8) to form the low-twist composite terry fabrics. The above procedures are all conventional technical means.

(62) (10). Cutting and sewing the low-twist composite terry fabrics formed in step (9) to form a soft and fluffy low-twist composite terry fabric product.

(63) The low-twist composite terry fabric formed by the above technical scheme has the following benefits:

(64) (i) Compared with traditional water-soluble or alkali soluble twist less terry fabrics: low pollution, low energy consumption, high yield, low depilation rate, similar product hand feel and fluffy degree; compared with the twist less yarn towel produced using the 97.2 tex/80s PVA yarn, the benefits are as follows:

(65) TABLE-US-00004 AATCC (American Association of Textile COD Chemists (Chemical and Colorists) Water for Steam for Oxygen Weight Standard 135 pre- pre- Demand) loss Product treatment treatment index of rate of depilation (ton/ton (ton/ton pre- product rate % after Variety yarn) yarn) treatment % 5 washes 97.2 t cotton/ 10 1.37 8548 7.9 4.5 27.8 t lyocell composite low- twist towel 97.2 t cotton/ 21 2.89 17546 12.4 6.8 7.3 PVA twist less towel

(66) Note: This test data is obtained under the same cotton assorting, the same pre-treatment process conditions, the same dyeing and post-treatment conditions. This data may vary slightly with different colors and different cotton assorting.

(67) (ii). Compared with the terry fabric with patent No. U.S. Pat. No. 7,810,308B2, it has the advantages of soft hand feel, low depilation rate, more stable yield efficiency.

Embodiment 4

(68) A composite low-twist yarn towel and production method thereof are described below.

(69) Take woven terry fabrics as an example: the specific steps are as follows:

(70) (1) Fiber selection of the composite low-twist yarn: the fine-count yarn is 75D/72F viscose filament, the fine-count yarn filament uses the man-made filament produced by Jilin Chemical Fiber Group Company, and the thick count yarn is 100% cotton.

(71) (2) The coarse yarn count of the composite low-twist yarn is 48.6 tex, the fine-count yarn is 75D/72F FDY viscose (equivalent to 8.33 tex).

(72) (3) The number of twists of the thick count yarn of the composite low-twist yarn is: any twist not higher than the twist factor 295, the twist direction of the thick count yarn is Z-twist.

(73) (4). The thick count yarn of the composite low-twist yarn is spun on the improved or added spinning frame, using siro, compact, false twist or its composite improved device. In this embodiment, the method D in embodiment 1 is selected for improvement, and the final thick count yarn obtained is about 10% higher than the strength of the yarn not improved, and the hairiness with length 3 mm and above decreases by 30%.

(74) (5) The thick count yarn and fine-count yarn of the composite low-twist yarn are combined and twisted to form the composite low-twist yarn. Its number of strand twists is 26 t/10 cm, and its twist direction is S-twist.

(75) (6) The ground warp yarn and the weft yarn of the composite low-twist towel fabric are 27.8 tex/2 and 36.4 tex respectively; conduct warping for the 27.8 tex/2 ground warp yarn of the composite low-twist towel fabric and the 48.6 tex/75D composite low-twist pile warp yarn separately to form the ground warp beam and the pile warp beam respectively.

(76) (7). Conduct sizing for the warp beams formed in step (6) separately to form the ground warp beam and the pile warp beam respectively. For the pile warp beam sizing, the sizing method of single immersion single compression should be used to reduce the number of pile warp breakages and ensure smooth weaving.

(77) (8). Using the pile warp and ground warp of step (7) and the 36.4 tex weft yarn to weave on a shuttle less towel loom to produce the low-twist composite semi-finished terry fabrics, or only use the pile warp and ground warp of step (7) to weave on the warp knitting towel loom to produce the warp knitting low-twist composite terry fabrics.

(78) (9). Conduct desizing, bleaching, dyeing, polishing, soaping, softening, dehydration, scutching, drying and setting for the low-twist composite terry fabrics woven in step (8) to form the low-twist composite terry fabrics. The above procedures are all conventional technical means.

(79) (10). Cutting and sewing the low-twist composite terry fabrics formed in step (9) to form a soft and fluffy low-twist composite terry fabric product.

(80) The low-twist composite terry fabric formed by the above technical scheme has the following benefits:

(81) (i) Compared with traditional water-soluble or alkali soluble twist less terry fabrics: low pollution, low energy consumption, high yield, low depilation rate, similar product hand feel and fluffy degree; compared with the twist less yarn towel produced using the 48.6 tex/80s PVA yarn, the benefits are as follows:

(82) TABLE-US-00005 AATCC (American Association of Textile COD Chemists (Chemical and Colorists) Water for Steam for Oxygen Weight Standard 135 pre- pre- Demand) loss Product treatment treatment index of rate of depilation (ton/ton (ton/ton pre- product rate % after Variety yarn) yarn) treatment % 5 washes 48.6 ton 10 1.3 7956 7.7 5.1 cottons/75D viscose composite low- twist towel 48.6 t cotton/ 21 2.92 20946 16 7.2 7.3 PVA twist less towel

(83) Note: This test data is obtained under the same cotton assorting, the same pre-treatment process conditions, the same dyeing and post-treatment conditions. This data may vary slightly with different colors and different cotton assorting.

(84) (ii). Compared with the terry fabric with patent No. U.S. Pat. No. 7,810,308B2, it has the advantages of soft hand feel, low depilation rate, more stable yield efficiency.

Embodiment 5

(85) A composite low-twist yarn towel and production method thereof are described below.

(86) Take woven terry fabrics as an example: the specific steps are as follows:

(87) (1) Fiber selection of the composite low-twist yarn: the fine-count yarn is 100% polyester staple fiber, which uses the recycled polyester staple fiber produced by Hangzhou Benma Chemical Fiber Spinning Company, and the model is: 1.1 dtexx38 mm, the thick count yarn is 100% cotton.

(88) (2) The coarse yarn count of the composite low-twist yarn is 18.2 tex, and the fine yarn count of the composite low-twist yarn is 7.3 tex.

(89) (3) The twist of the thick count yarn of the composite low-twist yarn is: any twist not higher than the twist factor 295, the twist of fine-count yarn is 130t/10 cm, and the twist directions of thick count yarn and fine-count yarn are both Z-direction twist.

(90) (4) The thick count yarn of the composite low-twist yarn is spun on the improved (modified) spinning frame as described herein. The improved spinning frame 100 selected in this embodiment is a spinning frame equipped with siro spinning, compact spinning and false twist composite devices. The process parameters of the 18.2 tex thick count yarn are as follows: the weight of the thick yarn is 3.5 g/10 m×2 pieces, and the number of spun yarns is 18.2 tex; total drafting multipliers: 42.7 times, the designed number of twists is 60 twists/10 cm, the spindle speed is 10320 rpm, the front roller speed is 219 rpm, and the ratio of the linear speed of the front roller to the linear speed of the false twist tangential belt is 1.33. The main indexes of thick count yarns obtained by this method are as follows: average strength: 276.2CN, the number of roots of the hairiness with length 3 mm is 37 counts/10 m, the coefficient of strength variation is 6.6%, meeting the weaving requirements. The conventional ring spinning can't produce the yarn of this twist without adding siro spinning, compact spinning and false twist compound devices.

(91) (5) The thick count yarn and fine-count yarn of the composite low-twist yarn are combined and twisted to form the composite low-twist yarn. Its number of strand twists is 15 t/10 cm, and its twist direction is S-twist.

(92) (6) The ground warp yarn and the weft yarn of the composite low-twist towel fabric are 14.5 tex/2 and 27.8 tex respectively; conduct warping for the 14.5 tex/2 ground warp yarn of the composite low-twist towel fabric and the 18.2 tex/7.3 tex composite low-twist pile warp yarn separately to form the ground warp beam and the pile warp beam respectively.

(93) (7). Conduct sizing for the warp beams formed in step (6) separately to form the ground warp beam and the pile warp beam respectively. For the pile warp beam sizing, the sizing method of single immersion single compression should be used to reduce the number of pile warp breakages and ensure smooth weaving.

(94) (8). Using the pile warp and ground warp of step (7) and the 27.8 tex weft yarn to weave on a shuttle less towel loom to produce the low-twist composite semi-finished terry fabrics, or only use the pile warp and ground warp of step (7) to weave on the warp knitting towel loom to produce the warp knitting low-twist composite terry fabrics.

(95) (9). The low-twist composite terry fabric in step (8) is desized and bleached according to the process of polyester cotton blended fabrics, and divided into two steps of dyeing (dyeing polyester first and then cotton), polishing, soaping, softening and dehydration, scutching, drying and setting to form low-twist composite terry fabrics. The above procedures are all conventional technical means.

(96) (10). Cutting and sewing the low-twist composite terry fabrics formed in step (9) to form a soft and fluffy low-twist composite terry fabric product.

(97) The low-twist composite terry fabric formed by the above technical scheme has the following benefits:

(98) (i) Compared with traditional water-soluble or alkali soluble twist less terry fabrics: low pollution, low energy consumption, high yield, low depilation rate, similar product hand feel and fluffy degree; compared with the twist less yarn towel produced using the 18.2 tex/80s PVA yarn, the benefits are as follows:

(99) TABLE-US-00006 AATCC (American Association of Textile COD Chemists (Chemical and Colorists) Water for Steam for Oxygen Weight Standard 135 pre- pre- Demand) loss Product treatment treatment index of rate of depilation (ton/ton (ton/ton pre- product rate % after Variety yarn) yarn) treatment % 5 washes 18.2 t cotton/ 10 1.32 8543 8 5.0 7.3 t polyester composite low- twist towel 18.2 t cotton/ 21 2.95 29775 22.5 7.1 7.3 PVA twist less towel

(100) TABLE-US-00007 AATCC (American Association of Textile COD Chemists (Chemical and Colorists) Water for Steam for Oxygen Weight Standard 135 pre- pre- Demand) loss Product treatment treatment index of rate of depilation (ton/ton (ton/ton pre- product rate % after Variety yarn) yarn) treatment % 5 washes 48.6 ton 10 1.3 7956 7.7 5.1 cottons/75D viscose composite low- twist towel 48.6 t cotton/ 21 2.92 20946 16 7.2 7.3 PVA twist less towel

(101) Note: This test data is obtained under the same cotton assorting, the same pre-treatment process conditions, the same dyeing and post-treatment conditions. This data may vary slightly with different colors and different cotton assorting.

(102) (ii). Compared with the terry fabric with patent No. U.S. Pat. No. 7,810,308B2, it has the advantages of soft hand feel, low depilation rate, more stable yield efficiency.

Embodiment 6

(103) A composite low-twist yarn towel and production method thereof are described below.

(104) Take woven terry fabrics as an example: the specific steps are as follows:

(105) (1) Fiber selection of the composite low-twist yarn: the fine-count yarn is 100% modal fiber. The modal fiber is a commodity of modal with the model of 1.3 dtex×38 mm produced by Austrian Lenzing Company with the trade name of LENZING™ Modal. The thick count yarn is 100% cotton.

(106) (2) The coarse yarn count of the composite low-twist yarn is 41.6 tex, and the fine yarn count of the composite low-twist yarn is 7.3 tex.

(107) (3) The twist of the thick count yarn of the composite low-twist yarn is: any twist not higher than the twist factor 295, the twist of fine-count yarn is 120t/10 cm, and the twist directions of thick count yarn and fine-count yarn are both Z-direction twist.

(108) (4). The thick count yarn of the composite low-twist yarn meets the quality requirements of the later process by improving yarn the grading cotton assorting to achieve its strength and hairiness index. The specific cotton assorting of thick count yarns is as follows: the cotton assorting of spinning thick count yarns is 50% long staple cotton (the fineness of the long staple cotton is about 1.6 dtex, and the length of main body of the long staple cotton is about 35 mm) and 50% fine staple cotton (the fineness of the long staple cotton is about 1.5 dtex, and the length of main body of the long staple cotton is about 28 mm). After the process of clearing, carding, combing, drawing and thick yarn according to the conventional technology, 12 s 35 twists/10 cm yarns can be obtained on the ordinary spinning frame according to the conventional technical means.

(109) (5) The thick count yarn and fine-count yarn of the composite low-twist yarn are combined and twisted to form the composite low-twist yarn. Its number of strand twists is 20 t/10 cm, and its twist direction is S-twist.

(110) (6) The ground warp yarn and the weft yarn of the composite low-twist towel fabric are 48.6 tex and 36.4 tex respectively; conduct warping for the 48.6 tex ground warp yarn of the composite low-twist towel fabric and the 41.6 tex/7.3 tex composite low-twist pile warp yarn separately to form the ground warp beam and the pile warp beam respectively.

(111) (7). Conduct sizing for the warp beams formed in step (6) separately to form the ground warp beam and the pile warp beam respectively. For the pile warp beam sizing, the sizing method of single immersion single compression should be used to reduce the number of pile warp breakages and ensure smooth weaving.

(112) (8). Using the pile warp and ground warp of step (7) and the 36.4 tex weft yarn to weave on a shuttle less towel loom to produce the low-twist composite semi-finished terry fabrics, or only use the pile warp and ground warp of step (7) to weave on the warp knitting towel loom to produce the warp knitting low-twist composite terry fabrics.

(113) (9). Conduct desizing, bleaching, dyeing, polishing, soaping, softening, dehydration, scutching, drying and setting for the low-twist composite terry fabrics woven in step (8) to form the low-twist composite terry fabrics. The above procedures are all conventional technical means.

(114) (10). Cutting and sewing the low-twist composite terry fabrics formed in step (9) to form a soft and fluffy low-twist composite terry fabric product.

(115) The low-twist composite terry fabric formed by the above technical scheme has the following benefits:

(116) (i) Compared with traditional water-soluble or alkali soluble twist less terry fabrics: low pollution, low energy consumption, high yield, low depilation rate, similar product hand feel and fluffy degree; compared with the twist less yarn towel produced using the 48.6 tex/80s PVA yarn, the benefits are as follows:

(117) TABLE-US-00008 AATCC (American Association of Textile COD Chemists (Chemical and Colorists) Water for Steam for Oxygen Weight Standard 135 pre- pre- Demand) loss Product treatment treatment index of rate of depilation (ton/ton (ton/ton pre- product rate % after Variety yarn) yarn) treatment % 5 washes 48.6 t 10 1.30 8465 7 3.5 cotton/ 7.3 t modal composite low-twist towel 48.6 t 21 2.9 20973 15.3 7.2 cotton/ 7.3 PVA twist less towel

(118) Note: This test data is obtained under the same cotton assorting, the same pre-treatment process conditions, the same dyeing and post-treatment conditions. This data may vary slightly with different colors and different cotton assorting.

(119) (ii). Compared with the terry fabric with patent No. U.S. Pat. No. 7,810,308B2, it has the advantages of soft hand feel, low depilation rate, more stable yield efficiency.