Pile Fabric and Methods for Manufacture of the Same
Field of the Invention
[001] The present invention relates to pile fabrics and methods for manufacture of pile
fabrics. In particular, the present invention relates to a pile fabric having improved
characteristics including improved bulkiness, particle pick-up, moisture absorbency,
reduced drying time, and an advantageous aesthetic appearance.
Background
[002] Pile fabrics are manufactured for several different end uses, including as towels,
terry fabrics, cleaning products, carpets and the like. Pile fabrics are considered
advantageous in view of their light weight, softness, ability to pick up particles and absorb
moisture. In cases where pile fabrics are used to manufacture towels or terry fabrics, there
is a growing need for improving moisture absorption and reducing drying time while
enabling manufacture of fabrics with a pleasant aesthetic look and feel.
[003] Figure 1A illustrates a pile fabric 100 of the towel type, having a surface region 102.
Pile fabrics of the kind illustrated in Figure 1A typically comprise a woven ground fabric
comprising a plurality of substantially parallel warp yarns, and a plurality of substantially
parallel weft yarns - wherein the plurality of weft yarns intersect the plurality of warp yams
substantially perpendicularly. Additionally, a plurality of pile yams are woven through the
ground fabric in a pile weave - which pile weave forms a plurality of pile loops above and
below the woven ground fabric.
[004] Figure 1B provides a magnified view of surface region 102 of pile fabric 100.
Surface region 102 illustrates the woven ground fabric comprising a plurality of warp yams
1 04a to 1 04c, substantially perpendicular weft yams 1 06a to 1 06c, and pile yams woven in
a pile weave so as to form pile loops 1 08a to 1 08c raised above the ground fabric. While
not illustrated in Figure 1B, it would be understood that a pile fabric may include pile loops
on both sides of the ground fabric.
2
[005) Pile yam is generally a low-twist yam, since pile loops seek provide surface area for
absorption of water, and the low-twist improves absorption by imparting wicking
properties. Watp and weft yams 'vithin the ground fabric are generally (but not necessarily)
hard twisted (i.e. are high-twist) in comparison with the pile yam.
[006] Manufacture of pile yams, warp yams and / or weft yams may involve doubling or
plying of two or more yams. Generally in the case of pile yam for manufacture of towel or
terry fabrics, doubling involves twisting a first non-water soluble yam (e.g. a cotton yam)
and a second water soluble yam (e.g. a yam made of polyvinyl alcohol (PVA)) together so
that the resulting 2-ply yam has improved strength and can be subjected to higher tension
during the weaving process. In certain cases, the first non-water soluble yam and the
second water soluble yarn are nvisted together in a direction opposite to the twist direction
of the non-water soluble yam. The water soluble yam or fibre is thereafter dissolved,
leaving behind a woven fabric comprising entirely of non-water soluble yam.
[007] In manufacturing terry fabrics, properties such as low twist, and increased thickness
or bulkiness are considered advantageous. Additionally, manufacturers constantly seek to
improve tactile feel and aesthetic characteristics of terry fabrics.
[008) In terms of aesthetic characteristics, pile fabrics present particular complexities,
since it is important to have consistent aesthetic characteristics across the dimension of the
fabric. While known methods for patterning pile fabrics include printing a pattern on the
fabric surface or forming the fabric using a jacquard weave or knit process, there is a need
for other improvements in pile manufacturing technologies for achieving advantageous
aesthetic and tactile characteristics.
[009) The present invention seeks to provide pile fabrics with improved tactile
properties, particle pick-up and moisture absotption and reduced drying time, while
presenting aesthetically pleasing characteristics.
3
Summary
[0010] The invention provides a pile fabric compnstng: (i) a woven ground fabric
comprising a plurality of wru.p yams and a plurality of weft yams intersecting the plurality
of warp yams, (ii) one or more pile yams woven to form a plurality of pile loops extending
from the ground fabric, wherein (a) at least one pile yam from among the one or more pile
yams is a multi-ply pile yam comprising a first pile component yam plied with a second
pile component yam, and (b) a turns-per-loop ratio of the multi-ply pile yam is less than
1.9 turns-per-loop.
[0011] The first pile component yarn may comprise a first non-soluble yam. The first pile
component yam may additionally comprises a first soluble yam plied with the first nonsoluble
yam, wherein solubility of the first soluble yam in a specified solvent (such as for
example, water, caustic soda (NaOH) or any other solvent) is higher than solubility of the
first non-soluble yam in said solvent.
[0012] The second pile component yam may comprise a second non-soluble yam. The
second pile component yam may additionally comprise a second soluble yam plied with
the second non-soluble yam, wherein solubility of the second soluble yam in a specified
solvent (such as for example, water, caustic soda (NaOH) or any other solvent) is higher
than solubility of the second non-soluble yam in said solvent.
[0013] The multi-ply pile yam may comprise a third pile component yam plied with the
first and second pile component yams. The third pile component yarn may comprise a
third non-soluble yam. The third pile component yam may additionally comprise a third
soluble yam plied \vith the third non-soluble yam, wherein solubility of the third soluble
yam in a specified solvent (such as for example, water, caustic soda (NaOH) or any other
solvent) is higher than solubility of the third non-soluble yam in said solvent.
[0014] In an embodiment, the turns-per-loop ratio of the multi-ply pile yarn within the
pile fabric is between 0.9 and 1.5 turns-per-loop.
4
[0015] At least one non-soluble yarn within the multi-ply pile yarn may comprise an stwisted
yarn having a count falling between 12s and 40s Ne. At least one water soluble yarn
within the multi-ply pile yam may comprise a yam having a count falling between 60s and
1 OOs (N e), wherein solubility of the soluble yarn in a specified solvent (such as for example,
water, caustic soda (NaOH) or any other solvent) is higher than solubility of the nonsoluble
yam in said solvent.
[0016] The first pile component yarn may have a different colour or colour affinity in
comparison with the second pile component yarn (which colour affinity may in an
embodiment be specific to a particular dye or colour). In an embodiment, the pile fabric
may be a towel or terry fabric.
[0017] The invention additionally present a method of producing a pile fabric, comprising
the steps of (i) plying at least a first pile component yam with a second pile component
yarn to form a pile yarn, (ii) weaving a pile fabric comprising (a) a plurality of ground warp
yams, (b) a plurality of weft yarns intersecting the plurality of warp yams, and (c) the pile
yam fanning a plurality of pile loops extending from the intersection of the ground warp
and weft yams, (iv) wherein a turns-per-loop ratio of the multi-ply pile yarn is less than 1.9
turns-per loop.
[0018] In a method embodiment, the first pile component yarn may comprise a first nonsoluble
yarn. The first pile component yam may additionally comprise a first -soluble yarn
plied with the first non-soluble yarn, wherein solubility of the first soluble yarn in a
specified solvent (such as for example, water, caustic soda (NaOH) or any other solvent)
is higher than solubility of the first non-soluble yarn in said solvent.
[0019] In another embodiment, the second pile component yarn may comprise a second
non-soluble yarn. The second pile component yarn may additionally comprise a second
water-soluble yam plied with the second non-water soluble yarn, wherein solubility of the
second soluble yarn in a specified solvent (such as for example, water, caustic soda (NaOH)
or any other solvent) is higher than solubility of the second non-soluble yarn in said solvent.
5
[0020] The multi-ply pile yarn may in a specific embodiment compnse a third pile
component yarn plied with the first and second pile component yarns. The third pile
component yarn comprises a third non-soluble yarn. The third pile component yarn may
additionally comprise a third soluble yarn plied with the third non-soluble yarn, wherein
solubility of the third soluble yarn in a specified solvent (such as for example, water, caustic
soda (NaOH) or any other solvent) is higher than solubility of the third non-soluble yarn
in said solvent.
[0021] In a particular embodiment of the method, the turns-per-loop ratio of the multiply
pile yarn is between 0.9 and 1.5 turns-per-loop. The first pile component yarn and
second pile component yarn may be plied together at a twists-per-inch ratio of between 3
and 4 twists-per-inch. Further, in weaving the pile fabric, pile height of pile loops formed
by the multi-ply pile yarn may be between 4 mm and 6 mm.
[0022] At least one non-soluble yarn plied into the multi-ply pile yarn may comprise an stwisted
yarn having a count falling between 12s and 40s Ne. At least one soluble yarn plied
into the multi-ply pile yarn may comprise a PV A yarn having a count falling between 60s
and 100s Ne.
[0023] In a method embodiment, the first pile component yarn may be selected to have
either a different colour or a different colour affinity in comparison with the second pile
component yam (which colour affinity may in an embodiment be specific to a particular
dye or colour).
[0024] In a specific method embodiment, the woven pile fabric is a towel or terry fabric.
Detailed Description
[0025] 1be present invention relates generally to pile fabrics, including towels- and more
particularly to a pile fabric with improved look and feel, particle pick-up and moisture
absorption, and reduced drying time.
[0026] Conventionally, pile yams used in terry or towelling fabrics are coarse and range
from 8s to 30s Ne (Number English) - either in a single yam configuration, or in a doubled
configuration. The coarser yams have a greater number of fibres in the cross section, which
improves moisture absorption. However beyond a point, increasing yam coarseness fails
to further increment moisture absorption. Additionally, simply increasing thickness of a
pile yam increases the yam volume without a commensurate increase in surface area of the
pile loops. Without sufficient surface area, the wicking and moisture absorption efficiency
as well as drying properties of the pile loops is adversely affected.
[0027] The present invention accordingly seeks to maximise the available surface area for
a given weight of the product - thereby improving the wicking properties as well as
reducing the drying time of the pile fabric.
[0028] The invention achieves this by the follm.ving steps:
(la) Plying a first yarn: a first yam is manufactured by plying (twisting or
doubling) at least a first non-soluble yam with a first soluble yam resulting in
a 2-ply (or multi-ply) first yam, wherein solubility of the first soluble yam in
a specific solvent is higher than solubility of the first non-soluble yam in said
solvent. In an embodiment, the first non-soluble yam is a non-water soluble
yam, while the first soluble yam is a water soluble yam or filament.
(lb) Plying a second yam: a second yarn is manufactured by plying (twisting or
doubling) at least a second non-soluble yam with a second soluble yam
resulting in a 2-ply (or multi-ply) second yam, wherein solubility of the
second soluble yam in a specific solvent is higher than solubility of the
second non-soluble yam in said solvent. In an embodiment, the second nonsoluble
yarn is a non-water soluble yarn, while the second soluble yam is a
water soluble yarn or filament.
(lc) Plying the 2-ply (or multi-ply) first yam and 2-ply (or multi-ply) second
yarn together: a pile yarn is manufactured by doubling at least the 2-ply (or
7
multi-ply) first yarn together with the 2-ply (or multi-ply) second yarn, at a
pre-determined twist ratio, wherein the pre-determined twist ratio is
specifically selected to maximise surface area of individual pile loops in the
pile fabric that is subsequently woven using the pile yarn.
(ld) Weaving a pile fabric: a pile fabric is woven usmg the pile yam and
appropriately selected warp and weft yams to produce a pile fabric of desired
size and weight.
(le) Washing the pile fabric: the pile fabric is exposed to conditions suitable to
dissolve the first soluble yam and the second soluble yarn within the pile
fabric. In an embodiment where the first soluble yarn and the second soluble
yarn are water soluble yarns, this step comprises exposing the pile fabric to
hot water at above 60°C, preferably above 80°C al)d yet more preferably
between 80°C and 95°C, to dissolve the soluble fibres, leaving a pile fabric
wherein the pile yarn comprises a loosely bound 2-ply (or multi-ply) yarn
comprising at least the first non-soluble yarn and the second non-soluble
yarn . .
[0029] For the purposes of the present invention, it will be understood that when
discussing a multi-ply pile yam comprising a soluble yam and a non-soluble yam, such
solubility and non-solubility is with respect to a specific solvent. Additionally, the solubility
and non-solubility of such yams need not be absolute and may be relative to each other.
In the broadest embodiments contemplated by the present invention, in a multi-ply yarn
comprising a soluble yam plied with a non-soluble yarn, solubility of the soluble yam in a
specified solvent (such as for example, water, caustic soda (NaOH) or any other solvent)
is higher than solubility of the non-soluble yarn in the same solvent.
[0030] In connection with metl10d steps (la) to (1e) described above, it has been
discovered that in addition to ensuring low-twist and suitable thickness for the pile yarn,
significant advantages arise from ensuring that tl1e turns-per-loop ratio of the pile yam falls
witlun a specified range. More specifically, it has been found that by ensuring that the turnsper-
loop ratio of the pile yarn in the woven pile fabric is between 0.9 to 1.9, the first nonsoluble
yarn and the second non-soluble yarn within each pile loop assume a "teased" or
"clustered" configuration after the woven pile fabric is exposed to the appropriate solvent
(such as hot water or NaOH) and the soluble yams are dissolved. This "teased" or
"clustered'' fabric geometry comprises a specific pile yam configuration wherein in each
pile loop, the first non-soluble yarn forms a first sub-loop and the second non-soluble yarn
forms a second sub-loop. The first sub-loop and second sub-loop are loosely twisted or
minimally intertwined together as a result of the selected turns-per-loop ratio, thereby
ensuring interspaces between the first sub-loop and second sub-loop of each pile loop with
a consequent increase in total available surface area of each pile loop.
[0031] Figure 2 illustrates a magnified section of a pile fabric 200 manufactured in
accordance with the method described in connection with steps (1a) to (1e) above. Pile
fabric 200 comprises warp yarns 204a and 204b, weft yams 206a and 206b, and a 2-ply pile
yarn comprising a first non-soluble yarn and a second non-soluble yam (for example first
and second non-water soluble yarns). In a first pile loop 202a, the first non-soluble yarn
forms a first sub-loop 208a and the second non-soluble yam forms a second sub-loop 21 Oa.
Likewise in a second pile loop 202b, the first non-soluble yam forms a first sub-loop 208b
and the second non-soluble yam forms a second sub-loop 210b. In the loosely twisted or
loosely intertwined configuration achieved by keeping the turns-per-loop ratio of the pile
yam between the prescribed limit of 0.9 and 1.9, it can be seen that the first and second
sub-loops of each pile loop have inter spaces between them, thereby increasing the ratio of
surface area to yarn (or fibre or ftlament) weight within each pile loop -with corresponding
improvements in wicking, bulkiness (voluminousness), and moisture absorption, as well as
a reduction of drying time.
[0032) It would be understood that the present invention is not limited to embodiments
where the pile yam is a 2-ply yam manufactured using a first 2-ply yam and a second 2-ply
yarn. The invention can accommodate a pile yam manufactured by plying together any
reasonable number of 2-ply (or multi-ply) yarns that may be contemplated by the skilled
person while maintaining the turns-per-loop ratio within the pre-determined ranges that
arc necessary for achieving the objectives of the invention.
9
[0033] The following exemplary embodiment of the invention involves manufacture of a
pile yam by plying together three 2-ply yams. In the exemplary embodiment, the invention
implements the following steps:
(2a) Plying a first yam: a first yam is manufactured by plying (twisting or
doubling) a first non-soluble yam with a first soluble yam resulting in a 2-ply
first yam, wherein solubility of the first soluble yam in a specific solvent is
higher than solubility of the first non-soluble yam in said solvent. In an
embodiment, the first non-soluble yam is a non-water soluble yam, while the
first soluble yam is a water soluble yam or filament.
(2b) Plying a second yam: a second yam is manufactured by plying (twisting or
doubling) a second non-soluble yam with a second soluble yam resulting in
a 2-ply second yam, wherein solubility of the second soluble yam in a specific
solvent is higher than solubility of the second non-soluble yam in said
solvent. In an embodiment, the second non-soluble yarn is a non-water
soluble yam, while the second soluble yam is a water soluble yam or filament.
(2c) Plying a third yam: a third yarn is manufactured by plying (twisting or
doubling) a third non-soluble yarn with a third soluble yarn resulting in a 2-
ply third yarn, wherein solubility of the third soluble yarn in a specific solvent
is higher than solubility of the third non-soluble yarn in said solvent. In an
embodiment, the third non-soluble yarn is a non-water soluble yam, while
the third soluble yarn is a water soluble yam or fllament.
(2d) Plying the 2-ply first yam, 2-ply second yam and 2-ply third yam
together: a pile yam is manufactured by plying (twisting or doubling) the 2-
ply first yam together with the 2-ply second yam and the 2-ply third yarn, at
a pre-determined twist ratio, wherein the pre-determined twist ratio is
specifically selected to maximise surface area of individual pile loops in the
pile fabric that is subsequently woven using the pile yarn.
10
(2e) Weaving a pile fabric: a pile fabric is woven using the pile yarn and
appropriately selected warp and weft yarns to produce a pile fabric of desired
size and weight.
(2f) Washing the pile fabric: the pile fabric is exposed to conditions suitable to
dissolve the first soluble yarn, the second soluble yarn and the third soluble
yarn within the pile fabric. In an embodiment where the first soluble yarn,
second soluble yam and third soluble yam are water soluble yarns, this step
comprises exposing the pile fabric to hot water at above 60°C, preferably
above 80°C and yet more preferably at between 80°C and 95°C, to dissolve
the soluble fibres, leaving a pile fabric wherein the pile yarn comprises a
loosely bound 3-ply pile yarn comprising the first non-soluble yam, the
second non-soluble yam and the third non-soluble yam.
[0034] Figure 3 illustrates a magnified section of a pile fabric 300 manufactured in
accordance with the teachings of steps (2a) to (2£) above. Pile fabric 300 comprises warp
yarns 304a and 304b, weft yarns 306a and 306b, and a pile yam comprising a first nonsoluble
yarn, a second non-soluble yarn and a third non-soluble yam. In a first pile loop
302a, the £irst non-soluble yam forms a first sub-loop 308a, the second non-soluble yarn
forms a second sub-loop 310a and the third non-soluble yam forms a third sub-loop 312a.
Likewise in a second pile loop 302b, the first non-soluble yam forms a first sub-loop 308b,
the second non-soluble yam forms a second sub-loop 310b and the third non-soluble yarn
forms a third sub-loop 312b. In the loosely intertwined configuration achieved by keeping
the turns-per-loop of the pile yam between the prescribed range of 0.9 to 1.9, it can be
seen that the £irst, second and third sub-loops of each pile loop have inter spaces between
them, thereby increasing the exposed surface area within each pile loop that is available to
interact with water or liquid (for absorption purposes), or to interact with particles (for
particle pick-up purposes), - with corresponding improvements in wicking, bulkiness
(voluminousness), moisture absorption and particle pick-up, and a reduction in drying time
of the pile fabric.
11
[0035] Figures 4 and 5 further illustrate advantages offered by pile fabric prepared in
accordance with the present invention in comparison with pile fabric prepared in
accordance with the methods known in the prior art.
[0036] Figure 4 illustrates a magnified top view of a conventional pile fabric 400, wherein
the pile yarn is a single ply yarn, or is a multi-ply yarn having turns-per-loop outside of the
ranges prescribed above. In comparison Figure 5 illustrates a magnified top view of a pile
fabric 500 prepared in accordance with steps (2a) to (2£) described herein above- resulting
in a pile yarn having three loosely twisted or intertwined sub-loops per pile loop.
[0037] As can be observed in Figure 4 each pile loop (402, 404, 406, 408) of pile fabric
400 presents a substantially unbroken or continuous surface area, with inter spaces only
observable between each pile loop. In contrast, as shown in Figure 5, each pile loop (502,
504, 506, 508} comprises three sub-loops (502a, 502b, 502c;504a, 504b, 504c; 506a, 506b,
506c;508a, 508b, 508c) with inter spaces observable not just between each pile loop, but
also between sub-loops of each pile loop. Additionally, the cumulative surface area
presented by each group of sub-loops within a pile loop in Figure 5 is significantly greater
than the surface area presented by each loop in Figure 4. It would be understood that the
increase in cumulative surface area and inter spaces within each loop significantly increases
not only "vicking properties and moisture absorption, and also reduces drying time of the
pile fabric.
[0038] In a first working example, a surface area comparison was carried out between (i)
a first pile fabric manufactured in accordance with steps (2a) to (2£) described above and
having a pile yarn comprising three 30s (Ne) count cotton yarns (i.e. a cumulative yarn
count of 10s (Ne)) plied together in the 3 sub-loop type fabric geometry illustrated in
Figure 3 and Figure 5 and (ii) a second conventionally manufactured pile fabric having a
pile yarn comprising a single 10s (Ne) count cotton yarn in a unified loop fabric geometry
of the type illustrated in Figure 1 B and Figure 4 -where both pile fabrics have an identical
loop length (L1).
12
[0039] It is known that yam diameter (D) of a yam may be derived in accordance with
equation (1) below:
1
D = -----------;-;:::::====== 28 x VY arn count inN e
[0040] Applying equation (1 ), it can be determined that:
... Equation (1)
• diameter Dl of each cotton yam having count 30s (Ne) within the first pile fabric
having the clustered configuration of the present invention is 0.0065 inches, and
• diameter D2 of a cotton yam having count lOs (Ne) within the second pile fabric
having a conventional non-clustered configuration is 0.0113 inches.
[0041] Surface area (area)of a pile loop may be determined in accordance with equation
(2) below:
SurfaceArea = rr x L x D
... Equation (2)
wherein L represents loop length and D represents yarn diameter.
[0042] The cumulative surface area of a pile loop having one or more than one sub-loops
may accordingly be determined in accordance with equation (3) below:
cumulative surface area of pile loop= N x rr x L x D
... Equation (3)
wherein L represents loop length, D represents yarn diameter, and N represents the
number of sub-loops within the pile loop.
[0043] Applying equation (3) and the computed values for Dl and D2 for the fust and
second pile fabrics under comparison, it can be determined that:
13
• For a pile loop (comprising 3 cotton yarns each of count 30s (Ne) and a loop length
Ll) within the first pile fabric having the clustered configuration of the present
invention (i.e. number of sub-loops N = 3, loop length = Ll and yarn diameter
Dl), cumulative surface area (SurfaceAreal) of the pile loop in accordance would
be:
SurfaceArea1 = 3 x rr x L1 x D1
• For a pile loop (comprising a cotton yarns of count lOs (Ne) and a loop length Ll)
within the second pile fabric having a conventional non-clustered configuration
(i.e. number of sub-loops N = 1, loop length = Ll and yarn diameter . D2)
cumulative surface area (SurfaceArea2) of the pile loop in accordance would be:
SurfaceArea2 = rr x L1 x D2
[0044] The percentage increase (Surfacelncreasel) in surface area exhibited by a pile loop
(within the first pile fabric ) having SurfaceArea 1 in comparison with a pile loop (within
the second pile fabric) having SurfaceArea2 would be:
((
SurfaceArea1 ) )
Surfacelncrease1 = S f A 2
x 100 - 100 % ur ace rea
t.e.
((
3 X rr X L1 X D1 ) )
Surfacelncrease1 = rr x L1 x D2 x 100 - 100 %
t.e.
Surfacelncrease1 = ( (
3
;:
1
x 100)- 100)%
1.e.
((
3 X 0.0065 ) )
Surfacelncrease1 = 0.0
113
x 100 - 100 %
1.e.
Surfacelncrease1 = 72%
14
[0045] Accordingly, in the first working example, the first pile fabric manufactured in a 3
sub-loop configuration in accordance with steps (2a) to (2£) described above, exhibits a
72% increase in surface area over the second pile fabric manufactured in accordance with
conventional techniques, despite the pile yarn in both fabrics having substantially the same
cumulative pile yarn count (and pile yam weight or pile loop weight).
[0046] In a second working example, a surface area comparison was carried out between
(i) a third pile fabric manufactured in accordance with steps (la) to (le) described above,
and having a pile yarn comprising two cotton yams having a count of 24s (Ne) each (i.e. a
cumulative yam count of 12s (Ne)) plied together in the 2 sub-loop type fabric geometry
of the type illustrated in Figure 2 and (ii) a fourth conventionally manufactured pile fabric
having a pile yam comprising a single cotton yam having a count of 12s (Ne) in a
conventional unified loop fabric geometry of the type illustrated in Figure lB and Figure 4
- where both pile fabrics have an identical loop length (L2).
[0047] Applying equation (1), it can be determined that:
• diameter D3 of each cotton yam having count 24s (Ne) within the third pile fabric
having the clustered configuration of the present invention is 0.0072 inches, and
• diameter D4 of a cotton yam having count 12s (Ne) within the fourth pile fabric
having a conventional non-clustered configuration is 0.0103 inches.
[0048) Applying equation (3) and the computed values for D3 and D4 for the third and
fourth pile fabrics under comparison, it can be determined that:
• For a pile loop (comp1-ising 2 cotton yams each of count 24s (Ne) and a loop length
L2) within the third pile fabric having the clustered configuration of the present
invention (i.e. number of sub-loops N = 2, loop length = L2 and yarn diameter
D3) cumulative surface area (SurfaceArea3) of the pile loop in accordance would
be:
IS
SurfaceArea3 = 3 x rr x L2 x D3
• For a pile loop (comprising a cotton yarns of count 12s (Ne) and a loop length L2)
within the fourth pile fabric having a conventional non-clustered configuration (i.e.
number of sub-loops N = 1, loop length= L2 and yam diameter D4) cumulative
surface area (SurfaceArea4) of the pile loop in accordance would be:
SurfaceArea4 = rr x L2 x D4
(0049] The percentage increase (Surfacelncrease2) in surface area exhibited by a pile loop
(within the third pile fabric) having SurfaceArea3 in comparison with a pile loop (within
the fourth pile fabric) having SurfaceArea4 would be:
((
SurfaceArea3 ) )
Surfacelncrease2 = SurfaceArea4 x 100 - 100 %
1.e.
((
2 X rr X L2 X D3 ) )
Surfacelncrease2 = rr x L
2
x D
4
x 100 - 100 %
1.e.
Surfacelncrease2 = ( (
2 ~:3
x 100)- 100) %
1.e.
((
2 X 0.0072 ) )
Surfacelncrease2 = 0.0
103
x 100 - 100 %
1.e.
Surfacelncrease2 = 39.8%
[0050] Accordingly, in the second working example, the third pile fabric manufactured in
a 2 sub-loop configuration in accordance with steps (1 a) to (1 e) described above, exhibits
a 39.8% increase in surface area over the fourth pile fabric manufactured in accordance
with conventional techni(jues, despite the pile yarn in both fabrics having substantially the
same cumulative pile yarn count (and pile yarn weight or pile loop weight).
16
[0051] The improvements in surface area of pile loops for the same pile yam count and
yam weight results in substantial improvements in moisture absorption, particle pick-up
and overall look and feel of the pile fabrics manufactured in accordance with the present
invention.
[0052] As established above, the advantages of the present invention can be achieved by
ensuring in the fabric weaving process that turns-per-loop ratio of the multi-ply pile yam
in the woven pile fabric is between 0.9 and 1.9. In a preferred embodiment the turns-perloop
ratio of the multi-ply pile yam in the woven fabric is between 0.9 and 1.5.It has been
discovered that as pile height of the woven pile fabric increases, the tru:ns-per-loop ratio
within the multi-ply pile yam can move towards the higher end of the prescribed range
while retaining the advantageous effects of the invention. Likewise, as pile height of the
woven pile fabric decreases, the turns-per-loop ratio within the multi-ply pile yam has to
move towards the lower end of the prescribed range to ensure that sub-loops within each
pile loop remain loosely twisted or intertwined (and as if the pile sub-loops are almost
separate) and thus resulting in increased inter spaces therebetween.
[0053] The turns-per-loop ratio of the pile yarn in a woven pile fabric can be modulated
in a number of ways, including by selection of appropriate twists ratio for the multi-ply pile
yarn, and / or selection of an appropriate pile height for the woven pile fab1-ic.
[0054] The below table provides examples of measured parameters corresponding to
multi-ply pile yarn within a woven pile fabric prepared in accordance with the teachings of
the present invention, and which were found to demonstrate the desired properties of
increased pile loop surface area, improved moisture absorption, particle pick-up and
wicking, and reduced drying times. It will be understood that the use of the below examples
(and any others) anywhere in the specification is only illustrative and is not intended to
limit the scope of the invention.
17
Example A Example Example Example Example
B c D E
TPL ratio of 0.9 1.0 1.5 1.9 1.9
the woven
pile fabric
(I'ums/loop)
Direction of S orZ S orZ S orZ S orZ S orZ
Twist of the
plied pile
yam
Pile Height 4.0 6.0 6.2 6.0 6.0
ofthewoven
pile fabric
(mm)
PlyingTPI 3.0 2.1 3.0 4.0 4.0
of the pile
yam
(number of
twists /inch)
[0055) The above examples are based on working examples conducted using a 2-ply pile
yarn within a pile fabric manufactured in accordance with steps (la) to (le) described
above, wherein the non-soluble yarns are cotton yams, and the soluble yams are polyvinyl
alcohol PVA yarns or fibres. The working examples were carried out using conventional
yam plying techniques and pile fabric weaving techniques that would be apparent to the
skilled person.
[0056) In a preferred embodiment of the invention, the twists-per-inch ratio implemented
while plying the multi-ply pile yam has been found to be between 3 and 4 twists-per-inch,
while the pile height selected while weaving the pile fabric (or that was measurable in the
woven pile fabric)has been found to be between 4mm and 6mm. In an embodiment at least
one (and preferably all) of the non-soluble yarns within the multi-ply pile yarn falls within
a count range of between 12s and 40s Ne and more preferably within a count range of
between 16s and 40s N e.
[0057) Non-soluble yarns for manufacturing the multi-ply pile yarn in accordance with
embodiments of the present invention may comprise any one or more natural fibres such
as cotton, wool, silk, jute, flax, bamboo or ramie, or one or more regenerated / synthetic
fibres such as lyocell, viscose, modal, soya, polyester, nylon, act)'lic, rayon, charcoal, linen,
18
com, milk fibre, PLA (poly lactic acid) fibre, etc. In a preferred embodiment of the
invention, the non-soluble yams used to manufacture a pile yam are yams that are nonsoluble
in water or caustic soda (NaOH).
[0058) Soluble yams for manufacturing each plied yam for subsequent spinning of the
multi-ply pile yam may include any of PV A, wool or a yam product that is sold under the
trade name "solucell". In embodiments of the pile yam or pile fabric, where the nonsoluble
yam is a non-water soluble yam and the intended solvent is water, PV A may be
selected as the corresponding water-soluble yam. In embodiments where the non-soluble
yam is a non-caustic soda (NaOH) soluble yam and the intended solvent is caustic soda
(NaOH), wool or solucell may be selected as the corresponding soluble yam. In an
embodiment, one or more of each soluble yams is in a count range between 60s and 1 OOs
Ne.
[0059] It would be understood that plying of each non-soluble yam with a corresponding
soluble yam in accordance with the embodiments described above may use any
conventional plying techniques known in the art. Likewise the plying of 2 or more multiply
yams to manufacture a single multi-ply pile yam, subsequent weaving of a pile fabric
and removal of the soluble yam from such pile fabric may use any one or more
conventional techniques known in the art.
[0060) The teachings of the present invention result in a pile fabric wherein each pile loop
comprises a plurality of loosely twisted or intertwined sub-loops, which loosely twisted of
intertwined sub-loops may in an embodiment comprise between 2 and 5 sub-loops per pile
loop. Additionally, in view of the loosely twisted or intertwined configuration of the subloops
within each pile loop, said sub-loops exhibit a clustered or petal-like configuration
within each pile loop.
(0061] In an embodiment of the invention at least a first non-soluble yarn within the pile
yam has a first colour affinity (which first colour affinity may be specific to a particular dye
or colour), while a second non-soluble yarn within the pile yarn has a second colour affinity
(which second colour afftnity may be specific to a specific dye or colour and which may be
19
different from the first colour affinity) - such that in a subsequent dyeing step, the first
non-soluble yarn acquires a different colouring from the second non-soluble yam.
Accordingly, subsequent to the steps of weaving of the pile fabric in accordance with the
teachings of the present invention, dissolving or washing out of soluble yams from the pile
fabric and dyeing, the resulting pile fabric comprises a plurality of pile loops, wherein each
pile loop includes a plurality of loosely twisted or intertwined sub-loops of which at least a
first sub-loop and a second sub-loop within each pile loop have different colours (as a
result of the different colour affinities of the first and second non-soluble yams
respectively).
[0062] In an alternative embodiment of the invention, at least a first non-soluble yam
having a first yarn colour is plied together with a first soluble yam to form a first 2-ply yam,
and at least a second non-soluble yam having a second yam colour(which in an
embodiment is different from the first yam colour) is plied together with a second soluble
yam to form a second 2-ply yam, whereinafter a multi-ply pile yam is manufactured using
at least the first 2-ply yam and the second 2-ply yarn. In this embodiment, subsequent to
weaving of the pile fabric in accordance with the teachings of the present invention, and
subsequent to dissolving or washing out of soluble yams, the resulting pile fabric includes
a plurality of pile loops wherein each pile loop comprises a plurality of loosely twisted or
intertwined sub-loops, and at least a first sub-loop and a second sub-loop within each pile
loop have different colours (i.e. corresponding to the first yam colour and the second yam
colour).
[0063] Having at least two different yarn colours within each pile loop, in combination
with the clustered or petal-like appearance exhibited by sub-loops within each pile loop
results in a striking plurality of tones, and consequent melange, heather-like, mottled or
tone-on-tone appearance of the pile fabric. In overall appearance, the resulting product has
been found to present pleasing aesthetic colour combinations, shades, tints, tones and hue
characteristics.
20
[0064] Accordingly, manufacture of pile fabrics, including terry fabrics or towel fabrics in
accordance with the teachings of the present invention results in the following
advantageous features:
• Fluffy, bulky appearance
• Improved absorption of moisture
• Reduced drying time
• Improved tactile feel
• Pleasing aesthetic colour characteristics
[0065] It would be understood that the examples and embodiment discussed anywhere in
the present specification are illustrative only. Those skilled in the art would immediately
appreciate that various modifications in form and detail may be made without departing
from or offending the spirit and scope of the invention as defined by the appended claims.

We Claim:
1. A pile fabric comprising:
a woven ground fabric comprising a plurality of ground warp yarns and a plurality
of weft yams intersecting the plurality of warp yams;
one or more pile yarns woven to form a plurality of pile loops extending from the
ground fabric, wherein:
at least one pile yarn from among the one or more pile yams is a multi-ply pile yam
comprising a first pile component yam plied with a second pile component yam; and
a turns-per-loop ratio of the multi-ply pile yam is less than 1.9 turns-per-loop.
2. The pile fabric as claimed in claim 1, wherein the first pile component yam
comprises a first non-soluble yam.
3. The pile fabric as claimed in claim 2, wherein the first pile component yam
comprises a first soluble yarn plied with the first non-soluble yam, wherein solubility of the
first soluble yam in a solvent is higher than solubility of the first non-soluble yam in said
solvent.
4. The pile fabric as claimed in claim 1, wherein the second pile component yam
comprises a second non-soluble yam.
5. The pile fabric as claimed in claim 4, wherein the second pile component yarn
comprises a second soluble yam plied with the second non-soluble yam, wherein solubility
of the second soluble yam in a solvent is higher than solubility of the second non-soluble
yam in said solvent.
6. The pile fabric as claimed in claim 1, wherein the multi-ply pile yam comprises a
third pile component yarn plied with the flrst and second pile component yarns.
7. The pile fabric as claimed in claim 6, wherein the third pile component yarn
comprises a third non-soluble yarn.
22
8. The pile fabric as claimed in claim 7, wherein the third pile component yam
comprises a third soluble yam plied with the third non-soluble yam, wherein solubility of
the third soluble yam in a solvent is higher than solubility of the third non-soluble yam in
said solvent.
9. The pile fabric as claimed in claim 1, wherein the turns-per-loop ratio of the multiply
yam is between 0.9 and 1.5 turns-per-loop.
10. The pile fabric as claimed in claim 1, wherein:
pile height of pile loops formed by the multi-ply yam is between 4 mm and 6 mm;
and
twists-per-inch ratio of the multi-ply yam is between 3 and 4.
11. The pile fabric as claimed in claim 1, wherein at least one non-soluble yam within
the multi-ply pile yarn is an s-twisted yam having a count falling between 12s and 40s Ne.
12. The pile fabric as claimed in claim 1, wherein at least one water soluble yam within
the multi-ply pile yam is a yam having a count falling between 60s and 100s Ne, wherein
solubility of the soluble yam in a solven.t is higher than solubility of the non-soluble yam
in said solvent.
13. The pile fabric as claimed in claim 1, wherein the first pile component yam has a
different colour or colour affinity from the second pile component yam.
14. The pile fabric as claimed in claim 1, wherein said pile fabric is a towel or terry
fabric.
15. A method of producing a pile fabric, comprising the steps of:
plying at least a first pile component yarn with a second pile component yarn to
form a pile yarn;
23
loop.
weaving a pile fabric comprising:
a plurality of ground warp yarns;
a plurality of weft yarns intersecting the plurality of ground warp yarns; and
the pile yarn forming a plurality of pile loops extending from the
intersection of the ground warp and weft yarns;
wherein a turns-per-loop ratio of the multi-ply pile yarn is less than 1.9 turns-per
16. The method as claimed in claim 15, wherein the first pile component yarn
comprises a first non-soluble yarn.
17. The method as claimed in claim 16, wherein the first pile component yarn
comprises a first -soluble yarn plied with the first non-soluble yarn, wherein solubility of
the first soluble yam in a solvent is higher than solubility of the first non-soluble yam in ·
said solvent.
18. The method as claimed in claim 16, wherein the second pile component yarn
comprises a second non-soluble yarn.
19. The method as claimed in claim 18, wherein the second pile component yam
comprises a second water-soluble yam plied with the second non-water soluble yam,
wherein solubility of the second soluble yam in a solvent is higher than solubility of the
second non-soluble yam in said solvent.
20. The method as claimed in claim 15, wherein the multi-ply pile yarn comprises a
third pile component yam plied with the fu:st and second pile component yarns.
21. The method as claimed in claim 20, wherein the third pile component yarn
comprises a third non-soluble yarn.
22. The method as claimed in claim 21, wherein the third pile component yarn
comprises a third soluble yarn plied with the third non-soluble yarn, wherein solubility of
24
the third soluble yam in a solvent is higher than solubility of the third non-soluble yam in
said solvent.
23. The method as claimed in claim 15, wherein the turns-per-loop ratio of the multiply
yam is between 0.9 and 1.5 turns-per-loop.
24. The method as claimed in claim 15, wherein:
the first pile component yam and second pile component yam are plied together
at a twists-per-inch ratio of between 3 and 4 twists-per-inch; and
in weaving the pile fabric, pile height of pile loops formed by the multi-ply yam is
between 4 mm and 6 mm.
25. The method as claimed in claim 15, wherein at least one non-soluble yam plied into
the multi-ply pile yam is an s-twisted yam having a count falling between 12s and 40s Ne.
26. The method as claimed in claim 15, wherein at least one soluble yarn plied into the
multi-ply pile yam is a PV A yarn having a count falling between 60s and 1 OOs Ne.
27. The method as claimed in claim 15, wherein the first pile component yarn is
selected to have either a different colour or a different colour affinity in comparison with
the second pile component yarn.
28. The method as claimed in claim 1 5, wherein the woven pile fabric is a towel or
terry fabric.