Heavy denim with double fabric structure and good covering

Abstract

The utility model discloses a kind of heavy denim with good coating and double-layer fabric structure, comprising: lining cloth and surface layer cloth;The surface layer cloth includes: surface warp yarn;Surface weft yarn, which is warp-weft interlaced with the surface warp yarn, so that the lower surface of surface layer cloth forms multiple surface warp yarn lower convex positions;The lining cloth includes: lining warp yarn;Lining weft yarn, which is warp-weft interlaced with the lining warp yarn, so that the upper surface of lining cloth forms multiple lining warp yarn upper convex positions corresponding to multiple surface warp yarn lower convex positions, the surface warp yarn lower convex position and the lining warp yarn upper convex position are connected with each other by interlacing point every N warp-weft intersection, form weft direction's joint, multiple joint places between limit cavity area, the cavity area is filled with fluffy hollow yarn.The utility model provides interjacent bonding force far more than traditional double-layer organization through joint point, prevent interlayer separation, and the limited cavity area provides stable space for filling fluffy hollow yarn.

Description

Technical Field

[0001] This utility model relates to the field of textile technology, and in particular to a heavy-duty denim fabric with a double-layer fabric structure that has good covering properties. Background Technology

[0002] Heavyweight denim (usually referring to denim with a weight exceeding 450g / m²) 2 Due to its unique stiffness, abrasion resistance, and warmth, denim is widely used in workwear, outerwear, and other fields. To enhance its functionality, double-layer structure design has become a common technical means. Existing double-layer heavy denim fabrics mainly achieve this through weft double weave, seam stitching, or composite layering.

[0003] In a double-weave structure, the connection is formed by the interleaving of the outer and inner weft threads. However, the joints (i.e., the points where the outer and inner yarns interweave) in this structure easily form regular streaks on the fabric surface, affecting its appearance. More importantly, to ensure smooth weaving, the number of joints within a single weave cycle is limited, resulting in insufficient interlayer bonding. This makes the outer and inner layers prone to separation during wear and washing, severely impacting the fabric's coverage stability and lifespan.

[0004] To address the issue of bonding strength, some solutions have proposed using additional high-count lead yarns as joining yarns. While this approach enhances bonding strength to some extent, the difference in shrinkage rates between the introduced new materials (such as polyester-nylon composite yarn) and cotton yarn can easily lead to localized wrinkling of the fabric during finishing, affecting the smoothness of the finished product. Furthermore, the stiff joints also make the fabric feel rigid, impacting its comfort against the skin. In addition, to improve warmth retention, existing technologies often fill the double-layer structure with fluffy materials or use composite layering methods. However, the filling material is prone to displacement and uneven distribution within the cavity, resulting in uneven warmth retention and poor coverage. Utility Model Content

[0005] The purpose of this invention is to provide a thick denim fabric with good coverage and a double-layer fabric structure, so as to solve one or more technical problems existing in the prior art, or 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 heavy-duty denim fabric with good coverage and a double-layer fabric structure, which has warp and weft directions, including: The inner fabric, and the outer fabric covering the inner fabric; The surface fabric includes: Outer warp yarn; The outer weft yarn is interwoven with the outer warp yarn, so that multiple outer warp yarn protrusions are formed on the lower surface of the outer fabric; The inner layer fabric includes: Inner warp yarn; The inner weft yarn is interwoven with the inner warp yarn, so that the upper surface of the inner fabric forms multiple inner warp yarn upper protrusions corresponding to multiple outer warp yarn lower protrusions. The outer warp yarn lower protrusions and the inner warp yarn upper protrusions are connected to each other through interlacing points at N warp-weft intersections to form weft direction joints. A cavity area is defined between multiple joints, and the cavity area is filled with fluffy hollow yarn.

[0007] This technical solution uses corresponding upper and lower convex joints to form a stable cavity between the two layers through mechanical interlocking. The joints provide interlayer bonding force far exceeding that of traditional double-layer structures, preventing layer separation. The defined cavity area provides a stable space for filling fluffy hollow yarn, which is the basis for achieving functions such as warmth and lightweight. The cavity area allows the fabric to deform within a certain range, thereby better adapting to human movement and improving the comfort of the wrapping.

[0008] As an extension of the above solution: the insertion length of the inner weft yarn is greater than that of the outer weft yarn, so that the inner fabric bulges outward in the cavity area. By differentiating the weft feed amount, the three-dimensional shape of the cavity is actively shaped. The outward bulge of the inner layer increases the cavity volume, improves the static air retention, enhances warmth retention, and creates more non-contact space with the skin inside the garment, which is conducive to air circulation and reduces stuffiness.

[0009] As an extension of the above solution: the outer and inner fabrics are arranged in a grid-like or parallel stripe pattern in the plane to divide the cavity into independent or interconnected three-dimensional cavities. Dividing the cavity into multiple independent units can effectively prevent the filling material from shifting within the cavity and ensure uniform heat retention.

[0010] As an extension of the above solution: the interlacing point is formed by a front warp yarn crossing over the inner warp yarn at the intersection of warp and weft, and interlacing with the inner weft yarn at the intersection. No additional yarn is needed; reliable connection can be achieved using the warp yarns themselves, resulting in lower costs and a mature technology.

[0011] As an extension of the above solution: the interlacing point is formed by an inner warp yarn crossing over the outer warp yarn at the intersection of warp and weft, and interlacing with the outer weft yarn at the intersection. No additional yarn is required, resulting in lower costs.

[0012] As an extension of the above solution: the interlacing point is formed by an independent connecting warp yarn interlacing with the outer and inner weft yarns, and the count of the connecting warp yarn is higher than that of the outer and inner warp yarns. This extension allows the connecting warp yarn to be hidden between the two layers or on the back of the fabric, without affecting the front appearance of the fabric. The high-count connecting warp yarn is finer and easily covered by the floats of the outer and inner warp and weft yarns, avoiding defects at the seam on the fabric surface and ensuring the fabric's aesthetic appeal.

[0013] As an extension of the above solution: the warp yarns used for bonding are water-soluble polyvinyl alcohol fibers. After washing, some or all of the interlacing points disappear, and the volume of the cavity area increases. This extended solution avoids the appearance problems and stiffness that may be caused by bonding points, and the reduced interlayer binding allows the cavity area to expand naturally, increasing its volume and further improving warmth and fluffiness.

[0014] As an extension of the above solution: the fluffy hollow yarn is used as the inner weft yarn of the inner layer fabric, woven into the inner layer fabric in a long float configuration. Using the fluffy hollow yarn directly as the inner weft yarn and adopting a long float configuration allows more hollow yarns to be exposed in a relaxed state on the inner layer surface and in the cavities, maximizing its fluffiness, warmth, and soft feel against the skin.

[0015] As an extension of the above solution: the fluffy hollow yarn is a blend of water-soluble vinylon and cotton. After washing, the water-soluble vinylon partially dissolves, causing the yarn volume within the cavity area to expand, forming a larger three-dimensional cavity. This extended solution leaves more gaps inside and around the yarn, allowing the entire cavity area to achieve an additional post-treatment expansion effect without changing the weaving structure, thus further enhancing warmth and softness.

[0016] As an extension of the above solution: the outer warp yarn and / or inner warp yarn are core-spun yarns of cotton and spandex, and the spandex content of the outer warp yarn is lower than that of the inner warp yarn. By differentiating the elasticity of the outer and inner warp yarns, a wrapping effect of being stiff on the outside and soft on the inside can be achieved. The high elastic modulus of the outer layer (low spandex content) ensures the crispness and shape retention of the denim fabric, while the low elastic modulus of the inner layer (high spandex content) makes it conform more to the curves of the human body, providing a comfortable and unrestricted wrapping feel during movement, and solving the problems of poor movement flexibility and stiff hand feel. Attached Figure Description

[0017] 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 double-layer fabric structure of the outer and inner layers of the embodiment.

[0018] In the attached diagram: 100: inner fabric, 110: inner warp yarn, 120: inner weft yarn, 130: upper convex part of inner warp yarn, 200: outer fabric, 210: outer warp yarn, 220: outer weft yarn, 230: lower convex part of outer warp yarn, 300: interlacing point, 400: hollow area, 500: fluffy hollow yarn. Detailed Implementation

[0019] 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.

[0020] 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.

[0021] 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.

[0022] 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.

[0023] Reference Figure 1 The following are several embodiments of a heavy-duty denim fabric with a double-layer fabric structure that provides good coverage according to this utility model.

[0024] In some embodiments, such as Figure 1 As shown, this utility model provides a heavy-duty denim fabric with good coverage and a double-layer fabric structure, which has warp and weft directions and includes: Inner layer fabric 100, and outer layer fabric 200 covering the inner layer fabric opposite to it; The outer fabric 200 includes: 210 warp yarns; The outer weft yarn 220 is interwoven with the outer warp yarn 210, so that multiple outer warp yarn protrusions 230 are formed on the lower surface of the outer fabric 200. The inner layer fabric 100 includes: 110 warp threads; The inner weft yarn 120 is interwoven with the inner warp yarn 110, so that the upper surface of the inner fabric 100 forms a plurality of inner warp yarn upper protrusions 130 corresponding to the plurality of outer warp yarn lower protrusions 230. The outer warp yarn lower protrusions 230 and the inner warp yarn upper protrusions 130 are connected to each other through interlacing points 300 at N warp and weft intersections to form weft direction joints. A cavity area 400 is defined between the plurality of joints, and the cavity area 400 is filled with fluffy hollow yarn 500.

[0025] In this embodiment, the upper and lower convex positions can be formed by using a 1 / 3 right-hand twill weave for the outer fabric, which naturally creates weft yarn floats on its reverse side, i.e., lower convex positions of the outer warp yarns; and using a 3 / 1 left-hand twill weave for the inner layer, which creates weft yarn floats on its front side, i.e., upper convex positions of the inner warp yarns. By adjusting the phases of the two weaves, the corresponding convex positions can be achieved. The value of N at every N warp-weft intersections ranges from 2 to 8. The specific value of N depends on the weight, density, and required cavity size of the designed fabric. When a large cavity is required, a larger value of N is used (e.g., 4, 5, 6); when a small cavity with high bonding strength is required, a smaller value of N is used (e.g., 2, 3). Those skilled in the art can determine the optimal N value through conventional testing based on the performance requirements of the target product. This embodiment constructs a stable structure with an internal cavity by aligning the upper and lower convex parts. Various optional joining techniques (warp joining / independent joining yarns) are used to form interlacing points, firmly bonding the outer and inner fabrics. For example, in an 8×8 weave cycle (i.e., N is 8), the 1st and 8th outer warp yarns exchange with the 1st and 8th inner warp yarns at specific weft points, forming a weft-direction joining. Simultaneously, the outer and inner warp yarns can also exchange at the 1st and 8th weft yarns, forming a warp-direction joining. In the area between the warp and weft joining points, the outer and inner layers remain separated. Because the fabric is taut during weaving, it naturally expands after weaving due to the release of yarn stress, creating a stable cavity area. Those skilled in the art will understand that the above weaving can typically be achieved using an electronic jacquard loom, which can independently control the movement of each warp yarn, enabling large-cycle weave exchanges.

[0026] This embodiment uses corresponding upper and lower protrusions to form a stable cavity between the two layers through mechanical interlocking. The joints provide interlayer bonding force far exceeding that of traditional double-layer structures, preventing layer separation. The defined cavity area provides a stable space for filling fluffy hollow yarn, which is the basis for achieving functions such as warmth and lightweight. The cavity area allows the fabric to deform within a certain range, thereby better adapting to human activities and improving the comfort of the wrapping.

[0027] In some embodiments, such as Figure 1As shown, the insertion length of the inner weft yarn 120 is greater than that of the outer weft yarn 220, so that the inner fabric 100 protrudes outward in the cavity area 400. The insertion length can be controlled by the weft feeding device of the loom. When weaving the cavity area, the inner weft yarn is controlled to be fed a longer yarn than the outer weft yarn. Specifically, the insertion length of the inner weft yarn can be 5% to 15% longer than that of the outer weft yarn to achieve a significant protrusion effect.

[0028] This embodiment actively shapes the three-dimensional shape of the cavity by varying the amount of weft fabric fed. The inner layer protrudes outward, increasing the cavity volume and improving the static air retention, which enhances warmth retention. It also creates more non-contact space with the skin on the inside of the garment, which is conducive to air circulation and reduces stuffiness.

[0029] In some embodiments, the outer and inner fabrics are arranged in a grid-like or parallel stripe pattern in the plane to divide the cavity into independent or interconnected three-dimensional cavities. Dividing the cavity into multiple independent units effectively prevents the filling material from shifting within the cavity, ensuring uniform warmth retention. Simultaneously, the honeycomb-like structure efficiently disperses stress, improving fabric durability. The parallel stripe pattern is easy to implement in production, and the channel structure facilitates airflow in a specific direction, aiding in heat and moisture management.

[0030] In some embodiments, such as Figure 1 As shown, the interlacing point 300 is formed when a front warp yarn 210 crosses the inner warp yarn 110 at the intersection of warp and weft, and interlaces with the inner weft yarn at the intersection. This embodiment does not require the introduction of additional yarns; reliable connection can be achieved using the warp yarns themselves, resulting in lower costs and a mature technology.

[0031] In some embodiments, such as Figure 1 As shown, the interlacing point 300 is formed when an inner warp yarn 110 crosses the outer warp yarn 210 at the warp-weft intersection and interlaces with the outer weft yarn at the intersection. Combining the above-described interlacing of the outer warp and inner weft yarns, this embodiment provides two equivalent and selectable solutions for implementation. At a predetermined joining position, such as a warp-weft intersection, when an inner weft yarn is woven in, an outer warp yarn that should be submerged is lifted by the heald lifting mechanism, crosses the inner warp yarn, and interlaces with it. At another joining position, when an outer weft yarn is woven in, an inner warp yarn that should be floating above is kept in a submerged state, crosses the outer warp yarn, and interlaces with it. This embodiment does not require additional yarn, resulting in lower costs.

[0032] In some embodiments, the interlacing point is formed by an independent knotted warp yarn (not shown) interlacing with the outer weft yarn and the inner weft yarn, and the count of the knotted warp yarn is higher than that of the outer warp yarn and the inner warp yarn.

[0033] In this embodiment, during weaving, the knotting warp yarn, like sewing thread, weaves up and down between the outer and inner layers. It interweaves with the outer warp yarn at one outer weft, and then interweaves with the inner warp yarn at the next inner weft, repeating this cycle to create a strong and concealed connection. This allows the knotting warp yarn to be hidden between the two layers or on the back of the weave, completely unaffected by the fabric's front appearance. High-count knotting warp yarns are finer and easily concealed by the floats of the outer and inner warp and weft yarns. For example, when the outer and inner warp yarns use coarse yarns of 10S-16S, the knotting warp yarn can be a fine yarn of 40S-60S. The high-count yarn ensures its fineness, making it easy to conceal and preventing defects at the knot point on the fabric surface, thus ensuring the fabric's aesthetic appeal.

[0034] In some embodiments, the warp yarns are water-soluble polyvinyl alcohol fibers. After washing, some or all of the interlacing points disappear, and the volume of the cavity region increases.

[0035] In this embodiment, before washing, the water-soluble fiber provides sufficient interlayer bonding force to ensure weaving and subsequent processing. After washing, the fiber dissolves, which can make the joints disappear, avoiding the appearance problems and stiffness that joints may cause. In addition, the interlayer binding is reduced, the cavity area naturally expands, the volume increases, and the warmth and fluffiness are further improved.

[0036] In some embodiments, the fluffy hollow yarn serves as the inner weft yarn of the inner fabric, woven into the inner fabric in a long float configuration. A long float configuration means that the yarn continuously floats above or below multiple warp yarns, which can be achieved using a satin weave or twill weave. For example, in a 5-end satin weave, one inner weft yarn can continuously float above four inner warp yarns, forming a long float, allowing the yarn's fluffy characteristics to be fully displayed. In this embodiment, the fluffy hollow yarn is directly used as the inner weft yarn, and a long float configuration (such as weft-faced satin) is adopted, allowing more hollow yarns to be exposed in a relaxed state on the inner surface and in the cavities, maximizing its fluffiness, warmth, and soft feel against the skin.

[0037] In some embodiments, the fluffy hollow yarn is a blend of water-soluble vinylon and cotton. After washing, the water-soluble vinylon partially dissolves, causing the yarn volume in the cavity area to expand and form a larger three-dimensional cavity.

[0038] Before washing in this embodiment, water-soluble vinylon provides yarn strength and facilitates weaving. After washing, the vinylon dissolves, making the yarn thinner and more fluffy and soft, leaving more gaps inside and around the yarn. This allows the entire cavity area to obtain additional finishing bulking effect without changing the weaving structure, thus further enhancing warmth and softness.

[0039] Those skilled in the art will understand that water washing refers to washing in hot water at 85-95℃ for 10-30 minutes. This water washing process is a mature existing technology, and this invention will not elaborate further on it. Water-soluble vinylon is a type of polyvinyl alcohol fiber, and its dissolution conditions are typically in hot water above 80℃. Those skilled in the art are familiar with its dissolution characteristics and will control them during the water washing process. The degree of dissolution (partial or complete) can be precisely controlled by the water washing temperature and time.

[0040] In some embodiments, the outer warp yarn and / or inner warp yarn are core-spun yarns of cotton and spandex, and the spandex content of the outer warp yarn is lower than that of the inner warp yarn, making the elastic modulus of the outer fabric greater than that of the inner fabric. By differentiating the elasticity of the outer and inner warp yarns, a wrapping effect of being stiff on the outside and soft on the inside can be achieved. The high elastic modulus of the outer layer (low spandex content) ensures the crispness and shape retention of the denim fabric, while the low elastic modulus of the inner layer (high spandex content) makes it more conform to the curves of the human body, providing a comfortable and unrestricted wrapping feel during movement, and solving the problems of poor mobility and stiff feel.

[0041] 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 heavy denim having a double-layer fabric structure with warp and weft directions, having a good cover, characterized in that, include: Inner fabric (100), and outer fabric (200) covering the inner fabric (100) on the opposite side; The outer fabric (200) includes: Outer warp yarn (210); The outer weft yarn (220) is interwoven with the outer warp yarn (210) to form multiple outer warp yarn protrusions (230) on the lower surface of the outer fabric (200). The inner fabric (100) includes: Inner warp yarn (110); The inner weft yarn (120) is interwoven with the inner warp yarn (110) to form multiple inner warp yarn upper protrusions (130) on the upper surface of the inner fabric (100) corresponding to multiple outer warp yarn lower protrusions (230). The outer warp yarn lower protrusions (230) and the inner warp yarn upper protrusions (130) are connected to each other through interlacing points (300) at N warp and weft intersections to form weft direction joints. A cavity area (400) is defined between multiple joints. The cavity area (400) is filled with fluffy hollow yarn (500).

2. A heavy denim having a double-layer fabric structure with good covering according to claim 1, characterized in that: The insertion length of the inner weft yarn (120) is greater than the insertion length of the outer weft yarn (220) so that the inner fabric (100) bulges outward in the cavity area (400).

3. The heavy denim having a double fabric structure with good covering according to claim 1, characterized in that: The outer fabric (200) and the inner fabric (100) are arranged in a grid pattern or parallel stripe pattern in the plane to divide the cavity area (400) into three-dimensional cavities that are independent or connected to each other.

4. A heavy denim having a double fabric structure with good covering according to claim 1, characterized in that: The interlacing point (300) is formed when a front warp yarn (210) crosses over the inner warp yarn (110) at the intersection of the warp and weft and interlaces with the inner weft yarn (120) at the intersection of the warp and weft.

5. The heavy denim having a double-layer fabric structure with good covering according to claim 1, characterized in that: The interlacing point (300) is formed when an inner warp yarn (110) crosses the outer warp yarn (210) at the intersection of the warp and weft and interlaces with the outer weft yarn (220) at the intersection of the warp and weft.

6. The heavy denim having a double-layer fabric structure with good covering according to claim 1, wherein: The interlacing point (300) is formed by an independent connecting warp yarn interlacing with the outer weft yarn (220) and the inner weft yarn (120), and the count of the connecting warp yarn is higher than that of the outer warp yarn (210) and the inner warp yarn (110).

7. A heavy denim having a double-layer fabric structure with good covering according to claim 6, characterized in that: The warp yarns are water-soluble polyvinyl alcohol fibers. After washing, some or all of the interlacing points disappear, and the volume of the cavity area (400) increases.

8. The heavy denim having a double-layer fabric structure with good covering according to claim 1, wherein: The fluffy hollow yarn (500) serves as the inner weft yarn (120) of the inner fabric (100) and is woven into the inner fabric (100) in a long float form.

9. A heavy denim having a double fabric structure with good covering according to claim 1, characterized in that: The fluffy hollow yarn (500) is a blend of water-soluble vinylon and cotton. After washing, the water-soluble vinylon partially dissolves, causing the yarn volume in the cavity area (400) to expand and form a larger three-dimensional cavity.

10. The heavy denim having a double-layer fabric structure with good covering according to claim 1, wherein: The outer warp yarn (210) and / or the inner warp yarn (110) are core-spun yarns of cotton and spandex, and the spandex content of the outer warp yarn (210) is lower than that of the inner warp yarn (110).

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