Comfortable and Warm Ribbed Velvet Denim Fabric and Production Method Thereof

The present application claims priority from Chinese Patent Application No. 202410463326.1 filed on Apr. 17, 2024, the contents of which are incorporated herein by reference in their entirety

The present disclosure relates to a comfortable and warm ribbed velvet denim fabric and a production method thereof, belonging to the field of textiles.

The traditional denim fabric is made by interweaving natural white weft yarns with pure cotton warp yarns dyed with an indigo dye in a twill weave structure, and is favored by people for its compact, twilled, and retro style. Based on the characteristics of the indigo dye itself, and after being produced, denim clothing undergoes a washing process to remove part of the indigo dye from fibers, which allows the denim clothing to present ever-changing imitation of old styles and become an irreplaceable important role in the clothing market.

Although the traditional denim clothing is relatively thick, its insulation effect is only average, so that technicians have developed various denim fabrics with insulation effects. For example, yarns with a heating effect are used as weft yarns for weaving, making fabrics have far-infrared, heating and other functional effects; and the fabrics are still effective after long-term use, but the insulation effect is not obvious. For another example, some technicians have developed composite denim fabrics by bonding the denim fabric with fluff through glue, creating a layer of fluff on a denim fabric underside; however, after long-term use, the aging of the glue will gradually make the composite fabrics stiff, and the viscosity of the glue will decrease after the aging of the glue; and the fluff will fall off during washing and be wound with the with the fluff which has not fallen off, forming wavy bulges that affect the comfort of wearing.

At present, there are also technicians who design a denim fabric as a double-layer cloth, with outside wefts and inside warps interwoven to form stitching points, and floating long yarns are formed on undersides of inside wefts for fleecing the fabric underside, so as to create a layer of fluff on a fabric underside. However, the fluff is mainly formed by fibers in the floating long yarns being hooked and broken and pulled out. Although the resulting fluff is long, it is not dense enough; and after the fabric is stretched, the fluff will become very sparse. Moreover, after fleecing, the fluff is also hooked out of many parts of the outside wefts and the inside warps while being hooked out of the inside wefts, so that the strength of the fabric is greatly reduced.

In order to overcome the shortcomings in the related art, the present disclosure provides a comfortable and warm ribbed velvet denim fabric and a production method thereof, so that the fabric is enabled to have higher strength, the fluff is relative dense after the fabric is stretched, and the fabric can keep warm for a long time.

The technical solutions adopted by the present disclosure to solve its technical problems are as follows.

In a first aspect, the present application provides a comfortable and warm ribbed velvet denim fabric. A fleece layer is provided on the underside. The fabric 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 the shrinkage rate of the outside wefts is greater than that of the inside wefts.

According to the comfortable and warm ribbed velvet denim fabric provided by the present application, there is no need for formation of floating long yarns on the underside, but the thicker multifilaments are used as the inside wefts, cooperating with the outside wefts having a higher shrinkage rate. Under the action of the outside wefts shrinking to tension the fabric, the outside wefts tie the interior of the fabric tight, causing the thicker inside wefts to expand and protrude downward, which can cover the outside wefts; and the fleece layer is mainly provided by the inside wefts, and therefore, the damage to the outside warps and the outside wefts is reduced in the process of fleecing. Moreover, the outside wefts and the inside wefts are interwoven with the inside warps in a manner of plain weave, which makes the bottom layer of the fabric more compact, and the outside wefts have a tensioning effect on the fabric, so that the strength of the fabric is high. In addition, due to the plain weave on a fabric underside, there is no relying on the floating long yarns for fleecing; and the inside wefts are made of thicker multifilaments, so that fluff in the fleece layer is short and abundant, very thick, and more comfortable when in contact with skin. The shorter fluff is less likely to tangle and form bulges. When the fabric is stretched within a certain range, it is only equivalent to reducing the expansion and protrusion of the inside wefts on the underside, so that the fluff will not become significantly sparse.

In the preferred implementation of spinning, the outside warps and the outside wefts 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.

In the preferred implementation of spinning, the outside warps are thicker than the inside warps, allowing the outside warps to cover the inside warps from the front of the fabric.

Further, the count of the inside warps is three times or more the count of the outside warps, which is beneficial for the fabric to display twill on the right side without exposing the plain at the bottom layer of the fabric.

Even further, the count of the insider warps is three to eight times the count of the outside warps.

Even further, the count of the outside warps is 8-32 S.

In the preferred implementation of spinning, the F number of the inside wefts is 114-900 F. F number, also known as the number of strands, is used to indicate how many filaments constitute a synthetic fiber multifilament. 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.

Further, the denier count of filaments in the inside wefts is 80-500 D, which can form fine and soft fluff after fleecing, making the fabric more comfortable when in contact with the skin.

Even further, the count of the outside wefts is 21-60 S, which is beneficial for the high F-number and high denier inside wefts to cover the outside wefts on the fabric underside while ensuring that the outside wefts provide sufficient shrinkage.

In the preferred implementation of spinning, the same inside warp has the same weave point type with each of the outside wefts, and the same inside warp has the same weave point type with each of the inside wefts; and on the same inside warp, the type of weave points formed by the outside wefts is always opposite to the type of weave points formed by the inside wefts. Therefore, the fabric underside is enabled to have raised vertical strips similar to corduroy before fleecing so as to be better in stability, and also have a stronger insulation effect after the fleece layer is formed.

In a second aspect, the present application 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.

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

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, thus effectively solving the problem of significantly reduced fabric strength of the existing fleece products after fleecing treatment.

Optionally, the selection and interweaving of various yarns can be carried out according to the first aspect, and the stitch slipping resistance of the fabric can be further improved in combination with fabric structure design and yarn matching.

Optionally, 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.

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.

First, after alkali treatment, the outside wefts will shrink greatly, and the fabric will become relatively compact, which will enhance 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 a surface layer of the fabric are enabled to be more compact. 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.

Optionally, 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. Single-sided singeing at a lower temperature and a faster speed is beneficial to reducing the damage of singeing to chemical fibers, especially the multifilaments in a fabric lining.

The present disclosure has the beneficial effects that: according to the comfortable and warm ribbed velvet denim fabric provided by the present disclosure, under the action of the outside wefts shrinking to tension the fabric, the outside wefts tie the interior of the fabric tight, causing the weft weave points of the thicker inside wefts to expand and protrude downward, which can cover the outside wefts and reduce the damage to the outside warps and the outside wefts in the process of fleecing. Moreover, the outside wefts and the inside wefts are interwoven with the inside warps in a manner of plain weave, which makes the bottom layer of the fabric more compact, and the outside wefts have a tensioning effect on the fabric, so that the strength of the fabric is high. In addition, due to the plain weave on the fabric underside, there is no relying on the floating long yarns for fleecing; and the inside wefts are made of thicker multifilaments, so that fluff in the fleece layer is short and abundant, fine and dense, and more comfortable when in contact with skin. When the fabric is stretched within a certain range, it is only equivalent to reducing the expansion and protrusion of the inside wefts on the underside, so that the fluff will not become significantly sparse.

The other features and advantages of the present application will be set forth in subsequent content of the specification, and in part will be apparent from the specification, or may be learned by practice of the present application. The objects and other advantages of the present application may be realized and obtained based on the structures particularly pointed out in the written specification and the accompanying drawings.

Reference numerals:, outside warp;, outside weft;, inside warp;, inside weft; and, fleece layer.

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.

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.

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

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.

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, 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 warpsand inside warps, and the weft yarns are divided into outside weftsand inside wefts; the outside weftsand the inside weftsare interwoven with the inside warpsin a manner of plain weave, the outside warpsand the outside weftsare interwoven in a manner of twill weave, and the outside warpsand the inside weftsare not interwoven; the inside weftsare thicker than the outside wefts; and the inside weftsare made of multifilaments, and the shrinkage rate of the outside weftsis greater than that of the inside wefts. The outside warpsand the outside weftsare interwoven to form a surface layer of the fabric, the inside warpsand the inside weftsare 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 layeris obtained.

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.

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

(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 weftsand the inside weftsare interwoven with the inside warpsin a manner of plain weave, with multiple interlacing points, resulting in a tight fabric weave structure.

(2) The outside weftshave a tensioning effect on the fabric.

(3) The inside weftsare thicker than the outside wefts, the shrinkage rate of the outside weftsis greater than that of the inside wefts, and the outside weftstie the interior (a middle part between the surface layer and bottom layer) of the fabric tight, causing the thicker inside weftsto expand and protrude downward (towards the underside), which can cover the outside wefts, so that the inside weftsare mainly damaged in the process of fleecing.

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

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

(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 weftsand the inside weftsare interwoven with the inside warpsin a manner of plain weave, so that the resulting fluff is short and abundant.

(2) The inside weftsare made of multifilaments, including a plurality of filaments that can be hooked and broken.

(3) The shrinkage rate of the outside weftsis greater than that of the inside wefts, 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 weftson the underside, so that the fluff will not become significantly sparse.

Referring to the example as shown in, the weave structure of a comfortable and warm ribbed velvet denim fabric in the specific example is illustrated. Into, 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.

is obtained based on a weave structure formed by the inside warps and the outside wefts exploded from.is obtained based on a weave structure formed by the inside warps and the inside wefts exploded from.is obtained based on a weave structure formed by the outside warps and the outside wefts exploded from.is obtained based on a weave structure formed by the outside warps and the inside wefts exploded from. From, 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, where the inside weftsare all below the outside warps.

As shown in, the outside warpsand the outside weftsare 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.

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 warpsare thicker than the inside warps, so that the outside warps can cover the inside warps on the front of the fabric. Specifically, the count of the inside warpsis three times or more the count of the outside warps, 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 warpsis three to eight times the count of the outside warps. Furthermore, the count of the outside warpsis 8-32 S, which can show the appearance texture effect of the conventional denim surfaces.

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 weftsis 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 weftsis 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 weftsis 21-60 S, which can be well covered by the multifilaments of 80-500 D and 114-900 F.

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.