NOVEL WOVEN WARP-KNIT-LIKE FABRIC

Abstract

A woven warp-knit-like fabric, includes a first warp yarn, a second warp yarn, a third warp yarn, and a weft yarn; the first warp yarn is interwoven with the weft yarn to form a surface layer of a fabric, the second warp yarn is interwoven with the weft yarn to form a middle layer of the fabric, and the third yarn is interwoven with the weft yarn to form an inner layer of the fabric; at least three weft weave points are provided between two adjacent groups of warp weave points on the third warp yarn; the first warp yarn is a non-elastic yarn, the third warp yarn is an elastic yarn or a non-elastic yarn, and elastic properties of the second warp yarn are greater than those of the first warp yarn and the third warp yarn.

Claims

1. A woven warp-knit-like fabric, comprising: a first warp yarn, a second warp yarn, a third warp yarn, and a weft yarn, wherein the first warp yarn is interwoven with the weft yarn to form a surface layer of a fabric, the second warp yarn is interwoven with the weft yarn to form a middle layer of the fabric, and the third yarn is interwoven with the weft yarn to form an inner layer of the fabric, wherein at least three weft weave points are provided between two adjacent groups of warp weave points on the third warp yarn, and the number of each group of warp weave points is at least one, wherein the first warp yarn is a non-elastic yarn, the third warp yarn is an elastic yarn or a non-elastic yarn, and elastic properties of the second warp yarn are greater than those of the first warp yarn and the third warp yarn.

2. The woven warp-knit-like fabric of claim 1, wherein 4-16 weft weave points are arranged between two adjacent groups of warp weave points on the third warp yarn.

3. The woven warp-knit-like fabric of claim 1, wherein the arrangement ratio of the first warp yarn to the third warp yarn is 1:5-4:1, and the arrangement ratio of the first warp yarn to the second warp yarn is 1:4-3:1.

4. The woven warp-knit-like fabric of claim 1, wherein in the surface layer and middle layer, there are 1-7 warp wave points where the warp yarn and weft yarn are interwoven.

5. The woven warp-knit-like fabric of claim 1, wherein the surface layer and middle layer are a 1/1 plain weave or the number of basic wave cycles is 3-8.

6. The woven warp-knit-like fabric of claim 1, wherein the surface layer and middle layer are a plain weave, twill weave or satin weave.

7. The woven warp-knit-like fabric of claim 2, wherein 7-13 weft weave points are arranged between two adjacent groups of warp weave points on the third warp yarn.

8. The woven warp-knit-like fabric of claim 1, wherein the first warp yarn is a yarn made of a staple fiber, wherein the second warp yarn is one of an elastic core spun yarn prepared by wrapping an elastic yarn with a staple fiber, a filament yarn with elasticity, and an elastic core spun yarn prepared by wrapping an elastic yarn with a filament yarn, wherein the third warp yarn is one of a yarn made of a staple fiber, a core spun yarn prepared by wrapping an elastic yarn with a staple fiber, and a core spun yarn prepared by wrapping a non-elastic filament yarn with a staple fiber, wherein when the first warp yarn or the third warp yarn is made of a staple fiber, the yarn count ranges from 6 S to 60 S, wherein when the third warp yarn is a core spun yarn prepared by wrapping an elastic yarn with a staple fiber, the yarn count ranges from 6 S to 60 S, and the yarn count of the elastic yarn ranges from 20 D to 300 D, wherein when the third warp yarn is a core spun yarn prepared by wrapping a non-elastic filament yarn with a staple fiber, the yarn count ranges from 6 S to 60 S, wherein when the second warp yarn is an elastic core spun yarn prepared by wrapping an elastic yarn with a staple fiber, the whole yarn count ranges from 6 S to 60 S, and the yarn count of the elastic yarn ranges from 20 D to 300 D, wherein when the second warp yarn is a filament yarn with elasticity, the yarn count ranges from 20 D to 450 D, and when the second warp is an elastic core spun yarn prepared by wrapping an elastic yarn with a filament yarn, the whole yarn count ranges from 40 D to 600 D, and the yarn count of the elastic yarn ranges from 20 D to 300 D.

9. The woven warp-knit-like fabric of claim 1, wherein the English yarn count of the third warp yarn is the same as that of the first warp yarn, or the English yarn count of the third warp yarn is greater than that of the first warp yarn.

10. The woven warp-knit-like fabric of claim 1, wherein the first warp yarn is cotton, and its yarn count ranges from 8 S to 38 S, wherein the second warp yarn is an elastic core spun yarn prepared by wrapping an elastic yarn with a filament yarn, the whole yarn count ranges from 50 D to 150 D, and the yarn count of the elastic yarn ranges from 20 D to 105 D, wherein the third warp yarn is made of a staple fiber, and the yarn count ranges from 16 S to 60 S, wherein alternatively, the third warp yarn made of a filament yarn, and the yarn count ranges from 50 D to 450 D.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] FIG. 1 is a conceptual diagram illustrating a fabric construction of the novel woven warp-knit-like fabric of the present invention;

[0028] FIG. 2 is a conceptual diagram illustrating a fabric construction of the novel woven warp-knit-like fabric in embodiment 1 of the present invention;

[0029] FIG. 3 is a conceptual diagram illustrating a fabric construction of the novel woven warp-knit-like fabric in embodiment 2 of the present invention;

[0030] FIG. 4 is a conceptual diagram illustrating a fabric construction of the novel woven warp-knit-like fabric in embodiment 3 of the present invention.

DETAILED DESCRIPTION

[0031] To make the purpose, technical solution and effect of the present invention clearer, embodiments are combined hereinafter to elaborate the present invention. It should be understood that the specific embodiments described herein are merely used to explain but not limit the present invention.

[0032] Referring to FIG. 1, a novel woven warp-knit-like fabric of the present invention, comprising a first warp yarn 1, a second warp yarn 2, a third warp yarn 3, and a weft yarn 4; the first warp yarn 1 is interwoven with the weft yarn 4 to form a surface layer of a fabric, the second warp yarn 2 is interwoven with the weft yarn 4 to form a middle layer of the fabric, and the third yarn 3 is interwoven with the weft yarn 4 to form an inner layer of the fabric; at least three weft weave points are provided between two adjacent groups of warp weave points on the third warp yarn 3, and the number of each group of warp weave points is at least one; the first warp yarn 1 is a non-elastic yarn, the third warp yarn 3 is an elastic yarn or a non-elastic yarn, and the elastic properties of the second warp yarn 2 are greater than those of the first warp yarn 1 and the third warp yarn 3.

[0033] It is worth mentioning that, the first, second and third warp yarns are used merely for the convenience of description, which do not necessarily represent the number of warp yarns and weft yarns.

[0034] The first warp yarn 1 and the weft yarn 4 are interwoven to form a front surface of the fabric, and the front surface of the fabric may be designed according to different styles, for example, a 3/1 twill weave, which is a classical jean style. The third warp yarn 3 and the weft yarn 4 are interwoven to form a rear surface of the fabric, by means of the weft weave points continuously arranged on the rear surface, the tightness of the fabric decreases after the third warp yarn 3 and the weft yarn 4 are interwoven, and the fabric is easy to be compressed, which significantly improve the air permeability, hand feeling and filling power of the fabric. The second warp yarn 3 and the weft yarn 4 are interwoven to form a middle layer between the surface layer and the inner layer of the fabric, which makes the hand feeling good while propelling the third warp yarn to contract to form loops with a certain radian. Referring again to FIG. 1, there are air storage spaces 30 formed between the third warp yarn 3 and the weft yarn 4, which makes the rear surface of the fabric feel soft, breathable and fluffy. Therefore, the rear surface of the fabric of the present invention has high comfort when contacting with the skin. In addition, because the first warp yarn adopts a non-elastic yarn, it is easier to make the yarn tension uniform during warping, and the phenomenon of reversely-twisted yarn after the yarn breakage is avoided. In this way, the warping process becomes smooth and the production efficiency is improved. Moreover, when dyeing, the color difference caused by an excessive difference between the tensile elongation of each first warp yarn is effectively avoided. By means of this design, even if the surface of the first warp is worn, an exposure of yarn core is avoided and a manual color correction becomes unnecessary. Thus, the labor cost is significantly reduced.

[0035] In actual use, for the conventional warp-knit-like fabric with a double-weave construction, the elastic performance of the surface yarn is easily damaged due to a prolonged stress formed at knees, elbows, hips and other parts of human bodies, which directly leads to the formation of bulges, failing to achieve tight and comfortable feeling. In the three-layer construction of the present invention, the second warp yarn has elasticity, capable of providing an elastic force in the warp direction while being stretched under the elastic force. The first warp yarn does not have elasticity, and therefore when being interwoven with the weft yarn, the front surface of the fabric is tightly interwoven, so that the fabric at knees, elbows, hips and other parts is close and tight. In this way, the appearance of the fabric is not affected by the bulges caused by the variation of yarn elasticity. Especially, for parts such as hips and abdomens, due to the tightness of the front surface of the fabric and the elasticity of the second layer, the fabric of the present invention plays a good role in hip lifting and body slimming. Through adopting the present invention, the tightness and comfort of the fabric as well as the effects of hip lifting and body slimming are achieved, and the formation of bulges caused by the variation of yarn elasticity is avoided.

[0036] In some preferred embodiments, 4-16 weft weave points are arranged between two adjacent groups of warp weave points on the third warp yarn 3. Because the fabric undergoes treatments such as de-sizing, soda boiling and washing during post finishing, when weft weave points are too many, the yarn fibers that are not interwoven between the warp yarns and weft yarns become loose. Meanwhile, the increased filoplume on the yarn surface damages the yarn strength. Even worse, the yarns may be tangled together. In daily wear, the rear surface of the fabric contacts and rubs with the skin, worsening the tangling of yarns such that the appearance style and hand feeling of the fabric are severely affected. When weft-weave points are too few, the warp yarns and weft yarns on the rear surface of the fabric are tightly interwoven, so that the fabric is not easy to be stretched. As a result, some parts of human bodies are stressed and feel squeezed, resulting in poor wearing experience. In the present invention, 4-16 weft weave points are arranged between two adjacent groups of warp weave points on the third warp yarn 3, which achieves a proper tightness, effectively preventing the yarns from being tangled together.

[0037] Preferably, the arrangement ratio of the first warp yarn to the third warp yarn is 1:5-4:1, and the arrangement ratio of the first warp yarn to the second warp yarn is 1:4-3:1.

[0038] In some embodiments, the number of complete weave cycles of warp yarns of the fabric is equal to the sum of the least common multiple of the number of basic weave cycles of warp yarns and the arrangement ratio, and the number of complete weave cycles of warp yarns is equal to the least common multiple of the number of basic weave cycles of warp yarns.

[0039] In some preferred embodiments, in the surface layer and middle layer of the fabric, there are 1-7 warp wave points where the warp yarn and weft yarn are interwoven. In this way, the front surface of the fabric exhibits a woven style, endowing the fabric with an appearance of traditional jeans.

[0040] The surface layer and middle layer may adopt a plain weave, twill weave or satin weave. Specifically, the surface layer and middle layer may adopt a 1/1 plain weave or the number of basic wave cycles is 3-8.

[0041] In some preferred embodiments, 7-13 weft weave points are arranged between two adjacent groups of warp weave points on the third warp yarn. The non-elastic yarn may be any non-elastic yarns in the prior art, such as cotton yarn, chemical fiber elastic yarn, Tencel, Modal, wool yarn, Tencel cotton blended yarn and cotton Modal blended yarn, etc. The elastic yarn may be any elastic yarns in the prior art, such as a single core spun yarn and a double core spun yarn. More specifically, the elastic yarn may be cotton wrapped Lycra, cotton wrapped polyester wrapped Lycra, cotton wrapped chemical fiber elastic yarn wrapped Lycra, and cotton wrapped chemical fiber elastic yarn, etc.

[0042] Further, the first warp yarn 1 may be a yarn made of a staple fiber. The second warp yarn 2 may be one of an elastic core spun yarn prepared by wrapping an elastic yarn with a staple fiber, a filament yarn with elasticity, and an elastic core spun yarn prepared by wrapping an elastic yarn with a filament yarn. The third warp yarn 3 may be one of a yarn made of a staple fiber, a core spun yarn prepared by wrapping an elastic yarn with a staple fiber, and a core spun yarn prepared by wrapping a non-elastic filament yarn with a staple fiber. The staple fiber may be a cotton fiber, hemp fiber, Tencel, Modal, acrylic fiber, viscose, rayon, polyester, nylon and sea island filament, etc. Preferably, the staple fiber is cotton fiber.

[0043] When the first warp yarn 1 or the third warp yarn 3 is made of a staple fiber, the yarn count ranges from 6 S to 60 S. When the third warp yarn 3 is a core spun yarn prepared by wrapping an elastic yarn with a staple fiber, the yarn count ranges from 6 S to 60 S, and the yarn count of the elastic yarn ranges from 20 D to 300 D. When the third warp yarn 3 is a core spun yarn prepared by wrapping a non-elastic filament yarn with a staple fiber, the yarn count ranges from 6 S to 60 S. When the second warp yarn 2 is an elastic core spun yarn prepared by wrapping an elastic yarn with a staple fiber, the whole yarn count ranges from 6 S to 60 S, and the yarn count of the elastic yarn ranges from 20 D to 300 D. When the second warp yarn 2 is a filament yarn with elasticity, the yarn count ranges from 20 D to 450 D, and when the second warp 2 is an elastic core spun yarn prepared by wrapping an elastic yarn with a filament yarn, the whole yarn count ranges from 40 D to 600 D, and the yarn count of the elastic yarn ranges from 20 D to 300 D.

[0044] In some preferred embodiments, the English yarn count of the third warp yarn 3 is the same as that of the first warp yarn 1, or the English yarn count of the third warp yarn 3 is greater than that of the first warp yarn 1. When the average size of yarns on the rear surface of the fabric is larger than that of yarns on the front surface, the appearance style of the front surface of the fabric may be severely affected, resulting in poor wale clearness of the fabric. Therefore, the English yarn count of the third warp yarn 3 is greater than or equal to that of the first warp yarn 1 (namely, the size of the third warp yarn 3 is not greater than that of the first warp yarn 1). In this way, the wale clearness of the front surface of the fabric is further improved. For example, the first warp yarn is cotton, and its yarn count ranges from 8 S to 38 S. The second warp yarn is an elastic core spun yarn prepared by wrapping an elastic yarn with a filament yarn, the whole yarn count ranges from 50 D to 150 D, and the yarn count of the elastic yarn ranges from 20 D to 105 D. The third warp yarn is made of a staple fiber, and the yarn count ranges from 16 S to 60 S. Alternatively, the third warp yarn made of a filament yarn, and the yarn count ranges from 50 D to 450 D.

[0045] The weft yarn 4 may be a yarn made of a staple fiber or a filament yarn. When the first weft yarn is made of a staple fiber, the yarn count ranges from 6 S to 60 S, and when the weft yarn 4 is made of a filament yarn, the yarn count ranges from 40 D to 600 D. If the weft yarn has elasticity, it may be an elastic core spun yarn prepared by wrapping an elastic yarn with a staple fiber (e.g., a spandex yarn wrapped with a staple fiber) or an elastic core spun yarn prepared by wrapping an elastic yarn with a filament yarn. If the weft yarn is an elastic core spun yarn prepared by wrapping an elastic yarn with a staple fiber, the whole yarn count ranges from 6 S to 60 S, and the yarn count of the elastic yarn ranges from 20 D to 300 D. The weft yarn may be a single core spun yarn or a double core spun yarn, for example, a cotton yarn wrapped with spandex, a cotton yarn wrapped with polyester and a cotton yarn wrapped with chemical fiber elastic yarn, etc. The optional scope of the second weft yarn is the same as that of the first weft yarn.

[0046] The novel woven warp-knit-like fabric of the present invention has the following advantages: [0047] 1. The fabric has the appearance style of a woven fabric, and also has the characteristics of good air permeability and good hand feeling of a warp-knitted fabric; [0048] 2. The fabric surface is fluffy and light; the novel woven warp-knit-like fabric adopts a structure with three interwoven layers of warp yarns and weft yarns; under the action of the elasticity of the second warp yarn, a plurality of loops with a certain radian are formed by the third warp yarn on the reverse surface of the fabric, thereby forming more air storage spaces; compared with fabrics with the same thickness, the weight of the novel woven warp-knit-like fabric is lower and the hand feeling is better; [0049] 3. Because the first warp yarn is a non-elastic yarn, when it is dyed, its color absorption is sufficient, effectively avoiding the color difference occurring when dyeing the outer surface of the fabric; [0050] 4. The color of warp yarns on both surfaces may be the same or different, achieving a stronger expression of fashion, enabling designers to design freely and allowing consumers to achieve more wearing styles with one piece of clothes; [0051] 5. The fabric has a good hand feeling; the present invention adopts a special weave construction; the loops with a certain radian on the rear surface of the fabric is vertically arranged; therefore, when the fabric rubs up and down with the skin, the loops with a certain radian are in the moving direction of the skin, facilitating the reduction of discomfort caused by the fabric.

[0052] The present invention is further described in the following embodiments:

Embodiment 1

[0053] FIG. 2 is a conceptual diagram illustrating a wave construction of the novel woven warp-knit-like fabric of the present invention.

[0054] In FIG. 2, the colored grids represent the warp weave points, and the blank grids represent the weft weave points. Area A of the fabric is a surface layer, and its weave construction is a 3/1 right twill. Area B is a middle layer, and its weave construction is a 1/1 plain weave. Area C is an inner layer, and its weave construction is a satin weave (R=8 and SW=5).

[0055] The healding method adopts the a flying healding. The healding method is: 1 5 7 2 6 8 3 5 9 4 6 10 1 5 11 2 6 12 3 5 13 4 6 14, and the reed-in method is 4 in one reed.

[0056] The first warp yarn: a pure cotton yarn having a yarn count of 8 S is adopted, and the yarn color is indigo;

[0057] The second warp yarn: a yarn prepared by wrapping a 40 D spandex with a 95 D polyester is adopted;

[0058] The third warp yarn: a pure cotton yarn having a yarn count of 50 S is adopted, and the yarn color is white;

[0059] The weft yarn: a core spun yarn prepared by wrapping 40 D spandex with a 16 S pure cotton yarn is adopted;

[0060] The reed count on the warp yarn is 62 reeds (4 in);

[0061] The weft yarn weaving density is 46T;

[0062] The first warp yarn covering rate is 62/28 (8)=78%;

[0063] The third warp yarn covering rate is 62/28 (50)=31%.

[0064] After testing the performances of the novel woven warp-knit-like fabric in this embodiment after conventional post finishing, the test results are shown in the following table:

TABLE-US-00001 Recovery Increase Stitch Rate Elongation Rate Slipping Warp Direction 23.5% 13.2% 2.3% 0.32 Weft Direction 86.1% 46.3% 5.6% 0.56

[0065] It can be seen from the above that, the air permeability of the fabric reaches 48.65 mm/s and the filling power reaches 322.26 cm.sup.3/g, achieving good air permeability and high filling power. The data in the table shows that the fabric has good elasticity and high slipping-resistance. Meanwhile, a clear twill-weave pattern, a three-dimensional sense, and tightly interwoven warp and weft yarns are achieved. The novel design of the weave construction makes the handing feeling of the fabric soft and comfortable. When touching the skin, a skin-friendly, comfortable, soft and natural feeling of the fabric is achieved.

Embodiment 2

[0066] FIG. 3 is a conceptual diagram illustrating a wave construction of the novel woven warp-knit-like fabric of the present invention.

[0067] In FIG. 3, the colored grids represent the warp weave points, and the blank grids represent the weft weave points. Area A of the fabric is a surface layer, and its weave construction is a 2/1 left twill. Area B is a middle layer, and its weave construction is a plain weave. Area C is an inner layer, and its weave construction is a 5/1 right twill satin weave.

[0068] The healding method adopts the a flying healding. The healding method is: 1 9 11 2 10 12 3 9 13 4 10 14 5 9 15 6 10 16 7 9 17 8 10 18, and the reed-in method is 4 in one reed.

[0069] The first warp yarn: a pure cotton slub yarn having a yarn count of 16 S is adopted, and the yarn color is indigo;

[0070] The second warp yarn: a yarn prepared by wrapping a 70 D spandex with a 50 D nylon is adopted;

[0071] The third warp yarn: a Tencel cotton yarn having a yarn count of 50 S is adopted, and the yarn color is white;

[0072] The weft yarn: a core spun yarn prepared by wrapping 70 D spandex with a 21S pure cotton yarn is adopted;

[0073] The reed count on the warp yarn is 70 reeds (4 in);

[0074] The weft yarn weaving density is 52T;

[0075] The first warp yarn covering rate is 70/28 (16)=62%;

[0076] The third warp yarn covering rate is 70/28 (50)=35%.

[0077] After testing the performances of the novel woven warp-knit-like fabric in this embodiment after conventional post finishing, the test results are shown in the following table:

TABLE-US-00002 Recovery Increase Stitch Rate Elongation Rate Slipping Warp Direction 23.5% 10.2% 2.5% 0.46 Weft Direction 91.2% 51.2% 4.1% 0.42

[0078] It can be seen from the above that, the air permeability of the fabric reaches 36.58 mm/s and the filling power reaches 302.36 cm.sup.3/g, achieving good air permeability and high filling power. The data in the table shows that the fabric has good elasticity and high slipping-resistance. Meanwhile, a clear twill-weave pattern, a three-dimensional sense, and tightly interwoven warp and weft yarns are achieved. The novel design of the weave construction makes the handing feeling of the fabric soft and comfortable. When touching the skin, a skin-friendly, comfortable, soft and natural feeling of the fabric is achieved.

Embodiment 3

[0079] FIG. 4 is a conceptual diagram illustrating a wave construction of the novel woven warp-knit-like fabric of the present invention.

[0080] In FIG. 4, the colored grids represent the warp weave points, and the blank grids represent the weft weave points. Area A of the fabric is a surface layer, and its weave construction is a warp satin weave (R=8 and SW=3). Area B is a middle layer, and its weave construction is a 1/1 plain twill. Area C is an inner layer, and its weave construction is a 5/1 weft right twill satin weave.

[0081] The first warp yarn: a pure cotton slub yarn having a yarn count of 21 S is adopted, and the yarn color is sulfur black;

[0082] The second warp yarn: a yarn prepared by wrapping a 20 D spandex with a 50 D nylon is adopted;

[0083] The third warp yarn: a Tencel cotton yarn having a yarn count of 60 S is adopted, and the yarn color is white;

[0084] The weft yarn: a core spun yarn prepared by wrapping 70 D spandex with a 26 S pure cotton yarn is adopted;

[0085] The reed count on the warp yarn is 82 reeds (4 in);

[0086] The weft yarn weaving density is 70T;

[0087] The first warp yarn covering rate is 82/28 (21)=63%;

[0088] The third warp yarn covering rate is 82/28 (60)=37%.

[0089] After testing the performances of the novel woven warp-knit-like fabric in this embodiment after conventional post finishing, the test results are shown in the following table:

TABLE-US-00003 Recovery Increase Stitch Rate Elongation Rate Slipping Warp Direction 36.5% 15.8% 3.2% 0.56 Weft Direction 88.8% 49.8% 3.5% 0.58

[0090] It can be seen from the above that, the air permeability of the fabric reaches 35.64 mm/s and the filling power reaches 289.64 cm.sup.3/g, achieving good air permeability and high filling power. The data in the table shows that the fabric has good elasticity and high slipping-resistance. Meanwhile, a clear twill-weave pattern, a three-dimensional sense, and tightly interwoven warp and weft yarns are achieved. The novel design of the weave construction makes the handing feeling of the fabric soft and comfortable. When touching the skin, a skin-friendly, comfortable, soft and natural feeling of the fabric is achieved.

[0091] It should be understood that the present invention is not limited by the aforesaid embodiments. For those skilled in the art, improvements and modifications may be made based on the specification of the present invention. Therefore, those improvements and modifications shall fall into the scope defined by the claims of the present invention.