HK1236587A1 - Woven fabric that performs like a knitted fabric and method of making thereof - Google Patents

Description

Woven fabric having properties similar to knitted fabric and method for producing same

The patent application of the invention is a divisional application of an invention patent application with the international application number of PCT/EP2011/000902, the international application date of 2011, 2, month and 24, the application number of 201180010682.9 entering the Chinese national stage and the name of a woven fabric with the appearance and performance like knitted fabric and a manufacturing method thereof.

Technical Field

Products and methods consistent with the present invention relate to textiles.

Background

Generally, woven fabrics (woven fabrics) and knitted fabrics are very different in quality. Woven fabrics such as denim tweed, mozzarella, and others are generally less deformable, but are stiffer than knitted fabrics, and therefore do not exhibit body shape well. Even with the use of inelastic yarns, the knitted fabric is soft, stretches in both the vertical and horizontal directions, and drapes well over the body.

Denim (denim), an indigo-dyed woven fabric, has gained popularity in the fashion industry, due at least in part to the ring dyeing process used in making indigo yarn. Typically, the indigo dyeing is located near the surface of the yarn, leaving the core undyed. Because the dyeing is on the surface of the yarn, the denim fabric fades differently than fabrics made from non-ring dyed yarns. In addition, different polishing techniques can be applied to denim to take advantage of these ring-dyed yarns. For example, the denim may be manually scraped, sand blasted, stone washed or treated in other ways that allow to vary the number of uncoloured cores of the indigo yarn to make the latter visible. The effects produced by these treatments have made denim a popular and fashionable fabric in the garment and textile industries.

Denim is rarely used to make tops, such as shirts, jackets, and sweaters, due to its woven nature. On the other hand, knitted indigo fabrics have not become popular because of the necessary expensive manufacturing costs. For example, to make a knitted fabric, the yarn used must be wound on a bobbin. This is an expensive, additional step required to make knitted indigo fabric. Some have attempted to dye fabrics after knitting, but this can also present problems. Dyeing after knitting is difficult to control due to the elastic properties of the fabric. In addition, if one wears the fabric jersey, the indigo dye on both sides of the fabric can stain. Still others have attempted to dye knitting yarns with indigo dye while on bobbins, but this has also yielded unsatisfactory results.

Disclosure of Invention

The object of the present invention is to solve the above problems and to provide a woven fabric having the look and properties of a knitted fabric. Preferably, the woven fabric is a denim-like fabric.

The present invention solves the above object. An exemplary embodiment of the present invention is to provide a product that looks and performs like a knitted fabric, but is manufactured by knitting (weave). Another exemplary embodiment of the present invention is to provide a method for manufacturing such a product.

According to an exemplary embodiment of the invention, there is provided an article comprising a fabric having a front side and a back side and comprising a plurality of warp yarns and a plurality of weft yarns woven together in a pattern, wherein the weft yarns comprise a first hard yarn and a second elastic yarn arranged in a predetermined arrangement comprising at least one hard yarn alternating with at least one elastic yarn, the elastic yarn having a shrinkage greater than the shrinkage of the hard yarn, wherein the hard yarn forms alternating lower and upper portions with respect to the warp yarns, the lower portions forming loop portions (loops) when the hard yarn passes along the back side of the warp yarns and defining connecting portions when the hard yarn passes along the front side of the warp yarns, wherein for each hard yarn the average number of warp yarns passed by a loop portion is at least 6, wherein the elastic yarns form alternating lower and upper portions in a tighter weave than the weave of the hard yarns with respect to the warp yarns.

It should be noted that although the present invention uses the terms "elastic" and "hard" to describe the yarn, for purposes of the present invention, "elastic" means that the yarn has a greater shrinkage than a "hard" yarn. It can be well adapted to the following situations: both "elastic" and "hard" yarns are elastic.

In other words, the invention relates to a woven fabric having warp yarns and weft yarns, the weft yarns extending over selected warp yarns to provide an upper portion, extending over a rear side of the fabric between two adjacent upper portions to define a lower portion of the weft yarns, characterized in that the weft yarns comprise a plurality of first weft yarns having a first shrinkage and a plurality of second weft yarns having a second shrinkage, wherein the second weft yarns have a shrinkage greater than the shrinkage of the first weft yarns, the first weft yarns being arranged alternately with the second weft yarns to provide a fabric pattern, and in that the lower portions of the plurality of first weft yarns form loops extending to cover at least 6 warp yarns, and the lower portions of the second weft yarns extend for a number of warp yarns less than 6.

Preferably, the shrinkage of the elastic yarn is at least 10% greater than the elastic modulus of the hard yarn, and defines that the number of warp yarns in the lower part of the first weft yarn (i.e. the number of warp yarns between two adjacent upper parts of the first weft yarn) is in the range of 6 to 24, when measured in the same way, i.e. using the same test. Suitable equipment for measuring shrinkage is known in the art, for example, the Uster Tensorapid tester (Uster, CH) may be used to determine shrinkage.

For the purposes of the present invention, the expression "weave more tightly than the weave of the hard yarns" means that one of the weft yarns (called the elastic yarn) goes up and down (up and down) more times between the warp yarns than the hard weft yarns. Up-down means that the weft yarn reaches up to the front side of the fabric and down to the back side of the fabric after passing over (defining the upper part) the warp yarns; the front side of the fabric is the visible side and the back side will be in contact with a user of a product or garment derived from or comprising the fabric. In other words, in the uniform length weft yarns, the number of warp yarns defined by the lower portion of the elastic yarn (or second yarn) is always smaller than the number of warp yarns defined by the lower portion of the stiff (or first) yarn, in terms of the number of warp yarns defined between one upper portion (inclusive) and the adjacent upper portion (exclusive). Preferably, for the same uniform number of fabrics, the number of up and down movements of the second elastic weft yarn is 2 to 12 times the number of up and down movements of the hard yarn, as defined by the weaving report (report) (see fig. 5-14 below); the result is an elastomeric/hard yarn upper ratio in the range of 2 to 12, preferably in the range of 3 to 6. In other words, in the same width fabric, the number of upper portions of the elastic (second) yarn is 2 to 12 times greater than the number of upper portions of the first (hard) yarn, and then the elastic yarn is woven more densely than the hard yarn. Preferably, the average ratio of elastic to hard yarns is between 2:1 and 1:5, inclusive. More preferably, the average ratio of elastomeric to hard yarns is between 1:2 and 1:3, including 1:2 and 1: 3. Furthermore, the ratio of elastic to hard yarns need not be regular, or the same, throughout the fabric.

In a preferred embodiment, the number of warp yarns defining the lower part of the second elastic weft yarn is 5 or less, the number of warp yarns crossed by the loop part of the hard yarn is in the range of 6 to 24, the shrinkage of the elastic yarn is at least 10% greater than the shrinkage of the hard yarn, the ratio of the upper part (or up and down movement) of one elastic yarn to one hard yarn is in the range of 2:1 to 12:1, preferably in the range of 3:1 to 6:1, and the ratio of the elastic yarn to the hard yarn is between 2:1 and 1:5, including 2:1 and 1: 5. The most preferred embodiment has a ratio of elastic to hard yarn of 1: 2; the ratio of the upper part in the elastic yarn to the upper part in one hard yarn is 4: 1; the back or loop portion of the hard yarn for 11 warp yarns per 1 warp yarn is the upper portion (11-1) and the back portion of the elastic yarn for 2 warp yarns per warp yarn is the elastic yarn (2-1), as shown by way of example in fig. 5.

According to an exemplary embodiment of the invention, the predetermined arrangement comprises a warp density of between about 20 and 70 warp yarns/cm, including 20 and 70 warp yarns/cm, after weaving and before shrinking.

According to another exemplary embodiment of the invention, the predetermined arrangement comprises a warp yarn density of between about 25 and 80 warp yarns/cm and a weft yarn density of between about 25 and 80 weft yarns/cm, both, after three home washes (performed according to BS 63302A or ASTM D3776/96).

In yet another embodiment of the invention, the predetermined arrangement comprises a weft yarn density of between 20 and 70 weft yarns/cm, including between 20 and 70 weft yarns/cm, after weaving and before shrinking.

In a further exemplary embodiment of the invention, the warp yarns have a count of english cotton yarns between about Ne 10 and Ne 40, inclusive of Ne 10 and Ne 40.

Similarly, in another exemplary embodiment of the invention, the elastic yarn has a denier between about 40 and 140 denier, including 40 and 140 denier.

In another exemplary embodiment of the invention, the hard yarn has a count of cotton yarn of about between Ne 10 and Ne 60, inclusive of Ne 10 and Ne 60.

In yet another embodiment of the invention, the warp yarn is ring dyed indigo yarn.

According to another exemplary embodiment of the present invention, there is provided a product comprising a fabric having a first weave (weave) and a second weave; wherein the first weave forms the front side of the product, the first weave substantially comprising warp yarns and elastic weft yarns tightly woven in accordance with a predetermined pattern, wherein the second weave forms the back side of the fabric, the second weave substantially comprising the warp yarns and hard weft yarns loosely woven in accordance with a predetermined pattern such that lower and upper portions of the hard weft yarns are alternately arranged with respect to the warp yarns, the lower portions forming and defining loop portions as the hard yarns pass along the back side of the warp yarns, and the upper portions forming and defining connection portions as the hard weft yarns pass along the front side of the warp yarns, wherein for each hard weft yarn the average number of warp yarns passed by the loop portions is at least 6, wherein the elastic weft yarns form alternately arranged lower and upper portions in a tighter weave than the weave of the hard yarns with respect to the warp yarns, and wherein the elastic yarns and the hard weft yarns are arranged in a predetermined arrangement comprising at least one hard yarn alternating with at least one elastic yarn, the elastic yarns having a shrinkage greater than that of the hard yarns.

According to another exemplary embodiment of the present invention, there is provided a method for manufacturing a fabric, the method including: providing warp yarns; providing a hard weft yarn; providing an elastic weft yarn having a shrinkage rate greater than that of the hard weft yarn; selecting a weave pattern in which at least one hard yarn is alternated with at least one elastic yarn, the hard yarn alternating through a predetermined number of warp yarns along a back side of the warp yarns, each crossing resulting in a series of hard under portions, and alternating through a predetermined number of warp yarns along a front side of the warp yarns, each crossing resulting in a hard over portion, and for each hard yarn the average number of warp yarns crossed by each under portion is at least 6, and the elastic yarn alternating through a predetermined number of warp yarns along a back side of the warp yarns, each crossing resulting in a series of elastic under portions, and alternating through a predetermined number of warp yarns along a front side of the warp yarns, each crossing resulting in a series of elastic over portions; weaving the fabric according to the selected pattern; contracting the woven fabric, wherein the elastic weft yarns contract more than the hard weft yarns such that the hard lower portions form loops.

The present invention provides several advantages over the prior art. The inclusion of alternating elastic and hard weft yarns results in an elastic "structure" within the fabric; when the finished fabric is removed from the loom, i.e. is no longer under tension, the first and second yarns shrink in a different manner and to a different extent, that is, the elastic yarns shrink more than the hard yarns, and the hard yarn lower portions provide a plurality of loops on the back of the fabric (i.e. on the side of the fabric that will face the user's body). This can give the hand, feel and appearance of a knitted fabric even if the fabric is made on a loom for woven fabrics. Thereby saving the cost for the knitting equipment. Furthermore, indigo dyed yarns, especially indigo ring dyed yarns, can be used without problems, since the ring will protect the user's body from possible fading of the indigo dye. When indigo-dyed yarns are used, the resulting fabric has the look and feel (hand) of knitted denim, an effect that cannot be achieved using the prior art.

Drawings

The foregoing and/or other aspects will become apparent and more readily appreciated from the following description of the exemplary embodiments, taken in conjunction with the accompanying drawings of which:

FIG. 1- -a fabric according to one exemplary embodiment.

FIG. 2- -front side of a fabric according to one exemplary embodiment.

FIG. 3- -backside of the fabric according to an exemplary embodiment.

FIG. 4- -functional representation of a method of making a fabric according to one exemplary embodiment.

FIG. 5- -woven report for an exemplary embodiment described in accordance with example 1 below.

FIG. 6- -woven report for an exemplary embodiment described in accordance with example 2 below.

FIG. 7- -woven report for an exemplary embodiment described in accordance with example 3 below.

FIG. 8- -woven report for an exemplary embodiment described in accordance with example 4 below.

FIG. 9- -woven report for the exemplary embodiment described in accordance with example 5 below.

FIG. 10- -woven report for an exemplary embodiment described in accordance with example 6 below.

FIG. 11- -woven report for an exemplary embodiment described in accordance with example 7 below.

FIG. 12- -woven report for an exemplary embodiment described in accordance with example 8 below.

FIG. 13- -woven report for an exemplary embodiment described in accordance with example 9 below.

FIG. 14- -woven report for an exemplary embodiment described in accordance with example 10 below.

FIG. 15- -a cross-sectional view of the fabric of the exemplary embodiment.

Detailed Description

The following exemplary embodiments will be described in detail with reference to the accompanying drawings so as to be easily understood by those skilled in the art. The inventive concept may be embodied in different forms and is not limited to the exemplary embodiments set forth herein. Descriptions of well-known components are omitted for brevity, and like reference numerals refer to like elements throughout.

A product according to a first exemplary embodiment is shown in fig. 1. Woven fabric 101 is shown having a front side 102 and a back side 103. The fabric 101 is woven together from warp yarns 104 and weft yarns 105, 106. According to a preferred embodiment, the warp yarns are dyed with indigo dye.

According to the exemplary embodiment, the weft yarns include elastic yarns 105 and hard yarns 106. In this exemplary embodiment, the elastic (or second) yarns 105 have a greater shrinkage than the hard (or first) yarns 106. The elastomeric yarns 105 and the hard yarns 106 are arranged in a predetermined arrangement comprising at least one hard yarn (105) alternating with at least one elastomeric yarn. According to the exemplary embodiment shown in fig. 1, a single elastic yarn 105 is arranged between two hard yarns 106, but the yarns may be arranged differently without departing from the inventive idea. For example, in a preferred embodiment, the ratio of elastic yarns 105 to hard yarns 106 is between 2:1 and 1:5, including 2:1 and 1: 5. More preferably, the average ratio of elastomeric yarns 105 to hard yarns 106 is between 1:2 and 1:3, including 1:2 and 1: 3. Furthermore, the ratio of elastic yarn 105 to hard yarn 106 need not be uniform, or the same, throughout the fabric.

The weave of the fabric is such that the hard yarns form lower portions 107 and upper portions 108 in alternating arrangement with respect to the warp yarns 104. The lower portion 107 is formed when the hard yarn passes along the rear side of the warp yarn 104 and defines a loop portion 107 a. The upper portion is formed when the hard yarn passes along the front side of the warp yarn 104 and defines the connecting portion 108 a.

In an exemplary embodiment, the fabric includes a hard weft yarn 106 for which hard weft yarn 106 the number of warp yarns 104 traversed by each loop portion 107a is at least 6, and preferably in the range of 6 to 24; the number of warp yarns 104 traversed by each loop portion 107a need not be the same for all loop portions 107 a. It is not strictly necessary that each single loop portion 107a passes through at least 6 warp yarns 104. As long as the average number of warp yarns 104 traversed by each loop is at least 6 for each hard yarn 106, the number of warp yarns 104 traversed by a single loop portion 107a can vary without departing from the concept of the invention, as would be known to those skilled in the art, provided that the desired loop is obtained on the backside of the fabric.

Although fig. 1 shows that the loop portion 107a passes through 11 warp yarns 104 as compared to one warp yarn 104 being passed through by each connecting portion 108a, in other exemplary embodiments, the ratio of the warp yarn 104 passed through by the loop portion 107a to the warp yarn passed through by the connecting portion 108a is between about 6:1 and 24:1, including 6:1 and 24: 1.

The elastic yarns form lower portions 109 and upper portions 110 in an alternating arrangement with respect to the warp yarns 104 in the woven fabric. These lower and upper portions 109, 110 form a tighter weave relative to the warp yarns 104 than the weave formed by the hard yarns 106. Although the weave patterns shown in fig. 1-3 illustrate the upper portion 110 passing through one warp yarn 104 and the lower portion 109 passing through two warp yarns 104, the number of warp yarns 104 passed through by the upper portion 110 and the lower portion 109 may vary without departing from the spirit of the present invention.

According to an exemplary embodiment, the loop portion 107a of the hard yarn is made such that it is under a much smaller pulling force than the lower portion 109 and the upper portion 110 made of the elastic weft yarn 105. This may also be the case where the ring portion 107a is one of balanced or compressed.

Loop portion 107a helps to increase the knit-like look and performance of the woven fabric. For example, the looser loop 107a may hang loosely on the back of the fabric so that it is drooping. The drooping nature of the looser loops 107a makes the fabric feel softer, much like a knitted fabric.

In addition, since knitting is made by connecting yarn loops together, the loop portion 107a gives the appearance of a knitted fabric on the back side of the fabric. In addition, due to its length and sag, the loop portion 107a can cover a much larger portion of the back side of the fabric than if it were tightly woven for warp yarns. This allows the ring portion 107a to substantially conceal the sometimes uncomfortable lower portion 109. This is typically the case when the loop portion 107a is made of soft cotton yarn, which provides a soft, comfortable backside to the fabric.

An additional benefit of the depending loop portion 107a is to help prevent the warp yarns 104 from contacting the skin. This benefit is particularly important for denim fabrics made from indigo dyed yarns. If these warp yarns 106 are indigo dyed and allowed to contact the wearer's skin, they may stain the skin when worn by the wearer.

As shown in fig. 1 and 3, the loop portions 107a form a pattern extending in a diagonal direction with respect to the warp yarns 104 and the weft yarns 105, 106. Similarly, the connecting portions 108a form a pattern extending diagonally with respect to the warp yarns 104 and the weft yarns 105, 106. As shown in fig. 1, the weave pattern of the hard yarns may be different from the weave pattern of the elastic yarns. For example, the weave pattern selected for the hard yarns, and some other type of pattern selected for the elastomeric yarns, may be a twill pattern. In an exemplary embodiment, the weave pattern and/or thread yarn selection allows the fabric 101 to stretch diagonally with respect to the warp yarns 104 and the weft yarns 105, 106.

By using a diagonal pattern, several benefits can be obtained. First, when the warp yarn 104 is dyed with indigo dye, the use of a diagonal pattern may give the fabric the appearance of a typical denim weave, while maintaining all of the sensory advantages and the performance of the knitted fabric. The diagonal pattern also allows the fabric to extend in a diagonal direction, further increasing the knit-like properties of the fabric.

In an exemplary embodiment, after weaving and before shrinking, the preferred warp yarn density is between about 20 and 70 ends per centimeter, including 20 and 70 ends per centimeter. Preferred warp density after treating the fabric and after three home washes is between about 25 and 80 ends per centimeter, including 25 and 80 ends per centimeter. The home washing can be performed at 60 ℃, followed by drying, and the last washing and drying is followed by a conditioning step of 8 hours; these tests are common in the art and are performed with reference to ASTM D3776/96 and BS 63302A. More preferably, the warp density after weaving and before shrinking is between about 25 and 60 ends per centimeter, inclusive, and between about 30 and 65 ends per centimeter after three home washes. More preferably, the warp density after weaving and before shrinking is between about 30 and 50 ends per centimeter, inclusive of 30 and 50 ends per centimeter, and between about 35 and 55 ends per centimeter after three home washes. Typically, warp and weft density measurements are made at 65% moisture 5%, and 20 ℃2 ℃.

Similar to the warp yarn density, exemplary embodiments may also define the weft yarn density. Preferably, the weft density after weaving and before shrinking is between about 30 and 90 picks per centimeter, including 30 and 90 picks per centimeter. After three home washes, it is preferred that the pick density be between about 35 and 95 picks per centimeter, including 35 and 95 picks per centimeter. In a preferred embodiment, it is more preferred that the weft yarn density after weaving and before shrinking is between about 40 and 80 picks per centimeter, including 40 and 80 picks per centimeter. After three home washes, it is more preferred that the pick density be between about 45 and 85 picks per centimeter, including 45 and 85 picks per centimeter. More preferably, the weft yarn density is between about 50 and 70 picks per centimeter, including 50 and 70 picks per centimeter, after weaving and before shrinking, and between about 55 and 75 picks per centimeter, including 55 and 75 picks per centimeter, after three home washes.

The selection of warp and weft yarn densities not only increases the knitting-like properties of the fabric, it also allows the manufacture of fabrics with different weights in combination with the selection of suitable yarns. For example, the weight may be selected to resemble the weight of a T-shirt, or alternatively, the weight of athletic pants. In an exemplary embodiment, the ratio of the average number of warp yarns traversed by the loop portion to the warp yarn density is between about 0.2 and 0.7, including 0.2 and 0.7. In other exemplary embodiments, the ratio of the average number of warp yarns traversed by the loop portion to the average number of warp yarns traversed by the connecting portion is between about 6 and 24, inclusive.

Another aspect of the exemplary embodiments is the thickness of the yarns used for the warp and weft yarns. Because the elastic (second) yarns will typically be synthetic, they will be described herein using denier, while the warp and hard (first) weft yarns will be described using cotton english yarn number (Ne). While numbering systems are used to describe the yarns, one of ordinary skill in the art will know how to switch from one system to another and will understand that the numbering system used does not limit the characteristics and composition of the yarns used.

Although not drawn to scale, it is shown in fig. 1 that the warp, stiff and elastic fibers may have different thicknesses, and it is preferred that the elastic fibers have a smaller thickness than the stiff fibers. In an exemplary embodiment, it is preferred that the warp yarns are between about Ne 10 and Ne 40, including Ne 10 and Ne 40. More preferably, the warp yarns are between about Ne 15 and Ne25, including Ne 15 and Ne 25. In an exemplary embodiment, it is preferred that the hard yarn is between about Ne 10 and Ne70, including Ne 10 and Ne 70. More preferably, the hard yarn is between about Ne 15 and Ne 50, including Ne 15 and Ne 50. In an exemplary embodiment, it is preferred that the elastic yarn is between about 40den and 140den, inclusive. More preferably the elastic yarns are between about 60den and 80den, inclusive.

By choosing a relatively thick yarn within the range of values of the inventive idea, a number of advantages can be obtained. For example, when the thickness of the hard weft yarns 106 is greater than the thickness of the elastic weft yarns 105, the thicker loop portions 107a can better hide the lower portion 109 from view and touch on the back of the fabric. Selecting the correct yarn thickness increases the knit-like feel and weight of the fabric.

Fig. 2 and 3 show another way of viewing an exemplary embodiment of the inventive idea. The exemplary embodiment may be considered as a fabric 101 having a first woven fabric 202 (shown in fig. 2) and a second woven fabric 203 (shown in fig. 3). The first weave 202 generally forms the face of the fabric 102 and basically includes warp yarns 104 and elastic weft yarns 105 that are tightly woven in a predetermined arrangement. The second woven fabric 203 generally forms the back of the fabric 103 and basically includes warp yarns 104 and hard weft yarns 106 loosely woven in a predetermined arrangement such that the hard weft yarns form lower portions 107 and upper portions 108 in an alternating arrangement with respect to the warp yarns 104. The lower portion 107 is formed when a hard weft yarn is passed along the rear side 103 of the weft yarn 104, thereby defining a loop portion 107 a. The upper portion 108 is formed when a hard weft yarn passes along the front side of the warp yarn 104, defining a connecting portion 108 a. As shown in fig. 3, the number of warp yarns 104 traversed by each loop portion 107a is 11, but in other exemplary embodiments, the number may be different.

In fig. 2, the first weave 202 is formed by the arrangement of the elastic weft yarns 105 relative to the warp yarns 104 in a predetermined arrangement that forms the upper portion 110 and the lower portion 109 in a more compact weave than the second weave 203.

In an exemplary embodiment, the second weave 203 substantially prevents the elastic fibers 1052 on the first weave 20 from being touched and seen through the warp yarns 104 from the back side 103 of the fibers 101.

Fig. 4 represents a method of manufacturing a fabric according to an exemplary embodiment of the inventive concept. The first step in the process is to provide warp yarns, as shown in functional block 401. This step may be considered to select the thickness of the yarn and determine the warp density. Other aspects of determining the warp yarns, known to those skilled in the art, may also be determined in this step. This is typically the case: this step will include selecting indigo dyed warp yarns. The use of indigo dyed warp yarns would allow the resulting fabric to take advantage of many of the unique aspects of the indigo dyeing process. These aspects include, but are not limited to, the unique aging (warming) effect that can be achieved with ring dyed indigo yarns.

Function block 402 is a step of providing a hard weft yarn. Similar to step 401, this step may include determining all aspects of hard weft yarns known to those skilled in the art, including but not limited to: thickness of yarn, shrinkage, elasticity, color, weft density, etc. The function block 403 represents a similar step as for the elastic weft yarns. In this step, all aspects of the elastic weft yarn can be selected.

The function block 404 represents the step of determining a weave pattern. In this step, any weave pattern known to those skilled in the art may be selected, as long as at least one hard yarn is arranged alternately with at least one elastic yarn; ensuring that the hard yarns alternate through a predetermined number of warp yarns along the back side of the warp yarns, each pass forming a series of upper and lower portions, and alternate through a predetermined number of warp yarns along the front side of the warp yarns, each pass forming a hard upper portion; the average number of warp yarns traversed by each lower portion is at least 6; and the elastic yarn alternates through a predetermined number of warp yarns along the back side of the warp yarns, each pass forming a series of elastic lower portions, and alternates through a predetermined number of warp yarns along the front side of the warp yarns, each pass forming a series of elastic upper portions.

Function block 405 represents weaving warp and weft yarns according to a selected weaving pattern.

The function block 406 represents the step of shrinking the fabric after weaving. During said shrinkage, the elastic yarns will shrink more than the hard yarns, so that the lower part becomes the loop part. As soon as the fabric is removed from the loom and the yarns are no longer under tension, shrinkage occurs naturally; further shrinkage is performed by wetting the fabric during the polishing (finish) process.

In an exemplary embodiment, the loop portions are under much less tension than the upper and lower portions formed by the elastic yarns. In other exemplary embodiments, the ring is at least one of in an equilibrium and compressed state.

Other exemplary embodiments may add steps to the processing of the manufactured fabric. These steps may include applying an aging effect to the finished fabric, such as bleaching, hand scraping, sand blasting, stone washing, and others known to those skilled in the art. These steps may include brushing the front or back side of the fabric. The process may also include printing fonts and pictures on the fabric, or embroidering patterns and logos on the fabric. The fabric can be lacerated and torn to meet the current trend of fashion. The process may also include cutting the fabric into garments, or other steps known to those skilled in the art.

The following is a very specific example of an exemplary embodiment according to the inventive idea. The inventive concept is capable of other and different embodiments without departing from the scope and spirit of the inventive concept. The examples should be considered as illustrative and not restrictive. The examples are illustrated with reference to the braided reports of fig. 5-14; as is known to the skilled person, the weaving report is a picture (grafic) reproduction of the smallest repeating unit (single part) of the fabric. This means that the weft and warp yarns will repeat the pattern shown by the weaving report. By way of example, in FIG. 5, weft yarn 37 would be the same as weft yarn 1, weft yarn 38 would be the same as weft yarn 2, and so on, the same applies for warp yarns: w13 is the same as W1, and so on.

Example 1

The result of this exemplary embodiment is a knitted fabric with the weight and feel of a knitted T-shirt, but which is achieved using indigo dyed yarns, which would allow the application of an abrasive effect which the knitted fabric could previously have only been able to achieve at great expense. The warp, weft, warp density, weft density, and loom settings were selected according to the values in table 1. These choices give the resulting fabric a weight of about 5-7oz/sqyd (170-240g/cm 2). The weave pattern may be selected according to the weave report depicted in fig. 5. Weaving is performed using a weaving loom of the dobby type with a weft selection system.

TABLE 1

After weaving, the fabric is wetted and stretched in the length (warp) direction. When this occurs, the fabric shrinks in the width (fill) direction and the lycra yarns pull the fill yarns together. Because the cotton weft yarns do not contain elasticity, they do not shrink much with the lycra yarns, and the cotton yarns float on the back of the fabric, forming long loops covering most of the back side of the fabric. After shrinking, the fabric is heat-set to reduce shrinkage in further garment washing.

The resulting fabric has the weight and feel of a knitted fabric, including the much softer feel typically associated with knitted fabrics. At the same time, the indigo warp gives the warp side fabric the appearance and quality of the denim fabric, e.g. the ability of the denim to be able to perform a polishing effect, e.g. an abrasion effect. The backside of the fabric is white in color due to the undyed warp yarns and extremely soft due to the long loops made thereon. By having the long loops dominating on the backside of the fabric, a person wearing a garment made of said fabric will be prevented from touching the uncomfortable polyester weft yarns. The long loop also prevents the indigo dye from contacting the person wearing the garment and from escaping while the person is wearing the garment.

The resulting fabric has high elastic properties due at least in part to the selection of the weave and elastic weft yarns. These properties include the ability to stretch in all directions rather than just the weft direction.

Example 2

The result of this example is a knitted fabric having the weight and feel of a knitted fabric. The warp, weft, warp density, weft density, and loom settings were selected according to the values in table 1. The weave pattern is selected according to the weave report depicted in fig. 6. Inspection of the knitting report showed a 2:1 ratio of elastic to hard yarns relative to 1:2 in example 1. The upper portion ratio of the elastic yarn/hard yarn is 4:1, that is, the number of times of up-and-down movement of the elastic yarn (reference numerals 1 and 2 in the second column from the left) is 4 times the number of times of up-and-down movement of the hard yarn (reference numeral 3 in the above-mentioned column).

Example 3

The result of this example is a knitted fabric having the weight and feel of a knitted fabric. The warp, weft, warp density, weft density, and loom settings were selected according to the values in table 1. The weave pattern is selected according to the weave report depicted in fig. 7. Inspection of the knitting report showed a 1:1 ratio of elastic to hard yarns relative to 1:2 in example 1. The upper portion ratio of the elastic yarn/hard yarn is 4:1, that is, the number of times of up-and-down movement of the elastic yarn (reference numeral 1 in the second column from the left) is 4 times the number of times of up-and-down movement of the hard yarn (reference numeral 2 in the above-mentioned column).

Example 4

The result of this example is a knitted fabric having the weight and feel of a knitted fabric. The warp, weft, warp density, weft density, and loom settings were selected according to the values in table 1. The weave pattern is selected according to the weave report depicted in fig. 8. As can be seen in the weave report, the weave on the front side of the fabric is a herringbone twill, and the number of warp yarns traversed by the elastic weft yarn (reference 1 in the second column from the left) need not be the same throughout the weave. For example, the number of warp yarns at weft yarn 27 that are bound by a weft yarn is different than the number of warp yarns at weft yarn 21 that are crossed by a weft yarn. Thus, according to the weft yarn (reference 1 in the above mentioned columns), the upper ratio of elastic yarn/hard yarn is 2:1, 3:1, and 4: 1.

Example 5

The result of this example is a knitted fabric having the weight and feel of a knitted fabric. The warp, weft, warp density, weft density, and loom settings were selected according to the values in table 1. Selecting a weave pattern according to the weave report depicted in FIG. 9; the ratio of the elastic yarn (reference numeral 1) to the upper part of the hard yarn (reference numeral 2) was 3: 1. This example uses another exemplary embodiment of a weave pattern.

Example 6

The result of this example is a knitted fabric having the weight and feel of a knitted fabric. The warp, weft, warp density, weft density, and loom settings were selected according to the values in table 1. Selecting a weave pattern according to the weave report depicted in FIG. 10; the ratio of the elastic yarn (reference numeral 1) to the upper part of the hard yarn (reference numeral 2) was 3: 1. This example uses another exemplary embodiment of a weave pattern.

Example 7

The result of this example is a knitted fabric having the weight and feel of a knitted fabric. The warp, weft, warp density, weft density, and loom settings were selected according to the values in table 1. Selecting a weave pattern according to the weave report depicted in FIG. 11; the ratio of the elastic yarn (reference numeral 1) to the upper part of the hard yarn (reference numeral 2) was 4: 1. As can be seen from the values plotted in table 1, this example uses a synthetic weft yarn comprising lycra.

Example 8

The result of this example is a knitted fabric having the weight and feel of a knitted fabric. The warp, weft, warp density, weft density, and loom settings were selected according to the values in table 1. The weave pattern is selected according to the weave report depicted in fig. 12. As can be seen in the weave pattern of fig. 12, the lower portion of the hard weft yarn passes through 20 warp yarns. The ratio of the elastic yarn (reference numeral 1) to the upper part of the hard yarn (reference numeral 2) was 7: 1.

Example 9

The result of this example is a knitted fabric having the weight and feel of a knitted fabric. The warp, weft, warp density, weft density, and loom settings were selected according to the values in table 1. Selecting a weave pattern according to the weave report depicted in FIG. 13; the ratio of the elastic yarn (reference numeral 1) to the upper part of the hard yarn (reference numerals 2 and 3) is 4: 1. As can be seen in table 1, the hard weft yarns of this example are polyester fiber yarns. As a result of these polyester fiber yarns, the resulting fabric had a greater weight than the previous example. Embodiments such as example 9, among other examples, can include brushing the back side of the fabric.

Example 10

The result of this example is a knitted fabric having the weight and feel of a knitted fabric. The warp, weft, warp density, weft density, and loom settings were selected according to the values in table 1. Selecting a weave pattern according to the weave report depicted in FIG. 14; the ratio of the elastic yarn (reference numeral 1) to the upper part of the hard yarn (reference numerals 2 and 3) is 4: 1. As can be seen in table 1, heavier cotton hard weft yarns were used, resulting in a heavier fabric weight for this example.

Claims (47)

1. A fabric (101), said fabric (101) having a front side (102) and a back side (103) and comprising a plurality of warp yarns (104) and a plurality of weft yarns (105,106) woven together in a pattern, wherein said weft yarns comprise first hard yarns (106) and second elastic yarns (105) arranged in a predetermined arrangement comprising at least one hard yarn (105) alternating with at least one elastic yarn,

wherein the hard yarn forms lower portions (107) and upper portions (108) in an alternating arrangement with respect to the warp yarn (104), the lower portions (107) forming and defining loop portions (107a) when the hard yarn passes along a rear side of the warp yarn (104), and the upper portions forming and defining connecting portions (108a) when the hard yarn passes along a front side of the warp yarn,

wherein the average number of warp yarns (104) passed through by the loop portions (107a) is at least 6 for each hard yarn (106),

wherein the elastic yarns (105) form lower portions (109) and upper portions (110) arranged alternately in a closer weave with respect to the warp yarns (104) than the weave of the hard yarns (106).

2. The fabric according to claim 1, wherein the number of warp yarns (104) traversed by the loop portion (107a) is at least 6 times the number of warp yarns traversed by the connecting portion (108 a).

3. A fabric according to claim 1 or 2, wherein the elastic yarn (105) and the hard yarn (106) provide an elastic structure in the fabric, the hard yarn lower portion (107) providing a plurality of loop portions (107a) on the back side of the elastic fabric when the elastic yarn is contracted more than the hard yarn.

4. A fabric according to any preceding claim, wherein the number of warp yarns (104) traversed by loop portions (107a) formed by lower portions of the first weft yarns is at least 6 times the number of warp yarns traversed by connecting portions (108a) formed by upper portions of the first weft yarns (106); the number of warp yarns (104) passed through by the loop portion (107a) is in the range of 6 to 24.

5. The fabric of any of the preceding claims, wherein loop portions (107a) of adjacent hard yarns (106) form a pattern extending in a direction relative to a diagonal of the warp (104) and weft yarns, wherein the fabric extends in the direction relative to the diagonal of the warp and weft yarns.

6. A fabric as claimed in any one of the preceding claims wherein the connecting portions of adjacent hard yarns form a pattern extending in a direction which is diagonal to the warp and weft yarns.

7. A fabric as claimed in any one of the preceding claims wherein the fabric extends in a direction which is diagonal to the warp and weft yarns.

8. The fabric of any of the preceding claims, wherein the weave pattern of the hard yarns (106) is different from the weave pattern of the elastic yarns (105).

9. The fabric of any of the preceding claims, wherein the weave pattern of the elastomeric yarns (105) is a twill pattern.

10. A fabric according to any one of the preceding claims, wherein the predetermined arrangement comprises a warp density of between about 20 and 70 warp yarns/cm, including 20 and 70 warp yarns/cm, after the weaving and before the shrinking.

11. A fabric according to any one of the preceding claims, wherein the predetermined arrangement comprises a warp yarn density of between about 25 and 80 warp yarns/cm after three home washes.

12. A fabric according to any one of the preceding claims, wherein the predetermined arrangement comprises a warp yarn density of between about 25 and 60 warp yarns/cm after the weaving and before the shrinking.

13. A fabric according to any one of the preceding claims, wherein the predetermined arrangement comprises a warp yarn density of between about 30 and 65 warp yarns/cm, including 30 and 65 warp yarns/cm, after three home washes.

14. A fabric according to any one of the preceding claims, wherein the predetermined arrangement comprises a warp yarn density of between about 30 and 50 warp yarns/cm after the weaving and before the shrinking.

15. A fabric according to any one of the preceding claims, wherein the predetermined arrangement comprises a warp yarn density of between about 35 and 55 warp yarns/cm, including 35 and 55 warp yarns/cm, after three home washes.

16. A fabric as claimed in any one of the preceding claims wherein said predetermined arrangement comprises a pick density of between about 30 and 90 picks per cm, including 30 and 90 picks per cm, after said weaving and before shrinking.

17. A fabric according to any one of the preceding claims, wherein the predetermined arrangement comprises a pick density of between about 35 and 95 picks/cm, including 35 and 95 picks/cm, after three home washes.

18. A fabric as claimed in any one of the preceding claims wherein said predetermined arrangement comprises a pick density of between about 40 and 80 picks per cm, including 40 and 80 picks per cm, after said weaving and before shrinking.

19. A fabric according to any one of the preceding claims, wherein the predetermined arrangement comprises a pick density of between about 45 and 85 picks/cm, including 45 and 85 picks/cm, after three home washes.

20. A fabric according to any one of the preceding claims, wherein the predetermined arrangement comprises a pick density of between about 50 and 70 picks/cm after the weaving and before the shrinking.

21. A fabric according to any one of the preceding claims, wherein the predetermined arrangement comprises a pick density of between about 55 and 75 picks/cm, including 55 and 75 picks/cm, after the three domestic washes.

22. A fabric according to any preceding claim, wherein the warp yarns have a count of english cotton yarns between about Ne 10 and Ne30, inclusive Ne 10 and Ne 30.

23. A fabric according to any preceding claim, wherein the warp yarns have a count of cotton in english between about Ne 15 and Ne25, inclusive Ne 15 and Ne 25.

24. A fabric according to any preceding claim, wherein the warp yarns have a count of english cotton yarns between about Ne 10 and Ne70, including Ne 10 and Ne70, preferably between about Ne 15 and Ne 50, including Ne 15 and Ne 50.

25. A fabric according to any preceding claim, wherein the elastomeric yarns have a denier of between about 40 and 140 denier, preferably between about 50 and 90 denier, including 40 and 140 denier, 50 and 90 denier.

26. The fabric of any of the preceding claims, wherein the elongation of the second elastic yarn (105) is at least 10% greater than the elongation of the first hard yarn (106).

27. A fabric according to any preceding claim, wherein the warp yarns (104) are indigo dyed yarns, preferably ring dyed yarns.

28. A fabric according to any preceding claim, wherein the ratio of warp yarns (104) traversed by the loop portions (107a) and the connecting portions (108a) is between 6:1 and 24:1, inclusive.

29. A fabric according to any preceding claim, wherein the ratio of elastic yarns (105) to hard yarns (106) is between 2:1 and 1:5, including 2:1 and 1: 5.

30. A fabric according to any preceding claim, wherein the ratio of elastic yarns (105) to hard yarns (106) is between 1:2 and 1:3, including 1:2 and 1: 3.

31. The fabric according to any of the preceding claims, wherein for a corresponding number of warp yarns (104) in the weaving pattern, the ratio of the number of upper portions (110) obtained by the up-and-down movement of the elastic yarns (105) is 2 to 12 times the number of upper portions obtained by the up-and-down movement of the hard yarns (106).

32. The fabric of any of the preceding claims, wherein the elastic lower portion (109) is substantially covered by the loop portion (107a), wherein the elastic lower portion (109) is difficult to see and touch when the fabric (101) is in a relaxed state.

33. The fabric of any of the preceding claims, wherein the loop portions (107a) substantially prevent warp yarns (104) traversed by the connecting portions from contacting a surface covered by the fabric.

34. A fabric as claimed in any one of the preceding claims wherein the ratio of the average number of warp yarns traversed by the loop portion to the warp yarn density is between about 0.2 and 0.7, inclusive of 0.2 and 0.7.

35. A fabric according to any preceding claim, wherein the ratio of the average number of warp yarns (104) traversed by the loop portion (107a) to the average number of warp yarns (104) traversed by the connecting portion (108a) is between 6 and 24, inclusive.

36. A fabric having a first weave and a second weave;

wherein the first woven fabric forms a front side of the product, the first woven fabric comprising warp yarns (104) and elastic weft yarns (105) tightly woven in a predetermined pattern, wherein the second woven fabric forms a back side of the fabric, the second woven fabric comprising the warp yarns (104) and hard weft yarns (106) loosely woven in a predetermined pattern such that lower and upper portions of the hard weft yarns are alternately arranged with respect to the warp yarns, the lower portions forming and defining loop portions (107a) when the hard weft yarns pass along a back side of the warp yarns (104), and the upper portions forming and defining connecting portions when the hard weft yarns pass along a front side of the warp yarns,

wherein the average number of warp yarns traversed by the loop portion is at least 6 for each hard weft yarn,

wherein the elastic weft yarns form lower parts (109) and upper parts (110) alternately arranged in a closer weave than the weave of the hard yarns with respect to the warp yarns, and

wherein the elastic yarns and hard weft yarns are arranged in a predetermined arrangement comprising at least one hard yarn alternating with at least one elastic yarn, the elastic yarn having a shrinkage greater than the shrinkage of the hard yarn (106), thereby forming an elastic structure in the fabric, the elastic yarn shrinking more than the hard yarn when the finished fabric is removed from the loom, and the hard yarn lower portion providing a plurality of loop portions (107a) on the rear side of the fabric.

37. The fabric of claim 36 wherein said second weave substantially prevents warp yarns (104) traversed by elastic yarns of said first weave from contacting a surface covered by said fabric.

38. A fabric as claimed in claim 36 or 37 wherein said second weave substantially covers the warp and elastic weft yarns of said first weave on the rear face of said fabric, wherein the warp and weft yarns of said first weave are difficult to see and touch on the rear face of said fabric.

39. A product having the fabric (101) of any one of claims 1-38.

40. The article of claim 39, wherein the article is a garment and the loop is on a back side of the garment.

41. A method for manufacturing a fabric, the method comprising:

providing warp yarns (104);

providing a hard weft yarn (106);

-providing an elastic weft yarn (105);

selecting a weave pattern in which

At least one hard yarn (106) alternating with at least one elastic yarn (105),

the hard yarns alternate through a predetermined number of warp yarns along the back side of the warp yarns, each pass forming a series of hard lower portions (107), and alternate through a predetermined number of warp yarns along the front side of the warp yarns, each pass forming a hard upper portion (108), and

the average number of warp yarns (104) traversed by each lower portion is at least 6 for each hard yarn, and

the elastic yarns (105) alternate across each pass along a back side of a warp yarn of the predetermined number of warp yarns to form a series of elastic lower portions and alternate across each pass along a front side of a warp yarn of the predetermined number of warp yarns to form a series of elastic upper portions, whereby the alternating elastic yarns and hard weft yarns form an elastic structure in the fabric;

weaving the fabric according to the selected pattern;

contracting the woven fabric, wherein the elastic weft yarns contract more than the hard weft yarns such that the hard lower portions form loop portions (107 a).

42. The method of claim 40, wherein the shrinking step occurs when the fabric is removed from the loom and the yarns are no longer under tension, further shrinkage being performed by wetting the fabric.

43. The method of claim 42, further comprising applying to the fabric at least one of: bleaching, manual scraping, sand blasting, stone washing, printing pictures, printing fonts, embroidery, brushing and abrasion.

44. The method of claim 42, further comprising cutting the fabric into a garment.

45. The method of any of claims 41 to 43, wherein the step of providing warp yarns comprises selecting a warp yarn density for the warp yarns.

46. The method of any of claims 41 to 44 wherein the step of providing hard weft yarns and elastic weft yarns further comprises selecting a weft yarn density.

47. A method according to claim 42, characterized in that the number of warp threads (104) traversed by the loop portion (107a) formed by the lower part of the first weft thread is at least 6 times the number of warp threads traversed by the connecting portion (108a) formed by the upper part of the first weft thread (106); the number of warp yarns (104) passed through by the loop portions (107a) is in the range of 6 to 24, and the loop portions (107a) are provided on the rear side of the fabric, whereby the loop portions (107a) of adjacent hard weft yarns (106) and connecting portions (108a) of adjacent hard weft yarns formed by upper portions of the first weft yarns (106) form a pattern extending in a direction relative to a diagonal of the warp yarns (104) and the weft yarns so as to provide a diagonal pattern, whereby the fabric extends in a direction relative to the diagonal of the warp yarns and the weft yarns.