Woven fabric and method of making same

Abstract

A woven fabric that includes a plurality of warp yarns and a plurality of stretch weft yarns. In one embodiment, all of the weft yarns have the same shrinkage ratio and same size of yarn count, and the repeat intersection points on the weft yarns are either 61 or 131. The weft yarns in the 61 pattern alternate with the weft yarns in the 131 pattern, with two 61 weft yarns followed by one 131 weft yarn. This results in a woven fabric that performs like a knitted fabric but with the look of woven denim when the warp yarns are indigo dyed.

Claims

1. A woven fabric comprising: a plurality of warp yarns; and a plurality of weft yarns woven through the plurality of warp yarns, wherein a first set of the plurality of weft yarns are woven through the plurality of warp yarns in a 61 pattern, and a second set of the plurality of weft yarns are woven through the plurality of warp yarns in a 131 pattern.

2. The woven fabric of claim 1, wherein each of the plurality of weft yarns is in either the first set or the second set.

3. The woven fabric of claim 1, wherein the plurality of weft yarns in the first set and the second set are arranged in a repeating pattern.

4. The woven fabric of claim 3, wherein the repeating pattern comprises two weft yarns woven in the 61 pattern followed by one weft yarn woven in the 131 pattern.

5. The woven fabric of claim 1, wherein the plurality of warp yarns comprise Ne 16/1 to Ne 32/1 ring-spun, 100-percent cotton, indigo-dyed yarns, and the plurality of weft yarns comprise 19/1 to 32/1 TR blended plus 40 Denier lycra spun yarn.

6. The woven fabric of claim 1, wherein the plurality of warp yarns have a warp yarn density of approximately 90 ends per inch after weaving, and the plurality of warp yarns have a warp yarn density between approximately 110 ends per inch to approximately 170 ends per inch after shrinking.

7. The woven fabric of claim 1, wherein the plurality of weft yarns have a weft yarn density of approximately 90 picks per inch after weaving, and the plurality of weft yarns have a weft yarn density between approximately 96 ends per inch to approximately 114 ends per inch after shrinking.

8. The woven fabric of claim 1, wherein the woven fabric has a fabric weight between approximately 7 ounces to 9 ounces per square yard.

9. The woven fabric of claim 1, wherein the plurality of warp yarns have a thickness between 16 S to 32 S, and the plurality of weft yarns have a thickness between 19 S to 32 S.

10. The woven fabric of claim 1, wherein the plurality of weft yarns have the same size of yarn count under the same tension, and perform with the same shrinkage ratio.

11. A method of weaving a woven fabric comprising: weaving a first plurality of weft yarns through a plurality of warp yarns in a 61 pattern; and weaving a second plurality of weft yarns through the plurality of warp yarns in a 131 pattern, wherein the first plurality of weft yarns and the second plurality of weft yarns are arranged in a repeating pattern.

12. The method of claim 11, wherein the repeating pattern comprises two weft yarns woven in the 61 pattern followed by one weft yarn woven in the 131 pattern.

13. The method of claim 11, wherein the plurality of warp yarns comprise Ne 16/1 to Ne 32/1 ring-spun, 100-percent cotton, indigo-dyed yarns, and the first and second pluralities of weft yarns comprise 19/1 to 32/1 TR blended plus 40 Denier lycra spun yarn.

14. The method of claim 11, wherein the plurality of warp yarns have a warp yarn density of approximately 90 ends per inch after weaving, and the plurality of warp yarns have a warp yarn density between approximately 110 ends per inch to approximately 170 ends per inch after shrinking.

15. The method of claim 11, wherein the first and second pluralities of weft yarns have a weft yarn density of approximately 90 picks per inch after weaving, and the first and second pluralities of weft yarns have a weft yarn density between approximately 96 ends per inch to approximately 114 ends per inch after shrinking.

16. The method of claim 11, wherein the plurality of warp yarns have a thickness between 16 S to 32 S, and the first and second pluralities of weft yarns have a thickness between 19 S to 32 S.

17. The method of claim 11, wherein the first and second pluralities of weft yarns have the same size of yarn count under the same tension and perform with the same shrinkage ratio.

18. The method of claim 11, wherein the first and second pluralities of weft yarns are woven through the plurality of warp yarns using a dobby-type weaving loom having a weft selection system.

19. The method of claim 11 further comprising: wetting the woven fabric, and stretching the woven fabric in a warp direction to allow the woven fabric to shrink in a weft direction.

20. The method of claim 11 further comprising heat setting the woven fabric.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows a front perspective view of a woven fabric in accordance with one embodiment of the technology described herein.

(2) FIG. 2 shows a front face view of a woven fabric in accordance with one embodiment of the technology described herein.

(3) FIG. 3 shows a weaving pattern for a woven fabric in accordance with one embodiment of the technology described herein.

DETAILED DESCRIPTION OF THE EMBODIMENTS

(4) Embodiments of the technology disclosed herein are directed toward woven fabrics and methods for making woven fabrics. More particularly, the various embodiments of the technology disclosed herein relate to woven fabrics having stretch weft yarns.

(5) FIGS. 1-3 depict a woven fabric in accordance with one embodiment of the technology described herein. The woven fabric includes a plurality of warp yarns and a plurality of stretch weft yarns. In FIGS. 1-3, the warp yarns are represented by the numbers running along the horizontal X-axis, while the plurality of weft yarns are represented by the numbers running along the vertical Y-axis. For example, warp yarn 1 extends vertically, while weft yarn 1 extends horizontally.

(6) In the weaving pattern, the weft yarns are woven in front of and in back of the warp yarns to create the woven fabric. For example, weft yarn 1 is woven in back of warp yarns 1-6 and in front of warp yarn 7, and then woven in back of warp yarns 8-13, and in front of warp yarn 14, and so forth. In certain embodiments, all of the weft yarns have the same shrinkage ratio and the same size of yarn count.

(7) As shown in the figures, the repeat intersection points on the weft yarns are either 61 or 131. In other words, some of the weft yarns have 6 warp yarns across on the back side of the fabric, followed by 1 warp yarn across on the front side of the fabric (e.g., warp yarn 1, warp yarn 2, warp yarn 4, warp yarn 5, etc.). The other weft yarns have 13 warp yarns across on the back side of the fabric, followed by 1 warp yarn across on the front side of the fabric (e.g., warp yarn 3, warp yarn 6, warp yarn 9, etc.).

(8) As shown in the figures, weft yarns 1,2, 4, 5, 7, 8, 10, 11, 13, 14, 16, 17, 19, 20, 22, 23, 25, 26, 28 and 29 are woven in the 61 pattern. Weft yarns 3, 6, 9, 12, 15, 18, 21, 24, 27 and 30 are woven in the 131 pattern. In the embodiment shown in FIGS. 1-3, the weft yarns in the 61 pattern alternate with the weft yarns in the 131 pattern, with two 61 weft yarns followed by one 131 weft yarn. The embodiment of FIGS. 1-3 results in a woven fabric that performs like a knitted fabric but with the look of woven denim when the warp yarns are indigo dyed.

(9) In one embodiment, the warp yarns are Ne 16/1 to Ne 32/1 ring-spun, 100-percent cotton, indigo-dyed yarns. The stretch weft yarns are 19/1 to 32/1 TR blended plus 40 Denier lycra spun yarn. The warp-yarn density is approximately 90 ends per inch after weaving and approximately 110 ends per inch to approximately 170 ends per inch after shrinking. The weft-yarn density is approximately 90 picks per inch after weaving and approximately 96 ends per inch to approximately 114 ends per inch after shrinking. The fabric weight is 7 ounces to 9 ounces per square yard. The thickness range of the warp yarns is 16 S to 32 S. The thickness range of the weft yarns is 19 S to 32 S. All of the weft yarns use the same size of yarn count under the same tension and perform with the same shrinkage ratio. A dobby-type weaving loom having a weft selection system can be used for the weaving. After weaving, the fabric may be wetted and stretched in the warp direction to allow the fabric to shrink in the weft direction, with the stretch weft yarns pulling the warp yarns closer together. After shrinking, the fabric may be heat set to reduce shrinking in further washings.

(10) While various embodiments of the disclosed technology have been described above, it should be understood that they have been presented by way of example only, and not of limitation. Likewise, the various figures may depict an example configuration for the disclosed technology, which is done to aid in understanding the features and functionality that can be included in the disclosed technology. The disclosed technology is not restricted to the illustrated example configurations, but the desired features can be implemented using a variety of alternative configurations. It is therefore intended that the scope of the invention be limited not by this detailed description, but rather by any claims that issue on an application based hereon. Accordingly, the disclosure of the embodiments of the invention is intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following claims.