COMFORTABLE AND WARM RIBBED VELVET DENIM FABRIC AND PRODUCTION METHOD THEREOF

Abstract

Disclosed is a comfortable and warm ribbed velvet denim fabric, which belongs to the field of textiles, and includes two systems of warp yarns and two systems of weft yarns, where the warp yarns are divided into outside warps and inside warps, and the weft yarns are divided into outside wefts and inside wefts; the outside wefts and the inside wefts are interwoven with the inside warps in a manner of plain weave, the outside warps and the outside wefts are interwoven in a manner of twill weave, and the outside warps and the inside wefts are not interwoven; the inside wefts are thicker than the outside wefts; and the inside wefts are made of multifilaments, and a fleece layer is provided on the underside.

Claims

1. A comfortable and warm ribbed velvet denim fabric, wherein the fabric comprises two systems of warp yarns and two systems of weft yarns, wherein the warp yarns are divided into outside warps (10) and inside warps (30), and the weft yarns are divided into outside wefts (20) and inside wefts (40); the outside wefts (20) and the inside wefts (40) are interwoven with the inside warps (30), the outside warps (10) and the outside wefts (20) are interwoven, and the outside warps (10) and the inside wefts (40) are not interwoven; the inside wefts (40) are thicker than the outside wefts (20).

2. The comfortable and warm ribbed velvet denim fabric according to claim 1, wherein the inside wefts (40) are made of multifilaments, and the shrinkage rate of the outside wefts (20) is greater than that of the inside wefts (40).

3. The comfortable and warm ribbed velvet denim fabric according to claim 1, the outside wefts (20) and the inside wefts (40) are interwoven with the inside warps (30) in a manner of plain weave, the outside warps (10) and the outside wefts (20) are interwoven in a manner of twill weave.

4. The comfortable and warm ribbed velvet denim fabric according to claim 1, wherein the count of the insider warps (30) is three to eight times the count of the outside warps (10).

5. The comfortable and warm ribbed velvet denim fabric according to claim 4, wherein the count of the outside warps (10) is 8-32 S.

6. The comfortable and warm ribbed velvet denim fabric according to claim 1, wherein the F number of the inside wefts (40) is 114-900 F.

7. The comfortable and warm ribbed velvet denim fabric according to claim 6, wherein the denier count of filaments in the inside wefts (40) is 80-500 D.

8. The comfortable and warm ribbed velvet denim fabric according to claim 7, wherein the count of the outside wefts (20) is 21-60 S.

9. The comfortable and warm ribbed velvet denim fabric according to claim 1, wherein the same inside warp (30) has the same weave point type with each of the outside wefts (20), and the same inside warp (30) has the same weave point type with each of the inside wefts (40); and on the same inside warp (30), the type of weave points formed by the outside wefts (20) is always opposite to the type of weave points formed by the inside wefts (40).

10. A production method of a comfortable and warm ribbed velvet denim fabric, comprising the steps of weaving and finishing, wherein in the step of weaving, two systems of warp yarns and two systems of weft yarns are employed, the warp yarns are divided into outside warps (10) and inside warps (30), and the weft yarns are divided into outside wefts (20) and inside wefts (40); the outside wefts (20) and the inside wefts (40) are interwoven with the inside warps (30) in a manner of plain weave, the outside warps (10) and the outside wefts (20) are interwoven in a manner of twill weave, and the outside warps (10) and the inside wefts (40) are not interwoven; the inside wefts (40) are thicker than the outside wefts (20); the inside wefts (40) are made of multifilaments, and the shrinkage rate of the outside wefts (20) is greater than that of the inside wefts (40); and the outside wefts (20) are made of polyester and polyamide composite yarns; and the finishing in turn comprises a singeing process, an alkali treatment process, a drying process, a pre-shrinking process, and a fleecing process.

11. The production method of a comfortable and warm ribbed velvet denim fabric according to claim 10, wherein a loose washing process is also carried out between the alkali treatment process and the drying process, with the treatment temperature of 40-50 C. and the treatment time of 20-30 min; and a fabric setting process is also carried out between the drying process and the pre-shrinking process, with the fabric setting temperature of 150-170 C. and the loom speed of 20-40 m/min.

12. The production method of a comfortable and warm ribbed velvet denim fabric according to claim 10, wherein in the singeing process, the treatment temperature is 250-350 C., the loom speed is 75-85 m/min, and only the right side is singed.

Description

BRIEF DESCRIPTION OF FIGURES

[0029] FIG. 1 is a schematic diagram of the structure of a comfortable and warm ribbed velvet denim fabric provided in examples of the present application.

[0030] FIG. 2 is a schematic diagram of the weave structure of a comfortable and warm ribbed velvet denim fabric provided in an example of the present application.

[0031] FIG. 3 is a schematic diagram of the weave structure formed by inside warps and outside wefts.

[0032] FIG. 4 is a schematic diagram of the weave structure formed by inside warps and inside wefts.

[0033] FIG. 5 is a schematic diagram of the weave structure formed by outside warps and

[0034] outside wefts.

[0035] FIG. 6 is a schematic diagram of the weave structure formed by outside warps and inside wefts.

[0036] Reference numerals: 10, outside warp; 20, outside weft; 30, inside warp; 40, inside weft; and 50, fleece layer.

DETAILED DESCRIPTION

[0037] The implementations of the present disclosure are described in detail below. Examples of the implementations are shown in the accompanying drawings, and reference numerals that are the same or similar always indicate the same or similar elements or elements with the same or similar functions. The implementations described below with reference to the drawings are exemplary, only intended to be illustrative of the present disclosure and not to be construed as limiting to the present disclosure.

[0038] The disclosure hereinafter provides a lot of different implementations or examples to implement the different structures of the present disclosure. In order to simplify the disclosure of the present disclosure, the parts and configurations of the specific examples are described hereinafter. Of course, they are only illustrative and not intended to limit the present disclosure. In addition, the present disclosure may repeat reference numbers and/or reference letters in different examples, and such repetition is intended for simplification and clarification and does not indicate the relation between the various implementations and/or configurations discussed.

[0039] Ribbed velvet denim fabric refers to a denim fabric with a layer of fluff on an underside of the fabric.

[0040] The shrinkage rate of a yarn refers to the proportion of the length decrease of the yarn after the yarn is subjected to a certain external force.

[0041] Regarding the unit of yarn count, S is the imperial count, which refers to a yarn weighing one pound at an official moisture regain. How many 840 yards there are in the length of the yarn, which is the count of the yarn. D is the abbreviation for Denier, which is a method of expressing the fineness of synthetic fibers. It refers to the weight in grams of a 9000-meter filament at the official moisture regain. Referring to FIG. 1, an example of the present application provides a comfortable and warm ribbed velvet denim fabric, which includes two systems of warp yarns and two systems of weft yarns, where the warp yarns are divided into outside warps 10 and inside warps 30, and the weft yarns are divided into outside wefts 20 and inside wefts 40; the outside wefts 20 and the inside wefts 40 are interwoven with the inside warps 30 in a manner of plain weave, the outside warps 10 and the outside wefts 20 are interwoven in a manner of twill weave, and the outside warps 10 and the inside wefts 40 are not interwoven; the inside wefts 40 are thicker than the outside wefts 20; and the inside wefts 40 are made of multifilaments, and the shrinkage rate of the outside wefts 20 is greater than that of the inside wefts 40. The outside warps 10 and the outside wefts 20 are interwoven to form a surface layer of the fabric, the inside warps 30 and the inside wefts 40 are interwoven to form a bottom layer of the fabric, and an underside of the bottom layer is subjected to fleecing treatment, so that a fleece layer 50 is obtained.

[0042] By adopting novel weave structures, in combination with yarn setting, the examples of the present application enable the inside wefts to cover more of the bottom layer of the fabric. A layer of fluff is formed on the underside through a fleecing process, achieving a comfortable and warm effect. Specifically, after being subjected to fleecing, the fabric still has a higher strength, with dense resulting fluff, and the fluff will not become significantly sparse after the fabric is stretched.

[0043] The principle for keeping the strength of the fabric high even after fleecing treatment:

[0044] (1) In the related art, a large number of floating long yarns are usually formed on an underside of the fabric subjected to fleecing, so that there is less interweaving between the inside wefts and warp yarns. In the examples of the present application, the outside wefts 20 and the inside wefts 40 are interwoven with the inside warps 30 in a manner of plain weave, with multiple interlacing points, resulting in a tight fabric weave structure.

[0045] (2) The outside wefts 20 have a tensioning effect on the fabric.

[0046] (3) The inside wefts 40 are thicker than the outside wefts 20, the shrinkage rate of the outside wefts 20 is greater than that of the inside wefts 40, and the outside wefts 20 tie the interior (a middle part between the surface layer and bottom layer) of the fabric tight, causing the thicker inside wefts 40 to expand and protrude downward (towards the underside), which can cover the outside wefts 20, so that the inside wefts 40 are mainly damaged in the process of fleecing.

[0047] (4) The inside wefts 40 are made of multifilaments, some of the filaments are broken after fleecing, while there are still multiple filaments maintaining the strength of the bottom layer.

[0048] The principle of dense fluff that does not significantly become sparse even after stretching of the fabric:

[0049] (1) In the related art, a large number of floating long yarns are usually formed on an underside of the fabric subjected to fleecing, resulting in long and sparse fluff. In the examples of the present application, the outside wefts 20 and the inside wefts 40 are interwoven with the inside warps 30 in a manner of plain weave, so that the resulting fluff is short and abundant.

[0050] (2) The inside wefts 40 are made of multifilaments, including a plurality of filaments that can be hooked and broken.

[0051] (3) The shrinkage rate of the outside wefts 20 is greater than that of the inside wefts 40, which provides a stretch allowance for the fabric. When the fabric is stretched within a certain range, it is only equivalent to reducing the expansion and protrusion of the inside wefts 40 on the underside, so that the fluff will not become significantly sparse.

[0052] Referring to the example as shown in FIG. 2, the weave structure of a comfortable and warm ribbed velvet denim fabric in the specific example is illustrated. In FIG. 2 to FIG. 6, the serial numbers of outside warps are represented by Arabic numerals, the serial numbers of inside warps are represented by Roman numerals, the serial numbers of inside wefts are represented by uppercase English letters, and the serial numbers of outside wefts are represented by lowercase English letters. As a drawing convention in the art, shaded cells represent warp weave points (viewed from the right side), and unfilled cells represent weft weave points (viewed from the right side). For example, the interlacing point between the weft yarn in the Dth row and the warp yarn in the column II is the warp weave point formed by an inside weft and an inside warp. If viewed from the wrong side, this point is a weft weave point.

[0053] FIG. 3 is obtained based on a weave structure formed by the inside warps and the outside wefts exploded from FIG. 2. FIG. 4 is obtained based on a weave structure formed by the inside warps and the inside wefts exploded from FIG. 2. FIG. 5 is obtained based on a weave structure formed by the outside warps and the outside wefts exploded from FIG. 2. FIG. 6 is obtained based on a weave structure formed by the outside warps and the inside wefts exploded from FIG. 2. From FIG. 6, it can be seen that all of them are warp weave points, that is, the outside warps are all only overlapped on the inside wefts, and there is no interweaving between the outside warps and the inside wefts, which corresponds to FIG. 1, where the inside wefts 40 are all below the outside warps 10.

[0054] As shown in FIG. 5, the outside warps 10 and the outside wefts 20 are interwoven in a manner of twill weave, with three woven at the upper part and one woven at the lower part, resulting in the surface of the fabric presenting the texture of denim fabric. Specifically, both the outside warps and the inside warps may be pure cotton warp yarns dyed with indigo or sulfur black, so as to prevent the front of the fabric from showing white at the bottom layer.

[0055] In addition, the configuration of yarns may also prevent the white of the bottom layer from being visible from the front of the fabric, for example, the outside warps 10 are thicker than the inside warps 30, so that the outside warps can cover the inside warps on the front of the fabric. Specifically, the count of the inside warps 30 is three times or more the count of the outside warps 10, which is beneficial for the fabric to display twill on the right side without exposing the plain at the bottom layer of the fabric. More preferably, the count of the inside warps 30 is three to eight times the count of the outside warps 10. Furthermore, the count of the outside warps 10 is 8-32 S, which can show the appearance texture effect of the conventional denim surfaces.

[0056] A multifilament contains a plurality of filaments, and F number is used to indicate the number of filaments contained in one multifilament. Preferably, the F number of the inside wefts 40 is 114-900 F. The inside wefts with high F number can form a lot of fluff during fleecing, and due to adoption of the plain weave structure, the short and abundant fluff will not become significantly sparse when the fabric is stretched. More preferably, the denier count of filaments in the inside wefts 40 is 80-500 D, which can form fine and soft fluff after fleecing, making the fabric more comfortable when in contact with the skin. Accordingly, the count of the outside wefts 20 is 21-60 S, which can be well covered by the multifilaments of 80-500 D and 114-900 F.

[0057] Moreover, the outside wefts are also used for connecting the surface layer and the inside layer of the fabric. When configuring the yarns, the outside wefts are slightly thinner than the outside warps, which is beneficial to making the bottom layer of the fabric not visible from the right side of the fabric. Specifically, outside wefts are made of polyester and polyamide composite yarns. After undergoing the necessary washing process for denim fabric, it can achieve better shrinkage effect on the outside wefts. Of course, other yarns with stronger shrinkage may also be used as the outside wefts.

[0058] Preferably, referring to FIG. 3 and FIG. 4, the same inside warp 30 has the same weave point type with each of the outside wefts 20, and the same inside warp 30 has the same weave point type with each of the inside wefts 40; and on the same inside warp 30, the type of weave points formed by the outside wefts 20 is always opposite to the type of weave points formed by the inside wefts 40.

[0059] As can be seen from FIG. 3 and FIG. 4, it seems to have no interlacing relationship between a single inside warp and a certain weft yarn, but on the same inside warp 30, the type of weave points formed by the outside wefts 20 is always opposite to the type of weave points formed by the inside wefts 40, and the outside wefts and the outside warps are interwoven in a manner of twill weave, so that the fabric weave structure is stable and will not be scattered. However, since the same inside warp 30 has the same weave point type with each of the outside wefts 20, and the same inside warp 30 has the same weave point type with each of the inside wefts 40, under the stretching of outside weft contraction, the inside wefts expand and protrude downward, and the fabric underside is enabled to have raised vertical strips similar to corduroy before being subjected to fleecing so as to achieve an insulation effect similar to the corduroy. In addition, the fleece layer 50 formed by fleecing can provide a stronger insulation effect for the fabric.

[0060] The example of the present application also provides a production method of a comfortable and warm ribbed velvet denim fabric, which includes the steps of weaving and finishing. In the step of weaving, two systems of warp yarns and two systems of weft yarns are employed, the warp yarns are divided into outside warps and inside warps, and the weft yarns are divided into outside wefts and inside wefts; the outside wefts and the inside wefts are interwoven with the inside warps in a manner of plain weave, the outside warps and the outside wefts are interwoven in a manner of twill weave, and the outside warps and the inside wefts are not interwoven; the inside wefts are thicker than the outside wefts; the inside wefts are made of multifilaments, and the shrinkage rate of the outside wefts is greater than that of the inside wefts; and the outside wefts are made of polyester and polyamide composite yarns.

[0061] The finishing in turn includes a singeing process, an alkali treatment process, a drying process, a pre-shrinking process, and a fleecing process.

[0062] The outside wefts are made of polyester and polyamide composite yarns, which will shrink strongly after alkali treatment, so that the fabric will be interwoven more tightly, and the stitch slipping resistance of the fabric is improved to a certain extent. Furthermore, the shrinkage of the outside wefts also causes the weft weave points on the undersides of the inside wefts to expand and protrude downward, which makes the inside wefts the first thing to bear the brunt during fleecing and protect the inside warps and the outside wefts from the downward protrusion of the inside wefts, thus reducing damage, and effectively solving the problem of significantly reduced fabric strength of the existing fleece products after fleecing treatment.

[0063] The polyester and polyamide composite yarn is a common polyester and polyamide composite yarn on the market, which may be specifically composed of 60% polyamide and 40% polyester, 42.9% polyamide and 57.1% polyester, 50% polyamide and 50% polyester, 66.7% polyamide and 33.3% polyester, or the like. The configuration of other yarns may refer to the examples of the comfortable and warm ribbed velvet denim fabric mentioned above. In the drying process, the drying temperature is 100-120 C., and the treatment time is 5-10 min.

[0064] Specifically, in the singeing process, the treatment temperature is 250-350 C., the loom speed is 75-85 m/min, and only the right side is singed. The singeing is used for removing hairiness on the surface of the fabric. In the examples of the present application, single-sided singeing at a lower temperature and a faster speed is beneficial to reducing the damage of singeing to synthetic fibers, especially the multifilaments in a fabric lining.

[0065] Preferably, a loose washing process is also carried out between the alkali treatment process and the drying process, with the treatment temperature of 40-50 C. and the treatment time of 20-30 min.

[0066] A fabric setting process is also carried out between the drying process and the pre-shrinking process, with the fabric setting temperature of 150-170 C. and the loom speed of 20-40 m/min.

[0067] In the process of loose treatment, the fabric is not stretched or applied with other forces, which makes the fabric in a natural state; the fabric is cleaned under low tension to eliminate the internal stress between warp cotton fibers, so that the fabric shrinks relatively, and the fabric becomes relatively compact; and therefore, the weft weave points of the inside wefts on the fabric underside are more protruding.

Example 1

[0068] 10 S pure cotton yarns were used as outside warps; 30 S pure cotton yarns were used as inside warps; 75 D polyester and polyamide composite yarns (composed of 50% polyamide and 50% polyester) were used as outside wefts; 300 D polyester yarns with F number of 536 were used as inside wefts; and spinning was performed according to a weave structure shown in FIG. 2. After being woven, the obtained fabric was subjected to finishing. The following processes were carried out in order: the right side was singed at the temperature of 300 C. and the loom speed of 85 m/min; alkali treatment was performed under the condition that the sodium hydroxide concentration was 12 g/L; the fabric was dried at 100 C. for 8 min; pre-shrinking was performed according to the conventional method; and the fabric underside was subjected to fleecing to form a fleece layer. The breaking strength of the fabric was determined according to GB/T 3923.1-2013 TextilesTensile properties of fabricsPart I: Determination of maximum force and elongation at maximum force using the strip method. The breaking strength of the obtained fabric was 723 N. The insulation rate of the fabric was tested according to GB/T 35762-2017 TextilesTest method for thermal transmittanceFlat plate test, and the obtained insulation rate was 33.6%.

Example 2

[0069] 10 S pure cotton yarns were used as outside warps; 30 S pure cotton yarns were used as inside warps; 75 D polyester and polyamide composite yarns (composed of 50% polyamide and 50% polyester) were used as outside wefts; 300 D polyester yarns with F number of 536 were used as inside wefts; and spinning was performed according to a weave structure shown in FIG. 2. After being woven, the obtained fabric was subjected to finishing. The following processes were carried out in order: the right side was singed at the temperature of 300 C. and the loom speed of 85 m/min; alkali treatment was performed under the condition that the sodium hydroxide concentration was 12 g/L; loose washing was carried out, with the treatment temperature of 50 C. and the treatment time of 20 min; the fabric was dried at 100 C. for 8 min; fabric setting was carried out, with the fabric setting temperature of 150 C. and the loom speed of 40 m/min; pre-shrinking was performed according to the conventional method; and the fabric underside was subjected to fleecing to form a fleece layer. The breaking strength of the fabric was determined according to GB/T 3923.1-2013 TextilesTensile properties of fabricsPart I: Determination of maximum force and elongation at maximum force using the strip method. The breaking strength of the obtained fabric was 741 N. The insulation rate of the fabric was tested according to GB/T 35762-2017 TextilesTest method for thermal transmittanceFlat plate test, and the obtained insulation rate was 34.2%.

Comparative Example 1

[0070] 10 S pure cotton yarns were used as outside warps; 30 S pure cotton yarns were used as inside warps; 10 S pure cotton yarns were used as outside wefts; 10 S pure cotton yarns were used as inside wefts; and during weaving, the surface layer was formed by weaving the yarns in a manner of twill weave, with three woven at the upper part and one woven at the lower part, and the inner layer was formed by weaving the yarns in a manner of five-pattern three-fly type satin and sateen weave, with inside warps and outside wefts interwoven to form stitching points. After being woven, the obtained fabric was subjected to finishing. The following processes were carried out in order: single-sided singeing was performed at the temperature of 500 C. and the loom speed of 60 m/min; pre-shrinking was performed according to the conventional method; and the fabric underside was subjected to fleecing to form a fleece layer. The breaking strength of the fabric was determined according to GB/T 3923.1-2013 TextilesTensile properties of fabricsPart I: Determination of maximum force and elongation at maximum force using the strip method. The breaking strength of the obtained fabric was 389 N. The insulation rate of the fabric was tested according to GB/T 35762-2017 TextilesTest method for thermal transmittanceFlat plate test, and the obtained insulation rate was 26.9%.

Comparative Example 2

[0071] 10 S pure cotton yarns were used as outside warps; 30 S pure cotton yarns were used as inside warps; 75 D polyester and polyamide composite yarns (composed of 50% polyamide and 50% polyester) were used as outside wefts; 300 D polyester yarns with F number of 536 were used as inside wefts; and during weaving, the surface layer was formed by weaving the yarns in a manner of twill weave, with three woven at the upper part and one woven at the lower part, and the inner layer was formed by weaving the yarns in a manner of five-pattern three-fly type satin and sateen weave, with inside warps and outside wefts interwoven to form stitching points. After being woven, the obtained fabric was subjected to finishing. The following processes were carried out in order: the right side was singed at the temperature of 300 C. and the loom speed of 85 m/min; alkali treatment was performed under the condition that the sodium hydroxide concentration was 12 g/L; the fabric was dried at 100 C. for 8 min; pre-shrinking was performed according to the conventional method; and the fabric underside was subjected to fleecing to form a fleece layer. The breaking strength of the fabric was determined according to GB/T 3923.1-2013 TextilesTensile properties of fabricsPart I: Determination of maximum force and elongation at maximum force using the strip method. The breaking strength of the obtained fabric was 453 N. The insulation rate of the fabric was tested according to GB/T 35762-2017 TextilesTest method for thermal transmittanceFlat plate test, and the obtained insulation rate was 27.4%.

[0072] The results indicate that in the case of adopting the weave structures and yarn configuration of Example 1 and Example 2, the fabric still has good strength after being subjected to fleecing. Although the yarns similar to those used in Example 1 and Example 2 were applied to Comparative Example 2, the weave structure of the comparative example can only result in longer fluff being hooked out; and even though the finishing process was adjusted to adapt to changing a weft yarn into a specific synthetic fiber in Comparative Example 2, its weave structure still resulted in a less compact fabric, which made the fabric lack the stitch slipping resistance and have a so-so insulation ability.

[0073] According to the examples of the present application, after weaving a double-layer fabric with a special yarn configuration, the fabric first undergoes alkali treatment, which causes significant shrinkage of the outside wefts and makes the fabric relatively compact, thus enhancing the strength of the fabric to a certain extent; then, during loose washing, the internal stress between warp cotton fibers can be released, so that the shrinkage rate of the warp yarns is reduced, and the yarns on the surface layer of the fabric are enabled to be more compact; and after fabric setting, the chemical fibers of the weft yarns will undergo structural changes under prolonged thermal treatment, which can make the fabric more stable and help to suppress the decrease in fabric strength caused by fleecing. The compact structure of the fabric ensures that the texture of the bottom layer is not exposed from the right side, while the wrong side presents protrusions formed by the weft weave points of the inside wefts. After fleecing, fine, soft and dense fluff is formed, which improves the insulation ability while ensuring the strength of the fabric.

[0074] In the description of this specification, the description with reference to the terms such as an implementation, some implementations, exemplary implementations, examples, specific examples, or some examples means that the specific features, structures, materials or characteristics described with reference to the implementations or examples are involved in at least one implementation or example of the present application. In this specification, the illustrative description of these terms does not necessarily refer to same implementations or examples. Furthermore, the specific features, structures, materials, or characteristics described may be combined in a suitable manner in any one or more implementations or examples.

[0075] The above mentioned are preferred implementations of the present disclosure. It should be noted that several improvements and refinements may be made by those of ordinary skill in the art without departing from the principles of the present disclosure, and these improvements and refinements are also to be considered within the scope of the present disclosure.