Woven multilayer fabric and method of making and use thereof

Abstract

The application relates to a multi-layer woven fabric and a preparation method and application thereof. The preparation method of the multi-layer woven fabric comprises the following steps: weaving each layer of fabric by using warp yarns and weft yarns and connecting the layer of fabric by using a binding stitch; when weaving each layer of fabric, the warp yarns of adjacent heddles are inserted into different reeds. Due to the fabric characteristics, a large number of yarns are repeatedly and rapidly gathered and separated during weaving, the yarn friction is maximized when the adjacent yarns are in the same reed, and the weaving cotton ball is particularly serious, so it is necessary to reduce the friction between the adjacent warp yarns as much as possible. The preparation method of the multi-layer woven fabric adjusts the insertion method of the reed, the warp yarns of adjacent heddles are inserted into different reeds, the probability of friction between the adjacent warp yarns is reduced, and then the yarn friction is reduced to reduce the generation of the cotton ball.

Description

Technical Field

[0001] This application relates to the field of textile materials technology, and in particular to a woven multilayer fabric, its preparation method, and its application. Background Technology

[0002] Woven fabric is made by interlacing yarns perpendicularly in both the warp and weft directions. The longitudinal yarns are called warp yarns, and the transverse yarns are called weft yarns. Multi-layer woven fabric is made by joining two or more independent layers together using various splicing methods to form a whole fabric. Traditional multi-layer woven fabrics, due to their loose structure, are not suitable for finishing treatments such as napping or brushing to achieve a soft hand feel, and excessive use of softeners is also not advisable during finishing. Due to the characteristics of the weave, during the weft insertion process, a large number of warp yarns will simultaneously gather in the upper or lower layers of the fabric, making it easy for the yarn fibers to clump and entangle, resulting in cotton balls.

[0003] Traditional methods to reduce cotton ball formation include lowering weaving speed to reduce warp friction or increasing warp sizing to make the warp fibers as close-fitting and stiff as possible to improve abrasion resistance. These methods, however, can lead to lower production efficiency and a stiffer hand feel in the finished fabric. Summary of the Invention

[0004] Therefore, it is necessary to provide a woven multilayer fabric, its preparation method, and its application. This method for preparing the woven multilayer fabric can reduce cotton ball formation while obtaining a woven multilayer fabric with high softness.

[0005] In a first aspect, this application provides a method for preparing a woven multilayer fabric, comprising the following steps:

[0006] Each layer of fabric is woven using warp and weft yarns and connected by a splicing structure.

[0007] When weaving the fabric in each layer, adjust the order of reed insertion. Each time the heddles are lifted and the weft is beaten, the warp yarns of adjacent heddle frames are inserted into the reed through different reed teeth.

[0008] In one embodiment, adjusting the reed insertion sequence, and inserting the warp yarns of adjacent heddle frames through different reed teeth each time the heddle is lifted for weft insertion, includes the following steps:

[0009] When performing the first heald pull and weft insertion, the warp yarns of heald frames 2, 3, and 4 are gathered in the lower layer; when performing the second heald pull and weft insertion, the warp yarns of heald frames 1, 2, and 3 are gathered in the upper layer; when performing the third heald pull and weft insertion, the warp yarns of heald frames 1, 2, and 4 are gathered in the lower layer; when performing the fourth heald pull and weft insertion, the warp yarns of heald frames 1, 3, and 4 are gathered in the upper layer; the warp yarns of adjacent heald frames are inserted into the reed through different reed teeth.

[0010] In one embodiment, adjusting the reed insertion sequence, and inserting the warp yarns of adjacent heddle frames through different reed teeth each time the heddle is lifted for weft insertion, includes the following steps:

[0011] During the first heald pull and beveling, the warp yarns of heddles 2, 3, 4, 5, 6, and 8 are gathered in the lower layer; during the second heald pull and beveling, the warp yarns of heddles 1, 2, 3, 5, 7, and 8 are gathered in the upper layer; during the third heald pull and beveling, the warp yarns of heddles 2, 4, 5, 6, 7, and 8 are gathered in the lower layer; during the fourth heald pull and beveling, the warp yarns of heddles 1, 2, 3, 4, 5, and 7 are gathered in the upper layer; during the fifth heald pull and beveling... The warp yarns of heddles on pages 1, 2, 4, 6, 7, and 8 are gathered in the lower layer; when beating the sixth heddle, the warp yarns of heddles on pages 1, 3, 4, 5, 6, and 7 are gathered in the upper layer; when beating the seventh heddle, the warp yarns of heddles on pages 1, 2, 3, 4, 6, and 8 are gathered in the lower layer; when beating the eighth heddle, the warp yarns of heddles on pages 1, 3, 5, 6, 7, and 8 are gathered in the upper layer; the warp yarns of adjacent heddle frames are inserted into the reed through different reed teeth.

[0012] In some embodiments, the warp yarn has a twist of 500 twists / meter to 1000 twists / meter; and / or, the weft yarn has a twist of 500 twists / meter to 1000 twists / meter.

[0013] In one embodiment, the warp yarn has a twist of 680 twists / meter to 880 twists / meter; and / or, the weft yarn has a twist of 680 twists / meter to 880 twists / meter.

[0014] In some embodiments, the warp yarn is 100% cotton yarn; and / or the weft yarn is 100% cotton yarn.

[0015] In some embodiments, the warp yarn has a count of 20 to 60 English count; and / or, the weft yarn has a count of 20 to 60 English count.

[0016] In some embodiments, the woven multilayer fabric is further subjected to a beating process.

[0017] Secondly, this application provides a woven multilayer fabric, which is prepared using the method for preparing woven multilayer fabric according to any one of claims 1 to 8.

[0018] Thirdly, this application provides a textile product, including the woven multilayer fabric as described in claim 9 or the woven multilayer fabric prepared by the preparation method of any one of claims 1 to 8.

[0019] The above-described method for preparing multi-layer woven fabric can reduce cotton ball formation while obtaining a soft multi-layer woven fabric. Due to the weave characteristics of multi-layer fabrics, a large number of yarns repeatedly and rapidly gather and separate during weaving. When adjacent yarns are in the same reed tooth, the friction between the yarns is maximized, and cotton ball formation becomes particularly severe. Therefore, it is necessary to minimize the friction between adjacent warp yarns. This method for preparing multi-layer woven fabric reduces the probability of friction between adjacent warp yarns by adjusting the reed insertion method so that the warp yarns of adjacent heald frames enter the reed through different reed teeth, thereby reducing yarn friction and reducing cotton ball formation. This method for preparing multi-layer woven fabric does not require increasing the sizing rate of the warp yarns, and can obtain a soft multi-layer woven fabric while reducing cotton ball formation, with high weaving efficiency.

[0020] Furthermore, the warp and weft yarns are made of low-twist cotton. By reducing the twist of the yarn, it becomes fluffier and softer, resulting in a multi-layered woven fabric with a fluffy and soft feel. Simultaneously, a patting process is added during the finishing of the fabric to give it an even fluffier and softer hand feel. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the basic weave of a plain 1:1 double-layer fabric provided in Embodiment 1 of this application;

[0022] Figure 2 This is a diagram illustrating the projection of the first latitude in Embodiment 1 of this application;

[0023] Figure 3 This is a diagram illustration of the second latitude projection provided in Embodiment 1 of this application;

[0024] Figure 4 This is a diagram illustration of the third latitude projection provided in Embodiment 1 of this application;

[0025] Figure 5 This is a diagram illustration of the fourth latitude projection provided in Embodiment 1 of this application;

[0026] Figure 6 This is a schematic diagram of the basic weave of a 2 / 2 twill 1:1 double-layer fabric provided in Embodiment 2 of this application;

[0027] Figure 7 This is a diagram illustration of the first latitude projection provided in Embodiment 2 of this application;

[0028] Figure 8 This is a diagram illustration of the second latitude projection provided in Embodiment 2 of this application;

[0029] Figure 9 This is a diagram illustration of the third latitude projection provided in Embodiment 2 of this application;

[0030] Figure 10 This is a legend for the fourth latitude projection provided in Embodiment 2 of this application;

[0031] Figure 11 This is a legend for the fifth latitude projection provided in Embodiment 2 of this application;

[0032] Figure 12 This is a diagram illustration of the sixth latitude projection provided in Embodiment 2 of this application;

[0033] Figure 13 This is a diagram illustration of the seventh latitude projection provided in Embodiment 2 of this application;

[0034] Figure 14 This is a diagram illustrating the projection of the eighth latitude, provided in Embodiment 2 of this application. Detailed Implementation

[0035] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0036] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0037] One embodiment of this application provides a method for preparing a woven multilayer fabric, characterized by comprising the following steps:

[0038] Each layer of fabric is woven using warp and weft yarns and connected by a splicing structure.

[0039] When weaving the fabric in each layer, adjust the order of reed insertion. Each time the heddles are lifted and the weft is beaten, the warp yarns of adjacent heddle frames are inserted into the reed through different reed teeth.

[0040] The above-described method for preparing multi-layer woven fabric can reduce cotton ball formation while obtaining a soft multi-layer woven fabric. Due to the weave characteristics of multi-layer fabrics, a large number of yarns repeatedly and rapidly gather and separate during weaving. When adjacent yarns are in the same reed tooth, the friction between the yarns is maximized, and cotton ball formation becomes particularly severe. Therefore, it is necessary to minimize the friction between adjacent warp yarns. This method for preparing multi-layer woven fabric reduces the probability of friction between adjacent warp yarns by adjusting the reed insertion method so that the warp yarns of adjacent heald frames enter the reed through different reed teeth, thereby reducing yarn friction and reducing cotton ball formation. This method for preparing multi-layer woven fabric does not require increasing the sizing rate of the warp yarns, and can obtain a soft multi-layer woven fabric while reducing cotton ball formation, with high weaving efficiency.

[0041] In one embodiment, the splicing structure consists of yarns that connect two layers of gauze at regular intervals, forming nodes between every two layers of fabric in a multi-layered fabric. The function of these nodes is to prevent the two layers of fabric from separating or shifting during use, thus preventing unevenness of the fabric surface.

[0042] In one embodiment, the splicing method of the splicing organization includes front warp splicing to inner weft or inner warp splicing to front weft.

[0043] In one embodiment, the joining method of the bonding structure is front warp to inner weft. When the inner and outer patterns are not easily exposed, the front warp to inner weft joining method is preferred.

[0044] In one embodiment, adjusting the reed insertion sequence, each time the heald is lifted for weft insertion, involves inserting the warp yarns of adjacent heald frames through different reed teeth, including the following steps: during the first heald lifting for weft insertion, the warp yarns of heald frames 2, 3, and 4 are gathered in the lower layer; during the second heald lifting for weft insertion, the warp yarns of heald frames 1, 2, and 3 are gathered in the upper layer; during the third heald lifting for weft insertion, the warp yarns of heald frames 1, 2, and 4 are gathered in the lower layer; during the fourth heald lifting for weft insertion, the warp yarns of heald frames 1, 3, and 4 are gathered in the upper layer; the warp yarns of adjacent heald frames are inserted into the reed through different reed teeth.

[0045] In one embodiment, adjusting the reed insertion sequence, and inserting the warp yarns of adjacent heddle frames through different reed teeth each time the heddles are lifted for weft insertion, includes the following steps:

[0046] During the first heald pull and beveling, the warp yarns of heddles 2, 3, 4, 5, 6, and 8 are gathered in the lower layer; during the second heald pull and beveling, the warp yarns of heddles 1, 2, 3, 5, 7, and 8 are gathered in the upper layer; during the third heald pull and beveling, the warp yarns of heddles 2, 4, 5, 6, 7, and 8 are gathered in the lower layer; during the fourth heald pull and beveling, the warp yarns of heddles 1, 2, 3, 4, 5, and 7 are gathered in the upper layer; during the fifth heald pull and beveling... The warp yarns of heddles on pages 1, 2, 4, 6, 7, and 8 are gathered in the lower layer; when beating the sixth heddle, the warp yarns of heddles on pages 1, 3, 4, 5, 6, and 7 are gathered in the upper layer; when beating the seventh heddle, the warp yarns of heddles on pages 1, 2, 3, 4, 6, and 8 are gathered in the lower layer; when beating the eighth heddle, the warp yarns of heddles on pages 1, 3, 5, 6, 7, and 8 are gathered in the upper layer; the warp yarns of adjacent heddle frames are inserted into the reed through different reed teeth.

[0047] In some embodiments, the warp twist is 500 twists / meter to 1000 twists / meter; and / or, the weft twist is 500 twists / meter to 1000 twists / meter. Both warp and weft yarns are low-twist yarns, which enables woven multilayer fabrics to achieve a soft hand feel. The lower the twist of the warp and weft yarns, the easier it is to achieve a soft hand feel. Within this range of warp and weft twist, woven multilayer fabrics have a better soft hand feel. When the twist is too low, the yarn sizing and weaving effects are poor; when the twist is too high, the soft hand feel of the multilayer fabric is poor.

[0048] In one embodiment, the warp twist is 680 twists / meter to 880 twists / meter; and / or, the weft twist is 680 twists / meter to 880 twists / meter. Within this range of warp and weft twists, the woven multilayer fabric has a better soft hand feel. Optionally, the warp twist is 680 twists / meter, 700 twists / meter, 720 twists / meter, 740 twists / meter, 760 twists / meter, 780 twists / meter, 800 twists / meter, 820 twists / meter, 840 twists / meter, 860 twists / meter, or 880 twists / meter. Optionally, the twist of the weft yarn is 680 twists / meter, 700 twists / meter, 720 twists / meter, 740 twists / meter, 760 twists / meter, 780 twists / meter, 800 twists / meter, 820 twists / meter, 840 twists / meter, 860 twists / meter, or 880 twists / meter.

[0049] In some embodiments, the warp yarns are 100% cotton yarn; and / or, the weft yarns are 100% cotton yarn. Using 100% cotton yarn for the warp or weft yarns enables the woven multi-layered fabric to have a fluffy and soft hand feel.

[0050] In one embodiment, the warp yarn is 100% cotton yarn.

[0051] In one embodiment, the weft yarn is 100% cotton yarn.

[0052] In one embodiment, the warp yarn is 100% cotton yarn, and the weft yarn is 100% cotton yarn.

[0053] In some embodiments, the warp yarn count is 20-60 English count; and / or, the weft yarn count is 20-60 English count. In the weaving process of multi-layered woven fabrics, two or more independent fabrics, one outer layer and one inner layer, are joined together to form a whole fabric using various splicing methods. During weaving, when the outer weft is inserted, the inner warp sinks completely; when the inner weft is inserted, the outer warp rises completely. Each layer of fabric is actually an independent fabric, connected only by interlacing at certain intervals. The weaving method and yarn count of each independent fabric layer can be the same or different. Within this yarn count range, multi-layered fabrics have a better fluffiness and soft hand feel. Optionally, the warp and / or weft yarn count is 30-50 English count. Alternatively, the yarn count of each layer of fabric may be 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or 50.

[0054] In some embodiments, the woven multilayer woven fabric is further subjected to a beating treatment. Beating the woven multilayer woven fabric can give it a fluffier and softer hand feel.

[0055] In one embodiment, the patting process includes at least one of mechanical patting and manual patting.

[0056] In one embodiment, the tapping process is high-speed tapping.

[0057] In one embodiment, the process further includes singeing the woven multilayer fabric. Singeing is a process in which the fabric is quickly passed through a flame or rubbed against a hot metal surface to burn off the surface fuzz, thereby reducing the fuzz generated during the weaving process.

[0058] In one embodiment, the process further includes a loose washing treatment of the woven multilayer woven fabric. Loose washing refers to immersing and padding the fabric in a relaxed state to remove the sizing agent from the fabric surface, which can make the surface of the multilayer fabric more natural and soft.

[0059] In one embodiment, the process further includes pre-shrinking the woven multilayer fabric. Pre-shrinking the woven multilayer fabric results in a fabric with better shrinkage resistance.

[0060] In one embodiment, the process further includes singeing, loose washing, patting, and setting of the woven multilayer woven fabric.

[0061] Another embodiment of this application provides a woven multilayer fabric, prepared using any of the above-described methods for preparing woven multilayer fabrics. This woven multilayer fabric has a relatively fluffy and soft hand feel, produces very few weaving balls on the fabric surface, and has high weaving efficiency.

[0062] Another embodiment of this application provides a textile product, including the above-described woven multilayer fabric or a woven multilayer fabric prepared by any of the above-described methods for preparing woven multilayer fabric.

[0063] The following are specific embodiments.

[0064] Example 1

[0065] In this embodiment, the woven multilayer fabric has the following specifications: 140×120 inches, 40×40 count plain weave 1:1 double-layer fabric.

[0066] (1) Use pure cotton low-twist yarn as warp and weft yarn, with a twist of 800 twists / meter.

[0067] (2) The warp and weft yarns are sized using conventional sizing processes and formulas.

[0068] (3) Use sized warp and weft yarns to weave a double-layer fabric. Refer to the basic weave diagram. Figure 1 During the weaving process, the warp yarns of adjacent heald frames are fed into different reed teeth for reed insertion, as follows:

[0069] Insert the warp threads from heddles 2 and 3, and 4 and 1, into the same reed tooth. (Refer to...) Figures 2-5 In Example 1, the warp lifting and friction during each weft insertion within a basic weave cycle are as follows: When inserting the first weft, the warp yarns of heddles 2, 3, and 4 are clustered in the lower layer. That is, the yarns of heddles 2 and 3 are inserted into the same reed tooth, the yarns of heddles 1 and 4 are inserted into the same reed tooth, and the warp yarns of adjacent heddle frames (pages 2 and 3) in the same layer are within the same reed tooth. When inserting the second weft, the warp yarns of heddles 1, 2, and 3 are clustered in the upper layer. That is, the yarns of heddles 2 and 3 are inserted into the same reed tooth, the yarns of heddles 1 and 4 are inserted into the same reed tooth, and the warp yarns of adjacent heddle frames (pages 2 and 3) in the same layer are within the same reed tooth. When inserting the third weft, the warp yarns of heddles 1, 2, and 4 are clustered in the lower layer. In this configuration, the yarns of heddles 2 and 3 are inserted into the same reed tooth, as are the yarns of heddles 1 and 4. Warp yarns in the same layer without adjacent heddle frames are placed within the same reed tooth. When the fourth weft is inserted, the warp yarns of heddles 1, 3, and 4 are gathered on the upper layer. That is, the yarns of heddles 2 and 3 are inserted into the same reed tooth, as are the yarns of heddles 1 and 4. Warp yarns in the same layer without adjacent heddle frames are placed within the same reed tooth.

[0070] (4) The double-layered fabric after weaving is successively singed, loosely washed, patted and shaped.

[0071] Traditional reed insertion methods involve inserting the warp yarns of pages 1 and 2 into the same reed tooth, and pages 3 and 4 into the same reed tooth. With each heald lift and beat-up, adjacent warp yarns inevitably end up in the same reed tooth. By adjusting the reed insertion starting point, the probability of adjacent heald frames' yarns being inserted into the same reed tooth is reduced by 50% within four beat-ups in one weave cycle. This reduces yarn friction during weaving, effectively reducing cotton ball formation. The double-layer fabric prepared in this embodiment has a better fluffiness and softness, and the production process does not require sacrificing production efficiency or increasing production costs, nor does it require special washing methods, yet it achieves a fabric softer than traditional fabrics.

[0072] Example 2

[0073] In this embodiment, the woven multilayer fabric has the following specifications: 120×100 inches, 32×32 count, 2 / 2 twill 1:1 double-layer fabric.

[0074] (1) Use pure cotton low-twist yarn as warp and weft yarn, with a twist of 680 twists / meter.

[0075] (2) The warp and weft yarns are sized using conventional sizing processes and formulas.

[0076] (3) Use sized warp and weft yarns to weave a double-layer fabric. Refer to the basic weave diagram. Figure 6 During the weaving process, the warp yarns of adjacent heald frames are fed into different reed teeth for reed insertion. The specific method is as follows:

[0077] Insert the warp threads of heddles 2 and 3, 4 and 5, 6 and 7, and 8 and 1 into the same reed tooth. (Refer to...) Figures 7-14In Example 2, the warp lifting and friction during each weft insertion within a basic weave cycle are as follows: When inserting the first weft, the warp yarns of heddles on pages 2, 3, 4, 5, 6, and 8 are gathered in the lower layer. Within the same layer, two sets of adjacent heddle frames (pages 2 and 3, and pages 4 and 5) have warp yarns within the same reed tooth. When inserting the second weft, the warp yarns of heddles on pages 1, 2, 3, 5, 7, and 8 are gathered in the upper layer. Within the same layer, one set of adjacent heddle frames (pages 2 and 3) have warp yarns within the same reed tooth. When inserting the third weft, the warp yarns of heddles on pages 2, 4, 5, 6, 7, and 8 are gathered in the lower layer. Within the same layer, two sets of adjacent heddle frames (pages 4 and 5, and pages 6 and 7) have warp yarns within the same reed tooth. When inserting the fourth weft, the warp yarns of heddles on pages 1, 2, 3, 4, 5, and 7 are gathered in the upper layer. In the same layer, the warp yarns of two adjacent heald frames (pages 2 and 3, and 4 and 5) are in the same reed tooth. When casting the fifth weft, the warp yarns of the healds on pages 1, 2, 4, 6, 7, and 8 are gathered in the lower layer, and in the same layer, the warp yarns of one adjacent heald frame (pages 6 and 7) are in the same reed tooth. When casting the sixth weft, the warp yarns of the healds on pages 1, 3, 4, 5, 6, and 7 are gathered in the upper layer, and in the same layer, the warp yarns of two adjacent heald frames (pages 4 and 5, and 6 and 7) are in the same reed tooth. When casting the seventh weft, the warp yarns of the healds on pages 1, 2, 3, 4, 6, and 8 are gathered in the lower layer, and in the same layer, the warp yarns of one adjacent heald frame (pages 2 and 3) are in the same reed tooth. When casting the eighth weft, the warp yarns of the heddles on pages 1, 3, 5, 6, 7, and 8 are gathered on the upper layer, and the warp yarns of one group of adjacent heddle frames (pages 6 and 7) on the same layer are in the same reed tooth.

[0078] (4) The double-layered fabric after weaving is successively singed, loosely washed, patted and shaped.

[0079] Traditional reed insertion methods involve inserting the yarns of heddles 1 and 2, 3 and 4, 5 and 6, and 7 and 8 into the same reed tooth. With each heddle lift and beat-up, there are always two sets of adjacent warp yarns in the same reed tooth. After adjusting the reed insertion starting point, the number of adjacent warp yarns in the same reed tooth is reduced by 4 in eight beat-ups within one weave cycle. This reduces the probability of warp yarns from adjacent heddle frames being inserted into the same reed tooth by 25%, lowering yarn friction during weaving and effectively reducing cotton ball formation. The double-layer fabric prepared in this embodiment has a better fluffiness and softness, and the production process does not require sacrificing production efficiency or increasing production costs, nor does it require special washing methods to obtain a fabric softer than traditional fabrics.

[0080] Example 3

[0081] In this embodiment, the woven multilayer fabric has the following specifications: 110×90 inches, 20×20 count plain weave 1:1 double-layer fabric.

[0082] (1) Use pure cotton low-twist yarn as warp and weft yarn, with a twist of 500 twists / meter.

[0083] (2) The warp and weft yarns are sized using conventional sizing processes and formulas.

[0084] (3) Double-layer fabric is woven using sized warp and weft yarns. During the weaving process, the warp yarns of adjacent heddle frames are inserted into different reed teeth. Specifically, the warp yarns of heddles 2 and 3, and heddles 4 and 1, are inserted into the same reed tooth. When the first weft is inserted, the warp yarns of heddles 2, 3, and 4 are gathered in the lower layer. That is, the yarns of heddles 2 and 3 are inserted into the same reed tooth, the yarns of heddles 1 and 4 are inserted into the same reed tooth, and the warp yarns of adjacent heddles (pages 2 and 3) in the same layer are in the same reed tooth. When the second weft is inserted, the warp yarns of heddles 1, 2, and 3 are gathered in the upper layer. That is, the yarns of heddles 2 and 3 are inserted into the same reed tooth, the yarns of heddles 1 and 4 are inserted into the same reed tooth, and the warp yarns of adjacent heddles (pages 2 and 3) in the same layer are in the same reed tooth. When casting the third weft, the warp yarns of heddles 1, 2, and 4 are clustered in the lower layer. That is, the yarns of heddles 2 and 3 are inserted into the same reed tooth, and the yarns of heddles 1 and 4 are inserted into the same reed tooth. Warp yarns in the same layer without adjacent heddle frames are placed in the same reed tooth. When casting the fourth weft, the warp yarns of heddles 1, 3, and 4 are clustered in the upper layer. That is, the yarns of heddles 2 and 3 are inserted into the same reed tooth, and the yarns of heddles 1 and 4 are inserted into the same reed tooth. Warp yarns in the same layer without adjacent heddle frames are placed in the same reed tooth.

[0085] (4) The double-layered fabric after weaving is successively singed, loosely washed, patted and shaped.

[0086] The double-layer fabric prepared in this embodiment has a good fluffy and soft hand feel, and the production process does not require sacrificing production efficiency or increasing production costs, nor does it require special washing methods, so that a softer fabric than traditional fabrics can be obtained.

[0087] Example 4

[0088] In this embodiment, the woven multilayer fabric has the following specifications: 130×110 inches, 50×50 count plain weave 1:1 double-layer fabric.

[0089] (1) Pure cotton low-twist yarn is used as warp and weft yarn, with a twist of 960 twists / meter.

[0090] (2) The warp and weft yarns are sized using conventional sizing processes and formulas.

[0091] (3) Double-layer fabric is woven using sized warp and weft yarns. During the weaving process, the warp yarns of adjacent heddle frames are inserted into different reed teeth. Specifically, the warp yarns of heddles 2 and 3, and heddles 4 and 1, are inserted into the same reed tooth. When the first weft is inserted, the warp yarns of heddles 2, 3, and 4 are gathered in the lower layer. That is, the yarns of heddles 2 and 3 are inserted into the same reed tooth, the yarns of heddles 1 and 4 are inserted into the same reed tooth, and the warp yarns of adjacent heddles (pages 2 and 3) in the same layer are in the same reed tooth. When the second weft is inserted, the warp yarns of heddles 1, 2, and 3 are gathered in the upper layer. That is, the yarns of heddles 2 and 3 are inserted into the same reed tooth, the yarns of heddles 1 and 4 are inserted into the same reed tooth, and the warp yarns of adjacent heddles (pages 2 and 3) in the same layer are in the same reed tooth. When casting the third weft, the warp yarns of heddles 1, 2, and 4 are clustered in the lower layer. That is, the yarns of heddles 2 and 3 are inserted into the same reed tooth, and the yarns of heddles 1 and 4 are inserted into the same reed tooth. Warp yarns in the same layer without adjacent heddle frames are placed in the same reed tooth. When casting the fourth weft, the warp yarns of heddles 1, 3, and 4 are clustered in the upper layer. That is, the yarns of heddles 2 and 3 are inserted into the same reed tooth, and the yarns of heddles 1 and 4 are inserted into the same reed tooth. Warp yarns in the same layer without adjacent heddle frames are placed in the same reed tooth.

[0092] (4) The double-layered fabric after weaving is successively singed, loosely washed, patted and shaped.

[0093] The double-layer fabric prepared in this embodiment has a good fluffy and soft hand feel, and the production process does not require sacrificing production efficiency or increasing production costs, nor does it require special washing methods, so that a softer fabric than traditional fabrics can be obtained.

[0094] Example 5

[0095] In this embodiment, the woven multilayer fabric has the following specifications: 150×116 inches, 60×60 count plain weave 1:1 double-layer fabric.

[0096] (1) Pure cotton low-twist yarn is used as both warp and weft yarns, with a twist of 1000 twists / meter. At the same time, appropriate long-staple cotton is added to the warp yarn to improve its strength, with a warp yarn strength ≥220CN.

[0097] (2) The warp and weft yarns are sized using conventional sizing processes and formulas.

[0098] (3) Double-layer fabric is woven using sized warp and weft yarns. During the weaving process, the warp yarns of adjacent heddle frames are inserted into different reed teeth. Specifically, the warp yarns of heddles 2 and 3, and heddles 4 and 1, are inserted into the same reed tooth. When the first weft is inserted, the warp yarns of heddles 2, 3, and 4 are gathered in the lower layer. That is, the yarns of heddles 2 and 3 are inserted into the same reed tooth, the yarns of heddles 1 and 4 are inserted into the same reed tooth, and the warp yarns of adjacent heddles (pages 2 and 3) in the same layer are in the same reed tooth. When the second weft is inserted, the warp yarns of heddles 1, 2, and 3 are gathered in the upper layer. That is, the yarns of heddles 2 and 3 are inserted into the same reed tooth, the yarns of heddles 1 and 4 are inserted into the same reed tooth, and the warp yarns of adjacent heddles (pages 2 and 3) in the same layer are in the same reed tooth. When casting the third weft, the warp yarns of heddles 1, 2, and 4 are clustered in the lower layer. That is, the yarns of heddles 2 and 3 are inserted into the same reed tooth, and the yarns of heddles 1 and 4 are inserted into the same reed tooth. Warp yarns in the same layer without adjacent heddle frames are placed in the same reed tooth. When casting the fourth weft, the warp yarns of heddles 1, 3, and 4 are clustered in the upper layer. That is, the yarns of heddles 2 and 3 are inserted into the same reed tooth, and the yarns of heddles 1 and 4 are inserted into the same reed tooth. Warp yarns in the same layer without adjacent heddle frames are placed in the same reed tooth.

[0099] (4) The double-layered fabric after weaving is successively singed, loosely washed, patted and shaped.

[0100] The double-layer fabric prepared in this embodiment has a good fluffy and soft hand feel, and the production process does not require sacrificing production efficiency or increasing production costs, nor does it require special washing methods, so that a softer fabric than traditional fabrics can be obtained.

[0101] Examples 1-5, through improvements in the reed insertion method, all reduce the generation of cotton balls during weaving and achieve a better fluffiness and softness. Among them, Examples 1 and 2 are preferred embodiments, resulting in multi-layered fabrics with even better fluffiness and softness.

[0102] Comparative Example 1

[0103] The woven multilayer fabric in this comparative example is a plain weave 1:1 double-layer fabric measuring 140×120 inches and 40×40 count.

[0104] (1) Use pure cotton yarn with conventional twist as warp and weft yarn, with a twist of 1050 twists / meter.

[0105] (2) The warp and weft yarns are sized using conventional sizing processes and formulas.

[0106] (3) Double-layer fabric is woven using sized warp and weft yarns. The reed insertion method during the weaving process is as follows: The yarns of heddles 1 and 2, and heddles 3 and 4 are inserted into the same reed tooth. When inserting the first weft, the warp yarns of heddles 1 and 2 are in the same reed tooth, the warp yarns of heddles 3 and 4 are in the same reed tooth, and the warp yarns of adjacent heddle frames in the same layer (pages 3 and 4) are in the same reed tooth. When inserting the second weft, the warp yarns of heddles 1 and 2 are in the same reed tooth, the warp yarns of heddles 3 and 4 are in the same reed tooth, and the warp yarns of adjacent heddle frames in the same layer (pages 1 and 2) are in the same reed tooth. When inserting the third weft, the warp yarns of heddles 1 and 2 are in the same reed tooth, the warp yarns of heddles 3 and 4 are in the same reed tooth, and the warp yarns of adjacent heddle frames in the same layer (pages 1 and 2) are in the same reed tooth. When casting the fourth weft, the warp yarns of the heddles on pages 1 and 2 are on the same reed tooth, and the warp yarns of the heddles on pages 3 and 4 are on the same reed tooth. Warp yarns of adjacent heddle frames in the same layer (pages 3 and 4) are on the same reed tooth.

[0107] (4) The double-layered fabric after weaving is successively singed, loosely washed, patted and shaped.

[0108] The traditional reed insertion method used in this comparative example involves inserting the warp yarns of pages 1 and 2 into the same reed tooth, and the warp yarns of pages 3 and 4 into the same reed tooth. Each time the healds are lifted and the weft is beaten, adjacent warp yarns are sometimes in the same reed tooth. This results in more cotton balls being produced during the weaving process and a stiffer hand feel.

[0109] Comparative Example 2

[0110] The woven multilayer fabric in this comparative example is a plain weave 1:1 double-layer fabric measuring 150×116 inches and 60×60 count.

[0111] (1) Use pure cotton yarn with conventional twist as warp and weft yarn, with a twist of 1200 twists / meter.

[0112] The other steps are the same as in Example 1.

[0113] The yarn used in this comparison was 1200 twists / meter, and the resulting fabric did not have a fluffy and soft feel.

[0114] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0115] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims, and the specification and drawings can be used to interpret the content of the claims.

Claims

1. A method of making a multi-layer woven fabric, characterized in that, comprising the following steps: weaving each layer of fabric using warp yarns and weft yarns, the warp yarns being all cotton yarns, the weft yarns being all cotton yarns, the linking mode of the linking stitch comprising over-end linking or under-end linking; the linking stitch being yarns connecting each layer of the fabric together at intervals, becoming the nodes between each two layers of the multi-layer fabric; when weaving each layer of the fabric, adjusting the entry sequence of the reed, and making the warp yarns of adjacent heald frames enter the reed through different reed teeth each time the healds are raised and the weft is beaten; reducing the probability of friction between adjacent warp yarns, and thereby reducing the generation of cotton balls.

2. The method of claim 1, wherein the woven multilayer fabric is prepared by weaving a plurality of layers of the fabric of claim 1. the adjusting of the entry sequence of the reed, and making the warp yarns of adjacent heald frames enter the reed through different reed teeth each time the healds are raised and the weft is beaten comprises the following steps: when the first healds are raised and the weft is beaten, the warp yarns of the 2nd, 3rd and 4th heald frames are gathered in the lower layer; when the second healds are raised and the weft is beaten, the warp yarns of the 1st, 2nd and 3rd heald frames are gathered in the upper layer; when the third healds are raised and the weft is beaten, the warp yarns of the 1st, 2nd and 4th heald frames are gathered in the lower layer; when the fourth healds are raised and the weft is beaten, the warp yarns of the 1st, 3rd and 4th heald frames are gathered in the upper layer; the warp yarns of adjacent heald frames enter the reed through different reed teeth.

3. The method of claim 1, wherein the woven multilayer fabric is prepared by weaving a plurality of layers of the fabric of claim 1. the adjusting of the entry sequence of the reed, and making the warp yarns of adjacent heald frames enter the reed through different reed teeth each time the healds are raised and the weft is beaten comprises the following steps: when the first healds are raised and the weft is beaten, the warp yarns of the 2nd, 3rd and 4th heald frames are gathered in the lower layer; when the second healds are raised and the weft is beaten, the warp yarns of the 1st, 2nd and 3rd heald frames are gathered in the upper layer; when the third healds are raised and the weft is beaten, the warp yarns of the 1st, 2nd and 4th heald frames are gathered in the lower layer; when the fourth healds are raised and the weft is beaten, the warp yarns of the 1st, 3rd and 4th heald frames are gathered in the upper layer; the warp yarns of adjacent heald frames enter the reed through different reed teeth.

4. The method of claim 1, wherein the woven multilayer fabric is prepared by weaving a plurality of layers of the fabric of claim 1. the twist of the warp yarns is 500 twists / meter to 1000 twists / meter; and / or, the twist of the weft yarns is 500 twists / meter to 1000 twists / meter.

5. The method of claim 4, wherein the weaving of the multi-layer fabric is performed by using a loom. the twist of the warp yarns is 680 twists / meter to 880 twists / meter; and / or, the twist of the weft yarns is 680 twists / meter to 880 twists / meter.

6. The method of claim 1, wherein the woven multilayer fabric is prepared by weaving a plurality of layers of the fabric of claim 1. the yarn count of the warp yarns is 20 English to 60 English; and / or, the yarn count of the weft yarns is 20 English to 60 English.

7. The method of making a woven multi-layer fabric according to any one of claims 1 to 6, wherein, the woven multi-layer fabric after weaving is further subjected to a beating treatment.

8. A multi-layer woven fabric, characterized by, obtained by using the method for preparing a woven multi-layer fabric according to any one of claims 1 to 7.

9. A textile, characterized in that, the woven multi-layer fabric according to claim 8 or the woven multi-layer fabric obtained by using the method for preparing a woven multi-layer fabric according to any one of claims 1 to 7.

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