Terry structure with selectively composite twist in pile and process of manufacturing

Abstract

The present disclosure relates to an improved terry structure with selectively composite twist in the pile yarns and a process of manufacturing the same. In particular, this disclosure is directed to methods of manufacturing terry cloth with high bulk, high absorbency, soft hand feel, low lint generation, and high durability. The process may include the steps of spinning, weaving, wet processing, and make-up. The present terry structure has high absorbency, soft hand feel, high bulk, low lint generation and a high durability end-to-end construction by using a combination of different yarns (zero-twist, low-twist, and high-twist) in pile with different recurrence to achieve desired attributes. The zero-twist yarn in the pile provides the bulky look, absorbency and soft feel, and the high twist yarn provides the durability and reduces the lint generation. The low-twist yarn balances the attributes of zero-twist and high-twist yarn.

1 . An improved terry fabric with selectively composite twist in a pile, comprising:
 a ground warp yarn and a ground weft yarn,   the ground weft yarn and warp yarn interlace to define a ground of said terry fabric,   said ground having a top surface and a bottom surface, and pile warp extending from said ground,   said pile warp comprising a plurality of sets of pile yarns with each set of pile yarns having a plurality of pile yarns, wherein said pile yarns of each sets of pile yarns form a plurality of adjacent loops above said top surface and then pass through said ground and extend to form a plurality of adjacent loops beneath said bottom surface,   said pile yarns of each set again pass through said ground and repeat in adjacent loops above said top surface and beneath said bottom surface across a dimension of terry structure, and each immediately adjacent pair of sets of yarns is staggered so as to provide a pattern defined by the sets of pile yarns and ground on each of said top and bottom surfaces, wherein the pile warp yarns have a composite twist yarns each having different type of twist in order to selectively use of different combinations of twist yarns in the pile.   
     
     
         2 . The improved terry fabric with selectively composite twist in the pile according to  claim 1 , wherein said warp and weft yarns have a range of yarn count 6$ Ne to 60$ Ne to make the terry fabric having a range from 350 to 900 GSM. 
     
     
         3 . The improved terry fabric with selectively composite twist in the pile according to  claim 1 , wherein the said terry fabric is made with different weave structures including one of the following: three pick, four pick, five pick, seven pick, eight pick and nine pick terry fabric formed with a dobby or jacquard loom. 
     
     
         4 . The improved terry fabric with selectively composite twist in the pile according to  claim 1 , wherein the said pile yarn contains composite twist having at least 50% by number of zero twist yarns having a twist multiplier in the range of 1.0 to 2.4, at least within the range of 25% to 50% by number of high twist yarns having a twist multiplier more then 3.5, and at least within the range of 0 to 33% by number of low twist yarn having twist multiplier in the range of 2.5 to 3.5. 
     
     
         5 . The improved terry fabric with selectively composite twist in the pile according to  claim 1 , wherein, in another preferred embodiment, the said pile yarn preferably contains composite twist as pile warp sheet having, up to 50% of any yarn twist including Zero Twist having Twist multiplier in the range of 1.0 to 2.4 and/or High twist yarn having Twist multiplier more than 3.5 and/or Low twist yarn having twist multiplier in the range of 2.5 to 3.5. 
     
     
         6 . The improved terry fabric with selectively composite twist in the pile according to  claim 1 , wherein, the terry fabric provides an optimized balance between composite yarns to provide 1) a bulky look, absorbency and soft feel through use of the zero twist yarns, 2) durability and low lint generation through the use of the high twist yarns, and 3) balancing the both 1) and 2) through use of low twist yarns. 
     
     
         7 . The process of manufacturing an improved terry fabric with selectively composite twist in pile as in  claim 2 , comprising:
 (i) spinning the warp, weft, and pile yarns;   (ii) weaving the warp, weft and pile yarns together to form a terry fabric; and   (iii) wet processing the terry fabric,
 wherein spinning further includes following sub-steps:
 [i] opening and blending of the different fibers in specific proportion send to next machine by a chute feed system; 
 [ii] carding to cleaning all the impurities, neps from the fibers to output a sliver; 
 [iii] drawings, via a draw frame, to draft and make the fibers in the sliver more parallel and remove thick-thin places and hooks; 
 [iv] combing the sliver to remove short fibers; 
 [v] drawing, via a finisher drawing frame, to do draft and make fibers drafting more parallel and remove thick-thin places and hooks; 
 [vi] speed framing the sliver to make a roving; and 
 [vii] ring framing the roving to make a yarn through twisting by imparting draft into the roving, 
 [viii] winding the yarns to make a yarn package; 
 [ix] steaming the yarns to remove the snarling and making the yarn relax and stable; 
 [x] parallel winding two yarns to make a plied yarn; and 
 [xi] twisting the plied to impart a required selective twist into the yarn, 
 
 wherein the weaving step includes:
 [i] warping to make warp sheet for a loom; and 
 [ii] sizing the warp sheet to enhance the weavability, 
 
 wherein the wet processing step includes:
 [i] bio-polishing the terry fabric to remove protruding fibers from the yarns by using a cellulose enzyme to give luster and improve piling; 
 [ii] de-sizing the terry fabric to remove size material; 
 [iii] scouring or bleaching to remove natural impurities and natural color; 
 [iv] dying to color the fabric; 
 [v] optionally printing the terry fabric; 
 [vii] air beating the terry fabric to make the pile open and provide a mechanically soft finish; 
 [vi] stentering the terry fabric to remove skew effect from the terry fabric, or to set its width and shrinkage; 
 
 wherein, the pile warp yarns have composite twist yarns having different types of twist in an optimized manner through selective use of different combination of twist in yarns in the pile with different recurrence to achieve requisite attributes of end user. 
   
     
     
         8 . The process of manufacturing an improved terry fabric with selectively composite twist in pile according to  claim 7 , wherein the said pile yarns contains composite twist having 1) at least 50% by number of zero twist yarn having a twist multiplier in the range of 1.0 to 2.4, 2) at least within the range of 25% to 50% by number of high twist yarns having a twist multiplier more then 3.5, and 3) at least within the range of 0 to 33% by number of low twist yarns having a twist multiplier in the range of 2.5 to 3.5. 
     
     
         9 . The process of manufacturing an improved terry fabric with selectively composite twist in the pile according to  claim 7 , wherein the said pile yarn contains composite twist having: 1) up to 50% of any yarn twist including zero twist, 2) a twist multiplier in the range of 1.0 to 2.4, 3) a high twist yarn having a twist multiplier more than 3.5, and/or 4) low twist yarn having a twist multiplier in the range of 2.5 to 3.5. 
     
     
         10 . The process of manufacturing an improved terry fabric with selectively composite twist in the pile according to  claim 7 , wherein the wet processing step optionally includes the dissolution of a soluble fiber or soluble yarn in the terry fabric.