Description:
FORM2
THE PATENTS ACT 1970 (39 of 1970)
&

THE PATENT RULES, 2003 COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

1. TITLE OF THE INVENTION

“EUNIC” A SUPER HYDROPHILIC COTTON YARN MADE FROM NATURAL POLYMER FOR HOME TEXTILES AND ITS METHOD OF PREPARATION THEREOF.”

2. APPLICANT (S)

(a) NAME: GOLDEN TERRY TOWEL PRIVATE LIMITED
(b) NATIONALITY: INDIAN
(c) ADDRESS: 671 KATRA NEEL CHANDNI CHOWK, NEW DELHI, DELHI, INDIA, 110006

3. . PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in which it is to be performed

“EUNIC” A SUPER HYDROPHILIC COTTON YARN MADE FROM NATURAL POLYMER FOR HOME TEXTILES AND ITS METHOD OF PREPARATION THEREOF.”

FIELD OF INVENTION:
The present invention discloses to process for making yarn suitable for making super soft terry towel and toweling fabric. Especially, the invention is directed at producing super absorbent “EUNIC “hydrophilic yarn.

BACK GROUND OF INVENTION:

The word “EUNIC “refers to the phenomenon of absorption of water or moisture by yarn. Generally, towels are made from 100 % cotton and blends of cotton with other natural, cellulosic and manmade hydrophilic fibers. Absorption depends upon Structure of fiber and yarn. The amount of twist in the yarn affects the properties of towel product. Generally, towels are made from medium coarser yarn because the coarser yarn has a

greater number of fibers in the cross section. The thicker the towel, the greater the surface area, and thus a greater amount of water can be absorbed. When a towel came in contact with water, the towel’s fiber typically made of cotton, absorb water through capillary action. This is due to fibers hydrophilic properties. As the fibers absorb water, they swell, increasing the towels thickness and weight. This swelling helps to create a larger surface area for dying. Water is drawn up the towel’s fibers through capillary action allowing the towel to absorb more water, finally as the towel absorbs water, it starts to wick the water away from the surface, helping to dry the skin or surface.

The formation of pile loops in terry weaving depends upon the creation of a gap between the fell of cloth and two successive picks. The length of this gap can be altered and adjusted according to the requirement of height of loops, to form this gap two succeeding picks are beaten up short of the true cloth fell forming a temporary false fell this achieved by the terry motion. In terry fabric manufacturing two sheets of warp threads run simultaneously of which one is kept under normal tension. Ground yarn kept hard twist, generally 4-4.5 twist factor can be single yarn or two-ply yarn depend upon construction of towel. 100 % cotton, or cotton blended with other man made cellulosic or polyester fibers. Yarn used in terry towel is 100 % cotton except for yarn used in decorative border design and embellishments on the terry towel. Decorative designs and embellishments are formed using any textile fibers like polyester, viscose made from bamboo, modified

viscose spun yarn etc.

The pile yarn is generally a low twist yarn, because higher twist levels can reduce the surface area of yarn. Surface area of yarn is critical parameter of yarn that affect its properties like absorbency, dyeability and texture. Pile loops provides maximum surface area for the absorption of water, and low twist aids in the absorption by imparting wicking properties of the yarn. Twist factor of pile yarn generally range from
3.2 to 3.8. Normally yarn used in terry for loops are medium coarser and rage from Ne 6’s to 30’s in single as well as double ply configuration of pile, ground and weft. The greater the amount of free air space available within the yarn, the quicker and more complete the absorption of the water. Hence, to increase the amount of free air space

Within the strands, lower the twist more air space in the yarn. When wool is combined with caustic lye (sodium hydroxide, NaOH), a chemical reaction occurs that breaks down the wool fibers, here is chemical equation:

Wool (keratin) + NaOH= Sodium Keratinate + water

Keratin is primary protein found in wool fibers. When caustic lye is applied, the sodium hydroxide (NaOH) breaks the disulfide bonds in the Keratin molecule, leading to the

formation of sodium Keratinate. Since the sodium Keratinate is a water soluble, causing wool fibers break down and dissolve. This equation exploits the dissolving property of wool by blending wool in to cotton.

OBJECTIVE OF THE INVENTION

Therefore, it is an object of the invention to provide a method of making a yarn that can be used to form a soft terry fabric, which are highly hydrophilic in nature and bulky, such highly hydrophilic can absorb between about 70 and 75 % of the water contacting the yarn or fabric. It is a further object of the invention to provide terry towel that are highly absorbent, quick drying, increase in bulk after drying, and have a lower tendency to lint.

SUMMARY OF THE INVENTION

The present invention relates to pile yarn in terry woven fabric, this pile yarn contains wool which is caustic lye dissolve in a defined method at the time of dyeing of towel.

A process is described wherein blended pile yarn is woven with cotton warp and weft to produce towels. This fabric is then processed with caustic lye before dying to dissolve wool. The number of wool fibers dissolved, depends upon the count of the yarn or yarn used. The amount of wool can vary from about 10 % to 25 % of the weight of yarn. By dissolving the wool fibers, a porous / hollow air space is produced throughout the pile yarn, corresponding to an increase in the air space in the pile yarn , by increasing air space in the pile yarn , the resulting towels are softer, fluffier , bulkier than towel made from normal ring spun pile yarn. Towel made from present invention can absorb more than 75 % of the water contacting the yarn. The cotton that forms outer surface of the pile yarn or warp and weft yarn of terry fabric can be of any origin; like s6, mcu5, mech1 Indian version of cotton or Egyptian, Australian etc. warp and weft yarn in terry can be blended with cellulosic or polyester blend.

BRIEF DESCRIPTION OF THE DIAGRAM

Fig.1: Fig. 1 shows Yarn Spinning Process. Fig.2: Fig. 2 shows Weaving Process Flow.
Fig.3: Fig. 3 shows Terry Weave.

Fig.4: On loom specification: loom card attached as Fig. 4

DETAIL DESCRIPTION OF INVENTION:

The present invention relates to pile yarn in terry woven fabric, this pile yarn contains wool which is caustic lye dissolve in a defined method at the time of dyeing of towel.

A process is described wherein blended pile yarn is woven with cotton warp and weft to produce towels. This fabric is then processed with caustic lye before dying to dissolve wool. The number of wool fibers dissolved, depends upon the count of the yarn or yarn used. The amount of wool can vary from about 10 % to 25 % of the weight of yarn. By dissolving the wool fibers, a porous / hollow air space is produced throughout the pile yarn, corresponding to an increase in the air space in the pile yarn , by increasing air space in the pile yarn , the resulting towels are softer, fluffier , bulkier than towel made from normal ring spun pile yarn. Towel made from present invention can absorb more than 75 % of the water contacting the yarn. The cotton that forms outer surface of the pile yarn or warp and weft yarn of terry fabric can be of any origin; like s6, mcu5, mech1 Indian version of cotton or Egyptian, Australian etc. warp and weft yarn in terry can be blended with cellulosic or polyester blend

• Method of making the pile yarn

The cut length of Wool fiber of any origin with 34 mm to 44 mm – 24 mic. Cut staple fibers are first processed through a blow room in cotton spinning system. It is here that

the fibers are made into slivers through the process of carding and use of draw frame. Cotton sliver is prepared by processing through the blow room, carding, after carding, the cotton sliver is subjected to combing to remove short fibers. The amount of noil, or fibers that are less than 13 mm, removed from range 8% to 24 % of the weight of the feed material. The yarn is spun in ring frames using the normal setting, all the setting parameters on ring frames are determined on type of cotton and wool and percentage of their blending

• Method of making towels

Terry towel is formed from three type of warp sheets. The first type of yarn is the ground warp. The ground warp is the longitudinal set of yarn forming the base fabric, the second type of yarn is the pile warp. The pile warp is placed in the longitudinal direction and produce the loops on the face, back or both directions. Pile loop provides a large surface area for maximizing the absorption of water. The third type of yarn is the weft yarn. The weft yarn is laid perpendicular to the pile yarn, and interlace with pile, ground to form the fabric or terry towel. The ground and weft yarn are standard cotton yarn that are generally used in towel manufacturing process.

The ground yarn has a count ranging from about Ne 2/24’s to 2/30’s and form about Ne 10’s to about Ne 20’s combed or carded. In the preferred

embodiment, the ground yarn is about 2/20’s carded. The weft yarn, has a count ranging from about 8’s to 30’s both carded, combed, ring and OE yarn.

Twist multiplier for weft and ground is from 4 -4.5 ‘z’ twist.

The ground, weft and pile are woven together under normal condition.

The terry fabric can be made with 56, 58, and 60 reed counted using Stockport system.

Terry woven can be 3, 4, 5, or 6 pick terry, generally preferred 3 pick terry (weave attached in fig). The pile height can range from 3.5 to 7.5 mm.

After completion of weaving, the fabric roll is scoured and dyed in normal fashion in a fabric dyeing machine. While scouring, bleaching and dyeing, the operating temperature range from 80 °Cto 100°C

The Liquor ratio is ratio of the material (weight) to water (volume) the liquor ratio is 1:6 for first bath then after every bath is 1:4 is preferred.

Material is typically wound into the shape of rope prior to entering the fabric dyeing machine. After dying and washing, the liquor is drained and fresh water is injected for rinsing to eliminate all the dissolve wool. The water temperature from 55°C to 60°C

• Drying and straightening the fabric

After unloading the material from the washing and rinsing vessel, the material is hydro extracted in hydro-extractor in the standard manner to reduce the moisture from 200 % to 50-55%. A rope is passed through rope opener which is equipped with drumbeater both at feed and delivery ends, to straighten the twist in the rope. Then the material is passed through hot air tumbler, this is to ensure proper lifting of pile. the first drying is carried out at about 110 °C, second drying occurs at a higher temperature, such as 150 °C for about four min to 5 min. the full width fabric is then passed through hot air stenter and a weft straightener to straighten the fabric and return it to its proper dimensions.

• Conditioning

To ensures reduced linting during washing of towel subsequently, fabric is passed through shearing machine to clean only protruding fibers from the fabric. This process I optional depending on the protruding fiber on the surface of towel. The fabric then carried through length cutting, length hemming, cross cutting, cross hemming, chocking folding and packing according to the standard practice

The Eunic yarn in the loop pile warp and weft, has a large amount of air spaces within the yarn structure, which permits easy air circulation. The air space provides room to absorb and vaporize water. Thus, the fabric is highly absorbent and quick drying, having a decreased likelihood of mildew formation. Typically, the fabric is 30 % more absorbent and quick drying compared to normal toweling fabric. When tested sinking methods, the

toweling fabric takes less than 5 seconds to absorb the water, whereas other towel takes 10 seconds or more. Testing methods AATCC-79-2000 (American association of textile chemist and colorists). The AATCC-79-2000 is a test to measure the absorbency of bleached textiles is a standard test method, which can be applied to determine the suitability of a fabric / toweling cloth. Test involve to check sinking time required for a droplet of water. The results of the test are usually measured in the number of seconds that it takes for a drop of water to sink. The diminishing of droplet, until it vanishes entirely leaving a wet spot, is analyzed for measuring the absorbency.

In the surface wetting methods, the toweling fabric absorbs 65 -75% water compared to normal toweling fabric (using ASTM -D-4772). The ASTM D -4772 method measures the surface water absorption of terry fabric for bath towels, bath sheets ,hand towels, kitchen towels, dish cloths wash cloths , beach wear , bathrobe and the like.to measure the amount of water completely absorbed by the specimen placed in an embroidery hoop at 60° angle. the amount is calculated in milliliters, by pouring 50 ml of distilled / demonized water and measuring the collected unabsorbed water in a beaker placed at bottom of the inclined frame. in the socking method, where the sample is totally immersed in water, taken out to drip and then weighed, the sample weighs 4 times its original weight; in other words, 400 % absorption.

• Pile yarn manufacturing parameters

The wool used in this example is 1.4 den 34 mm 24 micron any origin and MECH1 of Indian origin with 2.5 % span length of 28.5 to 29.5 mm, Micronaire of 3.5 to 4.5, fiber strength of 29 Gtex ( gram per tex ) uniformity ratio 45-47 % and short fiber index 3.5 to 5.5. The cotton and wool fibers were blended to produce a pile yarn containing 80 % MECH1 combed (18 % noil) and 20 % wool

• The spinning process parameters and yarn properties for cotton; wool pile yarn is described below

Cotton sliver preparation combed, cotton used for the preferred embodiment of 13’s is MECH1, 2.5 % Span length: 28.5 TO 29.5 MM Micornaire: 3.5 TO 4.5 fibers strength
25 to 29 gtex Uniformity ration 45 to 47%, short fibers index 3.5 to 5.5 %

The cotton is processed from mixing and blow room through to carding where the fibers are individualized. The cotton sliver from carding is then processed through a breaker drawing. Since combing is necessary to remove short fibers, the draw frame slivers are processed through unilap machine with 24 doubling and formed into a lap of 75 gms/ mtr. The lap is processed on the combing machine. The extracted noil is 18%.The combed cotton sliver is than passed through a finisher draw frame. Twisting and winding on the bobbin on speed frame is normal as with any other cotton system

• Ring spinning:

Blended roving produce on the speed frame is then spun into yarn on the cotton ring spinning frame. In the preferred embodiment Ne 13’S and spun into yarn with 13.5 TPI with ‘z’ twist.

The yarn from ring frame bobbin is wound into large packages on the winding machine to make cone ready for warping in weaving preparatory

• Yarn parameters:

Average count: 13.00 Average lea strength: 208 lbs.
CSP (count strength product) 2600 Count CV % 1.32
Strength CV % 5.03 Average TPI: 13.50 AVERAGE U % 8.46
THIN PLACES/KM (-50%): 0.1

THICK PLACES/KM (+50%) 8.9

NEPS /KM (+200)-9.0

TOTAL IMPERFACTION /KM 17.9 HAIRINESS INDEX 9.32

AVERAGE BREAK FORCE (GMS):634 AVERAGE RKM (nm/kgt)-15.77
RKM CV: 9.60

Elongation at break %-5.81 Elongation CV % -9.31
• Bleaching and dying process

The towel with blended cotton wool in the pile and cotton yarn in weft and ground is processed in the dye house in rope form. The bleaching duration is for 30 min at 90°C after the bleach, the water is drained at 80°C. It self in order to drain all the dissolved chemical during the process. After bleaching an alkali boil is given with caustic lye of 48% strength, 5 GPL caustic lye as per weight of material and 1:6 liquor ratio for a period of 30 minutes at 100 °c. After scouring peroxide killer is used. Followed by core alkali neutralizer used at 60°c for 20 minutes.

The dyeing is carried out in the soft flow machine with following dyes and chemicals for 2 hours at 60°c. The dyes used are astik meactive / mohizol -bi functional. After dyeing the bath is neutralized with acetic acid at 60°c for 10 minutes. This is followed by soaping and followed by softener treatment for 10 minutes.

On loom specification: loom card attached (as Fig.4)

The properties of the fabric when it is removed from the loom grey towel Listed below

The properties are the finished soft terry towel are listed here-

1. Terry fabric comprising two warp sheet longitudinal warp in which one is tight and other is slack tensioned.
2. Weft perpendicular yarn interlace both the warp sheet to make a base fabric.

ADVANTAGE OF INNOVATION

Air space created in yarn without any poly vinyl alcohol in used during manufacturing. In comparison with normal ring spun yarn 8-20 % more air pockets created by blending natural polymer. In process temperature not required more than 100 °C. The greater the amount of free air space available within the yarn, the quicker and more complete the absorption of the water. The Eunic yarn in the loop pile warp and weft, has a large amount of air spaces within the yarn structure, which permits easy air circulation. The air space provides room to absorb and vaporize water. Thus, the fabric is highly absorbent and quick drying. In the surface wetting methods, the toweling fabric absorbs 65 -75% water compared to normal toweling fabric (using ASTM -D-4772). When tested sinking methods, the toweling fabric takes less than 5 seconds to absorb the water, whereas other towel takes 10 seconds or more. It takes less drying time in comparison with same weight towel made from normal ring spun yarn.

WE CLAIM
1. Terry fabric made with two warp beams and weft yarn.

2. With comparison normal ring spun yarn Eunic pile yarn has less weight per unit length between 10-25%.

3. Terry fabric claim that no PVA is used during making of pile yarn.

4. Where pile, ground and weft are comprising 100 % cotton.

5. Terry fabric claim pile height less than 7.5 mm.

6. Terry fabric claim pile height more than 3.2 mm.

7. Terry fabric claim pile height between 3.2 to 7.5 mm.

8. Terry fabric claim wherein terry fabric has a water droplet sinking measured according to ATCC -79 of less than 3 sec.

9. Terry fabric claim, where in the terry fabric has a surface water absorption measured according to ASTM D-4772 of 75 to 83%.

10. Terry fabric claim, wherein a gram per square meter of the terry fabric is 550 or more.

11. Terry fabric claim, wherein terry fabric having greater than 38 picks per inch.

12. Terry fabric claim, wherein pile yarn twist factor between 3.2 to 3.8.

13. Terry fabric claim wherein terry weave of the terry fabric is one of the 3 pick, 4 pick, 5 pick or 6 pick.
, C , Claims:WE CLAIM

1. Terry fabric made with two warp beams and weft yarn.

2. With comparison normal ring spun yarn Eunic pile yarn has less weight per unit length between 10-25%.

3. Terry fabric claim that no PVA is used during making of pile yarn.

4. Where pile, ground and weft are comprising 100 % cotton.

5. Terry fabric claim pile height less than 7.5 mm.

6. Terry fabric claim pile height more than 3.2 mm.

7. Terry fabric claim pile height between 3.2 to 7.5 mm.

8. Terry fabric claim wherein terry fabric has a water droplet sinking measured according to ATCC -79 of less than 3 sec.

9. Terry fabric claim, where in the terry fabric has a surface water absorption measured according to ASTM D-4772 of 75 to 83%.

10. Terry fabric claim, wherein a gram per square meter of the terry fabric is 550 or more.

11. Terry fabric claim, wherein terry fabric having greater than 38 picks per inch.

12. Terry fabric claim, wherein pile yarn twist factor between 3.2 to 3.8.

13. Terry fabric claim wherein terry weave of the terry fabric is one of the 3 pick, 4 pick, 5 pick or 6 pick.