Stiff, non-deformed and non-pilling woven air layer fabric and its manufacturing method

Abstract

The present invention proposes a woven air layer fabric that is stiff, non-deformed and non-pilling, comprising a fabric body, the fabric body comprising a surface layer, an inner layer and an intermediate layer, the surface layer is formed by interweaving a surface warp and a surface weft in a woven manner, the inner layer is formed by interweaving a inner warp and an inner weft in a woven manner, the intermediate layer is a binding weft extending along the weft direction, the binding weft is interwoven in the surface layer and the inner layer in a sinking and floating manner, the surface warp and the inner warp are both first core-spun yarns, the first core-spun yarns are yarns formed by 75D / 72F polyester coated with 40D spandex, the surface weft and the inner weft are both second core-spun yarns, the second core-spun yarns are yarns formed by 75D / 36F polyester coated with 40D spandex, and the binding weft is 150D / 288F polyester. On the basis of having the bulkiness, skin-friendliness, air permeability and ductility of knitted plus silk cloth and air layer, it also avoids the problems of easy hair loss, easy deformation, easy pilling and easy fading, making the woven air layer more comfortable and stylish. The invention also provides a method for making the fabric.

Description

Technical Field

[0001] The invention relates to a woven air layer fabric which is crisp, non-deformed and non-pilling, and a method for manufacturing the woven air layer fabric. Background Art

[0002] In spring and autumn, knitted pullover sweatshirts, knitted zipper tops, and knitted trousers are popular among consumers for their excellent skin-friendliness, breathability, and ductility. There are currently three mainstream methods on the market:

[0003] (1) The solution of choosing knitted sweater fabric: The terry fabric has good air permeability and ductility, can retain more air inside, and can obtain better warmth retention, but the terry fabric is very loose, which leads to easy shedding, deformation, and pilling during wearing and washing. In addition, the terry on the back of the sweater is raised, which has the risk of snagging and pulling. At the same time, sweater fabric generally contains cotton material and has a relatively serious problem of fading after washing;

[0004] (2) The scheme of using knitted silk cloth and air layer: the surface layer and the inner layer are generally made of 26S-60S combed cotton, and the middle weft layer is generally made of 75D-150D polyester yarn, forming a cotton-polyester structure, which is tighter than the sweater fabric. It not only has good skin-friendliness, but also greatly improves the stiffness and shape retention, and basically avoids the problem of hair loss. However, the surface and inner layers are made of cotton. During the wearing and washing process, the deformation and pilling problems have improved but still occur frequently, and there is also a relatively serious problem of water washing and color fading;

[0005] (3) The scheme of using woven fabrics with reverse polar fleece: the surface layer is made of 30D-50D polyester natural stretch, or 30-50D polyester + 20D-40D spandex, or 30-40D nylon + 20-40 spandex, woven into plain or twill weave, and the reverse polar fleece is made of 160g-240g single brushed single shake. The reverse side of the surface layer is compounded with the polar fleece using TPU glue by point-sticking technology. The point-sticking area reaches 30%-40%, and the hollow area reaches 60-70%. The fluffiness, breathability, skin-friendliness and ductility of knitted silk cloth and air layer can be obtained, and the problems of easy deformation and fading of silk cloth and air layer can be avoided. However, due to the composite method and the polar fleece surface in the middle, the composite fastness is not good enough, and it can barely ensure that it will not fall off or bubble after washing. The problem of obvious wrinkling after washing is inevitable. At the same time, the polar fleece non-fleece surface exposed outside is easy to pilling during wearing and washing.

[0006] In view of this, the inventors of this case conducted in-depth research on the above-mentioned issues, which led to the creation of this case. Summary of the Invention

[0007] The purpose of the present invention is to provide a woven air layer fabric, which has the bulkiness, skin-friendliness, breathability and ductility of knitted silk cloth and air layer, and avoids the problems of easy shedding, deformation, pilling and fading, making the woven air layer more comfortable and stylish.

[0008] In order to achieve the above object, the present invention adopts such technical solution:

[0009] A crisp, non-deformable and non-pilling woven air layer fabric comprises a fabric body, wherein the fabric body comprises a surface layer, an inner layer and an intermediate layer formed between the surface layer and the inner layer, the surface layer is woven by surface warp and surface weft, the inner layer is woven by inner warp and inner weft, the surface warp and inner warp extend in the warp direction, and the surface weft and inner weft extend in the weft direction, the intermediate layer is a tied weft extending in the weft direction, and the tied weft is woven in the surface layer and the inner layer in a sinking and floating manner, the surface warp and the inner warp are both first core-spun yarns, the first core-spun yarns are yarns formed by 75D / 72F polyester coated with 40D spandex, the surface weft and the inner weft are both second core-spun yarns, the second core-spun yarns are yarns formed by 75D / 36F polyester coated with 40D spandex, and the tied wefts are 150D / 288F polyester.

[0010] As a preferred embodiment of the present invention, the number of the outer warps and the number of the inner warps are the same.

[0011] As a preferred embodiment of the present invention, the number of the surface wefts and the number of the inner wefts are the same.

[0012] As a preferred embodiment of the present invention, the weight of the fabric is 260g / m 2 .

[0013] As a preferred embodiment of the present invention, along the weft direction, the total number of the surface warp and the lining warp per inch on the fabric body is 292, and along the warp direction, the total number of the surface weft, the lining weft and the binding weft per inch on the fabric body is 246.

[0014] As a preferred embodiment of the present invention, in the surface layer, a cycle structure is composed of 12 surface warps, 8 surface wefts and 4 binding wefts interwoven in the following manner: along the weft direction, the interweaving manner of the first surface weft and the 12 surface warps is: sinking-sinking-sinking-floating-sinking-sinking-sinking-floating-sinking-floating-sinking-floating-sinking-floating; along the weft direction, the interweaving manner of the 12 surface warps and the first binding weft is: floating-floating-sinking-floating-floating-floating-sinking-floating-floating-floating-sinking-floating; along the weft direction, the second surface weft and the 12 binding weft are interwoven in the following manner: floating-floating-sinking-floating ... The interweaving modes of the surface weft and the 12 surface warps are: sinking-floating-sinking-sinking-sinking-floating-sinking-sinking-sinking-sinking-sinking-sinking; along the weft direction, the interweaving modes of the third surface weft and the 12 surface warps are: sinking-sinking-sinking-floating-sinking-sinking-sinking-floating-sinking-floating-sinking-floating; along the weft direction, the interweaving modes of the 12 surface warps and the second binding weft are: floating-floating-floating-sinking-floating-floating-floating-sinking-floating-floating-floating-sinking; along the weft direction, the interweaving modes of the fourth surface weft and the 12 surface warps are: The interweaving patterns of the fifth surface weft and the 12 surface warps are: sinking-floating-sinking-sinking-floating-sinking-sinking-floating-sinking-floating-sinking-floating-sinking-floating; along the weft direction, the interweaving patterns of the 12 surface warps and the third binding weft are: sinking-floating-floating-floating-sinking-floating-floating-floating-sinking-floating-floating-floating-floating-floating; along the weft direction, the interweaving patterns of the sixth surface weft and the 12 surface warps are: sinking-floating-sinking-sinking-sinking -float-sink-sink-sink-sink-sink-sink; along the weft direction, the interweaving modes of the seventh surface weft and the 12 surface warps are respectively: sink-sink-sink-float-sink-sink-sink-float-sink-float-sink-float-sink-float; along the weft direction, the interweaving modes of the 12 surface warps and the fourth binding weft are respectively: float-sink-float-float-float-sink-float-float-sink-float-float-sink-float-float-float; along the weft direction, the interweaving modes of the eighth surface weft and the 12 surface warps are respectively: sink-float-sink-sink-sink-float-sink-sink-float-sink-sink-float-sink-sink-float-sink.

[0015] As a preferred embodiment of the present invention, in the inner layer, a cycle structure is composed of 12 inner warps, 8 inner wefts and 4 binding wefts interwoven in the following manner: along the weft direction, the interweaving manner of the first inner weft and the 12 inner warps is: sinking-floating-floating-floating-sinking-floating-floating-floating-sinking-floating-floating-sinking-floating-floating; along the weft direction, the interweaving manner of the first binding weft and the 12 inner warps is: floating-floating-floating-sinking-floating-floating-floating-sinking-floating-floating-floating-floating; along the weft direction, the interweaving manner of the first binding weft and the 12 inner warps is: floating-floating-floating-sinking-floating-floating-floating-sinking-floating-floating-floating-floating; along the weft direction, the second The interweaving modes of the inner weft and the 12 inner warps are: float-float-sink-float-float-float-sink-float-float-float-float-float; along the weft direction, the interweaving modes of the third inner weft and the 12 inner warps are: sink-float-float-float-sink-float-float-float-sink-float-float-sink-float-float; along the weft direction, the interweaving modes of the second binding weft and the 12 inner warps are: sink-float-float-float-sink-float-float-float-sink-float-float-float-float; along the weft direction, the interweaving modes of the fourth inner weft and the 12 inner warps are: sink-float-float-float-sink-float-float-float-float-float-float-float The interweaving patterns of the fifth inner weft and the 12 inner warps are: sinking-floating-floating-floating-sinking-floating-floating-floating-sinking-floating-floating-sinking-floating-floating; along the weft direction, the interweaving patterns of the third binding weft and the 12 inner warps are: floating-sinking-floating-floating-floating-sinking-floating-floating-floating-sinking-floating-floating-floating-floating-floating-floating-floating-floating; along the weft direction, the interweaving patterns of the sixth inner weft and the 12 inner warps are: floating-floating-sinking-floating-floating -float-sink-float-float-float-float-float; along the weft direction, the interweaving modes of the seventh inner weft and the 12 inner warps are respectively: sink-float-float-float-sink-float-float-float-sink-float-float-sink-float-float; along the weft direction, the interweaving modes of the fourth binding weft and the 12 inner warps are respectively: float-float-sink-float-float-float-sink-float-float-float-sink-float-float-float; along the weft direction, the interweaving modes of the eighth inner weft and the 12 inner warps are respectively: float-float-sink-float-float-float-float-sink-float-float-float-float-sink-float.

[0016] The present invention also provides a method for manufacturing a woven air layer fabric that is crisp, non-deformed, and non-pilling, which is characterized by comprising the following steps:

[0017] Material selection: The first core-spun yarn is used for both the surface warp and the lining warp. The first core-spun yarn is 75D / 72F polyester covered with 40D spandex. The second core-spun yarn is 75D / 36F polyester covered with 40D spandex for both the surface weft and the lining weft. The binding weft is 150D / 288F polyester.

[0018] Weaving: Using a water jet loom, the surface warp and the inner weft are interwoven to form the surface layer, and the inner warp and the inner weft are interwoven to form the inner layer. An independent weft yarn system is added between the surface weft and the inner weft. The weft points formed by the weft binding and the surface warp are covered with the surface weft floats, and the weft points formed by the weft binding and the inner warp are covered with the weft floats. The surface layer and the inner layer are connected by the weft binding to form the grey fabric;

[0019] Dyeing and finishing: After the grey cloth is degreased, it enters the dyeing vat, is dyed with disperse dyes, and is set using setting dyes.

[0020] After adopting the technical solution of the present invention, a woven structure is adopted, and the surface layer and inner layer are tightly structured. The weft binding serves as a stable intermediate layer structure, making the fabric crisp and stylish, avoiding the problem of easy deformation of knitted silk cloth and air layer. The weft binding intermediate layer has a fluffiness comparable to that of knitted silk cloth and air layer, which can retain a large amount of air, making the fabric warm, breathable, and soft to the touch. At the same time, the presence of spandex gives the fabric good ductility, making the clothing made of the fabric very comfortable to wear. The surface and inner layers are made of polyester imitation cotton filament material, which is woven into a dense and tight woven structure, making the fabric color fastness and fastness very good, avoiding the problems of shedding, pilling, and fading caused by knitted silk cloth and the use of cotton material in the air layer. The cost of the present invention is more expensive than knitted sweater fabric of the same gram weight, close to that of knitted silk cloth of the same gram weight, and cheaper than knitted air layer of the same gram weight. The present invention also proposes a method for making the fabric, which has the advantage of simple process. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a structural diagram of the present invention;

[0022] Figure 2 It is a schematic structural diagram of a cyclic organization of the present invention;

[0023] In the picture:

[0024] Surface layer 10 Surface diameter 11

[0025] Surface weft 12, inner weft 20

[0026] Longitude 21 Li Latitude 22

[0027] Middle layer 30 Weft binding 31 DETAILED DESCRIPTION

[0028] In order to further explain the technical solution of the present invention, it is described in detail below with reference to embodiments.

[0029] Reference Figures 1 to 2 , in order to better represent the interweaving points of the yarns, Figure 2In the figure, color blocks or boxes of different depths are used to represent the interweaving points. Among them, type A squares are the interweaving points of surface warp 11 and surface weft 12, with surface warp 11 floating on top; type E squares are the interweaving points of inside warp 21 and inside weft 22, with inside warp floating on top; type C squares are the interweaving points of surface warp 11 and binding weft 31, with surface warp 11 floating on top; type F squares are the interweaving points of inside warp 21 and binding weft 31, with inside warp 21 floating on top; surface weft 12: inside weft 22: binding weft 31 = 2:2:1; type B squares: surface weft floating points; type D squares: inside weft floating points.

[0030] The D in 75D, 40D, and 150D of the present invention refers to the denier in the industry and refers to the weight of 9000 meters of yarn (in grams). The F in 36F, 72F, and 288F of the present invention refers to the number of microfibers in a yarn.

[0031] The present invention provides a crisp, non-deformable and non-pilling woven air layer fabric, comprising a fabric body, which comprises a surface layer 10, an inner layer 20 and an intermediate layer 30 formed between the surface layer 10 and the inner layer 20. The surface layer 10 is formed by weaving together a surface warp 11 and a surface weft 12, and the inner layer 20 is formed by weaving together a inner warp 21 and a inner weft 22. The surface warp 11 and the inner warp 21 extend in the warp direction, and the surface weft 12 and the inner weft 22 extend in the weft direction. The intermediate layer 30 is a binding weft 31 extending in the weft direction, and the binding weft 31 is interwoven in the surface layer 10 and the inner layer 20 in a sinking and floating manner.

[0032] Polyester is crisp, stylish, and quick-drying, with a thermal conductivity as low as 0.084 W / (m·K). It's non-cooling to the touch, keeping skin dry in the summer and comfortable in the spring and autumn. Since knitted pullovers, knitted zippered tops, and knitted trousers are typically worn close to the skin in spring and autumn, with temperatures typically between 8°C and 20°C, the fabric needs to offer both warmth and breathability, making polyester a suitable material. For excellent stretchability, spandex, an elastic fiber, is also used.

[0033] In the present invention, both the surface warp 11 and the lining warp 21 are first core-spun yarns, made of 75D / 72F polyester covered with 40D spandex. The surface wefts 12 and the lining wefts 22 are second core-spun yarns, made of 75D / 36F polyester covered with 40D spandex. The binding weft 31 is 150D / 288F polyester. More preferably, the first core-spun yarn is semi-matte DTY, the second core-spun yarn is DTY, and the binding weft 31 is semi-matte DTY. DTY is a stretch-textured yarn that curls like a spring, adding shape to the fabric. The semi-gloss polyester yarn has a sheen that's neither as blazing as glossy yarn nor as subtle as matte. The spandex core-spun yarn, made of 75D polyester as the sheath and 40D spandex as the core, ensures the fabric possesses stretch comparable to knitted fabrics with added silk and air layers. Both the first and second core-spun yarns are cotton-feel yarns, giving the fabric a cotton feel comparable to knitted silk fabric and air layers (with combed cotton inner and outer layers), achieving good skin-friendliness while also avoiding the color fading problem associated with cotton materials when washed. 150D / 288F polyester is selected as the weft binding 31, located in the middle layer 30. This high denier and F-number yarn is thick and soft, giving the fabric a crisp and stylish look, offering better shape retention than knitted silk fabric and air layers. Furthermore, the thick and soft yarn gives the middle layer 30 a loftiness comparable to that of the weft binding 31 layer of knitted silk fabric and air layers, retaining a large amount of air and making the fabric comfortable, warm, and stylish. In the present invention, the weft binding 31 is made of a thick and soft polyester material, allowing for the formation of a fluffy weft binding 31 layer directly in the middle layer 30, thereby achieving the objectives of the present invention.

[0034] As a preferred embodiment of the present invention, the number of the outer warps 11 and the number of the inner warps 21 are the same.

[0035] As a preferred embodiment of the present invention, the number of the surface wefts 12 and the number of the inner wefts 22 are the same.

[0036] As a preferred embodiment of the present invention, the weight of the fabric is 260g / m 2 .

[0037] As a preferred embodiment of the present invention, along the weft direction, the total number of the surface warp 11 and the lining warp 21 per inch on the fabric body is 292, and along the warp direction, the total number of the surface weft 12, the lining weft 22 and the binding weft 31 per inch on the fabric body is 246.

[0038] As a preferred embodiment of the present invention, in the surface layer 10, a cycle structure is interwoven by 12 surface warps 11, 8 surface wefts 12 and 4 binding wefts 31 in the following manner: along the weft direction (specifically, Figure 2In the weft direction, from left to right, the same below), the interweaving patterns of the first surface weft 12 and the 12 surface warps 11 are respectively: sinking-sinking-sinking-floating-sinking-sinking-sinking-floating-sinking-floating-sinking-floating; along the weft direction, the interweaving patterns of the 12 surface warps 11 and the first binding weft 31 are respectively: floating-floating-sinking-floating-floating-floating-sinking-floating-floating-floating-sinking-floating; along the weft direction, the interweaving patterns of the second surface weft 12 and the 12 surface warps 11 are respectively: sinking-floating-sinking-sinking-sinking-floating-sinking-sinking- Sink-sink-sink-sink; along the weft direction, the interweaving modes of the third surface weft 12 and the 12 surface warps 11 are: sink-sink-sink-float-sink-sink-sink-float-sink-float-sink-float-sink-float; along the weft direction, the interweaving modes of the 12 surface warps 11 and the second binding weft 31 are: float-float-float-sink-float-float-float-sink-float-float-float-sink-float-float-sink; along the weft direction, the interweaving modes of the fourth surface weft 12 and the 12 surface warps 11 are: sink-float-sink-sink-sink-float-sink-float-sink-float-sink-float-sink -sink-sink; along the weft direction, the interweaving modes of the fifth surface weft 12 and the 12 surface warps 11 are respectively: sink-sink-sink-float-sink-sink-sink-float-sink-float-sink-float-sink-float; along the weft direction, the interweaving modes of the 12 surface warps 11 and the third binding weft 31 are respectively: sink-float-float-float-float-sink-float-float-float-sink-float-float-float-float; along the weft direction, the interweaving modes of the sixth surface weft 12 and the 12 surface warps 11 are respectively: sink-float-sink-sink-sink-float-sink-sink-sink-sink-sink-sink-sink-sink -sink; along the weft direction, the interweaving modes of the seventh surface weft 12 and the 12 surface warps 11 are respectively: sink-sink-sink-float-sink-sink-sink-float-sink-float-sink-float-sink-float; along the weft direction, the interweaving modes of the 12 surface warps 11 and the fourth binding weft 31 are respectively: float-sink-float-float-float-sink-float-float-sink-float-float-sink-float-float; along the weft direction, the interweaving modes of the eighth surface weft 12 and the 12 surface warps 11 are respectively: sink-float-sink-sink-sink-float-sink-sink-sink-float-sink-sink-float-sink-sink-float.

[0039] As a preferred embodiment of the present invention, in the inner layer 20, a cycle structure is composed of 12 inner warps 21, 8 inner wefts 22 and 4 binding wefts 31 interwoven in the following manner: along the weft direction, the interweaving manner of the first inner weft 22 and the 12 inner warps 21 is: sinking-floating-floating-floating-floating-sinking-floating-floating-floating-sinking-floating-floating-sinking-floating; along the weft direction, the interweaving manner of the first binding weft 31 and the 12 inner warps 21 is: floating-floating-floating-sinking-floating-floating-floating-sinking-floating-floating-floating-floating; along the weft direction, the interweaving manner of the first binding weft 31 and the 12 inner warps 21 is: floating-floating-floating-sinking-floating-floating-floating-floating-sinking-floating-floating-floating-floating; along the weft direction, the second The interweaving patterns of the inner weft 22 and the 12 inner warps 21 are: float-float-sink-float-float-float-sink-float-float-float-float-float-float; along the weft direction, the interweaving patterns of the third inner weft 22 and the 12 inner warps 21 are: sink-float-float-float-float-sink-float-float-float-sink-float-float-float-sink-float; along the weft direction, the interweaving patterns of the second binding weft 31 and the 12 inner warps 21 are: sink-float-float-float-float-sink-float-float-float-sink-float-float-float; along the weft direction, the fourth inner weft 22 and the 12 inner warps 21 are: sink-float-float-float-float-sink-float-float-float-float-float The interweaving modes of the fifth inner weft 22 and the 12 inner warps 21 are respectively: floating-floating-sinking-floating-floating-floating-sinking-floating-floating-sinking-floating-floating-floating-sinking-floating-floating; along the weft direction, the interweaving modes of the third binding weft 31 and the 12 inner warps 21 are respectively: floating-sinking-floating-floating-floating-sinking-floating-floating-floating-sinking-floating-floating-floating-floating-floating-floating-floating-floating; along the weft direction, the interweaving modes of the sixth inner weft 22 and the 12 inner warps 21 are respectively: floating-floating-sinking-floating -float-float-sink-float-float-float-float-float; along the weft direction, the interweaving modes of the seventh inner weft 22 and the 12 inner warps 21 are respectively: sink-float-float-float-sink-float-float-float-sink-float-float-sink-float-float; along the weft direction, the interweaving modes of the fourth binding weft 31 and the 12 inner warps 21 are respectively: float-float-sink-float-float-float-sink-float-float-float-float-sink-float; along the weft direction, the interweaving modes of the eighth inner weft 22 and the 12 inner warps 21 are respectively: float-float-sink-float-float-float-float-sink-float-float-float-float-sink-float-float.

[0040] The present invention also provides a method for manufacturing a woven air layer fabric that is crisp, non-deformed, and non-pilling, which is characterized by comprising the following steps:

[0041] Material selection: The first core-spun yarn is used for both the surface warp 11 and the lining warp 21. The first core-spun yarn is 75D / 72F polyester covered with 40D spandex. The second core-spun yarn is 75D / 36F polyester covered with 40D spandex for both the surface weft 12 and the lining weft 22. The second core-spun yarn is 150D / 288F polyester.

[0042] Weaving: Using a water jet loom, according to the above-mentioned organization, the surface warp 11 and the inner weft 22 are interwoven into the surface layer 10, the inner warp 21 and the inner weft 22 are interwoven into the inner layer 20, and an independent weft yarn system is added between the surface weft 12 and the inner weft 22 to interweave the binding weft 31 with the surface warp 11. The weft organization points formed are covered by the floating long lines of the surface weft 12, and the weft organization points formed by the interweaving of the binding weft 31 and the inner warp 21 are covered by the floating long lines. The surface layer 10 and the inner layer 20 are connected by the binding weft 31 to form a grey cloth; when weaving, the present invention uses polyester imitation cotton filament material, and the density is high, so that the fabric has good elasticity, feel, and fastness, avoiding the problems of hair loss, pilling, and fading caused by knitted silk cloth and the use of cotton material for the air layer. The weft binding 31 of the middle layer 30 is made of 150D / 288F polyester. It is interwoven with the surface warp 11, creating weft points covered by the floats of the surface weft 12. It is then interwoven with the lining warp 21, creating weft points covered by the floats of the lining weft 22. This creates a stylish, micro-wrinkle effect on the fabric surface. It also securely connects the front and back layers 20, effectively reducing yarn slippage and strengthening the double-layer structure. The coarse and soft weft binding 31 gives the middle layer 30 a loft comparable to knitted silk fabrics and air layers, retaining a large amount of air, resulting in a rich, crisp, stylish, warm, breathable, and soft feel. The high-density, compact surface layer 10 and lining layer 20, combined with the stable and secure weft binding 31 of the middle layer 30, ensures the fabric's excellent shape retention, avoiding the deformation problems of knitted silk fabrics and air layers.

[0043] Dyeing and finishing: After the grey cloth is degreased, the subsequent fabric dyeing effect and the feel of the finished fabric are guaranteed. The grey cloth needs to go through two processes to remove the oil on the grey cloth. First, it is degreased by the degreaser, and then the cloth is boiled in the vat for degreasing; after degreasing, it is dyed in the vat and dyed with disperse dyes; it is shaped using a setting machine to ensure that the dimensional stability, width, gram weight, and warp and weft density meet the predetermined specifications. After shaping, the finished fabric is obtained. The composition of the present invention is 88% (mass percentage) polyester fiber and 12% spandex, with a gram weight of 260g / m 2 The weight is similar to the knitted sweater fabric, plus silk fabric, and air layer commonly used in spring and autumn 250-300g / m 2 The gram weight range is very consistent with the warp density 292*weft density 246 (the sum of the warp and weft densities of the double layer).

[0044] The present invention also includes garment-making steps: 1. Pattern making: Based on a design (sports suit), pattern marking is made and printed; 2. Cutting: Cutting the fabric according to the pattern to obtain garment pieces; 3. Sewing and pressing: Sewing and pressing the prepared garment pieces with relevant accessories. These steps produce a crisp, shape-resistant, and pilling-resistant woven air-layer zippered top. This fabric is not limited to making pullovers, zippered tops, or sports pants.

[0045] Through the above steps, the relevant test parameters of the fabric are as follows:

[0046]

[0047]

[0048] The present invention achieves a bulkiness that is 80% of that of knitted fabrics. The fabric's rise, while tested against a knitted cotton-polyester-silk fabric with a height of 8.6mm, is very prone to deformation, while the fabric's rise is 1.9mm, showing excellent resistance to deformation. Surface roughness testing also reveals a surface roughness of 50µm, while the average surface roughness of the knitted samples tested is 110µm, exceeding that of most fabrics. The fabric's surface is extremely smooth and skin-friendly.

[0049] The product form of the present invention is not limited to the embodiments of this case. Any appropriate changes or modifications made by anyone with similar ideas should be deemed to be within the patent scope of the present invention.

Claims

1. A woven air layer fabric that is crisp, non-deformed and non-pilling, comprising a fabric body, the fabric body comprising a surface layer, an inner layer and an intermediate layer formed between the surface layer and the inner layer, the surface layer is woven by a surface warp and a surface weft, the inner layer is woven by a inner warp and an inner weft, the surface warp and the inner warp extend in the warp direction, and the surface weft and the inner weft extend in the weft direction, characterized in that: The middle layer is a weft binding extending in the weft direction, and the weft binding is interwoven in the surface layer and the inner layer in a sinking and floating manner, the surface warp and the inner warp are both first core-spun yarns, and the first core-spun yarns are yarns formed by 75D / 72F polyester covered with 40D spandex, the surface weft and the inner weft are both second core-spun yarns, and the second core-spun yarns are yarns formed by 75D / 36F polyester covered with 40D spandex, and the weft binding is 150D / 288F polyester; The number of the surface warp and the lining warp is the same; the weight of the fabric is 260g / m 2 .

2. The crisp, non-deformed and non-pilling woven air layer fabric according to claim 1, characterized in that: The number of the surface wefts and the number of the inner wefts are the same.

3. The crisp, non-deformed and non-pilling woven air layer fabric according to claim 2, characterized in that ： 4. The crisp, non-deformed and non-pilling woven air layer fabric according to claim 3, characterized in that: Along the weft direction, the total number of the surface warp and the lining warp per inch on the fabric body is 292, and along the warp direction, the total number of the surface weft, the lining weft and the binding weft per inch on the fabric body is 246.

5. The crisp, non-deformed and non-pilling woven air layer fabric according to claim 1, characterized in that: In the surface layer, one cycle structure is interwoven with 12 surface warps, 8 surface wefts and 4 binding wefts in the following manner: along the weft direction, the interweaving manner of the first surface weft and the 12 surface warps is: sinking-sinking-sinking-floating-sinking-sinking-sinking-floating-sinking-floating-sinking-floating; along the weft direction, the interweaving manner of the 12 surface warps and the first binding weft is: floating-floating-sinking-floating-floating-floating-sinking-floating-floating-floating-sinking-floating; along the weft direction, the interweaving manner of the second surface weft and the 12 surface warps is: floating-floating-sinking-floating-floating-floating-floating-floating-sinking-floating-floating-floating-floating-sinking-floating; The interweaving modes of the first and second surface wefts are as follows: sink-float-sink-sink-sink-float-sink-sink-sink-sink-sink-sink-sink-sink; along the weft direction, the interweaving modes of the third surface weft and the 12 surface warps are as follows: sink-sink-sink-float-sink-sink-sink-float-sink-float-sink-float-sink-float; along the weft direction, the interweaving modes of the 12 surface warps and the second binding weft are as follows: float-float-float-sink-float-float-float-float-sink-float-float-float-sink-float; along the weft direction, the interweaving modes of the fourth surface weft and the 12 surface warps are as follows: sink- Float-sink-sink-sink-float-sink-sink-float-sink-sink-sink; along the weft direction, the interweaving modes of the fifth surface weft and the 12 surface warps are: sink-sink-sink-float-sink-sink-float-sink-float-sink-float-sink-float; along the weft direction, the interweaving modes of the 12 surface warps and the third binding weft are: sink-float-float-float-float-sink-float-float-float-sink-float-float-float-float; along the weft direction, the interweaving modes of the sixth surface weft and the 12 surface warps are: sink-float-sink-sink-sink-float-sink-float-sink-float -sink-sink-sink-sink-sink; along the weft direction, the interweaving modes of the seventh surface weft and the 12 surface warps are: sink-sink-sink-float-sink-sink-sink-float-sink-float-sink-float; along the weft direction, the interweaving modes of the 12 surface warps and the fourth binding weft are: float-sink-float-float-float-sink-float-float-sink-float-float-sink-float-float; along the weft direction, the interweaving modes of the eighth surface weft and the 12 surface warps are: sink-float-sink-sink-sink-float-sink-sink-sink-float-sink-sink-float-sink-float.

6. The crisp, non-deformed and non-pilling woven air layer fabric according to claim 5, characterized in that: In the inner layer, a cycle structure is composed of 12 inner warps, 8 inner wefts and 4 binding wefts interwoven in the following manner: along the weft direction, the interweaving manner of the first inner weft and the 12 inner warps is: sink-float-float-float-sink-float-float-float-sink-float-float-sink-float-float; along the weft direction, the interweaving manner of the first binding weft and the 12 inner warps is: float-float-float-sink-float-float-float-sink-float-float-float-float-sink; along the weft direction, the interweaving manner of the second inner weft and the 12 inner warps is: float-float-float-sink-float-float-float-float-sink-float-float-float-sink; The interweaving modes of the third inner weft and the 12 inner warps are: floating-floating-sinking-floating-floating-floating-sinking-floating-floating-floating-floating-floating; along the weft direction, the interweaving modes of the third inner weft and the 12 inner warps are: sinking-floating-floating-floating-floating-sinking-floating-floating-floating-sinking-floating-floating-floating-sinking-floating-floating; along the weft direction, the interweaving modes of the second binding weft and the 12 inner warps are: sinking-floating-floating-floating-floating-sinking-floating-floating-floating-sinking-floating-floating-floating; along the weft direction, the interweaving modes of the fourth inner weft and the 12 inner warps are: floating- Float-sink-float-float-float-sink-float-float-sink-float-float-float; along the weft direction, the interweaving mode of the fifth inner weft and the 12 inner warps is: sink-float-float-float-float-sink-float-float-float-sink-float-float-float-float; along the weft direction, the interweaving mode of the third binding weft and the 12 inner warps is: float-sink-float-float-float-float-sink-float-float-float-float-sink-float-float; along the weft direction, the interweaving mode of the sixth inner weft and the 12 inner warps is: float-float-sink-float-float-float-float-sink-float-float -float-float-float-float-float; along the weft direction, the interweaving modes of the seventh inner weft and the 12 inner warps are: sink-float-float-float-sink-float-float-float-sink-float-float-sink-float-float; along the weft direction, the interweaving modes of the fourth binding weft and the 12 inner warps are: float-float-sink-float-float-float-sink-float-float-float-float-sink-float; along the weft direction, the interweaving modes of the eighth inner weft and the 12 inner warps are: float-float-sink-float-float-float-float-float-float-float-sink-float-float-float-sink.

7. A method for producing a stiff, non-deformed and non-pilling woven air layer fabric, characterized in that: The steps include: Material selection: The first core-spun yarn is used for both the surface warp and the inner warp, and the first core-spun yarn is a yarn formed by 75D / 72F polyester covered with 40D spandex. The second core-spun yarn is used for both the surface weft and the inner weft, and the second core-spun yarn is a yarn formed by 75D / 36F polyester covered with 40D spandex. The binding weft is 150D / 288F polyester. The number of the surface warp and the inner warp is the same; Weaving: Using a water jet loom, the surface warp and the inner weft are interwoven into the surface layer, the inner warp and the inner weft are interwoven into the inner layer, and an independent weft yarn system is added between the surface weft and the inner weft to cover the weft tissue points formed by the weft binding and the surface warp with the surface weft floating long lines, and the weft tissue points formed by the weft binding and the inner warp are covered by the weft floating long lines, and the surface layer and the inner layer are connected by the weft binding to form a grey cloth; the gram weight of the fabric is 260g / m2; Dyeing and finishing: After the grey cloth is degreased, it enters the dyeing vat, is dyed with disperse dyes, and is fixed using a setting tool.

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