Method of making textile products from hygro material

Abstract

A process is described wherein pile yarn is woven with cotton weft and warp yarns to produce terry fabrics, such as towels. The fabric is then washed in warm water to dissolve the PVA fibers. The amount of fibers dissolved, depends upon the count of the yarn or yarns used. By dissolving the PVA fibers, a hollow air space is produced throughout the pile yarn, corresponding to an increase in the air space in the pile yarn. By increasing the air space in the pile yarn, the resulting towels are softer and bulkier than standard cotton towels. The present invention further relates to pile yarn in terry woven fabric (warp yarn), or weft yarn, in the case of flat fabrics.

1 - 24 . (canceled) 
     
     
         25 . A method of making a textile product, comprising:
 (a) forming a plurality of slivers comprising,
 (i) a first sliver made from one of cotton; blends of polyester and cotton; blends of polyester and viscose; blends of cotton and modal; blends of cotton; silk and modal; blends of cotton and bamboo; blends of cotton and sea weed fibers; blends of cotton and silver fibers; blends of cotton and charcoal fibers; and any combination thereof, and 
 (ii) a water-soluble sliver made from water-soluble fibers; 
   (b) forming a roving from the plurality of slivers, comprising forming a twist in the roving by wrapping the plurality of slivers such that the water-soluble sliver forms a core of the roving, and such that a sheath is formed around the core, the sheath comprising the first sliver;   (c) spinning the roving into a yarn; and   (d) using the yarn to make the textile product, including dissolving the water-soluble fibers from the water-soluble sliver of the yarn to provide space within the yarn itself for absorbing water.   
     
     
         26 . The method of  claim 25 , wherein the spinning of the roving is performed using a ring spinning frame. 
     
     
         27 . The method of  claim 25 , wherein the forming of the roving is performed using a speed frame 
     
     
         28 . The method of  claim 27 , wherein the forming of the twist in the roving is performed using the speed frame. 
     
     
         29 . The method of  claim 25 , wherein the first sliver comprises cotton fibers, and wherein the method further comprises forming the first sliver by carding the cotton fibers and drawing the cotton fibers on a draw frame. 
     
     
         30 . The method of  claim 25 , wherein, prior to dissolving the water-soluble fibers, only the water-soluble fibers from the water-soluble sliver define the core of the yarn. 
     
     
         31 . The method of  claim 25 , wherein the first sliver comprises cotton fibers, and wherein the water-soluble fibers comprise polyvinyl alcohol (PVA) fibers. 
     
     
         32 . The method of  claim 31 , wherein the PVA fibers are present in an amount of between about 8% to about 25% by weight of the yarn after performing the spinning of said step (d). 
     
     
         33 . The method of  claim 31 , wherein a hollow core is defined throughout the yarn resulting from and characteristic of the PVA fibers from the water-soluble sliver having been dissolved 
     
     
         34 . The method of  claim 25 , wherein the textile product is a towel. 
     
     
         35 . The method of  claim 25 , wherein the textile product is an undergarment. 
     
     
         36 . The method of  claim 25 , wherein the textile product is a sweater. 
     
     
         37 . The method of  claim 25 , wherein the textile product is a baby article. 
     
     
         38 . The method of  claim 25 , wherein the textile product is a tablecloth. 
     
     
         39 . The method of  claim 25 , wherein the textile product is a washcloth. 
     
     
         40 . The method of  claim 25 , wherein the textile product is a robe. 
     
     
         41 . The method of  claim 25 , wherein the textile product is sheeting. 
     
     
         42 . The method of  claim 25 , wherein the textile product is an apparel. 
     
     
         43 . A method of making a textile product, comprising:
 (a) forming a plurality of slivers comprising,
 (i) a water-soluble sliver made from water-soluble fibers, and 
 (ii) a second sliver comprised of at least one of cotton; cotton blends; silk fibers; modal fibers; acrylic fibers; blends of cotton and bamboo; blends of cotton and sea weed fibers; blends of cotton and silver fibers; and blends of cotton and charcoal fibers; 
   (b) forming a roving from the plurality of slivers, comprising forming a twist in the roving by wrapping the plurality of slivers such that the water-soluble sliver forms a core of the roving, and such that the second sliver forms a sheath around the core;   (c) spinning the roving into a pile yarn; and   (d) using the pile yarn to make the textile product, including dissolving the water-soluble fibers from the water-soluble sliver of the pile yarn to provide space within the pile yarn itself for absorbing water.   
     
     
         44 . A method of making a textile product, comprising:
 (a) forming a plurality of slivers comprising,
 (i) a water-soluble sliver made from water-soluble fibers, and 
 (ii) a second sliver comprised of at least one of cotton; blends of polyester and cotton; blends of polyester and viscose; blends of cotton and modal; blends of cotton; silk and modal; blends of cotton and bamboo; blends of cotton and sea weed fibers; blends of cotton and silver fibers; and blends of cotton and charcoal fibers; 
   (b) forming a roving from the plurality of slivers, comprising forming a twist in the roving by wrapping the plurality of slivers such that the water-soluble sliver forms a core of the roving, and such that the second sliver forms a sheath around the core;   (c) spinning the roving into a yarn; and   (d) using the yarn as a weft yarn or a warp yarn in making the textile product, including dissolving the water-soluble fibers from the water-soluble sliver of the yarn to provide space within the yarn itself for absorbing water.