Patent Grant
9534323
The present invention relates to terry fabric weaves, methods for weaving terry fabrics comprising such weaves, and resulting terry fabrics. In particular, the invention relates to terry fabrics having improved material efficiencies, pull resistance, absorbency, softness and uniformity of texture.
Terry fabrics are manufactured for several different end uses, including as towels, bathrobes, blankets, cleaning products, carpets and the like. Terry fabrics are considered advantageous in view of the fast drying, softness, ability to pick up particles, and ability to absorb moisture.
Terry fabrics typically comprise a woven ground fabric comprising a plurality of substantially parallel ground warp yarns and a plurality of substantially parallel ground weft yarns (or picks)—wherein the plurality of ground weft yarns intersect the plurality of ground warp yarns substantially perpendicularly. Additionally, a plurality of pile warp yarns are interwoven into the ground fabric in a direction substantially parallel to the ground warp yarns—and the pile weave forms a plurality of pile loops or terry loops above and below the woven ground fabric.
Ground warp yarns are interwoven with ground weft yarns at a relatively high tension and forms the base or substrate of the terry fabric. The pile warp yarns are interwoven at a lower tension and are advanced or “let off” from the loom beam at a higher rate than the ground warp yarns. During weaving, a series of adjacent ground weft yarns are subjected to a partial beat-up or “loose beat-up”, where the weft yarn(s) may be pushed partially together using a comb (or “reed”) or where the fell of the cloth is moved forward to enable a partial beat-up, while the pile warp yarns are permitted to “float” over two or more adjacent ground weft yarns. On an ensuing ground weft yarn (at the conclusion of a weaving repeat), the previously partially beat up ground weft yarns as well as the ensuing ground weft yarn are subjected to a “fast beat up”, where all ground weft yarns are pushed fully up to the fell of the woven fabric—resulting in the floating pile threads forming loops that extend away from the ground substrate. A common terry pattern comprises a 3 pick sequence, wherein pile loops are interwoven into the ground fabric in a repeating pattern such that pile loops are formed using (and repeated every) 3 ground weft yarns. Less commonly known are 4, 5, 6 and 7 pick sequences—where interweaving a pile yarn into the ground fabric comprises repeating a pile loop every 4, 5, 6, or 7 ground weft yarns.
While prior art weave sequences have been widely used in the past, it is desired to increase pick density of terry fabrics beyond the pick densities permitted by prior art weave sequences, as well as to improve pull resistance, absorbency, softness and uniformity of texture of the terry fabrics.
The invention provides a terry fabric comprising a plurality of longitudinally oriented ground warp yarns pairs, a plurality of longitudinally oriented pile warp yarns, and a plurality of weft yarns oriented substantially perpendicular to the ground warp yarn pairs. The terry fabric comprises a repeated weave sequence, said repeated weave sequence comprising a first interlacing arrangement comprising a first ground warp yarn pair and a first pile warp yarn interlaced adjacent to and in contact with at least one yarn within the first ground warp yarn pair, the first interlacing arrangement comprising (a) first, second and third weft yarns positioned within a first shed formed by the first ground warp yarn pair, (b) a fourth weft yarn positioned within a second shed formed by the first ground warp yarn pair, wherein the second and third weft yarns are positioned between the first and fourth weft yarns, (c) fifth, sixth and seventh weft yarns positioned within a third shed formed by the first ground warp yarn pair, (d) an eighth weft yarn positioned within a fourth shed formed by the first ground warp yarn pair, wherein the sixth and seventh weft yarns are positioned between the fifth and eighth weft yarns, (f) a first pile loop formed by the first pile yarn, wherein said first pile loop is formed over the first, second, third and fourth weft yarns on one of a face surface or a back surface of a ground substrate, (g) a first region on a surface of the ground substrate that is opposite to the surface on which the first pile loop is formed, said first region having boundaries defined by (I) the first ground warp yarn pair, (II) a second ground warp yarn pair adjacent to the first ground warp yarn pair, (III) the first weft yarn and (IV) the fourth weft yarn, wherein said first region is free of pile loop formation, (h) a second pile loop formed by the first pile yarn, wherein said second pile loop is formed over the fifth, sixth, seventh and eighth weft yarns on one of the face surface or the back surface of the ground substrate, (i) a second region on a surface of the ground substrate that is opposite to the surface on which the second pile loop is formed, said second region having boundaries defined by (I) the first ground warp yarn pair, (II) the second ground warp yarn pair, (III) the fifth weft yarn and (IV) the eighth weft yarn, wherein said second region is free of pile loop formation;
The repeated weave sequence additionally comprises a second interlacing arrangement comprising the second ground warp yarn pair and a second pile warp yarn interlaced adjacent to and in contact with at least one yarn within the second ground warp yarn pair. The second interlacing arrangement additionally comprises (a) the first, second and third weft yarns positioned within a fifth shed formed by the second ground warp yarn pair, (b) the fourth weft yarn positioned within a sixth shed formed by the second ground warp yarn pair, (c) the fifth, sixth and seventh weft yarns positioned within a seventh shed formed by the second ground warp yarn pair, (d) the eighth weft yarn positioned within an eighth shed formed by the second ground warp yarn pair, (e) a third pile loop formed by the second pile yarn, wherein said third pile loop is formed over the first, second, third and fourth weft yarns on one of the face surface or the back surface of the ground substrate, (f) a third region on a surface of the ground substrate that is opposite to the surface on which the third pile loop is formed, said third region having boundaries defined by (I) the second ground warp yarn pair, (II) a third ground warp yarn pair adjacent to the second ground warp yarn pair and positioned such that the second ground warp yarn pair is interposed between the third ground warp yarn pair and the first ground warp yarn pair, (III) the first weft yarn and (IV) the fourth weft yarn, wherein said third region is free of pile loop formation, (g) a fourth pile loop formed by the second pile yarn, wherein said fourth pile loop is formed over the fifth, sixth, seventh and eighth weft yarns on one of the face surface or the back surface of the ground substrate, and (h) a fourth region on a surface of the ground substrate that is opposite to the surface on which the fourth pile loop is formed, said fourth region having boundaries defined by (I) the second ground warp yarn pair, (II) the third ground warp yarn pair, (III) the fifth weft yarn and (IV) the eighth weft yarn, wherein said fourth region is free of pile loop formation.
Further, in the repeated weave sequence, one of the first pile loop and the third pile loop is formed on the face surface of the ground substrate, and the other of the first pile loop and the third pile loop is formed on the back surface of the ground substrate. Additionally, one of the second pile loop and the fourth pile loop is formed on the face surface of the ground substrate, and the other of the second pile loop and the fourth pile loop is formed on the back surface of the ground substrate.
In an embodiment of the terry fabric, the repeated weave sequence may ensure one or more of, positioning the second shed adjacent to the first shed, positioning the third shed adjacent to the second shed, positioning the fourth shed adjacent to the third shed, positioning the sixth shed adjacent to the fifth shed, positioning the seventh shed adjacent to the sixth shed, and positioning the eighth shed adjacent to the seventh shed.
The repeated weave sequence may also ensures that at least one additional weft yarn is positioned between any of the second shed and the first shed, the third shed and the second shed, the fourth shed and the third shed, the sixth shed and the fifth shed, the seventh shed and the sixth shed, or the eighth shed and the seventh shed.
Any of the first shed, third shed, fifth shed or seventh shed may have more than three weft yarns positioned therewithin. Any one of the second shed, fourth shed, sixth shed or eighth shed may have more than one weft yarn positioned therewithin.
In an embodiment, in the first interlacing arrangement, the first pile loop and the second pile loop may be formed on opposite surfaces of the ground substrate, while in the second interlacing arrangement, the third pile loop and the fourth pile loop may be formed on opposite surfaces of the ground substrate.
In an embodiment, in the first interlacing arrangement, the first pile loop and the second pile loop may be formed on one of the face surface or the back surface of the ground substrate, while in the second interlacing arrangement, the third pile loop and the fourth pile loop may be formed on the other of the face surface or the back surface of the ground substrate.
The first ground warp yarn pair and the second ground warp yarn pair may be adjacent yarn pairs, having only a single pile yarn interposed therebetween. Alternately, the first ground warp yarn pair and the second ground warp yarn pair may have at least one additional ground warp yarn pair interposed therebetween.
In an embodiment of the terry fabric, a plurality of instances of the repeated weave sequences may be implemented within the terry fabric. In a specific embodiment, a first instance of the repeated weave sequence may be located immediately adjacent to a second instance of the repeated weave sequence.
In an embodiment of the terry fabric, the first pile warp yarn and the second pile warp yarn may be adjacent pile warp yarns.
The first pile yarn or the second pile yarn may be interlaced into the ground substrate in a repeating sequence that forms each pile loop over 4 or more weft yarns. In a more specific embodiment, the first pile yarn or the second pile yarn may be interlaced into the ground substrate in a repeating sequence that forms each pile loop over 4 to 6 weft yarns.
The invention additionally provides a method of manufacturing a terry fabric comprising a plurality of longitudinally oriented ground warp yarns pairs, a plurality of longitudinally oriented pile warp yarns, and a plurality of weft yarns oriented substantially perpendicular to the ground warp yarn pairs. The method comprises weaving a terry fabric using a plurality of instances of a repeated weave sequence.
Weaving each repeated weave sequence comprises weaving a first interlacing arrangement comprising a first ground warp yarn pair and a first pile warp yarn interlaced adjacent to and in contact with at least one yarn within the first ground warp yarn pair, comprising the steps of (a) placement of first, second and third weft yarns within a first shed formed by the first ground warp yarn pair, (b) placement of a fourth weft yarn within a second shed formed by the first ground warp yarn pair, wherein the second and third weft yarns are positioned between the first and fourth weft yarns, (c) placement of fifth, sixth and seventh weft yarns within a third shed formed by the first ground warp yarn pair, (d) placement of an eighth weft yarn within a fourth shed formed by the first ground warp yarn pair, wherein the sixth and seventh weft yarns are positioned between the fifth and eighth weft yarns, (e) forming a first pile loop, wherein said first pile loop is formed with the first pile yarn, and wherein said first pile loop is formed over the first, second, third and fourth weft yarns, on one of a face surface or a back surface of a ground substrate (f) forming a first region on a surface of the ground substrate that is opposite to the surface on which the first pile loop is formed, said first region having boundaries defined by (I) the first ground warp yarn pair, (II) a second ground warp yarn pair adjacent to the first ground warp yarn pair, (III) the first weft yarn and (IV) the fourth weft yarn, wherein said first region is free of pile loop formation, (g) forming a second pile loop, wherein said second pile loop is formed by the first pile yarn, and wherein said second pile loop is formed over the fifth, sixth, seventh and eighth weft yarns, on one of the face surface or the back surface of the ground substrate, (h) forming a second region on a surface of the ground substrate that is opposite to the surface on which the second pile loop is formed, said second region having boundaries defined by (I) the first ground warp yarn pair, (II) the second ground warp yarn pair, (III) the fifth weft yarn and (IV) the eighth weft yarn, wherein said second region is free of pile loop formation.
Weaving each repeated weave sequence additionally comprises weaving a second interlacing arrangement comprising the second ground warp yarn pair and a second pile warp yarn interlaced adjacent to and in contact with at least one yarn within the second ground warp yarn pair, comprising the steps of (a) placement of the first, second and third weft yarns within a fifth shed formed by the second ground warp yarn pair, (b) placement of the fourth weft yarn within a sixth shed formed by the second ground warp yarn pair, (c) placement of the fifth, sixth and seventh weft yarns within a seventh shed formed by the second ground warp yarn pair, (d) the eighth weft yarn positioned within an eighth shed formed by the second ground warp yarn pair, (e) forming a third pile loop, wherein said third pile loop is formed by the second pile yarn, and wherein said third pile loop is formed over the first, second, third and fourth weft yarns, on one of the face surface or the back surface of the ground substrate, (f) forming a third region on a surface of the ground substrate that is opposite to the surface on which the third pile loop is formed, said third region having boundaries defined by (I) the second ground warp yarn pair, (II) a third ground warp yarn pair adjacent to the second ground warp yarn pair and positioned such that the second ground warp yarn pair is interposed between the third ground warp yarn pair and the first ground warp yarn pair, (III) the first weft yarn and (IV) the fourth weft yarn, wherein said third region is free of pile loop formation, (g) forming a fourth pile loop, wherein said fourth pile loop formed by the second pile yarn, and wherein said fourth pile loop is formed over the fifth, sixth, seventh and eighth weft yarns on one of the face surface or the back surface of the ground substrate, (h) forming a fourth region on a surface of the ground substrate that is opposite to the surface on which the fourth pile loop is formed, said fourth region having boundaries defined by (I) the second ground warp yarn pair, (II) the third ground warp yarn pair, (III) the fifth weft yarn and (IV) the eighth weft yarn, wherein said fourth region is free of pile loop formation.
The method of weaving each repeated sequence may additionally ensure that (a) one of the first pile loop and the third pile loop is formed on the face surface of the ground substrate, and the other of the first pile loop and the third pile loop is formed on the back surface of the ground substrate, and (b) one of the second pile loop and the fourth pile loop is formed on the face surface of the ground substrate, and the other of the second pile loop and the fourth pile loop is formed on the back surface of the ground substrate.
In an embodiment of the invention, the method of manufacturing the terry fabric additionally comprises shearing one or more of the first pile loop, second pile loop, third pile loop and/or fourth pile loop, to generate cut tufted pile tuft on at least one surface of the ground substrate.
The present invention comprises a terry fabric weave sequence, resulting terry fabric and a method for manufacturing a terry fabric implementing the specific terry fabric weave sequence. In particular the terry fabric weave sequence of the present invention comprises a repeating weave sequence that has been found to be significantly advantageous in comparison with prior art terry weaves.
For the purposes of the present invention each terry fabric weave sequence comprises a plurality of longitudinally oriented ground warp yarn pairs, a plurality of pile warp yarns interwoven in parallel with the ground warp yarn pairs, and a plurality of weft yarns oriented substantially perpendicular to the ground warp yarn pairs. The terry weave sequence is a repeating weave sequence, wherein each repeated weave sequence comprises of first and second interlacing arrangement.
An embodiment of the terry weave sequence of the present invention is explained in detail below with reference to
First pile warp yarn 308a is interlaced within first interlacing arrangement 300A so as to form a first pile loop 310a and a second pile loop 310b. First pile loop 310a is formed over first weft yarn 304a, second weft yarn 304b, third weft yarn 304c and fourth weft yarn 304d. More specifically first pile loop 310a is formed by passing first pile warp yarn 308a (i) between first weft yarn 304a and second weft yarn 304b, (ii) over second weft yarn 304b and third weft yarn 304c in a loop (formed on a top surface/face surface of the ground substrate), (iii) between third weft yarn 304c and fourth weft yarn 304d, and (iv) between fourth weft yarn 304d and fifth weft yarn 304e. Likewise, second pile loop 310b is formed over fifth weft yarn 304e, sixth weft yarn 304f, seventh weft yarn 304g and eighth weft yarn 304h. Specifically, second pile loop 310b is formed by passing first pile warp yarn 308a (i) between fifth weft yarn 304e and sixth weft yarn 304f, (ii) over sixth weft yarn 304f and seventh weft yarn 304g in a loop (formed on a bottom surface/back surface of the ground substrate), (iii) between seventh weft yarn 304g and eighth weft yarn 304h, and (iv) between eighth weft yarn 304h and ninth weft yarn 304i.
Second pile warp yarn 308b is interlaced within second interlacing arrangement 300B so as to form a third pile loop 310c and a fourth pile loop 310d. Third pile loop 310c is formed over first weft yarn 304a, second weft yarn 304b, third weft yarn 304c and fourth weft yarn 304d. More specifically, third pile loop 310c is formed by passing second pile warp yarn 308b (i) between first weft yarn 304a and second weft yarn 304b, (ii) over second weft yarn 304b and third weft yarn 304c in a loop (formed on a bottom surface/back surface of the ground substrate), (iii) between third weft yarn 304c and fourth weft yarn 304d and (iv) between fourth weft yarn 304d and fifth weft yarn 304e. Likewise, fourth pile loop 310d is formed over fifth weft yarn 304e, sixth weft yarn 304f, seventh weft yarn 304g and eighth weft yarn 304h. Specifically, fourth pile loop 310d is formed by passing second pile warp yarn 308b (i) between fifth weft yarn 304e and sixth weft yarn 304f, (ii) over sixth weft yarn 304f and seventh weft yarn 304g in a loop (formed on a top surface/face surface of the ground substrate), (iii) between seventh weft yarn 304g and eighth weft yarn 304h and (iv) between eighth weft yarn 304h and a ninth weft yarn 304i.
As illustrated in
Likewise, second pile loop 310b is formed on a back surface of the ground substrate. Simultaneously an opposite surface (i.e. the face surface) of the ground substrate comprises a second region having boundaries defined by (a) first ground warp yarn pair 302a, 302b, (b) second ground warp yarn pair 302c, 302d, (c) fifth weft yarn 304e and (d) eighth weft yarn 304h—which second region is devoid or free of pile loop formation (i.e. no pile loop is provided in this region on said face surface of the ground substrate).
Additionally, as illustrated in
Likewise, fourth pile loop 310d is formed on a face surface of the ground substrate. Simultaneously an opposite surface (i.e. the back surface) of the ground substrate comprises a fourth region having boundaries defined by (a) second ground warp yarn pair 302c, 302d, (b) the third ground warp yarn pair, (c) fifth weft yarn 304e and (d) eighth weft yarn 304h—which fourth region is devoid or free of pile loop formation (i.e. no pile loop is formed over this region on back surface of the ground substrate).
Additionally, as is apparent from weave sequence 500 as illustrated in
The terry weave sequence 500 illustrated in
The illustrations in
First pile warp yarn 608a is interlaced within first interlacing arrangement 600A so as to form a first pile loop 610a and a second pile loop 610b. First pile loop 610a is formed over first weft yarn 604a, second weft yarn 604b, third weft yarn 604c and fourth weft yarn 604d. More specifically first pile loop 610a is formed by passing first pile warp yarn 608a (i) between first weft yarn 604a and second weft yarn 604b, (ii) over second weft yarn 604b and third weft yarn 604c in a loop (formed on a top surface/face surface of the ground substrate), (iii) between third weft yarn 604c and fourth weft yarn 604d, and (iv) beneath fourth weft yarn 604d and fifth weft yarn 604e. Likewise, second pile loop 610b is formed over fifth weft yarn 604e, sixth weft yarn 604f, seventh weft yarn 604g and eighth weft yarn 604h. Specifically, second pile loop 610b is formed by passing first pile warp yarn 608a (i) between fifth weft yarn 604e and sixth weft yarn 604f, (ii) over sixth weft yarn 604f and seventh weft yarn 604g in a loop (formed on a top surface/face surface of the ground substrate), (iii) between seventh weft yarn 604g and eighth weft yarn 604h, and (iv) thereafter beneath eighth weft yarn 604h and ninth weft yarn 604i.
Second pile warp yarn 608b is interlaced within second interlacing arrangement 600B so as to form a third pile loop 610c and a fourth pile loop 610d. Third pile loop 610c is formed over first weft yarn 604a, second weft yarn 604b, third weft yarn 604c and fourth weft yarn 604d. More specifically, third pile loop 610c is formed by passing second pile warp yarn 608b (i) between first weft yarn 604a and second weft yarn 604b, (ii) over second weft yarn 604b and third weft yarn 604c in a loop (formed on a bottom surface/back surface of the ground substrate), (iii) between third weft yarn 604c and fourth weft yarn 604d and (iv) and over fourth weft yarn 604d and fifth weft yarn 604e. Likewise, fourth pile loop 610d is formed over fifth weft yarn 604e, sixth weft yarn 604f, seventh weft yarn 604g and eighth weft yarn 604h. Specifically, fourth pile loop 610d is formed by passing second pile warp yarn 608b (i) between fifth weft yarn 604e and sixth weft yarn 604f, (ii) over sixth weft yarn 604f and seventh weft yarn 604g in a loop (formed on a bottom surface/back surface of the ground substrate), (iii) between seventh weft yarn 604g and eighth weft yarn 604h and (iv) over eighth weft yarn 604h and a ninth weft yarn 604i.
As illustrated in
Likewise, second pile loop 610b is formed on a face surface of the ground substrate. Simultaneously an opposite surface (i.e. the back surface) of the ground substrate comprises a second region having boundaries defined by (a) first ground warp yarn pair 602a, 602b, (b) second ground warp yarn pair 602c, 602d, (c) fifth weft yarn 604e and (d) eighth weft yarn 604h—which second region is devoid or free of pile loop formation (i.e. no pile loop is provided in this region on said back surface of the ground substrate).
Additionally, as illustrated in
Likewise, fourth pile loop 610d is formed on a back surface of the ground substrate. Simultaneously an opposite surface (i.e. the face surface) of the ground substrate comprises a fourth region having boundaries defined by (a) second ground warp yarn pair 602c, 602d, (b) the third ground warp yarn pair, (c) fifth weft yarn 604e and (d) eighth weft yarn 604h—which fourth region is devoid or free of pile loop formation (i.e. no pile loop is formed over this region on the face surface of the ground substrate).
Additionally, as is apparent from weave sequence 800 as illustrated in
The terry weave sequence 800 illustrated in
The invention embodiments described above relate to terry fabrics having a repeating ground weave sequence comprising 3 ground weft yarns positioned within a first shed formed by a ground warp yarn pair, followed by one ground weft yarn positioned within a second shed formed by the ground warp yarn pair, wherein the first shed and second shed may be adjacent to each other. It would be understood that one or both of the first shed and the second shed may have a larger number of ground weft yarns positioned therein.
First pile warp yarn 908a is interlaced within first interlacing arrangement 900A so as to form a first pile loop 910a and a second pile loop 910b. First pile loop 910a is formed over first weft yarn 904a, second weft yarn 904b, additional weft yarn 904j, third weft yarn 904c and fourth weft yarn 904d. More specifically first pile loop 910a is formed by passing first pile warp yarn 908a (i) between first weft yarn 904a and second weft yarn 904b, (ii) over second weft yarn 904b, additional weft yarn 904j and third weft yarn 904c in a loop (formed on a top surface/face surface of the ground substrate), (iii) between third weft yarn 904c and fourth weft yarn 904d, and (iv) between fourth weft yarn 904d and fifth weft yarn 904e. Likewise, second pile loop 910b is formed over fifth weft yarn 904e, sixth weft yarn 904f, additional weft yarn 904k, seventh weft yarn 904g and eighth weft yarn 904h. Specifically, second pile loop 910b is formed by passing first pile warp yarn 908a (i) between fifth weft yarn 904e and sixth weft yarn 904f, (ii) over sixth weft yarn 904f, additional weft yarn 904k, and seventh weft yarn 904g in a loop (formed on a bottom surface/back surface of the ground substrate), (iii) between seventh weft yarn 904g and eighth weft yarn 904h, and (iv) between eighth weft yarn 904h and ninth weft yarn 904i.
Second pile warp yarn 908b is interlaced within second interlacing arrangement 900B so as to form a third pile loop 910c and a fourth pile loop 910d. Third pile loop 910c is formed over first weft yarn 904a, second weft yarn 904b, additional weft yarn 904j, third weft yarn 904c and fourth weft yarn 904d. More specifically, third pile loop 910c is formed by passing second pile warp yarn 908b (i) between first weft yarn 904a and second weft yarn 904b, (ii) over second weft yarn 904b, additional weft yarn 904j, and third weft yarn 904c in a loop (formed on a bottom surface/back surface of the ground substrate), (iii) between third weft yarn 904c and fourth weft yarn 904d and (iv) between fourth weft yarn 904d and fifth weft yarn 904e. Likewise, fourth pile loop 910d is formed over fifth weft yarn 904e, sixth weft yarn 904f, additional weft yarn 904k, seventh weft yarn 904g and eighth weft yarn 904h. Specifically, fourth pile loop 910d is formed by passing second pile warp yarn 908b (i) between fifth weft yarn 904e and sixth weft yarn 904f, (ii) over sixth weft yarn 904f, additional weft yarn 904k and seventh weft yarn 904g in a loop (formed on a top surface/face surface of the ground substrate), (iii) between seventh weft yarn 904g and eighth weft yarn 904h and (iv) between eighth weft yarn 904h and a ninth weft yarn 904i.
As illustrated in
Likewise, second pile loop 910b is formed on a back surface of the ground substrate. Simultaneously an opposite surface (i.e. the face surface) of the ground substrate comprises a second region having boundaries defined by (a) first ground warp yarn pair 902a, 902b, (b) second ground warp yarn pair 902c, 902d, (c) fifth weft yarn 904e and (d) eighth weft yarn 904h—which second region is devoid or free of pile loop formation (i.e. no pile loop is provided in this region on said face surface of the ground substrate).
Additionally, as illustrated in
Likewise, fourth pile loop 910d is formed on a face surface of the ground substrate. Simultaneously an opposite surface (i.e. the back surface) of the ground substrate comprises a fourth region having boundaries defined by (a) second ground warp yarn pair 902c, 902d, (b) the third ground warp yarn pair, (c) fifth weft yarn 904e and (d) eighth weft yarn 904h—which fourth region is devoid or free of pile loop formation (i.e. no pile loop is formed over this region on back surface of the ground substrate).
As is apparent from weave sequence 1100 as illustrated in
The terry weave sequence 1100 illustrated in
The illustrations in
Additionally, an eighth weft yarn 1204h is positioned within a fourth shed 1206d formed by first ground warp yarn pair 1202a and 1202b. Eighth weft yarn 1204h is followed by immediately adjacent weft yarn 1204i. Yet further, second weft yarn 1204b and third weft yarn 1204c have an additional weft yarn 1204j interposed therebetween, which additional weft yarn 1204j is positioned within first shed 1206a formed by ground warp yarn pair 1202a and 1202b. Sixth weft yarn 1204f and seventh weft yarn 1204g also have an additional weft yarn 1204k interposed therebetween, which additional weft yarn 1204k is positioned within third shed 1206c formed by ground warp yarn pair 1202a and 1202b.
First pile warp yarn 1208a is interlaced within first interlacing arrangement 1200A so as to form a first pile loop 1210a and a second pile loop 1210b. First pile loop 1210a is formed over first weft yarn 1204a, second weft yarn 1204b, additional weft yarn 1204j, third weft yarn 1204c and fourth weft yarn 1204d. More specifically, first pile loop 1210a is formed by passing first pile warp yarn 1208a (i) between first weft yarn 1204a and second weft yarn 1204b, (ii) over second weft yarn 1204b, additional weft yarn 1204j, and third weft yarn 1204c in a loop (formed on a top surface/face surface of the ground substrate), (iii) between third weft yarn 1204c and fourth weft yarn 1204d, and (iv) beneath fourth weft yarn 1204d and fifth weft yarn 1204e. Likewise, second pile loop 1210b is formed over fifth weft yarn 1204e, sixth weft yarn 1204f, additional weft yarn 1204k, seventh weft yarn 1204g, and eighth weft yarn 1204h. Specifically, second pile loop 1210b is formed by passing first pile warp yarn 1208a (i) between fifth weft yarn 1204e and sixth weft yarn 1204f, (ii) over sixth weft yarn 604f, additional weft yarn 1204K, and seventh weft yarn 1204g in a loop (formed on a top surface/face surface of the ground substrate), (iii) between seventh weft yarn 1204g and eighth weft yarn 1204h, and (iv) thereafter beneath eighth weft yarn 1204h and ninth weft yarn 1204i.
Second pile warp yarn 1208b is interlaced within second interlacing arrangement 1200B so as to form a third pile loop 1210c and a fourth pile loop 1210d. Third pile loop 1210c is formed over first weft yarn 1204a, second weft yarn 1204b, additional weft yarn 1204j, third weft yarn 1204c and fourth weft yarn 1204d. More specifically, third pile loop 1210c is formed by passing second pile warp yarn 1208b (i) between first weft yarn 1204a and second weft yarn 1204b, (ii) over second weft yarn 1204b, additional weft yarn 1204j, and third weft yarn 1204c in a loop (formed on a bottom surface/back surface of the ground substrate), (iii) between third weft yarn 1204c and fourth weft yarn 1204d and (iv) and over fourth weft yarn 1204d and fifth weft yarn 1204e. Likewise, fourth pile loop 1210d is formed over fifth weft yarn 1204e, sixth weft yarn 1204f, additional weft yarn 1204k, seventh weft yarn 1204g and eighth weft yarn 1204h.
Specifically, fourth pile loop 1210d is formed by passing second pile warp yarn 1208b (i) between fifth weft yarn 1204e and sixth weft yarn 1204f, (ii) over sixth weft yarn 1204f, additional weft yarn 1204k, and seventh weft yarn 1204g in a loop (formed on a bottom surface/back surface of the ground substrate), (iii) between seventh weft yarn 1204g and eighth weft yarn 1204h and (iv) over eighth weft yarn 1204h and a ninth weft yarn 1204i.
As illustrated in
Likewise, second pile loop 1210b is formed on a face surface of the ground substrate. Simultaneously an opposite surface (i.e. the back surface) of the ground substrate comprises a second region having boundaries defined by (a) first ground warp yarn pair 1202c, 1202d, (b) second ground warp yarn pair 1202c, 1202d, (c) fifth weft yarn 1204e and (d) eighth weft yarn 1204h—which second region is devoid or free of pile loop formation (i.e. no pile loop is provided in this region on said back surface of the ground substrate).
Additionally, as illustrated in
Likewise, fourth pile loop 1210d is formed on a back surface of the ground substrate. Simultaneously an opposite surface (i.e. the face surface) of the ground substrate comprises a fourth region having boundaries defined by (a) second ground warp yarn pair 1202a, 1202b, (b) the third ground warp yarn pair, (c) fifth weft yarn 1204e and (d) eighth weft yarn 1204h—which fourth region is devoid or free of pile loop formation (i.e. no pile loop is formed over this region on the face surface of the ground substrate).
Additionally, as is apparent from weave sequence 1400 as illustrated in
The terry weave sequence 1400 illustrated in
The present invention additionally provides terry weaves fabrics which comprise one or more instances of the terry weave sequences described above in connection with
In an embodiment of the terry fabric of the present invention, the terry weave sequence ensures positioning the second shed adjacent to the first shed, positioning the third shed adjacent to the second shed, positioning the fourth shed adjacent to the third shed, positioning the sixth shed adjacent to the fifth shed, positioning the seventh shed adjacent to the sixth shed and/or positioning the eighth shed adjacent to the seventh shed.
The repeated weave sequence may alternately ensure that at least one additional weft yarn is positioned between any of the second shed and the first shed, the third shed and the second shed, the fourth shed and the third shed, the sixth shed and the fifth shed, the seventh shed and the sixth shed and/or the eighth shed and the seventh shed.
In an embodiment of the invention, any of the first shed, third shed, fifth shed or seventh shed may have more than three weft yarns positioned therewithin. Likewise, any one of the second shed, fourth shed, sixth shed or eighth shed may have more than one weft yarn positioned therewithin.
It would be understood that the first ground warp yarn pair and the second ground warp yarn pair may be adjacent yarn pairs, having only a single pile yarn interposed therebetween. The first ground warp yarn pair and the second ground warp yarn pair may alternately have at least one additional ground warp yarn pair interposed therebetween. In an embodiment, the first pile warp yarn and the second pile warp yarn may be adjacent pile warp yarns.
In weaving a terry fabric, a plurality of instances of the terry weave sequences described above may be implemented within the terry fabric. In an embodiment, a first instance of the terry weave sequence may be located immediately adjacent to a second instance of the terry weave sequence. In another embodiment, the first pile yarn or the second pile yarn may be interlaced into the ground substrate in a repeating sequence that forms each pile loop over 4 or more weft yarns.
The invention additionally provides methods of weaving a terry fabric, the method comprising repeating at least one of the terry weave sequences described above in a plurality of instances while weaving a terry fabric.
A particular method embodiment of the present invention comprises a method of manufacturing a terry fabric comprising a plurality of longitudinally oriented ground warp yarns pairs, a plurality of longitudinally oriented pile warp yarns, and a plurality of weft yarns oriented substantially perpendicular to the ground warp yarn pairs. The method comprises weaving a terry fabric using a plurality of instances of a repeated weave sequence.
Weaving each repeated weave sequence includes weaving a first interlacing arrangement comprising a first ground warp yarn pair and a first pile warp yarn interlaced adjacent to and in contact with at least one yarn within the first ground warp yarn pair, and comprising the steps of (i) placement of first, second and third weft yarns within a first shed formed by the first ground warp yarn pair, (ii) placement of a fourth weft yarn within a second shed formed by the first ground warp yarn pair, wherein the second and third weft yarns are positioned between the first and fourth weft yarns, (iii) placement of fifth, sixth and seventh weft yarns within a third shed formed by the first ground warp yarn pair, (iv) placement of an eighth weft yarn within a fourth shed formed by the first ground warp yarn pair, wherein the sixth and seventh weft yarns are positioned between the fifth and eighth weft yarns, (v) forming a first pile loop, wherein said first pile loop is formed with the first pile yarn, and wherein said first pile loop is formed over the first, second, third and fourth weft yarns, on one of a face surface or a back surface of a ground substrate, (vi) forming a first region on a surface of the ground substrate that is opposite to the surface on which the first pile loop is formed, said first region having boundaries defined by (a) the first ground warp yarn pair, (b) a second ground warp yarn pair adjacent to the first ground warp yarn pair, (c) the first weft yarn and (d) the fourth weft yarn, wherein said first region is free of pile loop formation, (vii) forming a second pile loop, wherein said second pile loop is formed by the first pile yarn, and wherein said second pile loop is formed over the fifth, sixth, seventh and eighth weft yarns, on one of the face surface or the back surface of the ground substrate, (viii) forming a second region on a surface of the ground substrate that is opposite to the surface on which the second pile loop is formed, said second region having boundaries defined by (a) the first ground warp yarn pair, (b) the second ground warp yarn pair, (c) the fifth weft yarn and (d) the eighth weft yarn, wherein said second region is free of pile loop formation.
Weaving each repeated weave sequence additionally includes weaving a second interlacing arrangement comprising the second ground warp yarn pair and a second pile warp yarn interlaced adjacent to and in contact with at least one yarn within the second ground warp yarn pair, and comprising the steps of (i) placement of the first, second and third weft yarns within a fifth shed formed by the second ground warp yarn pair, (ii) placement of the fourth weft yarn within a sixth shed formed by the second ground warp yarn pair, (iii) placement of the fifth, sixth and seventh weft yarns within a seventh shed formed by the second ground warp yarn pair, (iv) the eighth weft yarn positioned within an eighth shed formed by the second ground warp yarn pair, (v) forming a third pile loop, wherein said third pile loop is formed by the second pile yarn, and wherein said third pile loop is formed over the first, second, third and fourth weft yarns, on one of the face surface or the back surface of the ground substrate, (vi) forming a third region on a surface of the ground substrate that is opposite to the surface on which the third pile loop is formed, said third region having boundaries defined by (a) the second ground warp yarn pair, (b) a third ground warp yarn pair adjacent to the second ground warp yarn pair and positioned such that the second ground warp yarn pair is interposed between the third ground warp yarn pair and the first ground warp yarn pair, (c) the first weft yarn and (d) the fourth weft yarn, wherein said third region is free of pile loop formation, (vii) forming a fourth pile loop, wherein said fourth pile loop formed by the second pile yarn, and wherein said fourth pile loop is formed over the fifth, sixth, seventh and eighth weft yarns on one of the face surface or the back surface of the ground substrate, (viii) forming a fourth region on a surface of the ground substrate that is opposite to the surface on which the fourth pile loop is formed, said fourth region having boundaries defined by (a) the second ground warp yarn pair, (b) the third ground warp yarn pair, (c) the fifth weft yarn and (d) the eighth weft yarn, wherein said fourth region is free of pile loop formation.
Weaving each repeated weave sequence includes ensuring that (i) one of the first pile loop and the third pile loop is formed on the face surface of the ground substrate, and the other of the first pile loop and the third pile loop is formed on the back surface of the ground substrate, and (ii) one of the second pile loop and the fourth pile loop is formed on the face surface of the ground substrate, and the other of the first pile loop and the third pile loop is formed on the back surface of the ground substrate.
In an embodiment of the invention, the method of manufacturing the terry fabric additionally comprises shearing one or more of the first pile loop, second pile loop, third pile loop and/or fourth pile loop, to generate cut tufted pile tuft on at least one surface of the ground substrate.
The terry weave sequences and terry weave fabrics in accordance with the above embodiments of the invention have been found to present several significant advantages.
Table A in
Terry fabric A corresponds to a fabric of the kind discussed in connection with
In addition to the above, terry fabrics manufactured in accordance with teachings of the present invention have been found to have a distinctive and aesthetically appealing appearance and improved uniformity of texture in comparison with terry fabrics manufactured in accordance with terry weaves known in the prior art.
The terry fabrics in accordance with the present invention may be manufactured using one or more non-soluble yarns and optionally one or more soluble yarns. Non-soluble yarns for manufacturing terry fabrics in accordance with teachings of the present invention may comprise any one or more natural fibers such as cotton, wool, silk, jute, flax, bamboo or ramie, or one or more regenerated/synthetic fibres such as lyocell, viscose, modal, soya, polyester, acrylic, rayon, charcoal, linen, corn, milk fibre, PLA (poly lactic acid) fibre etc. Soluble yarns for manufacturing ply yarns (or for that matter ground yarns) may include any of polyvinyl alcohol (PVA), wool or a yarn product that is sold under the trade name “solucell”.
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.
| Number | Date | Country | Kind |
|---|---|---|---|
| 201611000874 | Jan 2016 | IN | national |
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