A comfortable and warm ribbed velvet jean fabric and its manufacturing method

Abstract

This invention discloses a comfortable and warm ribbed fleece denim fabric, belonging to the textile field. It comprises two warp systems and two weft systems. The warp yarns are divided into front warp and back warp, and the weft yarns are divided into front weft and back weft. The front and back wefts are interwoven with the back warp in a plain weave, while the front warp and back weft are interwoven in a twill weave. The front warp and back weft do not interweave. The back weft is thicker than the front weft and is made of multifilament. A napped layer is provided on the bottom surface. When the front weft contracts and tightens the fabric, it pulls inward, causing the back weft to expand downward and bulge, effectively covering the front weft. This minimizes damage to the front warp and back weft during the napping process. The plain weave structure makes the bottom layer of the fabric relatively dense, and the combined effect of the front weft tightening the fabric results in high fabric strength. The back weft is made of thicker multifilament, and combined with the plain weave structure, the napped layer has short, numerous, fine, and dense fibers. When the fabric is stretched within a certain range, the fibers do not become significantly sparse.

Description

Technical Field

[0001] This invention relates to a comfortable and warm ribbed denim fabric and its manufacturing method, belonging to the textile field. Background Technology

[0002] Traditional denim fabric is made by weaving pure cotton warp yarns dyed with indigo dye with off-white weft yarns in a twill weave. Its tight fit, twill texture, and vintage style have made it popular. Due to the inherent properties of indigo dye, the washing process removes some of the indigo dye from the fibers, allowing denim garments to achieve a wide variety of distressed styles, making it an irreplaceable and important element in the clothing market.

[0003] Traditional denim clothing, while relatively thick, offers only average warmth. Therefore, technicians have developed various denim fabrics with improved insulation. For example, using heat-generating yarns as weft yarns in the weft weave gives the fabric far-infrared and heat-generating properties, which remain effective even after long-term use, but the warmth retention is not significant. Another example is composite denim fabric, where denim is bonded to fleece using adhesive, creating a fleece layer on the underside of the denim. However, with prolonged use, the adhesive ages, causing the composite fabric to gradually stiffen. Furthermore, as the adhesive ages, its stickiness decreases, causing the fleece to detach during washing and entangle with the remaining fleece, forming wavy bulges that affect wearing comfort.

[0004] Some existing technicians design denim fabric as a double-layered fabric, with the outer weft and inner warp interlacing to form joints. Simultaneously, the inner weft forms floats on the bottom surface, creating a nap on the underside of the fabric. However, the nap is mainly formed by the fibers in the floats being hooked and pulled out. While the resulting nap is relatively long, it is not dense enough and becomes sparse after stretching the fabric. Moreover, during the napping process, while some fibers on the inner weft are hooked out, a significant portion of the outer weft and inner warp are also hooked out, resulting in a substantial reduction in fabric strength. Summary of the Invention

[0005] In order to overcome the shortcomings of the prior art, the present invention provides a comfortable and warm ribbed fleece denim fabric and its manufacturing method. The fabric has high strength and the fleece remains relatively dense after stretching, so it can maintain its warmth for a long time.

[0006] The technical solution adopted by this invention to solve its technical problem is:

[0007] In a first aspect, this application provides a comfortable and warm ribbed fleece denim fabric with a fleece nap layer on the bottom surface. The fabric includes two systems of warp yarns and two systems of weft yarns. The warp yarns are divided into front warp and back warp, and the weft yarns are divided into front weft and back weft. The front weft and the back weft are interwoven with the back warp in a plain weave. The front warp and the front weft are interwoven in a twill weave. The front warp and the back weft are not interwoven. The back weft is thicker than the front weft. The back weft is multifilament. The shrinkage rate of the front weft is greater than that of the back weft.

[0008] The comfortable and warm ribbed fleece denim fabric provided in this application does not require the formation of floats on the bottom surface. Instead, it uses thicker multifilament yarns as the inner weft, which works in conjunction with the outer weft, which has a higher shrinkage rate. Under the effect of the outer weft shrinking and tightening the fabric, the outer weft is pulled inward into the fabric, causing the thicker inner weft to expand and bulge downward, thus covering the outer weft. The fleece layer is mainly provided by the inner weft. The formation of the fleece layer causes less damage to the outer warp and outer weft. Moreover, the outer weft and inner weft are interwoven with the inner warp in a plain weave, making the bottom layer of the fabric relatively tight. In addition, the effect of the outer weft tightening the fabric results in high fabric strength. Furthermore, since the bottom surface of the fabric is plain weave and does not rely on floats for fleece formation, and the inner weft is a thicker multifilament yarn, the fleece layer has short, numerous, and very dense fibers, making it more comfortable to the skin. The shorter fibers are less likely to tangle and form bulges. When the fabric is stretched within a certain range, it only reduces the degree of expansion and bulging of the inner weft on the bottom surface, so the fleece does not become significantly sparse.

[0009] In a preferred embodiment of spinning, the front warp and the front weft are interwoven in a three-up-one-down twill weave, giving the fabric surface a denim-like texture.

[0010] In a preferred embodiment of spinning, the outer warp is thicker than the inner warp, such that the outer warp can cover the inner warp on the front side of the fabric.

[0011] Furthermore, the thread count of the inner warp is more than three times that of the outer warp, which is beneficial for the fabric to display a twill weave on the front side without revealing the plain weave underneath.

[0012] Furthermore, the number of branches of the inner meridian is three to eight times the number of branches of the outer meridian.

[0013] Furthermore, the number of threads in the said facet is 8S-32S.

[0014] In the preferred spinning process, the F number of the inner weft is 114F-900F. The F number, also known as the strand count, indicates how many single fibers make up a single synthetic multifilament. Inner wefts with a high F number can form many fibers during napping and raising, and combined with the plain weave structure, the short and numerous fibers will not become noticeably sparse when the fabric is stretched.

[0015] Furthermore, the denier of the single fiber in the weft is 80D-500D, which can form fine and soft fluff after being brushed and napped, making the fabric more comfortable when in contact with the skin.

[0016] Furthermore, the count of the outer weft is 21S-60S, which, while ensuring that the outer weft provides sufficient shrinkage, facilitates the inner weft with high F count and high denier to cover the outer weft on the bottom surface of the fabric.

[0017] In the preferred spinning process, the same inner warp and each of the outer wefts have the same type of weft dot, and the same inner warp and each of the inner wefts have the same type of weft dot; and on the same inner warp, the type of weft dot formed by the outer weft is always opposite to the type of weft dot formed by the inner weft, which enables the fabric bottom surface to have corduroy-like vertical stripes before it is piled up, and gives the fabric better stability, and it can have a stronger warmth retention effect after the piled layer is formed.

[0018] Secondly, this application provides a method for manufacturing a comfortable and warm ribbed denim fabric, the steps of which include weaving and finishing. In the weaving step, two systems of warp yarns and two systems of weft yarns are used. The warp yarns are divided into front warp and back warp, and the weft yarns are divided into front weft and back weft. The front weft and the back weft are interwoven with the back warp in a plain weave. The front warp and the front weft are interwoven in a twill weave. The front warp and the back weft are not interwoven. The back weft is thicker than the front weft. The back weft is multifilament. The shrinkage rate of the front weft is greater than that of the back weft. The front weft is a polyester-nylon composite yarn.

[0019] The post-processing includes, in sequence, a singeing process, an alkali treatment process, a drying process, a pre-shrinking process, and a brushing process.

[0020] The outer weft is made of polyester-nylon composite yarn, which undergoes strong shrinkage after alkali treatment, making the fabric more tightly interwoven. This can improve the fabric's resistance to tearing to a certain extent. Furthermore, the shrinkage of the outer weft causes the inner weft to bulge downwards at the weft stitch point on the bottom surface, taking the lead in brushing and protecting the inner warp and outer weft. This effectively solves the problem of significant reduction in fabric strength after brushing treatment in existing brushed products.

[0021] Alternatively, the selection and interweaving of various yarns can be carried out in accordance with the first aspect. Combined with the design of the fabric structure and the yarn matching, the fabric's resistance to tearing can be further improved.

[0022] Optionally, a loose water washing process is further included between the alkali treatment process and the drying process, with a treatment temperature of 40℃-50℃ and a treatment time of 20min-30min;

[0023] Between the drying process and the pre-shrinking process, there is also a shaping process, with a shaping temperature of 150℃-170℃ and a machine speed of 20m / min-40m / min.

[0024] First, after alkali treatment, the surface and weft fibers shrink significantly, making the fabric relatively tighter and enhancing its strength to a certain extent. Then, during loose washing, the internal stress between the warp cotton fibers is released, reducing the shrinkage rate of the warp yarns and making the yarns on the surface of the fabric even tighter. After setting treatment, the chemical fibers of the weft yarns undergo structural changes under prolonged heat treatment, which makes the fabric more stable and helps to suppress the decrease in fabric strength caused by fuzzing.

[0025] Optionally, the singeing process is performed at a temperature of 250℃-350℃ and a speed of 75m / min-85m / min, singeing only on the front side. Performing single-sided singeing at a lower temperature and higher speed helps reduce damage to the synthetic fibers, especially the multifilaments in the inner layer of the fabric.

[0026] The beneficial effects of this invention are as follows: The comfortable and warm ribbed fleece denim fabric of this invention, under the action of the outer weft shrinkage and tensioning fabric, causes the outer weft to pull inwards, making the weft points of the thicker inner weft appear to expand downwards and bulge, thus covering the outer weft. This minimizes damage to the outer warp and weft during the formation of the napped layer. Furthermore, the outer and inner wefts interweave with the inner warp in a plain weave, resulting in a denser fabric base. Combined with the effect of the outer weft tensioning fabric, this results in higher fabric strength. In addition, because the fabric base is plain weave and does not rely on float yarns for napping, and the inner weft is a thicker multifilament, the napped layer has short, numerous, fine, and dense fibers, making it more comfortable to the skin. When the fabric is stretched within a certain range, it only reduces the degree of expansion and bulging of the inner weft on the base, so the nap does not become significantly sparse.

[0027] Other features and advantages of this application will be set forth in the following description and will be apparent in part from the description or may be learned by practicing the application. The objectives and other advantages of this application may be realized and obtained by means of the structures particularly pointed out in the written description and the accompanying drawings. Attached Figure Description

[0028] Figure 1 This is a structural schematic diagram of a comfortable and warm ribbed denim fabric provided in an embodiment of this application.

[0029] Figure 2 This is a schematic diagram of the fabric structure of a comfortable and warm ribbed denim fabric provided in an embodiment of this application.

[0030] Figure 3 This is a schematic diagram of the organizational structure formed by the inner warp and the outer weft.

[0031] Figure 4 This is a schematic diagram of the organizational structure formed by the inner meridian and the inner latitude.

[0032] Figure 5 This is a schematic diagram of the organizational structure formed by the warp and weft threads.

[0033] Figure 6 This is a schematic diagram of the organizational structure formed by the outer warp and inner weft.

[0034] Attached label: 10, outer warp; 20, outer weft; 30, inner warp; 40, inner weft; 50, napped layer. Detailed Implementation

[0035] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0036] The following disclosure provides many different embodiments or examples for implementing different structures of the invention. To simplify the disclosure, specific examples of components and arrangements are described below. Of course, these are merely examples and are not intended to limit the invention. Furthermore, reference numerals and / or letters may be repeated in different examples; such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed.

[0037] Reference Figure 1 This application provides a comfortable and warm ribbed fleece denim fabric, comprising two warp systems and two weft systems. The warp yarns are divided into front warp 10 and back warp 30, and the weft yarns are divided into front weft 20 and back weft 40. The front weft 20 and back weft 40 are interwoven with the back warp 30 in a plain weave, the front warp 10 and the front weft 20 are interwoven in a twill weave, the front warp 10 and the back weft 40 are not interwoven, the back weft 40 is thicker than the front weft 20, the back weft 40 is multifilament, and the shrinkage rate of the front weft 20 is greater than that of the back weft 40. The front warp 10 and the front weft 20 interweave to form the outer layer of the fabric, and the back warp 30 and the back weft 40 interweave to form the bottom layer of the fabric. The bottom surface of the bottom layer is then treated with a napping process to obtain a napped layer 50.

[0038] This application's embodiments employ a novel organizational structure and yarn configuration to allow the inner weft to cover a greater portion of the fabric's bottom layer. After a napping process, a layer of fluff is formed on the bottom surface, achieving a comfortable and warm effect. Specifically, the fabric maintains high strength after napping, and the resulting fluff is dense and does not significantly become sparse after stretching.

[0039] The principle behind why fabrics retain high strength even after being brushed and napped:

[0040] (1) In the prior art, the napped fabric usually forms a large number of floating long lines on the bottom surface of the fabric, so the weft and warp yarns interweave less; in the embodiment of this application, the outer weft 20 and inner weft 40 are interwoven with the inner warp 30 in plain weave, with many interweaving points and a tight fabric structure.

[0041] (2) The tensioning effect of the 20mm weft on the fabric.

[0042] (3) The inner weft 40 is thicker than the outer weft 20. The shrinkage rate of the outer weft 20 is greater than that of the inner weft 40. The outer weft 20 is tightened into the inside of the fabric (between the outer and bottom layers), causing the thicker inner weft 40 to expand and bulge downward (towards the bottom), which can cover the outer weft 20. When the fabric is brushed and piled, the inner weft 40 is the main one that is damaged.

[0043] (4) The inner weft 40 is a multifilament. After being pulled, some single fibers break, but there are still many single fibers to maintain the bottom layer strength.

[0044] The principle behind the dense pile that doesn't become significantly sparse after stretching the fabric:

[0045] (1) In the prior art, the fabric with pile usually forms a large number of floating long lines on the bottom surface of the fabric, and the resulting pile is long and sparse; in the embodiment of this application, the front weft 20 and the inner weft 40 are interwoven with the inner warp 30 in plain weave, and the resulting pile is short and numerous.

[0046] (2) The weft 40 is a multifilament, containing multiple single fibers that can be hooked and broken.

[0047] (3) The shrinkage rate of the outer weft 20 is greater than that of the inner weft 40, which provides a stretch margin for the fabric. When the fabric is stretched within a certain range, it is only equivalent to reducing the degree of expansion of the inner weft 40 on the bottom surface. Therefore, the pile will not become significantly sparse.

[0048] Reference Figure 2 The illustrated embodiment demonstrates the weave structure of a comfortable and warm ribbed denim fabric in one specific example. Figures 2 to 6 In this diagram, Arabic numerals represent the warp threads, Roman numerals represent the inner warp threads, uppercase English letters represent the inner weft threads, and lowercase English letters represent the outer weft threads. As a convention in this field, shaded squares represent warp weft points (viewed from the front of the process), and unshaded squares represent weft weft points (viewed from the front of the process). For example, the intersection of the weft yarn in row D and the warp yarn in column II is the warp weft point formed by the inner weft and inner warp threads; viewed from the reverse side of the process, this point is the weft weft point.

[0049] from Figure 2 Decompose the weave structure formed by the inner warp and outer weft to obtain Figure 3 ;from Figure 2 Decompose the organizational structure formed by the inner warp and the inner latitude to obtain Figure 4 ;from Figure 2 Decompose the weave structure formed by the warp and weft to obtain Figure 5 ;from Figure 2 Decompose the tissue structure formed by the outer warp and inner weft to obtain Figure 6 .from Figure 6 It is evident that all points are warp organization points, meaning the surface warp only "overlaps" with the inner latitude, and the surface warp and inner latitude do not intersect. This is consistent with... Figure 1 All of the 40° latitude in the middle of the river correspond to the longitude 10° below the surface.

[0050] like Figure 5 As shown, the outer warp 10 and outer weft 20 are interwoven in a three-up-one-down twill weave, giving the fabric surface a denim-like texture. Specifically, both the outer and inner warp can be pure cotton warp yarns dyed indigo or sulfur black to prevent the underlying white from being visible on the right side of the fabric.

[0051] Furthermore, the yarn configuration can also prevent the underlying white from being visible on the front of the fabric. For example, the face warp (10) is thicker than the lining warp (30), allowing the face warp to cover the lining warp on the front of the fabric. Specifically, the lining warp (30) has a yarn count more than three times that of the face warp (10), which helps to show the twill weave on the front of the fabric without revealing the plain weave underneath. More preferably, the lining warp (30) has a yarn count three to eight times that of the face warp (10). Meanwhile, the face warp (10) has a yarn count of 8S-32S, which can achieve the surface texture effect of regular denim.

[0052] Multifilaments contain multiple single fibers, with the number of single fibers in a single multifilament represented by the F number. Preferably, the F number of the inner weft 40 is 114F-900F. Inner wefts with high F numbers can form numerous fibers during napping, and combined with the plain weave structure, the short and numerous fibers do not become noticeably sparse when the fabric is stretched. More preferably, the denier of the single fibers in the inner weft 40 is 80D-500D, which, after napping, forms fine and soft fibers, making the fabric more comfortable against the skin. Correspondingly, the count of the outer weft 20 is 21S-60S, which can be well covered by multifilaments of 80D-500D and 114F-900F.

[0053] Meanwhile, the outer weft is also used to connect the outer and inner layers of the fabric. When configuring the yarns, the outer weft is slightly finer than the outer warp, which helps to prevent the inner fabric from being visible on the front side during fabric processing. Specifically, the outer weft can be a polyester-nylon composite yarn. After undergoing the washing treatment required for denim fabric, it can achieve a better shrinkage effect. Of course, other yarns with strong shrinkage can also be used for the outer weft.

[0054] Preferably, refer to Figure 3 and Figure 4The same inner longitude 30 and each outer latitude 20 have the same type of organization point, and the same inner longitude 30 and each inner latitude 40 have the same type of organization point; and on the same inner longitude 30, the type of organization point formed by outer latitude 20 is always opposite to the type of organization point formed by inner latitude 40.

[0055] although Figure 3 and Figure 4 While individual warp threads appear uninterrupted with a particular weft yarn, the type of weave points formed by the face weft 20 on the same warp 30 is always opposite to that formed by the weft 40. Since the face weft and face warp interweave in a twill pattern, the fabric structure is stable and won't unravel. Furthermore, because the weave point types of the same warp 30 and each face weft 20 are the same, and the same warp 30 and each weft 40 are the same, the weft threads expand downwards and bulge under the stretching of the face weft. Before being brushed, the fabric's underside forms corduroy-like vertical ridges, achieving a similar warmth. Combined with the brushed nap layer 50, the fabric achieves even stronger warmth.

[0056] This application also provides a method for manufacturing a comfortable and warm ribbed denim fabric. The steps include weaving and finishing. In the weaving step, two systems of warp yarns and two systems of weft yarns are used. The warp yarns are divided into front warp and back warp, and the weft yarns are divided into front weft and back weft. The front weft and back weft are interwoven with the back warp in plain weave, and the front warp and front weft are interwoven in twill weave. The front warp and back weft do not interweave. The back weft is thicker than the front weft. The back weft is multifilament. The shrinkage rate of the front weft is greater than that of the back weft. The front weft is a polyester-nylon composite yarn.

[0057] The finishing process includes singeing, alkali treatment, drying, pre-shrinking, and brushing.

[0058] The outer weft is made of polyester-nylon composite yarn, which undergoes strong shrinkage after alkali treatment, making the fabric more tightly interwoven. This improves the fabric's resistance to tearing to a certain extent. Furthermore, the shrinkage of the outer weft causes the inner weft to bulge downwards at the weft stitch point on the bottom surface. When the fabric is brushed, the inner warp and outer weft are protected by the downward bulge of the inner weft, resulting in less damage. This effectively solves the problem of significant reduction in fabric strength after brushing treatment in existing brushed products.

[0059] Polyester-nylon composite yarn is a common type of polyester-nylon composite yarn on the market, specifically 60% nylon + 40% polyester, 42.9% nylon + 57.1% polyester, 50% nylon + 50% polyester, 66.7% nylon + 33.3% polyester, etc. The configuration of the remaining yarns can be referenced in the example of the comfortable and warm ribbed denim fabric above. In the drying process, the drying temperature is 100℃-120℃, and the processing time is 5-10 minutes.

[0060] Specifically, the singeing process is carried out at a temperature of 250℃-350℃ and a speed of 75m / min-85m / min, and only the front side of the fabric is singed. Singeing is used to remove fuzz from the surface of the fabric. In this embodiment, single-sided singeing at a lower temperature and a higher speed helps to reduce damage to the synthetic fibers, especially the multifilaments in the inner layer of the fabric.

[0061] Preferably, a loose water washing process is included between the alkali treatment process and the drying process, with a treatment temperature of 40℃-50℃ and a treatment time of 20min-30min;

[0062] Between the drying process and the pre-shrinking process, there is also a shaping process, with a shaping temperature of 150℃-170℃ and a machine speed of 20m / min-40m / min.

[0063] During the loose treatment process, the fabric is not stretched or subjected to other forces, allowing it to remain in its natural state. The fabric is washed under low tension, eliminating the internal stress between the warp cotton fibers and causing the fabric to shrink relatively, thus making the fabric relatively tighter and making the weft stitch points on the bottom surface of the fabric more prominent.

[0064] Example 1

[0065] The outer warp is 10S pure cotton yarn; the inner warp is 30S pure cotton yarn; the outer weft is 75D polyester-nylon composite yarn (50% nylon + 50% polyester); the inner weft is 300D polyester, with an F number of 536; according to Figure 2 The fabric is woven with a specific weave structure. After finishing, the fabric undergoes the following process: singeing the front side at 300℃ and 85m / min; alkali treatment with sodium hydroxide at 12g / L; drying at 100℃ for 8min; pre-shrinking using standard methods; and napping the bottom surface of the fabric to form a raised nap layer. The breaking strength of the fabric was determined according to GB / T 3923.1-2013 Textiles - Tensile Properties of Fabrics - Part 1: Determination of Breaking Strength and Elongation at Break - Strip Method. The breaking strength of the fabric was found to be 723N. The heat retention rate of the fabric was tested according to GB / T 35762-2017 Textiles - Test Method for Heat Transfer Properties - Plate Method, and the measured heat retention rate was 33.6%.

[0066] Example 2

[0067] The outer warp is 10S pure cotton yarn; the inner warp is 30S pure cotton yarn; the outer weft is 75D polyester-nylon composite yarn (50% nylon + 50% polyester); the inner weft is 300D polyester, with an F number of 536; according to Figure 2The fabric is woven with a specific weave structure. After finishing, the fabric undergoes the following process: singeing the front side at 300℃ and 85m / min; alkali treatment with sodium hydroxide at 12g / L; loose washing at 50℃ for 20min; drying at 100℃ for 8min; setting at 150℃ and 40m / min; pre-shrinking using standard methods; and brushing the bottom surface of the fabric to form a napped layer. The breaking strength of the fabric was determined according to GB / T 3923.1-2013 Textiles - Tensile Properties of Fabrics - Part 1: Determination of Breaking Strength and Elongation at Break - Strip Method. The breaking strength of the fabric was found to be 741N. The heat retention rate of the fabric was tested according to GB / T 35762-2017 Textiles - Test Method for Heat Transfer Properties - Plate Method, and the heat retention rate was found to be 34.2%.

[0068] Comparative Example 1

[0069] The outer warp is 10S pure cotton yarn; the inner warp is 30S pure cotton yarn; the outer weft is 10S pure cotton yarn; the inner weft is 10S pure cotton yarn. During weaving, the outer layer is a three-up-one-down twill weave, and the inner layer is a five-end three-fly satin weave. The joining point is the inner warp joining the outer weft. After finishing, the fabric undergoes the following steps: single-sided singeing at 500℃ and a machine speed of 60m / min; pre-shrinking using conventional methods; and brushing the bottom surface of the fabric to form a brushed nap layer. The breaking strength of the fabric is determined according to GB / T 3923.1-2013 Textiles - Tensile Properties of Fabrics - Part 1: Determination of Breaking Strength and Elongation at Break - Strip Method. The breaking strength of the fabric is found to be 389N. The heat retention rate of the fabric is tested according to GB / T35762-2017 Textiles - Test Method for Heat Transfer Properties - Plate Method, and the heat retention rate is found to be 26.9%.

[0070] Comparative Example 2

[0071] The outer warp is 10S pure cotton yarn; the inner warp is 30S pure cotton yarn; the outer weft is 75D polyester-nylon composite yarn (50% nylon + 50% polyester); the inner weft is 300D polyester, with an F number of 536. During weaving, the outer layer is a 3-up-1-down twill weave, and the inner layer is a 5-end 3-fly satin weave, with the seam where the inner warp joins the outer weft. After finishing, the fabric undergoes the following process: singeing the front side at 300℃ and a speed of 85m / min; alkali treatment with sodium hydroxide at a concentration of 12g / L; drying at 100℃ for 8 minutes; pre-shrinking using conventional methods; and brushing the bottom surface of the fabric to form a brushed nap layer. The breaking strength of the fabric was determined according to GB / T 3923.1-2013 "Textiles - Tensile Properties of Fabrics - Part 1: Determination of Breaking Strength and Elongation at Break - Strip Method". The breaking strength of the fabric was found to be 453N. The heat retention rate of the fabric was tested according to GB / T 35762-2017 Test Method for Heat Transfer Properties of Textiles - Flat Plate Method, and the measured heat retention rate was 27.4%.

[0072] The results showed that the fabric with the weave structure and yarn configuration of Examples 1 and 2 still had good fabric strength after napping. Although Comparative Example 2 used the same yarn as Examples 1 and 2, its weave structure could only produce longer nap; even though Comparative Example 2 adjusted the finishing process to adapt the weft yarn to a specific chemical fiber, its weave structure still made the resulting fabric not dense enough, the tear resistance was still insufficient, and the heat retention was average.

[0073] In this embodiment, a double-layer fabric is woven using a special yarn configuration. First, after alkali treatment, the surface weft undergoes significant shrinkage, making the fabric relatively denser and enhancing its strength to a certain extent. Then, during a loose washing process, the internal stress between the warp cotton fibers is released, reducing the warp shrinkage rate and further tightening the yarns in the surface layer. Following a setting treatment, the chemical fibers in the weft undergo structural changes under prolonged heat treatment, making the fabric more stable and helping to suppress the decrease in fabric strength caused by napping. The dense structure of the fabric ensures that the underlying texture is not visible on the processed front, while the processed reverse side shows protrusions formed by the weft stitches of the inner weft. After napping, this creates fine, soft, and dense fluff, improving warmth while maintaining the fabric's strength.

[0074] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0075] The above description represents the preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications are also considered to be within the scope of protection of the present invention.

Claims

1. A comfortable and warm ribbed denim fabric, wherein the underside is provided with a fleece layer (50), characterized in that, The fabric comprises two systems of warp yarns and two systems of weft yarns. The warp yarns are divided into front warp (10) and back warp (30), and the weft yarns are divided into front weft (20) and back weft (40). The front weft (20) and the back weft (40) are interwoven with the back warp (30) in plain weave. The front warp (10) and the front weft (20) are interwoven in twill weave. The front warp (10) and the back weft (40) are not interwoven. The back weft (40) is thicker than the front weft (20). The inner weft (40) is multifilament, and the shrinkage rate of the outer weft (20) is greater than that of the inner weft (40); the same inner warp (30) and each outer weft (20) have the same type of weaving point, and the same inner warp (30) and each inner weft (40) have the same type of weaving point; and on the same inner warp (30), the type of weaving point formed by the outer weft (20) is always opposite to the type of weaving point formed by the inner weft (40).

2. The comfortable and warm ribbed denim fabric according to claim 1, characterized in that, The number of branches of the inner meridian (30) is three to eight times the number of branches of the outer meridian (10).

3. The comfortable and warm ribbed denim fabric according to claim 2, characterized in that, The number of branches of the dial (10) is 8S-32S.

4. The comfortable and warm ribbed denim fabric according to claim 1, characterized in that, The F number of the latitude (40) is 114F-900F.

5. The comfortable and warm ribbed denim fabric according to claim 4, characterized in that, The denier of the single fiber of the weft (40) is 80D-500D.

6. The comfortable and warm ribbed denim fabric according to claim 5, characterized in that, The number of branches of the weft (20) is 21S-60S.

7. A method for manufacturing a comfortable and warm ribbed denim fabric, comprising the steps of weaving and finishing, characterized in that, In the weaving process, two systems of warp yarns and two systems of weft yarns are used. The warp yarns are divided into front warp (10) and back warp (30), and the weft yarns are divided into front weft (20) and back weft (40). The front weft (20) and the back weft (40) are interwoven with the back warp (30) in plain weave. The front warp (10) and the front weft (20) are interwoven in twill weave. The front warp (10) and the back weft (40) are not interwoven. The back weft (40) is thicker than the front weft (20). 0) is a multifilament yarn, and the shrinkage rate of the outer weft (20) is greater than that of the inner weft (40); the outer weft (20) is a polyester-nylon composite yarn; the weft (30) of the same inner warp (30) and each outer weft (20) have the same weft point type, and the weft (30) of the same inner warp (30) and each inner weft (40) have the same weft point type; and on the same inner warp (30), the type of weft point formed by the outer weft (20) is always opposite to the type of weft point formed by the inner weft (40); The post-processing includes, in sequence, a singeing process, an alkali treatment process, a drying process, a pre-shrinking process, and a brushing process.

8. The method for manufacturing comfortable and warm ribbed denim fabric according to claim 7, characterized in that, The process between the alkali treatment process and the drying process also includes a loose water washing process, with a treatment temperature of 40℃-50℃ and a treatment time of 20min-30min; Between the drying process and the pre-shrinking process, there is also a shaping process, with a shaping temperature of 150℃-170℃ and a machine speed of 20m / min-40m / min.

9. The method for manufacturing comfortable and warm ribbed denim fabric according to claim 7, characterized in that, The singeing process is carried out at a temperature of 250℃-350℃ and a speed of 75m / min-85m / min, and singeing is performed only on the front side of the process.

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