[TECHNICAL FIELD]
[0001] The present invention relates to a towel product having a honeycomb weave structure.
[BACKGROUND ART]
[0002] Honeycomb weave towel products have been widely used mainly in Europe as a birthplace
thereof. Recently, the honeycomb weave towel products are used also in Japan. For
example, the honeycomb weave towel products are used widely in many fields such as
towels, bath towels, and gowns, e.g., towel-made robes, in addition to kitchen dishcloths.
The honeycomb weave is sometimes referred to as a waffle fabric since it has a texture
similar to Waffles (see, patent literature 1).
[0003] Unlike a typical towel having loop piles on its surface, a honeycomb weave towel
has a woven fabric structure obtained by deforming a plain weave which is woven in
a manner that a single warp yarn is crossed over a single weft yarn to continue weaving
in this manner. Thus deformed woven fabric is characterized by having a concave-convex
surface generated by shrinkage of fabric itself. This structure can provide the following
advantageous effects.
[0004] For example, when one wipes off his sweat, he presses a towel against his skin softly.
At the time, only convex parts of the towel touch his skin to absorb moisture. The
moisture absorbed by the convex parts is partially evaporated and partially transferred
to concave parts of the towel. As a result thereof, the convex parts can always keep
a dry state.
[0005] With the above feature, the user of the towel can be provided with a dry touch feeling
every time when the user repeats to wipe off his sweat. In other words, no stickiness
remains in the towel after the use thereof. Equivalent effect can be produced when
the above described feature is applied to a bath mat to be used in a bath room.
[0006] Further, the honeycomb weave towel is thinner than a towel having loop piles on its
surface. Therefore, the honeycomb weave towel is compact. Still further, in the honeycomb
weave towel, loosening of pile yarns hardly occurs and fluff comes out only a little.
[CITATION LIST]
[PATENT LITERATURE]
[0007] [PATENT LITERATURE 1] Japanese Unexamined Patent Application, First Publication No.
2009-160212
[SUMMARRY OF INVENTION]
[TECHNICAL PROBLEM]
[0008] However, in different perspectives, the above described feature of the honeycomb
weave towel product may raise another problem.
[0009] Generally, it is preferable for towel products to have a well-balanced performance
between water absorbency, a drying property, lightness, and a good touch feeling.
For example, towels are frequently used in order to wipe off wet body after bathing,
and thus the water absorbency is a performance essential for towels. Towels are used
every day. Also, towels are used by people of all ages from children to the elderly.
Therefore, it is preferable to achieve weight reduction. Since a towel directly touches
a human skin, and thus its touch feeling affects on a comfort level of the user. Rough
touch feeling and hard touch feeling make the user uncomfortable. Further, indoor
drying for a long time invites growth of bacteria and generation of unpleasant smell.
Drying with a drying machine for a long time invites waste of energy.
[0010] On the other hand, the conventional honeycomb weave towel has the following problem
with respect to the water absorbency, the lightness, and the good touch feeling.
[0011] When wiping off moisture, one presses a towel against his skin softly. At the time,
only convex parts touch his skin. In other words, a touch area is small. As a result
thereof, satisfactory water absorbency cannot be realized.
[0012] Weaving densely achieved by using thick yarns improves the water absorbency. However,
this leads to a heavy weight and a hard touch feeling.
[0013] Further, in the honeycomb weave towel, a densely woven structure is further shrunk
to generate concaves and convexes on its surface. Therefore, weight per area becomes
relatively large. More specifically, the honeycomb weave towel degrades in lightness
for its compact appearance.
[0014] With the use of thin ordinary yarns, the lightness improves. However, since the thin
ordinary yarns have a little shrinkage ratio, it is impossible for the thin ordinary
yarns to make a large concave-convex surface in a fabric. In other words, it is difficult
to feel a three-dimensional appearance of the honeycomb weave. Further, the water
absorbency degrades.
[0015] Still further, the honeycomb weave towel provides a bounce feeling by the concave-convex
surface. However, in comparison with the towel with loop piles, the honeycomb weave
towel has less soft touch feeling. Specifically, the touch feeling touched by the
convex parts is hard.
[0016] A combination of the ordinary yarns made by less number of twisting and a loosely
woven structure improves a soft touch feeling. However, both of the ordinary yarns
made by less number of twisting and the loosely woven structure have a little shrinkage
ratio. Thus, it is impossible to make a large concave-convex surface in the fabric.
This makes it difficult to provide a feeling of three-dimensional appearance of the
honeycomb weave. Further, the water absorbency degrades.
[0017] As described above, the conventional honeycomb weave towel has problem with respect
to the water absorbency, the lightness, and the good touch feeling. Improvement of
any one of the above listed performances degrades other performances. More specifically,
it is difficult to improve all of the water absorbency, the lightness, and the good
touch feeling at the same time.
[0018] The present invention is made to solve the above described problem. The present invention
is directed to provide a towel product capable of maintaining features of honeycomb
weave produced by the conventional technique as well as improving the water absorbency,
the lightness, and the good touch feeling more than the towel products produced by
the conventional technique.
[SOLUTION TO PROBLEM]
[0019] In order to solve the above described problem, the towel product of the present invention
has a honeycomb weave structure and is woven by hollow yarns.
[0020] In the honeycomb weave structure, warp yarns and weft yarns are shrunk. Therefore,
mutual binding becomes loose. This ensures that hollow portions are not crushed remarkably
even with the use of hollow yarns. In other words, shapes of hollow yarns can be kept.
[0021] With the above described structure, the water absorbency, the lightness, the good
touch feeling, and the drying property can be improved more than the towel products
produced by the conventional technique.
[0022] Preferably, the hollow yarns have a hollow ratio of a range between 30% and 60%.
[0023] With the above range of hollow ratio, a person can actually feel, specifically, improved
lightness.
[0024] Further preferably, the hollow yarns have a hollow ratio of a range between 40% and
50%.
[0025] With the above range of hollow ratio, more specific effects can be produced, and
a concern about maintaining of shapes of hollow yarns can be eliminated.
[0026] Preferably, the hollow yarns are made by twisting fibers of raw cottons having an
effective fiber length of a range between 25 mm and 42 mm.
[0027] Since the hollow yarns have a small cross sectional area, strength in an axis direction
of the hollow yarns needs to be checked. That is, the hollow yarns have a problem
in durability.
[0028] With the above described structure, it is possible to prevent the durability from
being degraded.
[0029] Further preferably, the hollow yarns are made by twisting fibers of raw cottons having
an effective fiber length of a range between 25 mm and 37 mm.
[0030] As a result, satisfactory durability can be produced as well as requirements of economic
efficiency and practicality can be satisfied.
[ADVANTAGEOUS EFFECT OF INVENTION]
[0031] According to the present invention, features of a honeycomb weave produced by the
conventional technique can be maintained as well as water absorbency, lightness, and
a good touch feeling can be improved more than the honeycomb weave produced by the
conventional technique.
[BRIEF DESCRIPTION OF DRAWINGS]
[0032] Fig. 1 is a schematic structural view.
[Description of Embodiments]
--Basic Structure--
[0033] An embodiment of the present invention will be described below. Fig. 1 illustrates
a structural view of a honeycomb weave structure. A honeycomb weave structure of the
present embodiment is similar to a typical honeycomb weave structure. The honeycomb
weave structure is a woven fabric structure obtained by deforming a plain weave which
is woven in a manner that a single warp yarn is crossed over a single weft yarn to
continue weaving in this manner. The honeycomb weave structure is characterized in
having a concave-convex surface obtained by shrinking a fabric itself. More detailed
descriptions thereof will be omitted here.
--Featured Structure 1--
[0034] It is a feature of the present embodiment to employ hollow yarns having a hollow
ratio of a range between 30% and 60%.
[0035] Meanwhile, in a case where the hollow ratio is less than 30%, satisfactory effects
as mentioned below cannot be produced. For example, in a case where the hollow ratio
is less than 30%, a weight of product decreases by less than 20%. This fails to make
a person feel improvement of lightness. On the other hand, in a case where the hollow
ratio is equal to or more than 30%, a weight of product decreases by more than 20%.
This ensures to make a person feel substantial effects such as improvement of lightness.
[0036] According to a search performed by the present inventor, almost all the persons could
feel difference in lightness between the honeycomb weave towel woven by using the
ordinary yarns (non- hollow yarn) and the 20% weight-decreased honeycomb weave towel
(using the hollow yarn).
[0037] In a case where the hollow ratio is beyond 60%, a hollow yarn itself cannot maintain
its shape. More specifically, the hollow ratio of 60% is an upper limit of practically
usable hollow yarns.
[0038] Further, a preferable hollow ratio is a range between 40% and 50%. This range produces
more pleasant effect as well as eliminates a concern about maintaining of a shape
of hollow yarns.
--Advantageous Effects--
[0039] In the honeycomb weave structure, warp yarns and weft yarns are caused to be shrunk,
and thus mutual binding is loose. Therefore, the hollow structure would not be crushed
remarkably even when the hollow yarns having a hollow ratio of a range between 30%
and 60% are used. In other words, shape of the hollow yarns can be maintained. Further,
descriptions will be made below as to water absorbency, lightness, a good touch feeling,
and a drying property.
[0040] For example, with the use of hollow yarns having a hollow ratio of 50%, weight of
the resulting product will be decreased by more than 30%. Therefore, one can actually
feel improvement of lightness.
[0041] Meanwhile, with the use of hollow yarns having the hollow ratio of 50%, the hollow
structure is slightly crushed and deformed. This decreases bulkiness of towel in comparison
with a towel woven by using the ordinary yarns (non- hollow yarn). In order to keep
the bulkiness of the towel at a level equivalent to the bulkiness of the towel woven
by the ordinary yarns, it is necessary to weave the towel with a higher structural
density (i.e., to weave the towel with the more number of yarns). As a result thereof,
it becomes impossible to decrease the weight of towel by 50% even with the use of
the hollow yarns having the hollow ratio of 50%.
[0042] When wiping off a small amount of moisture such as sweat, one presses a towel against
his skin softly. At the time, only convex parts touch his skin. If the amount of moisture
is small, the moisture can be absorbed only with the convex parts.
[0043] When one wipes off his wet body after bathing, one presses the towel against his
body to cause the towel to closely touch his skin. The hollow yarns having the hollow
ratio of the range between 30% and 60% has highly improved flexibility and pliability
in comparison with those of the ordinary yarns. As a result thereof, the concave parts
also come to touch his skin in addition to the convex parts. In other words, a touch
area increases to provide him with satisfactory water absorbency.
[0044] A hollow yarn having the hollow ratio of the range between 30% and 60% has remarkably
improved flexibility and pliability in comparison with those of the ordinary yarns.
This can provide a soft good touch feeling of a towel itself.
[0045] Further, the use of hollow yarns having the hollow ratio of the range between 30%
and 60% facilitates quick drying.
[0046] As described above, the lightness, the water absorbency, the good touch feeling,
and the drying property can be improved more than those of a towel produced by the
conventional technique,.
[0047] On the other hand, even with the use of the hollow yarns having the hollow ratio
of the range between 30% and 60%, features of the honeycomb weave of the conventional
technique can be maintained.
--Newly Arising Problem--
[0048] However, in a case where a towel is woven only with hollow yarns having a specially
large hollow ratio, e.g., hollow ratio of the range between 30% and 60%, the resulting
towel is weak in strength as a fabric and, therefore, would be damaged largely by
washing thereof. Therefore, such towel lacked in value (durability) as an item for
sale. Therefore, it was essential to study how to weave a towel when weaving the towel
using hollow yarns.
[0049] Meanwhile, as a result of various experiments, the inventor confirmed that the hollow
structure would not be crushed remarkably if hollow yarns had the hollow ratio of
a value equal to or less than 60% (see, the above description). More specifically,
there is no problem in strength in a cross sectional direction of the hollow yarns.
Next, it becomes necessary to study about strength in an axis direction of the hollow
yarns.
--Featured Structure 2--
[0050] The hollow yarns of the present embodiment are characterized in that fibers of raw
cottons having an effective fiber length of a range between 25 mm and 42 mm are twisted.
[0051] When raw cottons are decomposed, fibers of various lengths can be obtained. Generally,
longer fiber cottons can provide yarns having only a small number of junctions when
they are formed into yarns. This can provide increased strength.
[0052] Generally, in manufacturing a towel, fibers of raw cottons having an effective fiber
length of a range between 20 mm and 25 mm are mixed, and cotton yarns having an average
value of the effective fiber length of a range between 22 mm and 23 mm are used.
[0053] To the contrary, in a case where hollow yarns are made by twisting fibers of raw
cottons having an effective fiber length less than 25 mm, satisfactory strength cannot
be obtained. However, in a case where hollow yarns are made by twisting fibers of
raw cottons having an effective fiber length equal to or more than 25 mm, practically
durable strength can be obtained.
[0054] An effective fiber length of 42 mm is an upper limit of a fiber length of typical
raw cottons. No fiber having a length beyond 42 mm can be obtained although there
are differences in fiber length between raw cottons.
[0055] Further, a preferable effective fiber length is of a range between 25 mm and 37 mm.
Fibers having the effective fiber length of 42 mm can be obtained only from limitative
specific kinds of raw cottons. Therefore, gathering fibers having the effective fiber
length of 42 mm is difficult in the light of economic efficiency and practicality.
Under the circumstances, fibers of raw cottons having the effective fiber length of
the range between 25 mm and 37 mm are distributed in markets for the use of luxury
garments and beddings. Use of the distributing raw cottons for the sake of towels
satisfies requirements of both of the economic efficiency and practicality.
--Advantageous Effects--
[0056] Use of the hollow yarns made by twisting fibers of raw cottons having the effective
fiber length of a range between 25 mm and 42 mm ensures obtainment of satisfactory
strength in its axis direction. As a result thereof, it becomes possible to obtain
durability for repetitive washing.
--Supplementary Note--
[0057] For achieving the present invention, the inventor studied about the use of hollow
yarns having a hollow ratio of 20% for producing a honeycomb weave towel. It is noted
that, for the following reasons, hollow yarns having the hollow ratio of about 20%
are generally used for various towels in order to achieve weight saving thereof.
[0058] When hollow yarns having the hollow ratio of 20% are used, a hollow structure is
somewhat crushed to be deformed. Therefore, bulkiness decreases in comparison with
towels woven by the ordinary yarns. In order to maintain the bulkiness equivalent
to the bulkiness of the towel woven by the ordinary yarns, it is necessary to weave
the towel with high structural density (with the increased number of yarns). As a
result thereof, even with the hollow yarns having the hollow ratio of 20%, the weight
could be decreased by only from 10% to 15%.
[0059] Satisfied improvement in lightness could not be actually felt from the decrease of
weight by 10%. More specifically, decrease of weight by 10% does not meet an actual
feeling of decrease of weight by 10%.
[0060] According to a research performed by the inventor, only a small number of persons
could feel a difference in lightness between a honeycomb weave towel woven by the
ordinary yarns and a honeycomb weave towel of which weight is decreased by 10%.
[0061] Apart from the honeycomb weave structure, the inventor made a hollow yarn having
a hollow ratio of 50% and studied about the use thereof. For example, in a simple
plain woven fabric structure, a towel is woven in a manner that warp yarns and weft
yarns are crossed alternately up and down, and thus the warp yarns and the weft yarns
are mutually constrained, i.e., the warp yarns bind the weft yarns and the vice versa.
Consequently, if hollow yarns having the hollow ratio of 50% are used, a hollow structure
thereof will be crushed, and thus a plain woven fabric structure cannot be maintained
as well as features of hollow yarns cannot be maintained. Therefore, it was essential
for the inventor to study the use of hollow yarns having the hollow ratio of 50% while
understanding features of a towel structure.
[0062] The inventor paid an attention to a fact that, in the honeycomb weave structure,
the mutual binding between the warp yarns and the weft yarns is loose since the warp
yarns and the weft yarns are shrunk. Then, the inventor studied about application
of the hollow yarns having the hollow ratio of 50%. Finally, the inventor achieved
the present invention.
[0063] The inventor could conceived of the present invention on the basis of his knowledge
about both of features of the honeycomb weave structure and features of the hollow
yarns.
[INDUSTRIAL APPLICABILITY]
[0064] The present invention is specifically effective for the use of products such as towels,
bath towels, and towel-made gowns. Further, the present invention is effective not
only for towel products but also for materials of clothes such as room wears and pajamas
and for materials of articles for infants.