Field of the invention
[0001] The present invention relates generally to making soft terry fabrics. More particularly, the present invention relates to making terry fabrics with an improved loop configuration using two ply yarn making loop in loop arrangement, without zero twist yarn, that exhibits high bulkiness, improved softness, less hairiness and superior absorbency with uniformity of texture and appearance.
Background of the invention
[0002] Terry fabrics are a group of pile fabrics that are produced by various ways of making fabric such as weaving. These fabrics have loops (also called pile loops) that are formed by way of introducing an additional yarn in a manner that result in the formation of loops. Typically, these fabrics consist of a woven layer with loops of yarns on the surface of the woven layer. These terry fabrics are, generally, used for making towels, bathrobe or any other product with a loop configuration.
[0003] Conventionally, for making soft terry fabrics, such as soft towels, "low twist" or "Zero twist" yarns are used. Low twist yarn or Zero twist yarns are those yarns where the fibres are untwisted using a water soluble fibre e.g. PVA before they are woven or in other words, in order for the yarns to have low or zero twist, the yarn is typically untwisted. It has been observed that a fabric produced from a zero-twist yarn, though soft, is weaker in strength as the cotton portion normally loses its strength and the

water soluble fibre e.g. Polyvinyl Alcohol (PVA) has low strength and very high elongation of about 15%. This causes a lot of difficulty in the weaving process. PVA is a non-biodegradable precipitate and adds to effluent, therefore, waste management of PVA poses serious environmental issues, apart from being uneconomical.
[0004] Furthermore, it has been observed that in fabrics made of low twist or zero twist yarns the loop configuration formed has a tendency to bend or compress due to softness of yarn components. Also, loose fibres start coming off the loop in such fabrics while washing, which results in formation of fuzz or hairiness that adversely affects the appearance of the fabric after washing. Further, the surface of the fabric appears to be irregular or uneven which would be appreciated as being aesthetically unappealing to a user. An image of a prior art terry fabric (towel) is depicted in Figs. 1A to 1 E. As shown in Fig. IB, the loops (pile loops) in the towel are bent and fuzz and irregular surface of the towel is depicted in Fig. 1A, B and C.
[0005] Further, pile profile which is measured by parameters such as pile inclination angle result in certain characteristics of fabrics such as bulk and softness. As depicted in Figs. 1A, B and C, in existing fabrics, it has been observed that pile inclination angle for any low twist, zero twist, or any other soft yarn is low and the pile formed is not soft. Due to the low pile inclination angle, it has been observed that pile yarns bend, and therefore, for the same length of the loop, thickness or bulk of the fabric product is lesser than actual pile height. Furthermore, as depicted in Figs.IE and ID, which are images of prior art fabrics, it can be seen that loops

are not formed with soft one-ply or two-ply yarn i.e. loops are not soft enough to be appreciated by users of the fabric, if, loops are at a high pile inclination angle.
[0006] In light of the above drawbacks, there is a need to manufacture fabrics with a high profile or a high pile inclination angle yet exhibiting increased softness. Also, there is a need to manufacture soft fabrics with an improved loop configuration which is firm and thereby exhibiting a regular uniform surface. In addition, there is a need to manufacture fabrics that exhibit high bulkiness, improved softness, less hairiness and superior absorbency with uniformity of texture and appearance.
Summary of the invention
[0007] A method for manufacturing a soft profiled terry fabric with an improved loop configuration including at least one pile yarn is provided with in accordance with various embodiments of the present invention. The method comprises binding a Z twisted or S twisted coarse yarn with a fine yarn having a twist direction opposite to the coarse yarn to form a two-ply yarn. The Z or S twisted coarse yarn has a low twist multiplier and the corresponding S or Z twisted fine yarn has a high twist multiplier. The method further comprises weaving a fabric out of the two-ply yarn, wherein a plurality of upright pile loops are formed. Each of the pile loop has a loop configuration that constitute a coarse yarn with a moderate twist level and a fine yarn twisted in a direction opposite to the coarse yarn with a high twist level. The coarse yarn and the fine yarn are twisted together with an optimum twist level, wherein a substantial separation between the two yarns within each

pile loop is formed such that the S twisted yarn exhibits a springing effect to hold the Z twisted yarn firmly upright.
[0008] A soft profiled terry fabric with an improved loop configuration is provided in accordance with various embodiments of the present invention. The soft profiled terry fabric comprises a fabric woven out of warp yarns and weft yarns, wherein a plurality of upright pile loops are formed on at least one of the surfaces of the fabric. At least one of the pile loop has a loop configuration that constitute a Z or S twisted coarse yarn with a moderate twist level and a fine yarn twisted in a direction opposite to the twist direction of coarse yarn with a high twist level, wherein a substantial separation between the two yarns within each loop is formed such that the S twisted yarn exhibits a springing effect to hold the Z twisted yarn firmly upright.
Brief description of the accompanying Drawings
[0009] The present invention is described by way of embodiments illustrated in the accompanying drawings wherein:
[0010] Figs. 1A, B, C, D and E are images of prior art terry fabrics (towel);
[0011] Fig. IF shows an image of a soft profiled terry fabric (towel) which is manufactured in accordance with various embodiments of the present invention;
[0012] Fig. 2 illustrates a perspective view of a fabric (towel) with an improved loop configuration, in accordance with various embodiments of the present invention;

[0013] Fig. 3 illustrates cross sections through the warp of the towel in accordance to various embodiment of the present invention;
[0014] Fig. 3A illustrates direction of twist for in each individual yarn component in accordance to various embodiment of the present invention;
[0015] Fig. 3B illustrates a weft side view of the two-ply yarn where the Z twisted coarse yarn and the S twisted fine yarn exerts balancing force in opposite direction; and
[0016] Fig. 3C illustrates a weft side view of the two-ply yarn at a high pile inclination angle in relation to the pile layer.
Detailed description of the invention
[0017] The present invention discloses making soft and profiled terry fabric with new and improved loop configuration at a high pile inclination angle, without zero twist and without use of PVA.
[0018] The disclosure is provided in order to enable a person having ordinary skill in the art to practice the invention. Exemplary embodiments herein are provided only for illustrative purposes and various modifications will be readily apparent to persons skilled in the art. The general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the invention. The terminology and phraseology used herein is for the purpose of describing

exemplary embodiments and should not be considered limiting. Thus, the present invention is to be accorded the widest scope encompassing numerous alternatives, modifications and equivalents consistent with the principles and features disclosed herein. For purposes of clarity, details relating to technical material that is known in the technical fields related to the invention have been briefly described or omitted so as not to unnecessarily obscure the present invention.
[0019] The present invention would now be discussed in context of embodiments as illustrated in the accompanying drawings.
[0020] Fig. IF shows an image of a soft terry fabric (towel) which is manufactured in accordance with various embodiments of the present invention. As depicted in Fig. 1 F, the improved loop (profiled pile loop) configuration obtained in accordance with various embodiments of the present invention is upright, firm, round and consistent. The towel manufactured in accordance with the present invention exhibits extremely high bulkiness, high softness, high absorbency, and fuzz free or hairiness free uniform surface. Further, the aforementioned characteristics are retained after several washings which is highly desirable and is demonstrative of a good quality soft terry fabric.
[0021] Fig. 2 illustrates a perspective view of a fabric (towel) with an improved loop configuration, in accordance with various embodiments of the present invention. As seen in Fig. 2, the loops do not bend at their respective places and is upright, firm, round and consistent in respect to the pile layer of the towel. It can be seen that pile yarns

are soft due to moderate twist and do not bend and is consistent across product giving a uniform appearance. This profiled loop formation results in high compression and its recovery behavior results in softness and high bulkiness which are the desirable features of a high quality towel.
[0022] Fig. 3 illustrates cross sections through the warp of the towel in accordance to various embodiment of the present invention. In an embodiment of the present invention, a two-ply yarn is used for making the fabric (towel) by weaving warp yarns and weft yarns. As depicted in Fig. 3, a plurality of pile loops 302 are formed on one or both the surface (s) of the resultant fabric (towel). Within each pile loop 302 of the fabric, it can be seen that a separation of yarn is achieved as shown by reference numerals 304 and 306. As a result of the new and improved pile loop, the surface profile of the towel is significantly improved as the new and improved loop contributes to the firmness and roundness of the loop configuration formed on the resultant towel. The loop configuration as shown in Fig. 3 results in excellent surface integrity of the towel due to lack of hairiness, uniformity in occurrence and distribution and lack of other noticeable defects throughout the cross-section of the resultant towel.
[0023] In an embodiment of the present invention, the new and improved loop configuration in the resultant fabric is achieved by the following process of making the fabric using two-ply yarn. Firstly, two yarns are selected for the pile of the fabric. Pile is the raised surface of the fabric. One of the yarns is a coarse or thick yarn with a specified range of TM and the other yarn is a very fine yarn with yet another specified range of TM. In an exemplary

embodiment of the present invention, the coarse or thick yarn with a yarn count of 9 Ne to 24 Ne is selected, and a very fine yarn with a yarn count of 40 Ne to 120 Ne is selected. In various exemplary embodiments of the present invention, a coarse and a very fine yarn is selected with yarn counts as per the product gsm and cover factor required.
[0024] Secondly, the two yarns are twisted in opposite directions (Z and S) for binding the yarns together to form a two-ply yarn as depicted in Fig.3A. Twisting of yarn is described by several parameters and twist level of a yarn is one of the important parameters, as it influences the constituent fibre characteristics of a yarn. Twist level of a yarn is the number of turns per unit length of a yarn. Twist multiplier (TM) is yet another important parameter and is determined on the basis of a given yarn count and yarn twist. In an embodiment of the present invention, the coarse yarn which is selected is a single ply yarn and is Z twisted having a specified TM.
[0025] Thirdly, the Z twisted coarse yarn is doubled with the S twisted fine yarn in the S direction to produce a double yarn having a coarse yarn component with a resultant low TM and a fine yarn component with a resultant very high TM.
[0026] Tables 1 and 2 herein below illustrates process parameters for doubling and making a pile yarn:

Table 1: Cheese Winding Parameters

Speed of
the
winding
machine
for
parallel
winding of
two yarn
components
on a
cheese
bobbin 350-550 MPM
Tension on
Coarse
Count 0.8-1.2 gm/Tex Coarse Yarn tension in gms >>Fine yarn tension in gms
Tension on Fine Count 0.8-1.2 gm/Tex Kept as low as possible ~ 0 gms dead wt or lowest setting of tension sprint
Table 2: TFO (Two for One) Parameters

Speed of spindle of a TFO machine 7000-9000 rpm
Tension minimum yarn tension by using minimum tension spring capsule
[0027] Table 3 illustrates various exemplary values and parameters of the resultant coarse and fine yarn, in accordance with an embodiment of the present invention.

Table 3

Compon ent Count(Ne) Doubling Twist (twist level) Component
Twist
Direction Doubling Twist Directio n. Final
resultant
Twist
Multiplier*
of
individual
component
after
doubling.
Coarse 9 to 24 6.5 to 12
twist per
inch Z or S Opposite
to
Coarse
yarn
twist
directio
n. Between 0.4 to 2. 6
Fine 40 to 120
Opposite of Coarse
More than 4.0
*Twist Multiplier = twist per inch/Square root of Count(Ne).
[0028] The twist level applied was sufficient to allow the constituent fibres of the two yarns to move apart for any contraction and expansion while twisting or loop formation in the process of making the fabric during weaving, dyeing and subsequent processes. Each of the yarns may take their own shape depending upon individual torsion behavior.
[0029] It has been observed that doubling in the same direction (i.e. S direction) of a fine yarn (i.e. the S twisted fine yarn) results in a very high twist on the fine yarn and a moderate twist on the coarse yarn. This further results in contraction in length of the fine component, increase in the elastic behavior, and the snarling behavior as a surprisingly superior outcome. It has been observed that, in an embodiment, the resultant coarse component having yarn count 14 Ne has a TM of 1.3 and the resultant fine component having yarn count 80 Ne has a TM of 5.1 after doubling at a doubling twist of 6.5 twist per inch.

[0030] As a result of the process followed in accordance with various embodiments of the present invention, a new and improved loop configuration (pile loop 302) was observed in the resultant fabric (towel) . As shown in Fig. 3, the pile loop 302 has a loop configuration which constitutes a Z twisted coarse yarn 304 of a moderate twist level and an S twisted fine yarn 306 with a high twist level with a marked substantial separation between the two yarns within the loop. Yet further, the S twisted fine yarn exhibits torsion behavior and snarling tendency and acts as a spring to advantageously hold the loop 302 firmly and prevent bending of the loop 302. The Z twisted coarse yarn has high weight and therefore does not itself snarl and further, the moderate twist caused because of the doubling process with low TM in the S direction result in the constituent fibres of the coarse yarn to slip apart thereby resulting in expanding and adopting to a desired round shape.
[0031] In an embodiment of the present invention, as shown in Fig, 3C which is the weft side view of the two-ply yarn, the Z twisted coarse yarn and the S twisted fine yarn by virtue of their individual strength exerts force in opposite directions (fl, f2) which balances the loop configuration. In particular, the Z moderate twisted coarse yarn's tendency to bend due to softness is countered by the S twisted fine yarn which on account of its torsion behavior prevents the Z twisted coarse yarn from bending by opposite force. Consequently, it was observed that the loop configuration provides for a high inclination angle in respect to the pile layer. In an exemplary embodiment of the present invention, the inclination angle ranges from 80

to 100 degree. Therefore, the pile profile towel, pile is improved with two plying of moderate twist and hard twist in such a way that these yarns are separable, thereby, achieving a high pile inclination angle with soft pile loops. Advantageously, as mentioned previously, this combination of moderate twist, high twist and separately twisted two-ply yarn forming the loop configuration at the given high inclination angle affords surprisingly high bulk and softness to the resultant fabric (towel) as compared to fabrics with low twist yarn.
[0032] While the exemplary embodiments of the present
invention are described and illustrated herein, it will be
appreciated that they are merely illustrative. It will be
understood by those skilled in the art that various
modifications in form and detail may be made therein
without departing from or offending the spirit and scope of
the invention.

We Claim:
1. A method for manufacturing a soft profiled terry fabric
with an improved loop configuration including at least
one pile yarn, comprising:
binding a Z twisted or S twisted coarse yarn with a fine yarn having a twist direction opposite to the coarse yarn to form a two-ply yarn, wherein the Z or S twisted coarse yarn has a low twist multiplier and the corresponding S or Z twisted fine yarn has a high twist multiplier; and
weaving a fabric out of the two-ply yarn, wherein a plurality of upright pile loops are formed, each of the pile loop has a loop configuration that constitute a coarse yarn with a moderate twist level and a fine yarn twisted in a direction opposite to the coarse yarn with a high twist level, the coarse yarn and the fine yarn twisted together with an optimum twist level, wherein a substantial separation between the two yarns within each pile loop is formed such that the S twisted yarn exhibits a springing effect to hold the Z twisted yarn firmly upright.
2. The method as claimed in claim 1, wherein the coarse yarn has a yarn count of between 9 Ne to 24 Ne.
3. The method as claimed in claim 1, wherein the fine yarn has a yarn count of between 40 Ne to 120 Ne.
4. The method as claimed in claim 1, wherein the coarse yarn has a resultant twist multiplier of between 0.4 and 2.6 after doubling.

5. The method as claimed in claim 1, wherein the fine yarn has a resultant twist multiplier greater than 4 . 0 after doubling.
6. The method as claimed in claim 1, wherein each of the pile loop has a pile loop inclination angle of between 80 degrees and 100 degrees in respect to the pile layer of the woven fabric.
7. The method as claimed in claim 1, wherein the Z twisted coarse yarn is doubled with the S twisted fine yarn in the S direction or vice-versa with a twist level of between 6.5 to 12 twist per inch such that twist direction of doubling is the same as twist direction of fine yarn.
8 . A soft profiled terry fabric with an improved loop configuration, comprising:
a fabric woven out of warp yarns and weft yarns, wherein a plurality of upright pile loops are formed on at least one of the surfaces of the fabric, at least one of the pile loop has a loop configuration that constitute a Z or S twisted coarse yarn with a moderate twist level and a fine yarn twisted in a direction opposite to the twist direction of coarse yarn with a high twist level, wherein a substantial separation between the two yarns within each loop is formed such that the S twisted yarn exhibits a springing effect to hold the Z twisted yarn firmly upright.

The soft profiled terry fabric as claimed in claim 8, wherein the S twisted fine yarn, with a high twist level, counter-balances the Z twisted coarse yarn, with a moderate twist level, with a torsional force to hold the Z twisted coarse yarn firmly, thereby resulting in formation of upright pile loops.
. The soft profiled terry fabric as claimed in claim 8, wherein each of the pile loop has a pile loop inclination angle of between 80 degrees and 100 degrees in respect to the pile layer of the woven fabric.