A waterproof and breathable composite denim fabric
Waterproof and breathable denim fabrics made with three-dimensional integrated weaving and gradient density design solve the problems of insufficient waterproofness and breathability of traditional denim fabrics, improve the durability and comfort of the fabric, and maintain the crispness and elasticity of the fabric.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- FOSHAN MINGJIE TEXTILE CO LTD
- Filing Date
- 2025-10-31
- Publication Date
- 2026-07-31
AI Technical Summary
Traditional denim fabrics are inadequate in terms of waterproofness and breathability. Furthermore, their multi-layered composite structure makes the fabric heavy and stiff, with weak interlayer bonding, making it prone to delamination after use. The coating is also prone to peeling, resulting in poor functional durability.
The three-dimensional integrated weaving process forms a gradient density structure of waterproof outer layer, breathable middle layer and moisture-wicking inner layer. It uses hollow structure fiber yarn and hydrophilic fiber to achieve integrated waterproof, breathable and moisture-wicking functions. The interlacing of the spliced warp yarns provides a strong interlayer bond.
While achieving waterproof and breathable properties, it also improves the durability and wearing comfort of the fabric, avoids problems such as delamination and bubbling, and maintains the crispness and elasticity of the denim fabric.
Smart Images
Figure CN224578427U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of textile technology, and in particular to a waterproof and breathable composite denim fabric. Background Technology
[0002] Denim, as a classic textile, is widely popular due to its unique style and durability. However, traditional denim is usually woven from pure cotton yarn in a twill weave, resulting in a dense structure that, while offering some abrasion resistance, is significantly lacking in waterproofing and breathability. In everyday wear, when exposed to rain or sweat, traditional denim easily absorbs water and becomes heavy, and it is difficult to wick away moisture quickly, leading to poor wearing comfort.
[0003] To address these performance deficiencies, multi-layered composite structures are widely used in the design of functional fabrics. Chinese patent CN206433784U discloses a multi-functional denim garment structure that employs a composite structure with up to seven layers, including an outer surface layer, a breathable layer, a bamboo fiber layer, a non-woven fabric layer, a thermal layer, a new silk comfort cotton layer, a fleece layer, and a base fabric layer, to simultaneously achieve both warmth and breathability. However, while such functional fabrics, obtained by simply stacking multiple layers of materials, improve single properties like warmth to some extent, the excessive number of layers results in an overall heavy and stiff fabric, losing the crispness and drape that denim fabric should possess. More importantly, the layers are mainly bonded together with adhesives, resulting in limited bonding strength. After repeated washing and use, delamination and bubbling easily occur, severely affecting the fabric's lifespan. Furthermore, excessive stacking of functional layers, especially with the use of dense materials such as non-woven fabrics, can actually hinder air circulation.
[0004] In addition, some technical solutions focus on improving fabric performance through finishing processes or single-yarn improvements. For example, some solutions use coatings to enhance water resistance, but these coatings easily clog fabric pores, severely sacrificing breathability, and the coatings themselves are prone to peeling off after friction and repeated washing, resulting in insufficient functional durability. Other solutions attempt to use special functional fibers, but these fibers often cannot withstand the high-intensity finishing processes in traditional denim processing (such as indigo dyeing, enzyme washing, stone washing, etc.), leading to functional failure or fiber damage. Utility Model Content
[0005] The purpose of this utility model is to provide a waterproof and breathable composite denim fabric to solve one or more technical problems existing in the prior art, and at least provide a beneficial option or create conditions.
[0006] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows: This utility model provides a waterproof and breathable composite denim fabric, comprising an integrated three-layer structure formed by a three-dimensional integrated weaving process, consisting of a waterproof outer layer, a breathable middle layer, and a moisture-wicking inner layer from the outside to the inside; the fabric density of the waterproof outer layer is greater than that of the moisture-wicking inner layer, and the fabric density of the moisture-wicking inner layer is greater than that of the breathable middle layer, forming a gradient density in the fabric thickness direction; the weft yarns of the breathable middle layer and / or the moisture-wicking inner layer contain hollow structure fiber yarns.
[0007] This invention achieves integrated waterproof, breathable, and moisture-wicking functions through three-dimensional integrated weaving and gradient density design, without relying on subsequent lamination or coating. The high-density waterproof outer layer effectively blocks liquid water intrusion, the low-density breathable middle layer forms a stable static air insulation layer, and the medium-density moisture-wicking inner layer, combined with hollow yarns, constructs a one-way moisture-wicking channel that can quickly absorb and transport sweat from the skin surface for evaporation. This avoids common problems in composite fabrics such as delamination, bubbling, and stiffness, and improves the functionality, durability, and wearing comfort of denim fabric.
[0008] As a further improvement of this utility model: the hollow structure fiber yarn is a multi-channel hollow irregular composite yarn, which includes a hollow polyester filament as the core and a hydrophilic nylon filament covering the outer layer of the core.
[0009] The hydrophilic nylon filament of this improved design can quickly capture liquid sweat on the skin surface, while the microporous channels inside the hollow polyester filament rapidly transport the captured moisture along the fiber axis to the low-density intermediate layer through a strong capillary effect (wicking), thereby accelerating evaporation and solving the contradiction that a single material cannot simultaneously achieve both moisture absorption and quick drying.
[0010] As a further improvement of this utility model: the cross-section of the hollow polyester filament is cross-shaped or H-shaped. Compared with a circular cross-section or a regular cross-section, the cross-shaped or H-shaped cross-section is like constructing multiple continuous microchannels inside the fiber, enhancing capillary force, and making the moisture-wicking capacity far exceed that of circular or ordinary hollow fibers. The cross-shaped or H-shaped cross-section has a higher specific surface area in the same volume, which is beneficial for bonding with hydrophilic materials and rapid moisture exchange.
[0011] As a further improvement to this invention, the multi-channel hollow irregular composite yarn is also combined and twisted with a spandex filament to form an elastic weft yarn. This improved design incorporates spandex filament to form an elastic weft yarn, which, while maintaining excellent waterproof and breathable properties, gives the denim fabric the necessary longitudinal or bi-directional elasticity. This significantly improves the fit, comfort, and freedom of movement, solving the problems of stiffness and restrictiveness in traditional denim fabrics.
[0012] As a further improvement of this utility model: the waterproof outer layer has a high-density twill or satin weave structure, and its outer surface is covered with a superhydrophobic functional layer. Due to its longer warp and weft floats, the high-density twill or satin weave structure more easily achieves high density and smaller pores. The superhydrophobic functional layer on the outer surface can be formed by padding, spraying with an environmentally friendly fluorocarbon compound finishing agent, and then baking and curing.
[0013] This improved design combines a high-density twill or satin weave with a superhydrophobic functional layer to ensure that the fabric has excellent water resistance when facing liquid water (such as rain). The high-density weave physically reduces the porosity between yarns, while the superhydrophobic functional layer prevents water droplets from spreading due to its extremely low surface energy, causing them to roll off quickly like a lotus leaf effect.
[0014] As a further improvement of this utility model: the breathable intermediate layer has a low-density plain weave or square plain weave. Both plain weave and square plain weave are variations of plain weave, which are structurally stable and easier to form a looser, lower-density structure compared to conventional plain weave. This effectively blocks the direct and rapid exchange of external low-temperature air and internal heat, providing good thermal insulation.
[0015] As a further improvement of this invention: the moisture-wicking inner layer has a medium-density variable twill weave structure, with the hollow fiber yarns exposed on the skin-contacting surface of the moisture-wicking inner layer. This improvement allows more of the functional hollow yarns to be exposed on the skin-contacting surface, enabling sweat on the skin surface to preferentially and efficiently contact and be guided into the moisture-wicking channels of the hollow yarns. The medium-density variable twill weave, while ensuring moisture-wicking efficiency, also provides durability and crispness to the fabric.
[0016] As a further improvement of this utility model: the waterproof outer layer, the breathable middle layer, and the moisture-wicking inner layer are interwoven and connected into a single structure in the thickness direction by splicing warp yarns. The single structure provides a strong interlayer bonding force, and this interwoven bonding is far more resistant to repeated washing, friction, and aging than chemical adhesives (glue), solving the lifespan problems of composite fabrics such as bubbling and failure caused by interlayer peeling.
[0017] As a further improvement of this invention, the surface energy of the warp yarns is lower than that of the weft yarns of the moisture-wicking inner layer. This improvement prevents moisture absorbed by the hydrophilic inner weft yarns from being directly conducted to the outer layer through the equally hydrophilic warp yarns, thus compromising the overall waterproof performance. This embodiment ensures that moisture is transported and evaporated along a preset unidirectional moisture-wicking path (i.e., along the axial direction of the hollow yarns).
[0018] As a further improvement to this utility model: the waterproof outer layer has a warp density ≥ 85 threads / inch and a weft density ≥ 60 threads / inch; the breathable middle layer has a warp density ≤ 60 threads / inch and a weft density ≤ 40 threads / inch; the moisture-wicking inner layer has a warp density of 70-80 threads / inch and a weft density of 45-55 threads / inch. This improved solution specifically defines a gradient density structure of high density, medium density, and low density, reliably producing the expected waterproof and breathable effect. Attached Figure Description
[0019] The present invention will be further described below with reference to the accompanying drawings and embodiments; Figure 1 This is a schematic diagram of the integrated three-layer structure of the denim fabric in the embodiment; Figure 2 This is a schematic diagram of the structure of the elastic weft yarn formed by twisting the hollow fiber yarn and spandex yarn in the embodiment. In the attached diagram: 1: Waterproof outer layer, 2: Breathable middle layer, 3: Moisture-wicking inner layer, 4: Hollow structure fiber yarn, 41: Hollow polyester filament, 42: Hydrophilic nylon filament, 5: Spandex yarn. Detailed Implementation
[0020] This section will describe in detail the specific embodiments of the present utility model. The preferred embodiments of the present utility model are shown in the accompanying drawings. The purpose of the drawings is to supplement the textual description with graphics, so that people can intuitively and vividly understand each technical feature and the overall technical solution of the present utility model, but they should not be construed as limiting the scope of protection of the present utility model.
[0021] In the description of this utility model, it should be understood that the directional descriptions, such as up, down, front, back, left, right, etc., indicate the directional or positional relationship based on the directional or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.
[0022] In the description of this utility model, if there are words such as "several", they mean one or more, "multiple" means two or more, "greater than", "less than", "exceeding" etc. are understood to exclude the number itself, and "above", "below", "within" etc. are understood to include the number itself.
[0023] In the description of this utility model, unless otherwise explicitly defined, terms such as "setting," "installation," and "connection" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this utility model in conjunction with the specific content of the technical solution.
[0024] Reference Figures 1 to 2The following are several embodiments of a waterproof and breathable composite denim fabric according to this utility model.
[0025] The embodiments provided by this utility model offer a waterproof and breathable composite structure denim fabric, such as... Figure 1 and Figure 2 As shown, it includes an integrated three-layer structure formed by a three-dimensional integrated weaving process, consisting of a waterproof outer layer 1, a breathable middle layer 2, and a moisture-wicking inner layer 3 from the outside to the inside; the fabric density of the waterproof outer layer 1 is greater than that of the moisture-wicking inner layer 3, and the fabric density of the moisture-wicking inner layer 3 is greater than that of the breathable middle layer 2, forming a gradient density in the fabric thickness direction; the weft yarns of the breathable middle layer 2 and / or the moisture-wicking inner layer 3 contain hollow structure fiber yarns 4.
[0026] In this embodiment, the gradient density progresses from the outside to the inside, with the yarn arrangement decreasing from dense to sparse and then moderately increasing. The high density of the waterproof outer layer results in small pores between the yarns, which, combined with the hydrophobic finishing, is sufficient to block water droplets under surface tension. The low-density middle layer of the breathable middle layer provides space for the lateral diffusion and expulsion of moisture and heat. The moisture-wicking inner layer needs to balance moisture wicking and durability, hence its moderate density. The three-dimensional integrated weaving ensures that each layer is interwoven in one go on the loom using warp and weft yarns (especially the splicing warp yarns), resulting in strong interlayer bonding.
[0027] It should be noted that the high density, medium density, and low density of this utility model are relative concepts. That is, the waterproof outer layer is high density relative to the moisture-wicking inner layer and the breathable middle layer, the breathable middle layer is low density relative to the waterproof outer layer and the moisture-wicking inner layer, and the moisture-wicking inner layer is medium density relative to the waterproof outer layer and the breathable middle layer. In implementation, technicians refer to industry standards and combine them with fabric tightness calculations to determine the specific density. The following embodiments of this utility model also provide specific density ranges for implementation purposes.
[0028] This embodiment achieves integrated waterproof, breathable, and moisture-wicking functions through three-dimensional integrated weaving and gradient density design without relying on subsequent lamination or coating. The high-density waterproof outer layer effectively blocks the intrusion of liquid water, the low-density breathable middle layer forms a stable static air insulation layer, and the medium-density moisture-wicking inner layer, combined with hollow yarns, constructs a one-way moisture-wicking channel that can quickly absorb and transport sweat from the skin surface and evaporate it. This avoids common problems of delamination, bubbling, and stiffness in composite fabrics, and improves the functional durability and wearing comfort of denim fabric.
[0029] In an optional embodiment, such as Figure 2 As shown, the hollow fiber yarn 4 is a multi-channel hollow profiled composite yarn, which includes a hollow polyester filament 41 as the core yarn and a hydrophilic nylon filament 42 covering the outer layer of the core yarn.
[0030] In this embodiment, the hydrophilic nylon filament can quickly capture liquid sweat on the skin surface, while the microporous channels inside the hollow polyester filament rapidly transport the captured moisture along the fiber axis to the low-density intermediate layer through a strong capillary effect (wicking), thereby accelerating evaporation and solving the contradiction that a single material cannot simultaneously achieve both moisture absorption and quick drying.
[0031] In an optional embodiment, such as Figure 2 As shown, the hollow polyester filament 41 has a cross-shaped or H-shaped cross section. Taking the cross-shaped cross section as an example, four significant longitudinal grooves are formed between its four petal-shaped structures. These grooves are the main channels for moisture conduction. Compared with a circular cross section or a regular cross section, the cross-shaped or H-shaped cross section is like building multiple continuous microchannels inside the fiber, enhancing capillary force and making its moisture-wicking capacity far exceed that of circular or ordinary hollow fibers. The cross-shaped or H-shaped cross section has a higher specific surface area in the same volume, which is beneficial for bonding with hydrophilic materials and rapid moisture exchange.
[0032] In an optional embodiment, such as Figure 2 As shown, the multi-channel hollow profiled composite yarn is also combined and twisted with a spandex filament 5 to form an elastic weft yarn. The spandex filament is composited with the multi-channel hollow profiled composite yarn through combination and twisting, a common process in the textile industry for preparing composite yarns. The degree of twisting (twist) needs to be effectively controlled. Excessive twist will compress the pores of the hollow yarn, affecting its moisture-wicking ability; insufficient twist may lead to unstable yarn structure, preventing the spandex from fully utilizing its resilience. In this embodiment, the elastic weft yarn is mainly introduced as a weft yarn during weaving, thereby giving the fabric lateral elasticity.
[0033] In this embodiment, spandex yarn is added to form an elastic weft yarn, which, while maintaining excellent waterproof and breathable functions, gives the denim fabric the necessary longitudinal or bi-directional elasticity. This not only significantly improves the fit, comfort, and freedom of movement, but also solves the problems of stiffness and restriction in traditional denim fabrics.
[0034] In an optional embodiment, the waterproof outer layer 1 has a high-density twill or satin weave structure, with its outer surface covered by a superhydrophobic functional layer. High-density twill or satin weaves, due to their longer warp and weft floats, more easily achieve high density and smaller pores. The superhydrophobic functional layer on the outer surface can be formed by padding, spraying with an environmentally friendly fluorocarbon compound finishing agent, and then baking and curing.
[0035] This embodiment combines a high-density twill or satin weave with a superhydrophobic functional layer to ensure that the fabric has excellent water resistance when facing liquid water (such as rain). The high-density weave physically reduces the porosity between yarns, while the superhydrophobic functional layer prevents water droplets from spreading due to its extremely low surface energy, causing them to roll off quickly like a lotus leaf effect.
[0036] In an optional embodiment, the breathable intermediate layer 2 has a low-density plain weave or square plain weave structure. Both plain weave and square plain weaves are variations of plain weave, which are structurally stable and easier to form a looser, lower-density structure compared to conventional plain weaves. This effectively blocks the direct and rapid exchange of external low-temperature air and internal heat, providing good thermal insulation (warmth retention). At the same time, it provides a large space for the lateral diffusion and discharge of water vapor conducted from the inner layer, preventing moisture from accumulating locally.
[0037] In an optional embodiment, the moisture-wicking inner layer 3 has a medium-density variable twill weave structure, with the hollow fiber yarns exposed on the inner surface of the moisture-wicking inner layer. The medium-density variable twill weave, through the design of different warp and weft float length combinations, ensures that the exposed area of the weft yarns (i.e., hollow yarns) is larger than that of the warp yarns on the inner surface of the fabric. For example, if a weft-faced twill is used, its characteristic is that the front side of the fabric mainly displays the warp yarns, while the reverse side (inner surface) mainly displays the weft yarns.
[0038] This embodiment exposes more of the functional hollow yarn on the skin-contacting surface, allowing sweat on the skin surface to be preferentially and efficiently contacted and guided into the moisture-wicking channels of the hollow yarn. The medium-density variation twill provides durability and crispness to the fabric while ensuring moisture-wicking efficiency.
[0039] In an optional embodiment, the waterproof outer layer 1, the breathable middle layer 2, and the moisture-wicking inner layer 3 are interwoven in the thickness direction by bonding warp yarns to form a single integrated structure. During the weaving process, the bonding warp yarns shuttle vertically according to a preset pattern. For example, the bonding warp yarns can start from the bottom inner layer, interweave upwards with a weft yarn of the middle layer, then continue upwards with a weft yarn of the outer layer, and then turn back, thus forming a continuous whole. The integrated structure provides a strong interlayer bond, and this interwoven bond is far more resistant to repeated washing, friction, and aging than chemical adhesives (glue), solving the lifespan problems of composite fabrics caused by interlayer peeling, such as bubbling and failure.
[0040] In an optional embodiment, the surface energy of the bonded warp fibers is lower than the surface energy of the weft yarns of the moisture-wicking inner layer 3. This effectively prevents moisture from being siphoned through the bonded warp. It also prevents moisture absorbed by the hydrophilic inner weft yarns from being directly conducted to the outer layer through the equally hydrophilic bonded warp yarns, thus compromising the overall waterproof performance. This embodiment ensures that moisture is transported and evaporated along a preset unidirectional moisture-wicking path (i.e., along the axial direction of the hollow yarns).
[0041] In one optional embodiment, the waterproof outer layer 1 has a warp density of ≥85 threads / inch and a weft density of ≥60 threads / inch; the breathable intermediate layer 2 has a warp density of ≤60 threads / inch and a weft density of ≤40 threads / inch; and the moisture-wicking inner layer 3 has a warp density of 70-80 threads / inch and a weft density of 45-55 threads / inch.
[0042] This embodiment specifically defines a gradient density structure of high density, medium density, and low density to reliably produce the expected waterproof and breathable effect. For example, the outer layer has a warp density of ≥85 threads / inch and a weft density of ≥60 threads / inch to ensure that the pores are small enough to achieve waterproofing; the middle layer has a warp density of ≤60 threads / inch and a weft density of ≤40 threads / inch to create a sufficiently large porosity to facilitate air circulation and moisture diffusion; and the inner layer has a warp density of 70-80 threads / inch and a weft density of 45-55 threads / inch to maintain the basic mechanical properties and dimensional stability of the fabric while ensuring moisture wicking efficiency.
[0043] The preferred embodiments of the present invention have been described in detail above, but the present invention is not limited to the described embodiments. Those skilled in the art can make various equivalent modifications or substitutions without departing from the spirit of the present invention, and these equivalent modifications or substitutions are all included within the scope defined by the claims of this application.
Claims
1. A waterproof and breathable composite structure denim fabric, characterized in that, It includes an integrated three-layer structure formed by a three-dimensional integrated weaving process, consisting of a waterproof outer layer (1), a breathable middle layer (2), and a moisture-wicking inner layer (3) from the outside to the inside; the fabric density of the waterproof outer layer (1) is greater than that of the moisture-wicking inner layer (3), and the fabric density of the moisture-wicking inner layer (3) is greater than that of the breathable middle layer (2), forming a gradient density in the fabric thickness direction; the weft yarns of the breathable middle layer (2) and / or the moisture-wicking inner layer (3) contain hollow structure fiber yarns (4).
2. The waterproof and breathable composite denim fabric according to claim 1, characterized in that: The hollow fiber yarn (4) is a multi-channel hollow profile composite yarn, which includes a hollow polyester filament (41) as the core and a hydrophilic nylon filament (42) covering the outer layer of the core.
3. The waterproof and breathable composite structure denim fabric according to claim 2, characterized in that: The hollow polyester filament (41) has a cross-shaped or H-shaped cross section.
4. The waterproof and breathable composite structure denim fabric according to claim 2, characterized in that: The multi-channel hollow irregular composite yarn is also combined and twisted with a spandex filament (5) to form an elastic weft yarn.
5. The waterproof and breathable composite structure denim fabric according to claim 1, characterized in that: The waterproof outer layer (1) has a high-density twill or satin weave structure, and its outer surface is covered with a superhydrophobic functional layer.
6. The waterproof and breathable composite denim fabric according to claim 1, characterized in that: The breathable intermediate layer (2) has a low-density weft-flat or square-flat weave structure.
7. The waterproof and breathable composite structure denim fabric according to claim 1, characterized in that: The moisture-wicking inner layer (3) has a medium-density variable twill weave structure, and the hollow fiber yarn (4) is exposed on the skin-contact surface of the moisture-wicking inner layer (3).
8. The waterproof and breathable composite structure denim fabric according to claim 1, characterized in that: The waterproof outer layer (1), the breathable middle layer (2), and the moisture-wicking inner layer (3) are connected as a whole by interlacing the warp yarns in the thickness direction.
9. The waterproof and breathable composite structure denim fabric according to claim 8, characterized in that: The surface energy of the warp yarn is lower than that of the weft yarn in the moisture-wicking inner layer (3).
10. The waterproof and breathable composite structure denim fabric according to claim 1, characterized in that: The waterproof outer layer (1) has a warp density of ≥85 threads / inch and a weft density of ≥60 threads / inch; the breathable middle layer (2) has a warp density of ≤60 threads / inch and a weft density of ≤40 threads / inch; the moisture-wicking inner layer (3) has a warp density of 70-80 threads / inch and a weft density of 45-55 threads / inch.