Towel product and manufacturing method for towel product

Abstract

Provided is a towel product that ensures equivalent performance as the prior art in terms of water absorbency property and the like, while improving pile retention property. A towel is formed from a warp, a weft and a pile. The warp comprises sets of warp yarns. The pile comprises pile yarns that form the upper and the lower. The warp density is 27-33 threads/inch, and the weft density is 49-58 threads/inch. The pile ratio is 3.8-6.2. The configuration of 1 repeat is composed of 5 picks, and the configurations of 1 repeat are repeated. The 3 picks corresponding to weft yarns W2-W4 and thereof. W7-W9 compose the pile forming section. The 2 picks corresponding to weft yarns W5 and W6 compose the ground woven fabric section. The pile formed in the pile forming section has 3-6 snarls, preferably 4-5, and in the diagram, 4.

Claims

1. A towel product formed from a plurality of warp yarns, a plurality of weft yarns, and a plurality of pile yarns, wherein: a warp density of said towel product is 27 ends/inch to 34 ends/inch, and a weft density of said towel cloth is 45 ends/inch to 60 ends/inch; a pile ratio is 3.8 to 7.0; a number of picks regarding a configuration of 1 repeat is 4 to 6, where the configuration of 1 repeat is repeated; said pile yarns have a pile forming section and a ground woven fabric section; and said pile yarns formed in said pile forming section have 3 snarls to 6 snarls in said pile forming section of said pile yarns, wherein a pile retention property is 4000 mN and more, and wherein the snarls are uniform.

2. The towel product according to claim 1, wherein: said number of picks is 5 per repeat, said pile forming section is formed of 3 picks per repeat, and said ground woven fabric section is formed of 2 picks per repeat.

3. The towel product according to claim 1, wherein: said number of picks is 5 per repeat, said pile forming section is formed of 4 picks per repeat, and said ground woven fabric section is formed of 1 pick per repeat.

4. The towel product according to claim 1, wherein: said number of picks is 6 per repeat, said pile forming section is formed of 4 picks per repeat, and said ground woven fabric section is formed of 2 picks per repeat.

5. The towel product according to claim 1, wherein: said number of picks is 6 per repeat, said pile forming section is formed of 3 picks per repeat, and said ground woven fabric section is formed of 3 picks per repeat.

6. The towel product according to claim 1, wherein: said number of picks is 4 per repeat, said pile forming section is formed of 3 picks per repeat, and said ground woven fabric section is formed of 1 pick per repeat.

7. The towel product according to claim 1, wherein: said pile yarns are formed of a single yarn.

8. The towel product according to claim 1, wherein: said pile yarns are formed of a double yarn.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a schematic and perspective diagram of the 1st embodiment.

(2) FIG. 2A is a cross-section diagram of the 1st embodiment.

(3) FIG. 2B is a weave diagram of the 1st embodiment.

(4) FIG. 2C is a design diagram of the 1st embodiment.

(5) FIG. 3A is a cross-section diagram of comparative example 1.

(6) FIG. 3B is a weave diagram of comparative example 1.

(7) FIG. 3C is a design diagram of comparative example 1.

(8) FIG. 4A is a cross-section diagram of comparative example 2.

(9) FIG. 4B is a weave diagram of comparative example 2.

(10) FIG. 4C is a design diagram of comparative example 2.

(11) FIG. 5A is a cross-section diagram of comparative example 3.

(12) FIG. 5B is a weave diagram of comparative example 3.

(13) FIG. 5C is a design diagram of comparative example 3.

(14) FIG. 6A is a cross-section diagram of the 2nd embodiment.

(15) FIG. 6B is a weave diagram of the 2nd embodiment.

(16) FIG. 6C is a design diagram of the 2nd embodiment.

(17) FIG. 7A is a cross-section diagram of the 3rd embodiment.

(18) FIG. 7B is a weave diagram of the 3rd embodiment.

(19) FIG. 7C is a design diagram of the 3rd embodiment.

(20) FIG. 8A is a cross-section diagram of the 4th embodiment.

(21) FIG. 8B is a weave diagram of the 4th embodiment.

(22) FIG. 8C is a design diagram of the 4th embodiment.

(23) FIG. 9A is a cross-section diagram of the 5th embodiment.

(24) FIG. 9B is a weave diagram of the 5th embodiment.

(25) FIG. 9C is a design diagram of the 5th embodiment.

DESCRIPTION OF EMBODIMENTS

The 1st Embodiment

(26) Overview of Configuration

(27) FIGS. 1 and 2 shows the towel product of the 1st embodiment of the present invention. FIG. 1 is a schematic and perspective diagram. FIG. 2A is a cross-section diagram. FIG. 2B is a weave diagram. FIG. 2C is a design diagram. A towel product is configured by using a warp, a weft, and a pile. The warp comprises sets of warp yarns (G1, G2). The warp density (number of reed, number of the warp/1 inch of length of a weft direction) thereof is 27 to 34 ends/inch, and the weft density (gear, number of the weft per 1 inch of length of a warp direction) thereof is 45 to 60 ends/inch. The pile ratio (pile scale factor, pile magnification, length of a pile yarn per length of a warp yarn) is 3.8 to 7.0.

(28) Preferably, the warp density thereof is 27 to 33 ends/inch, and the weft density thereof is 50 to 58 ends/inch. The pile ratio is 4.0 to 6.0.

(29) More preferably, the warp density thereof is 28.5 to 32 ends/inch, and the weft density thereof is 53.5 to 56.5 ends/inch. The pile ratio is 4.5 to 5.5.

(30) The pile comprises pile yarns P1 (bold line in figure) that form the upper pile and pile yarns P2 (double line in figure) that form the lower pile. For convenience of the explanation, only pile yarn P1 will be described, as follows.

(31) The number of pick is 5. That is, 1 repeat is configured with 5 picks and the configurations of 1 repeat are repeated.

(32) The configuration of the 1 repeat (5 picks) has a pile forming section formed of 3 picks and a ground woven fabric section formed of 2 picks.

(33) The pile yarn rises between the weft yarns W2 and W3, and returns between the weft yarns W4 and W5. In order to compare with conventional and general product, the pile forming section is defined as the 3 picks correspond to the weft yarns W2-W4, though the weft yarn W5 involves in formation of pile actually. Similarly, the 3 picks correspond to the weft yarns W7-W9 compose the pile forming section.

(34) At the 2 picks correspond to the weft yarns W5-W6, pile yarn crosses weft yarn without forming pile. The ground woven fabric section is defined as the 2 picks. Similarly, the 2 picks correspond to the weft yarns W10-W11 is the ground woven fabric section.

(35) The pile formed in the pile forming section has snarls. The number of snarls is 3 to 6. Preferably, the number of snarls is 4 to 5. In the diagram, the number of snarls is 4.

(36) Here, 1 snarl is defined as a part formed by nodal point and approximately annulation (ring form), while pile yarn twists in pile.

(37) In addition, a hollow yarn is used for a pile yarn so as to further improve water absorbency property, drying property, lightness property and the like.

(38) Formation of Snarl

(39) In some cases, a single yarn is used for a pile, and in other cases, a double yarn is used for a pile.

(40) In the case of a single yarn, after forming towel cloth, it is submerged in water tank having water flow and kneaded in water flow. Water amount is set to 10 to 15 times of towel cloth weight. A single yarn is twisted in one direction, so that shape stability is lost by kneading in water flow and snarl is formed.

(41) In the case of a double yarn, after forming towel cloth, the rotary motion with the special brush is added to towel cloth. A double yarn is formed by twisting two single yarns mutually in opposite direction and the twist of two single yarns are cancelled each other, so that the double yarn has shape stability. It is not easily lost by kneading in water flow. Consequently snarl is formed by adding the rotary motion with the special brush.

(42) However, even in the case of double yarn, long time kneading makes the shape stability lost so as to form snarl.

(43) Demonstration Test About Pile Retention Property

(44) The operation of the ground woven fabric section and the operation of the snarl will be explained, while comparing the present embodiment with comparative examples 1 to 3. Pile retention property is estimated by the method JIS L 1075 B. Table 1 shows the overview of the demonstration test and the comparison results.

(45) TABLE-US-00001 TABLE 1 ground pile woven fabric retention approximate overview 1 repeat section snarl property average comparative conventional 3 picks non non 500~1000 mN 750 mN example 1 and general product -unused- comparative conventional 3 picks non 2 snarls 1000~2000 mN 1500 mN example 2 and general product -temporal change- comparative prior art 5 picks 2 picks non 1000~2000 mN 1500 mN example 3 patent document 1 the 1st the 1st 5 picks 2 picks 4 snarls 4000 mN~ embodiment embodiment

(46) FIG. 3A is a cross-section diagram of comparative example 1 (conventional and general product). FIG. 3B is a weave diagram thereof. FIG. 3C is a design diagram thereof. Comparative example 1 has 3 picks structure and the pile forming section is formed of 3 picks. The pile yarn rises between the weft yarns W2 and W3, and returns between the weft yarns W4 and W5. Though the weft yarn W5 involves in formation of one pile actually, the weft yarn W5 involves also in formation of next pile. So, the pile forming section is defined as the 3 picks correspond to the weft yarns W2-W4, Similarly, the 3 picks correspond to the weft yarns W5-W7 compose next pile forming section and the 3 picks correspond to the weft yarns W8-W10 compose the pile forming section next to the next (the pile forming section correspond to W5-W7). Namely, comparative example 1 has no ground woven fabric section.

(47) Further the pile of comparative example 1 is a loop pile and has no snarl.

(48) Pile retention property of comparative example 1 is 500 to 1000 mN (approximate average 750 mN).

(49) FIG. 4A is a cross-section diagram of comparative example 2 (conventional and general product with snarl). FIG. 4B is a weave diagram thereof. FIG. 4C is a design diagram thereof. In the case of a single yarn, temporal change by repeated washing may make snarl(s) formed. Pile length of a conventional and general product is short, so that 1 or 2 snarl(s) becomes formed. In this case, 2 snarls are added intentionally to the pile of comparative example 1 so as to form comparative example 2. Other configurations of comparative example 2 are similar to comparative example 1. Namely, comparative example 2 has no ground woven fabric section as well as comparative example 1, but it has 2 snarls in pile.

(50) However, snarls of comparative example 2 are formed intentionally so as to become uniform, while the snarl formed area and the snarl unformed area are mixed, in the case of snarl formation by temporal change.

(51) Pile retention property of comparative example 2 is 1000 to 2000 mN (approximate average 1500 mN). If the external force to pull out the adjacent pile acts, the formed snarl acts as resistance at the root of the piles. This may be the reason that pile retention property of comparative example 2 becomes twice as much as comparative example 1.

(52) FIG. 5A is a cross-section diagram of comparative example 3 (conventional art, e.g. FIG. 2 of patent document 1). FIG. 5B is a weave diagram thereof. FIG. 5C is a design diagram thereof. Comparative example 3 has 5 picks structure. That is, 1 repeat is configured with 5 picks. The configuration of 1 repeat (5 picks) has the pile forming section formed of 3 picks and the ground woven fabric section formed of 2 picks (similar to the present embodiment). Namely, comparative example 3 has the ground woven fabric section as well as the present embodiment, but it has no snarl.

(53) Pile retention property of comparative examples 3 is 1000 to 2000 mN (approximate average 1500 mN). If the external force to pull out the pile acts, the ground woven fabric section acts as resistance. This may be the reason that pile retention property of comparative examples 3 becomes twice as much as comparative example 1.

(54) The present embodiment as shown in FIG. 2 is compared with comparative examples 1 to 3.

(55) The present embodiment has 5 picks structure. That is, 1 repeat is configured with 5 picks. The configuration of 1 repeat (5 picks) has the pile forming section formed of 3 picks and the ground woven fabric section formed of 2 picks. Namely, the present embodiment has the ground woven fabric section. Further, it has 4 snarls.

(56) Pile retention property of the present embodiment is stably 4000 mN and more. If the external force to pull out the pile acts, the ground woven fabric section acts as resistance. If the external force to pull out the adjacent pile acts, the formed snarl acts as resistance at root of the pile. In the case of comparative examples 2, if the stronger force to pull out the pile acts, the snarl becomes unable to resist. On the other hand, in the case of the present embodiment, even if one snarl becomes unable to resist, the next snarl resists. Thus, the present embodiment can resist surely.

(57) The present embodiment comprises the characteristic configuration of comparative example 2 and the characteristic configuration of comparative example 3. However, the excellent pile retention property beyond the mere combination can be obtained stably.

(58) Effect

(59) As explained above, using the results of the demonstration tests, in the present embodiment, if the external force to pull out the pile acts, the excellent pile retention property can be obtained stably compared with the conventional art (comparative example 3).

(60) Further, in the present embodiment, snarls are formed uniformly. Thus, the opening area of the pile becomes smaller compared with the conventional art (compare FIG. 2A with FIG. 5A). This makes the loop not easy to be hooked by projection or something. In this point, the pile retention property can be improved too, compared with the conventional art. Also, uniformity of snarl formation can contribute to improvement of pile retention property.

(61) As described above, in the point of view that the snarls resist against act of the external force to pull out the pile and that the loop is hardly hooked by projection, pile retention property of the present embodiment can be improved compared with the conventional art.

(62) Meanwhile, the present embodiment comprises the characteristic configuration of the conventional art so as to maintain various performances such as water absorbency property, drying property, lightness property, touch feeling, and the like equivalent to the conventional art. In other word, while maintaining the same bulkiness (volume feeling) as conventional and general product, adapting 5 picks structure enables drying property and lightness property and adapting longer pile enables absorbency property and good touch feeling.

(63) Thus, the present embodiment can improve various performances such as drying property, lightness property, touch feeling, and the like, compared with a conventional business use towel such as the towel for guest rooms of luxury hotels, while maintaining pile retention property equivalent thereto.

(64) Also, the present embodiment can improve various performances such as water absorbency property, touch feeling, and the like, compared with a conventional business use towel such as the towel for guest rooms of business hotels, while maintaining pile retention property equivalent thereto.

(65) The present embodiment can satisfy with various performances, which are required for a towel, such as water absorbency property, drying property, lightness property, touch feeling, pile retention property (durability), and the like in proper balance to be compatible with all the performances. So the present embodiment can be applied to any use such as a household use towel, a towel for guest rooms of luxury hotels, a towel for guest rooms of business hotels without distinction of use. This makes mass production possible, so that it can reduce production cost.

(66) Supplementary Explanation

(67) The applicant of the present application has proposed the towel product that is excellent in various performances such as water absorbency property, drying property, lightness property, touch feeling, and the like. (See patent document 1). Subsequently, further, the applicant of the present application has studied pile retention property thereof. As the results of study, it has become clear that the embodiments having the ground woven fabric section have high pile retention property compared with other embodiments. In other word, the applicant of the present application has found out the action and the effect of the ground woven fabric section.

(68) The applicant of the present application has studied pile retention property in another viewpoint and focused on the relationship between snarl and pile retention property. The applicant has become aware that temporal change by repeated washing makes snarl formed, in the case of single yarn used for pile of conventional and general product.

(69) However, in the case of snarl formation by temporal change, snarls are sometimes formed, but are not formed at other times. Thus, it is difficult to form snarls uniformly.

(70) Further, pile of conventional and general product (comparative example 1) is short. So the number of snarls is about 1 or 2, even if snarl is formed (See comparative example 2). If the external force to pull out the adjacent pile acts, the snarl acts as resistance at root of the pile. But, if the stronger force to pull out the pile acts, the snarl becomes unable to resist. In this manner, comparative example 2 cannot obtain pile retention property sufficiently.

(71) In the present embodiment, the combination of the snarl and the ground woven fabric section can obtain the remarkable effect beyond the mere combination.

The 2nd to 5th Embodiment

(72) The present invention is not limited to the above-mentioned embodiment. Various changes and modifications may be made within the scope of the invention. Other embodiments of the present invention are illustrated below.

The 2nd Embodiment

(73) FIG. 6 shows the towel product of the 2nd embodiment of the present invention. FIG. 6A is a cross-section diagram. FIG. 6B is a weave diagram. FIG. 6C is a design diagram. The warp density thereof is 27 to 34 ends/inch, and the weft density thereof is 45 to 60 ends/inch. The pile ratio is 3.8 to 7.0.

(74) Preferably, the warp density thereof is 27 to 33 ends/inch, and the weft density thereof is 50 to 58 ends/inch. The pile ratio is 4.0 to 6.0.

(75) More preferably, the warp density thereof is 28.5 to 32 ends/inch, and the weft density thereof is 53.5 to 56.5 ends/inch. The pile ratio is 4.5 to 5.5.

(76) The number of picks is 5. That is, 1 repeat is configured with 5 picks and the configurations of 1 repeat are repeated.

(77) The configuration of the 1 repeat (5 picks) has the pile forming section formed of 4 picks and the ground woven fabric section formed of 1 pick.

(78) The pile yarn rises between the weft yarns W2 and W3, and returns between the weft yarns W5 and W6. The pile forming section is composed of the 4 picks correspond to the weft yarns W2-W5. Similarly, the 4 picks correspond to the weft yarns W7-W10 compose the pile forming section.

(79) At the 1 pick correspond to the weft yarn W1 or W6 or W11, pile yarn crosses weft yarn without forming pile. The pick correspond to the weft yarn W1 or W6 or W11 composes the ground woven fabric section.

(80) The pile formed in the pile forming section has snarls. The number of snarls is 3 to 6. Preferably, the number of snarls is 4 to 5. In the diagram, the number of snarls is 4.

(81) The 2nd embodiment comprises the ground woven fabric section and snarls so that the same effect as the 1st embodiment can be obtained.

(82) Incidentally, in the 2nd embodiment, the upper pile and the lower pile invert alternately. Therefore, the 2nd embodiment can be applied to a plain towel and the like, having no pattern.

The 3rd Embodiment

(83) FIG. 7 shows the towel product of the 3rd embodiment of the present invention. FIG. 7A is a cross-section diagram. FIG. 7B is a weave diagram. FIG. 7C is a design diagram. The warp density thereof is 27 to 34 ends/inch, and the weft density thereof is 45 to 60 ends/inch. The pile ratio is 3.8 to 7.0.

(84) Preferably, the warp density thereof is 27 to 33 ends/inch, and the weft density thereof is 50 to 58 ends/inch. The pile ratio is 4.0 to 6.0.

(85) More preferably, the warp density thereof is 28.5 to 32 ends/inch, and the weft density thereof is 53.5 to 56.5 ends/inch. The pile ratio is 4.5 to 5.5.

(86) The number of pick is 6. That is, 1 repeat is configured with 6 picks and the configurations of 1 repeat are repeated.

(87) The configuration of the 1 repeat (6 picks) has the pile forming section formed of 4 picks and the ground woven fabric section formed of 2 picks.

(88) The pile yarn rises between the weft yarns W2 and W3, and returns between the weft yarns W5 and W6. The pile forming section is composed of the 4 picks correspond to the weft yarns W2-W5. Similarly, the 4 picks correspond to the weft yarns W8-W11 compose the pile forming section.

(89) At the 2 picks correspond to the weft yarn W6-W7, pile yarn crosses weft yarn without forming pile. The 2 picks correspond to the weft yarns W6-W7 compose the ground woven fabric section.

(90) The pile formed in the pile forming section has snarls. The number of snarls is 3 to 6. Preferably, the number of snarls is 4 to 5. In the diagram, the number of snarls is 4.

(91) The 3rd embodiment comprises the ground woven fabric section and snarls so that the same effect as the 1st embodiment can be obtained.

The 4th Embodiment

(92) FIG. 8 shows the towel product of the 4th embodiment of the present invention. FIG. 8A is a cross-section diagram. FIG. 8B is a weave diagram. FIG. 8C is a design diagram. The warp density thereof is 27 to 34 ends/inch, and the weft density thereof is 45 to 60 ends/inch. The pile ratio is 3.8 to 7.0.

(93) Preferably, the warp density thereof is 27 to 33 ends/inch, and the weft density thereof is 50 to 58 ends/inch. The pile ratio is 4.0 to 6.0.

(94) More preferably, the warp density thereof is 28.5 to 32 ends/inch, and the weft density thereof is 53.5 to 56.5 ends/inch. The pile ratio is 4.5 to 5.5.

(95) The number of pick is 6. That is, 1 repeat is configured with 6 picks and the configurations of 1 repeat are repeated.

(96) The configuration of the 1 repeat (6 picks) has the pile forming section formed of 3 picks and the ground woven fabric section formed of 3 picks.

(97) The pile yarn rises between the weft yarns W2 and W3, and returns between the weft yarns W4 and W5. The pile forming section is composed of the 3 picks correspond to the weft yarns W2-W4. Similarly, the 3 picks correspond to the weft yarns W8-W10 compose the pile forming section.

(98) At the 3 picks correspond to the weft yarn W5-W7, pile yarn crosses weft yarn without forming pile. The 3 picks correspond to the weft yarns W5-W7 compose the ground woven fabric section.

(99) The pile formed in the pile forming section has snarls. The number of snarls is 3 to 6. Preferably, the number of snarls is 4 to 5. In the diagram, the number of snarls is 5.

(100) The 4th embodiment comprises the ground woven fabric section and snarls so that the same effect as the 1st embodiment can be obtained.

The 5th Embodiment

(101) FIG. 9 shows the towel product of the 5th embodiment of the present invention. FIG. 9A is a cross-section diagram. FIG. 9B is a weave diagram. FIG. 9C is a design diagram. The warp density thereof is 27 to 34 ends/inch, and the weft density thereof is 45 to 60 ends/inch. The pile ratio is 3.8 to 7.0.

(102) Preferably, the warp density thereof is 27 to 33 ends/inch, and the weft density thereof is 50 to 58 ends/inch. The pile ratio is 4.0 to 6.0.

(103) More preferably, the warp density thereof is 28.5 to 32 ends/inch, and the weft density thereof is 53.5 to 56.5 ends/inch. The pile ratio is 4.5 to 5.5.

(104) The number of pick is 4. That is, 1 repeat is configured with 4 picks and the configurations of 1 repeat are repeated.

(105) The configuration of the 1 repeat (4 picks) has the pile forming section formed of 3 picks and the ground woven fabric section formed of 1 pick.

(106) The pile yarn rises between the weft yarns W3 and W4, and returns between the weft yarns W5 and W6. In order to compare with conventional and general product, the pile forming section is defined as the 3 picks correspond to the weft yarns W3-W5, though the weft yarn W6 involves in formation of pile actually. Similarly, the 3 picks correspond to the weft yarns W7-W9 compose the pile forming section.

(107) At the 1 pick correspond to the weft yarn W2 or W6 or W10, pile yarn crosses weft yarn without forming pile. The pick correspond to the weft yarn W2 or W6 or W10 composes the ground woven fabric section.

(108) The pile formed in the pile forming section has snarls. The number of snarls is 3 to 6. Preferably, the number of snarls is 3 to 5. In the diagram, the number of snarls is 4.

(109) Incidentally, in the 5th embodiment, the upper pile and the lower pile invert alternately. Therefore, the 5th embodiment can be applied to plain towel and the like, having no pattern.

Other Embodiment

(110) The 2nd to 5th embodiments are illustrated above. But the present invention is not limited to the 2nd to 5th embodiments. However, the following points regarding the number of picks and the number of snarls should be remarked.

(111) In the case the number of picks is less than 4, the towel is similar to conventional and general product so that it is unable to implement drying property and lightness property. On the other hand, in the case the number of picks is more than 6, the towel is unable to implement water absorbency property. In other words, extremely longer pile is required so as to compensate a loss of water absorbency property. That is hardly realized.

(112) In the case the number of snarls is less than 3, pile retention property cannot be expected sufficiently. On the other hand, extremely longer pile is limited, so that the number of snarls is limited not to be more than 6.