OBJECT OF THE INVENTION
The invention has as its object bathwear items for personal
use, especially for drying purposes, such as towels, bath rugs, bathrobes, bath
slippers and the like, and the process for manufacturing the same.
FIELD OF THE INVENTION
The bathwear items for personal use of the invention, especially
for the drying of the user, are used in the home as well as in hotels, hospitals,
BACKGROUND OF THE INVENTION
The towels existing at present have some improvable aspects
such as the drying time both for the user and for the actual towel, the absorption
power, the amount of water and detergent being necessary for the washing of the
towel, the heat and energy input for the cleaning of the towel, the durability and
useful life, and the hygienic power.
The improved quality of the polymers being used, the new
extrusion technologies and the new spinning, drawing and texturising processes have
on the other hand made it possible to carry out the manufacture of fibres of sufficient
fineness for what is technically known as microfibres (a multitude of long and artificial,
synthetic fibres), as opposed to the cotton fibre, which is a natural and short
There are on the other hand technical fields around what
constitutes the object of the invention from among which can be cited the dimensional
stability being given to the microfibre by the weaving operation being carried out
on a shed loom and with a three-yarn weave, this latter weaving process having nothing
to do with that being used for making the knitted fabrics existing in the market,
these latter being manufactured through the use of special (circular) knitting machines
and with a two-yarn weave and without the possibility of forming different widths
or selvages forming part of the actual body of the fabric, these latter fabrics
finding their application in the field of the wipes being intended for the cleaning
of kitchens, cars, television sets, etc.
The invention also evidently has nothing to do with the
applications of the upholstery world for furniture linings, curtains, etc., where
a vertical yarn (warp) and another one (weft) being arranged in a transversal arrangement
are used in order to make the textile weave.
The present invention has as its object bathwear items
for personal use ostensibly improving the known bathwear items for personal use.
The bathwear items of the invention thus comprise microfibres producing neither
fuzz nor pilling and thanks to their high wickability being in a position to absorb
eight times more moisture as compared with the traditional cotton and thus acting
as a sponge when being used for drying purposes.
Their maintenance is as well much more economical than
that of the cotton towels, with an approximate 40% reduction in the water consumption
in the washing process and with a 35-45% reduction in the use of detergents because
of the oleophilic nature of the microfibre, and with no need to use said detergents
with an aggressive pH, with all the environmental advantages and improvements and
energy savings being associated to this.
Based on the tests having been carried out their durability
and useful life is at least four or five times higher than that of the cotton towels,
their dry and wet tensile strength being barely reduced after successive washes.
In a traditional textile a moisture residue always remains
after the drying and thus promotes the growth of bacteria and mould, the amount
of bacteria being present on the skin after the drying hence only experiencing a
30% reduction. Nevertheless, thanks to the wicking and static effect and action
taking place in the case of the microfibres the drying becomes much more efficient
with a higher dirt and moisture retention, the amount of bacteria being present
on the skin surface after the drying thus experiencing a reduction of between 96
The use of towels and bathrobes being made of microfibre
is hence absolutely recommendable for all those staff members being posted or supposed
to intervene in critical or semicritical areas in hospitals, clinics and the like,
said bathwear items being besides able to withstand the action of surgical alcohols.
With respect to the manufacture of traditional cotton towels,
apart from the fact that the composition of the warp yarns is a different one the
transverse density is also different. The machines and the order of the process
are the same, but with different computer control parameters and mechanical adjustments,
since without them it would be impossible to achieve a smooth operation at all stages
in the manufacturing process.
The making up technique of the present invention is the
same one being used for the standard towels, a strength and dimensional stability
being achieved which are adequate for the needs of the product.
The most outstanding coincidence between the conventional
cotton terry towel and that being made of microfibre lies in the appearance and
the order of the manufacturing process, since as for the components as for the raw
materials, the technical adjustment of the existing machines in the process, the
behaviour of the fibres during and after the manufacturing process and the performance
of said fibres there is no relation whatsoever between one towel type and the other.
The invention obviates the drawbacks of the known towels
and the like as has been set forth above.
SUMMARY OF THE INVENTION
According to what has been set forth above the bathwear
items for personal use, especially for drying purposes, are essentially characterised
in that they are made up of terry cloth fabrics being made of microfibre on a flat
loom with a three-yarn weave, two of said three yarns being microfibre warp yarns
whereas the other yarn being the weft yarn is made of cotton and/or polyester/cotton.
One of the two warp yarns is loose and makes up the terry pile, whereas the other
one is taut and makes up the ground.
The bathwear items of the invention can incorporate designs
and/or logos on the actual surface of the fabric, with the desired colour combination.
The thickness (textile titre) of the yarns can span the whole range being possibly
allowed by the loom without modifying the fabric's performance or the technical
adjustments being necessary for its manufacture.
The process for the manufacture of bathwear items for personal
use as per the invention is characterised in that it starts at a warping preparation
stage wherein by using a sectional warper being specially parametrised for the preparation
of the microfibre this latter can be readied to pass over to the ulterior weaving
stage, and in said weaving one proceeds to fit to the shed loom the upper beam feeding
the terry loop yarn and the lower beam feeding the ground yarn and to pass each
of the yarns of each beam through the eyelets of the jacquard mounting and through
According to the process of the invention one also proceeds
to equip in the same way a shed loom wherein the eyelets guiding each of the yarns
passing through them are not of the jacquard type but of the dobby type. Both in
the warping process (1st stage) and in the weaving process (2nd
stage) the machines are equally in a position to weave both a conventional terry
cloth fabric or one being made of microfibre. The terry cloth fabric when woven
on a shed loom, both of the jacquard or of the dobby type, can be woven in several
sizes thereby finishing the ends of the terry cloth fabric in a special fabric with
no terry pile in order to thus be in a position to make up the selvages and to directly
on the loom provide each wear item being woven with the necessary strength and finish
thus avoiding ulterior processes for the making up of added selvages already not
forming part of the very fabric.
Since each of the yarns is passed through the jacquard
mounting this allows to directly weave and thereby insert designs and/or logos in
any area of the fabric and with the desired colour combination. The cutting and
making up processes to be carried out after the weaving are the 3d and
4th stages of the making up process, respectively. A machine being specially
designed for cutting between the longitudinal selvages having been previously woven
with no terry pile on the loom takes charge of separating the different widths having
been woven by the loom, it being thus possible to go over to the subsequent selvage
making up process wherein the double-folding and lock stitching operations are carried
out in order to provide the selvages with the shape and strength being necessary
for an optimum performance in the ulterior washing processes.
These and other characterising features will be best made
apparent by the following detailed description whose understanding will be made
easier by the accompanying two sheets of drawings showing a practical embodiment
being cited only by way of example not limiting the scope of the present invention.
DESCRIPTION OF THE DRAWINGS
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION
- Figs. 1A and 1B diagrammatically illustrate the terry cloth weave on a shed
loom of the flat loom type as used in the making up of bathwear items as per the
- Fig. 2 illustrates an enlarged detail of a piece of a bathwear item of the invention
perfectly showing at its edge the three-yarn weave being made up of two warp yarns
being made of microfibre and one weft yarn being made of cotton and/or polyester/cotton
as per the invention.
- Fig. 3 shows a plan-view of a portion of a bathwear item as per the invention
allowing to appreciate the designs being incorporated in it.
According to the object of the invention this latter has
been conceived in form of bathwear items for personal use, especially for drying
purposes, such as towels, bath rugs, bathrobes, bath slippers and the like, and
at the same time comprises the way of manufacturing the same.
As can be appreciated in Figs. 2 and 3, the bathwear item
-RB- being the object of the invention is made up by a terry cloth fabric -TE- being
made of microfibre and cotton on a shed loom of the flat loom type and with a three-yarn
weave, two of said three yarns being warp yarns -U- being made of microfibre (vertical
direction) whereas the other one is a weft yarn -T- (horizontal direction) being
made of cotton and/or polyester/cotton, the textile weave of the fabric being thus
given the indispensable dimensional stability and the necessary solidity.
The microfibre is made up of a multitude of long and artificial,
synthetic fibres of texturised polyester.
One of the two warp yarns is besides a loose yarn making
up the terry pile -R- whereas the other one is taut and makes up the ground -B-
(Figs. 1A and 1B). Said Fig. 1A illustrates said yarns and the number of the pick
(pick number) -PN- corresponding to the top surface weave -LCS- and to the bottom
surface weave -LCI- of the fabric.
The tying up of the terry cloth fabric together in the
conventional way consists in at every three picks (see -3-, -6-, -9- in Fig. 1A)
carrying out a beating up operation and thus forming a terry loop, the tyings of
the top and bottom surfaces being arranged in an alternate arrangement, the weft
tying each pick irrespective of the number of colours being one or several colours.
The textile titre (count/size), which is after all the
thickness of the yarns, can span the whole range possibly being technically allowed
by the loom, since a modification of the titre only affects the visual texture of
the fabric, such as that being appreciable in Figs. 2 and 3, without in any way
modifying the fabric's performance or the technical adjustments being necessary
for its manufacture.
The bathwear items -RB- being the object of the present
invention, as can be appreciated in Figs. 2 and 3, can incorporate jacquard designs
-D-, logos -L-, anagrams, borders, etc. directly on the actual surface of the fabric,
said features being possibly made in any colour combination.
The microfibre towels allow to carry out the body drying
operation in a much faster way and with less effort as compared with the traditional
ones being made of cotton. They produce an immediate drying effect even if applied
with an only slight pressure on the body or the hair.
The texturised polyester of this microfibre has a high
tensile and rubbing strength and a good elasticity and washability and allows to
obtain a good binding of the dyes.
The microfibre towels must be considered as ultraabsorbent
ones since thanks to their high wickability and static electricity they absorb more
water and even oils.
As a consequence of the treatment being applied to the
linear mass of the filaments the surface of the polyester multifilament filament
is improved (cross-section, fineness, indefinite length), an item being thus obtained
which has a good appearance and a pleasant feel. As a consequence of this, the microfibre
towels and bathrobes are very silky, flexible and soft products.
The vapour being produced during the user's perspiration
can pass through the fabric without accumulating on the skin, this being most advantageous
in the case of the bathrobes.
As for the bathwear manufacturing process making up the
other object of the present invention, it comprises a number of stages starting
at the warping preparation stage wherein by using a sectional warper -not shown-being
specially parametrised for the preparation of the microfibre this latter can be
readied to pass over to the ulterior process, this latter being that of the weaving
stage. Already in the weaving process one proceeds to fit to the shed loom the upper
beam feeding the terry loop yarn and the lower beam feeding the ground yarn and
to pass each of the yarns of each beam (which depending on the width of the shed
loom can contain up to 4800 yarns per beam or bobbin) through the eyelets of the
jacquard mounting and through the reed.
It is also possible to proceed to equip in the same way
a shed loom wherein the eyelets through which each of the yarns passes is not of
the "jacquard" type but of the "dobby" type (heddles in our jargon).
Both in the warping (1st stage) and in the weaving
process (2nd stage) machine-specific computer control and mechanical
adjustments are necessary in order to thus finally enable the machines to be operated
in a multipurpose manner and to thus be in a position to equally weave (always after
a reprogramming) a conventional or a microfibre terry cloth fabric on them.
It is also important o point out that the terry cloth fabric
when woven on a shed loom both of the jacquard or of the dobby type allows to weave
in several sizes (those being standardised in each market) thereby finishing the
ends of the terry cloth fabric in a special fabric with no terry pile in order to
thus be in a position to make up the selvages and to directly on the loom provide
each wear item being woven with the necessary strength and finish thus avoiding
ulterior processes for the making up of added selvages already not forming part
of the very fabric. The terry cloth fabric and the selvages of the towel are hence
of one and the same body.
The passage of each of the yarns through the jacquard mounting
is what allows to directly weave and thereby insert personalised designs in any
area of the fabric and with the desired colour combination.
The cutting and making up process to be carried out after
the weaving are the 3d and 4th stages of the making up process,
A machine being specially designed for cutting between
the longitudinal selvages having been previously woven with no terry pile on the
loom takes charge of separating the different widths having been woven by the loom,
it being thus possible to go over to the subsequent selvage making up process wherein
the double-folding and lock stitching operations are carried out in order to provide
the selvages with the shape and strength being necessary for an optimum performance
in the ulterior industrial washing processes being carried out in hotels, hospitals,
industrial laundries, etc.
The system having been shown above can have the configuration
and components being best suited for such functions. It is thus possible to use
the components having been described or any other components as best suited for
carrying out the same type of job.