Method for producing durable fluffy and soft loop fabric having embedded weft floats

Abstract

A method for producing durable fluffy and soft loop fabric having embedded weft floats, including: 1) yarn selection; 2) winding; 3) warping; 4) sizing; 5) weaving; and 6) dyeing and finishing. During the weaving process, low-twist or zero-twist yarns or filament long floats are embedded into loops. During the dyeing and finishing process, due to weft-wise shrinkage, the embedded weft floats shrink and expand, thereby supporting the loops upright without lodging. In addition, the fluffy zero-twist yarns and interlaced yarn floats form a stacked stereoscopic structure with other weft yarns fixedly connected to the loops, thereby facilitating the extension of the loops and enlarging moisture diffusion surfaces of the loops during baking and air-drying processes to create a rapid drying condition for towels. Therefore, a loop fabric which has a special style and a fluffy and soft hand feeling and is still fluffy and soft after being washed is obtained.

Claims

1. A method for producing durable fluffy and soft loop fabric having embedded weft floats, comprising: selecting fixed loop weft yarns and embedded floating weft yarns, which are yarns with a twist factor less than 260, wherein a ratio of the fixed loop weft yarns and the embedded floating weft yarns is 3:n to 7:n, where n is a number equal to or greater than 1; winding the fixed loop weft yarns and the embedded floating weft yarns; warping the fixed loop weft yarns and the embedded floating weft yarns; sizing the fixed loop weft yarns and the embedded floating weft yarns; weaving the fixed loop weft yarns and the embedded floating weft yarns, wherein during the weaving: a loop structure adopts 2/1 modified warp-rib weaves, a ground structure adopts 2/1 warp-rib weaves, two short beating up and one long beating up for each loop; a number of warp yarns crossed by the embedded floating weft yarns of a pile loop fabric is not less than 6, a number of the embedded floating weft yarns is not less than 1; and interlacing structures of the embedded float weft yarns and ground warps are 13/1 or 16/1 or 24/1 or 32/1 weft-rib weaves; dyeing and finishing the fixed loop weft yarns and the embedded floating weft yarns.

2. The method according to claim 1, wherein the embedded floating weft yarns are 5-16s untwisted yarns in polyester or 200D-800D draw texturing yarn filament yarns in polyester.

3. The method according to claim 1, wherein the number of warp yarns crossed by the embedded floating weft yarns of the pile loop fabric is 10 to 32, the number of the embedded floating weft yarns is 2 to 4.

4. The method according to claim 1, wherein the dyeing and finishing process includes: removing water soluble silk, wherein fabric is added when water reaches 90° C. and treated at 100° C. for 50 minutes; deoiling polyester, wherein a dosage of polyester deoiling agent is 3 g/l, treating for 30 min at 100° C.; refining and bleaching, wherein fabric is contacted with a solution containing chelating agent: 0.5 g/l, hydrogen peroxide: 5 g/l, ionic membrane caustic soda: 8 g/l, stabilizer of hydrogen peroxide: 0.3 g/l, highly concentrated refining agent in dosage of 1.5 g/l at 98° C. for 60 minutes; dyeing and heating, wherein heating up from 30° C. to 60° C., at a speed of 1° C./min, and maintaining the temperature of 60° C. for 30 minutes, reactive dyes are adopted; thermal washing, and soaping, wherein out thermal washing for 10 minutes at 85° C., and carrying out soaping for 15 minutes at 95° C.; polishing, wherein a polishing enzyme is used for polishing, a dosage of the polishing enzyme is 0.05% on weight of fabric, take polishing treatment for 40 minutes at 55° C.; soft finishing, wherein softening agent with antistatic function is selected in the process of soft finishing.

5. The method according to claim 4, wherein the polishing enzyme is a neutral polishing enzyme.

6. The method according to claim 4, wherein the drying is carried out by a loose dryer.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIGS. 1A-1C are schematic diagrams of a single-faced pile loop fabrics with one weft float embedded in the loops, where FIG. 1A is a section schematic diagram of the warp direction of the corresponding loop fabrics, FIG. 1B is a weave pattern of ground warp yarns and two weft yarns of the corresponding loop fabrics, and FIG. 1C is a weave pattern of pile warp yarns and two weft yarns of the corresponding loop fabrics;

(2) FIGS. 2A-2C are schematic diagrams of a double-faced pile loop fabrics with one weft float embedded in the loops, where FIG. 2A is a section schematic diagram of the warp direction of the corresponding loop fabrics, FIG. 2B is a weave pattern of ground warp yarns and two weft yarns of the corresponding loop fabrics, and FIG. 2C is a weave pattern of pile warp yarns and two weft yarns of the corresponding loop fabrics;

(3) FIGS. 3A-3C are schematic diagrams of a single-faced pile loop fabrics with three weft floats embedded in the loops, where FIG. 3A is a section schematic diagram of the warp direction of the corresponding loop fabrics, FIG. 3B is a weave pattern of ground warp yarns and two weft yarns of the corresponding loop fabrics, and FIG. 3C is a weave pattern of pile warp yarns and two weft yarns of the corresponding loop fabrics; and

(4) FIGS. 4A-4C are schematic diagrams of a double-faced pile loop fabrics with three weft floats embedded in the loops, where FIG. 4A is a section schematic diagram of the warp direction of the corresponding loop fabrics, FIG. 4B is a weave pattern of ground warp yarns and two weft yarns of the corresponding loop fabrics, and FIG. 4C is a weave pattern of pile warp yarns and two weft yarns of the corresponding loop fabrics;

SPECIFIC EMBODIMENTS

(5) The use of these and other examples anywhere in the specification is illustrative only, and in no way limits the scope and meaning of the invention or of any exemplified form. Likewise, the invention is not limited to any particular preferred embodiments described herein. Indeed, modifications and variations of the invention may be apparent to those skilled in the art upon reading this specification, and can be made without departing from its spirit and scope. All the technologies realized based on above mentioned contents of this invention are included in the scope of this invention, and unless specially stated, the following embodiments are completed by conventional prior art.

Embodiment 1

(6) FIGS. 1A-1C and 3A-3C illustrate a durable fluffy and soft single-faced pile loop fabric having embedded weft floats with the single-faced pile loop towel structure of three-weft pile embedded with 1 and 3 floating weft yarns of polyester filament respectively. FIGS. 1A-1C and 3A-3C illustrate embedded floating weft yarns 2, fixed loop weft yarns 4, pile warp yarns 6 and ground warp yarns 8. In FIGS. 1A-1C and 3A-3C, the empty diamond indicates that when the pile warp yarns 6 are interwoven with the fixed loop weft yarns 4, the pile warp yarns 6 are under the weft yarns 4; the filled diamond indicates that when the pile warp yarns 6 are interwoven with the fixed loop weft yarns 4, the pile warp yarns 6 are above the weft yarns 4; the empty circle indicates that when the ground warp yarns 8 are interwoven with the fixed loop weft yarns 4, the ground warp yarns 8 are under the weft yarns 4; the filled circle indicates that when the ground warp yarns 8 are interwoven with the fixed loop weft yarns 4, the warp yarns 8 are above the weft yarns 4; the empty triangle indicates that when the warp yarns 8 are interwoven with the embedded floating weft yarns 2, the warp yarns 8 are under the weft yarns 2; and the filled triangle indicates that when the warp yarns 8 are interwoven with the embedded floating weft yarns 2, the warp yarns 8 are above the weft yarns 2.

(7) The production method of embedded weft floats loop fabrics with weaving process is as follows: winding, warping, weaving, dyeing and sewing.

(8) 1. Yarn selection: prepare the yarns with prior arts: pile warp yarns are 12s cotton untwisted yarns, the ground warp yarns are 21s/2 polyester dyed yarns, fixed loop weft yarns are 16s cotton yarns, and embedded floating weft yarns are polyester 600D/576F draw texturing yarn filament yarns.

(9) 2. Winding: the existing well-known technology is used for winding on a winder such as the SAVIO winder which is made in Japan.

(10) 3. Warping: the existing well-known technology is used to prepare a pile warp beam and a ground warp beam on a warping machine such as a BENNINGER batch warping machine.

(11) 4. Sizing: sizing the ground warp beam on a sizing machine such as the KAL-MAYER sizing machine using the existing well-known technology.

(12) 5. Weaving: for the single-faced pile loop fabric, a loop structure of fixed loop structure adopts 2/1 modified warp-rib weaves, a ground structure adopts 2/1 warp-rib weaves, two short beating up and one long beating up for each loop; interlacing structures of embedded float weft yarns and ground warps are 13/1 weft-rib weaves. Towel rapier loom such as G6300 rapier loom is used.

(13) 6. Dyeing and finishing: the specific steps are as follows:

(14) Removal of water soluble silk: the fabric is added when water reaches 90° C. and treated at 100° C. for 50 minutes.

(15) Deoiling of polyester: a dosage of polyester deoiling agent such as TF-129T of TRANSFAR® is 3 g/l, treating for 30 min at 100° C.

(16) Refining and bleaching: the fabric is contacted with a solution containing chelating agent: 0.5 g/l, hydrogen peroxide (mass concentration of 27%): 5 g/l, ionic membrane caustic soda (mass concentration of 32%): 8 g/l, stabilizer of hydrogen peroxide: 0.3 g/l, highly concentrated refining agent in dosage of 1.5 g/l at 98° C. for 60 minutes.

(17) Dyeing: heat up from 30° C. to 60° C., at a speed of 1° C./min, and maintain the temperature of 60° C. for 30 minutes, reactive dyes are adopted (reactive dye such as REMAZOL® navy blue RGB etc.).

(18) Thermal washing, soaping: carry out thermal washing for 10 minutes at 85° C., and carry out soaping for 15 minutes at 95° C.

(19) Polishing: a neutral polishing enzyme of NOVOZYMES 8000L is used for polishing, a dosage of the polishing enzyme is 0.05% on weight of fabric, take polishing treatment for 40 minutes at 55° C.

(20) Soft finishing: a softening agent such as HUNTSMAN softening agent SFC, with dosage of 3 g/l, carry out soft finishing for 30 minutes at 40° C.

(21) Dehydrating, drying, a loose dryer is used for drying, sewing, and a single-faced towel fabric is obtained.

Embodiment 2

(22) FIGS. 2A-2C and 4A-4C illustrate a durable fluffy and soft double-faced pile loop fabric having embedded weft floats with the double-faced pile loop towel structure of three-weft pile embedded with 1 and 3 floating weft yarns of polyester filament respectively.

(23) The production method of embedded weft floats loop fabrics with weaving process is as follows: winding, warping, weaving, dyeing and sewing.

(24) 1. Yarn selection: prepare the yarns with prior arts: pile warp yarns are 12s cotton untwisted yarns, the ground warp yarns are 21s/2 polyester dyed yarns, fixed loop weft yarns are 16s cotton yarns, and embedded floating weft yarns are polyester 600D/576F draw texturing yarn filament yarns.

(25) 2. Winding: the existing well-known technology is used for winding on winder such as the SAVIO winder which is made in Japan.

(26) 3. Warping: the existing well-known technology is used to prepare a pile warp beam and a ground warp beam on a warping machine such as a BENNINGER batch warping machine.

(27) 4. Sizing: sizing the ground warp beam on a sizing machine such as the KAL-MAYER sizing machine using the existing well-known technology.

(28) 5. Weaving: for the double-faced pile loop fabric, a loop structure of fixed loop structure adopts 2/1 modified warp-rib weaves, a ground structure adopts 2/1 warp-rib weaves, two short beating up and one long beating up for each loop; interlacing structures of embedded float weft yarns and ground warps are 13/1 weft-rib weaves. Towel rapier loom such as G6300 rapier loom is used.

(29) 6. Dyeing and finishing: the specific steps are as follows:

(30) Removal of water soluble silk: the fabric is added when water reaches 90° C. and treated at 100° C. for 50 minutes.

(31) Deoiling of polyester: a dosage of polyester deoiling agent such as TF-129T of TRANSFAR® is 3 g/l, treating for 30 Min at 100° C.

(32) Refining and bleaching: the fabric is contacted with a solution containing chelating agent: 0.5 g/l, hydrogen peroxide (mass concentration of 27%): 5 g/l, ionic membrane caustic soda (mass concentration of 32%): 8 g/l, stabilizer of hydrogen peroxide: 0.3 g/l, highly concentrated refining agent in dosage of 1.5 g/l at 98° C. for 60 minutes.

(33) Dyeing: heat up from 30° C. to 60° C., at a speed of 1° C./min, and maintain the temperature of 60° C. for 30 minutes, reactive dyes are adopted.

(34) Thermal washing, soaping: carry out thermal washing for 10 minutes at 85° C., and carry out soaping for 15 minutes at 95° C.

(35) Polishing: a neutral polishing enzyme of NOVOZYMES 8000L is used for polishing, a dosage of the polishing enzyme is 0.05% on weight of fabric, take polishing treatment for 40 minutes at 55° C.

(36) Soft finishing: a softening agent such as HUNTSMAN softening agent SFC, with dosage of 3 g/l, carry out soft finishing for 30 minutes at 40° C.

(37) Dehydrating, drying, a loose dryer is used for drying, the loose dryer is made in Jiangyin, Jiangsu, model: WMH240.

(38) sewing, and a towel fabric is obtained.

(39) The weft yarns of the fixed loops are natural fiber yarn, and the embedded floating weft yarns are chemical fiber untwist yarns or chemical fiber draw texturing yarn filament.

Embodiment 3

(40) A durable fluffy and soft single-faced four-weft pile loop fabric having embedded weft floats, the pile structure in the preparation steps is changed from three-weft pile to four-weft pile on the basis of embodiment 2, and the other parts of the embodiment are similar to that of embodiment 2.

Embodiment 4

(41) A durable fluffy and soft double-faced four-weft pile loop fabric having embedded weft floats, the pile structure in the preparation steps is changed from three-weft pile to four-weft pile on the basis of embodiment 2, and the other parts of the embodiment are similar to that of embodiment 2.

(42) In conclusion, the towels in above mentioned embodiments are tested and show excellent properties of durable softness, high water absorption and quick drying properties. And compared with the existing ordinary towel on the market, the towels has better performance and is very suitable for promotion and use.