Weaving process for unidirectional moisture-wicking woven fabric
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- FUJIAN HUAFENG NEW MATERIALS
- Filing Date
- 2025-04-16
- Publication Date
- 2026-07-02
Smart Images
Figure CN2025089316_02072026_PF_FP_ABST
Abstract
Description
A weaving process for a single-weave fabric Technical Field
[0001] This invention relates to the field of textile technology, and in particular to a weaving process for a single-weave fabric. Background Technology
[0002] The moisture-wicking properties of fabrics, as a key indicator of clothing comfort, are of paramount importance. When the human body is active during exercise or in high-temperature environments, the skin regulates body temperature and prevents overheating through perspiration. If the clothing worn at this time has poor moisture-wicking properties, sweat cannot be effectively absorbed by the fabric and quickly conducted to the outer layer for evaporation, remaining between the fabric and the skin and creating a damp environment. This dampness not only directly reduces the wearer's comfort but may also accelerate bacterial growth, leading to odors, and in severe cases, even causing skin inflammation or infection, posing a potential threat to the wearer's health.
[0003] Traditional single-layer fabrics primarily rely on two techniques to address moisture absorption and quick-drying issues: First, hydrophilic / hydrophobic finishing. This involves chemical treatments or coatings to impart hydrophilic and hydrophobic properties to the front and back of the fabric, respectively. The hydrophilic side absorbs sweat, while the hydrophobic side promotes moisture migration to the outside of the fabric for evaporation. While this improves moisture-wicking efficiency to some extent, the chemicals used in the process may have environmental and health risks, and the finishing effect tends to diminish after repeated washing. Second, the interweaving of hydrophilic and hydrophobic warp and weft yarns. This method utilizes yarns with different hydrophilic and hydrophobic properties to create a fabric with differentiated moisture-wicking structures. This allows sweat to spread rapidly along the hydrophilic yarns and be guided through the fabric structure to the hydrophobic yarn areas, ultimately evaporating to the outside. However, even with this design, for single-layer structures, when sweat volume is high, the similar or identical yarn materials of the inner and outer layers make it difficult to completely avoid the damp and cold feeling caused by an inner layer of moisture, especially before the garment is completely dry, significantly reducing the wearer's comfort. Summary of the Invention
[0004] Therefore, a weaving process for single-weave fabrics is needed to solve the problem of poor moisture wicking performance of existing fabrics.
[0005] To achieve the above objectives, the present invention provides a weaving process for a single-weave fabric, including a fabric weaving process. In the fabric weaving process, a first weft yarn and a second weft yarn are arranged on the same horizontal plane and interwoven with warp yarns respectively. The first weft yarn and the warp yarn are hydrophilic yarns; the second weft yarn is a hydrophobic yarn; the second weft yarn interweaves with the warp yarns at intervals, forming a float below the warp yarns; and the interweaving point of the first weft yarn and the warp yarn on the outer periphery of the float is greater than the interweaving point of the second weft yarn and the warp yarn, so as to compress the float and cause it to bulge on the back of the fabric, forming a raised area.
[0006] Furthermore, several of the aforementioned floats are adjacent to the back of the single-guide woven fabric to form a raised area.
[0007] Furthermore, the raised area is rectangular, and within the same raised area, several floating lines are of equal length.
[0008] Furthermore, the first weft yarn and the second weft yarn are arranged in a weft direction cyclic pattern of m:n, where m and n are positive integers and m ≥ n.
[0009] Furthermore, the distance between adjacent protruding areas is 0.5-0.8 mm.
[0010] Furthermore, the length of the float is 1.2-1.4 mm; or the height of the float protruding on the back of the single-guide woven fabric is 0.4-0.5 mm.
[0011] Furthermore, the second weft yarn is a waterproof polyester yarn.
[0012] Furthermore, the first weft yarn and warp yarn are open-wrap yarns in which polyester forms a network around the spandex.
[0013] Furthermore, the fabric weaving process is followed by a dyeing and finishing process, in which the fabric woven in the fabric weaving process is subjected to the following steps: fabric preparation → pre-setting → refining → overflow dyeing → dehydration → spreading → finishing. An absorption and discharge aid is added in the overflow dyeing step.
[0014] Unlike existing technologies, the above-mentioned technical solution uses hydrophilic yarns for the first weft and warp, which have excellent moisture absorption and wicking capabilities; the second weft is a hydrophobic yarn, which has waterproof properties; the second weft interweaves with the warp, with some of the second weft forming floats. During the interweaving process, the interweaving points of the first weft and warp around the floats are made larger than the interweaving points of the second weft and warp, so as to compress the floats and create raised areas on the back of the fabric. By increasing the number of interweaving points of the first weft and warp around the floats, a tighter and more stable fabric structure can be formed, reducing quality problems caused by the loose structure of single-weave woven fabrics and improving product quality. Attached Figure Description
[0015] Figure 1 is a structural schematic diagram of the single-guide shuttle woven fabric described in the embodiment;
[0016] Figure 2 is a schematic diagram of the structure of the single-guide woven fabric described in the embodiment;
[0017] Figure 3 is a schematic diagram of the structure of the single-guide shuttle woven fabric described in the embodiment;
[0018] Figure 4 is a schematic diagram of the front structure of the single-guided woven fabric described in the embodiment;
[0019] Figure 5 is a schematic diagram of the back structure of the single-guided woven fabric described in the embodiment;
[0020] Figure 6 is a schematic diagram of the structure of the single-guide shuttle woven fabric described in the embodiment;
[0021] Figure 7 is a physical image of the single-guide woven fabric described in the embodiment.
[0022] Explanation of reference numerals in the attached diagram: 10, first weft yarn; 20, second weft yarn; 201, float yarn; 30, warp yarn; 40, raised area. Detailed Implementation
[0023] To explain in detail the technical content, structural features, objectives, and effects of the technical solution, the following description is provided in conjunction with specific embodiments and accompanying drawings.
[0024] In this document, the term "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The term "embodiment" appearing in various places throughout the specification does not necessarily refer to the same embodiment, nor does it specifically limit its independence or connection with other embodiments. In principle, in this application, as long as there are no technical contradictions or conflicts, the technical features mentioned in each embodiment can be combined in any way to form corresponding implementable technical solutions.
[0025] Unless otherwise defined, the technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the use of related terms herein is merely for the purpose of describing particular embodiments and is not intended to limit this application.
[0026] In the description of this application, the term "and / or" is used to describe the logical relationship between objects, indicating that three relationships can exist. For example, A and / or B means: A exists, B exists, and A and B exist simultaneously. Additionally, the character " / " in this document generally indicates that the preceding and following objects have an "or" logical relationship.
[0027] In this application, terms such as “first” and “second” are used only to distinguish one entity or operation from another, and do not necessarily require or imply any actual quantity, hierarchy or order relationship between these entities or operations.
[0028] Unless otherwise specified, the use of terms such as “comprising,” “including,” “having,” or other similar expressions in this application is intended to cover non-exclusive inclusion, which does not exclude the presence of additional elements in a process, method, or product that includes the stated elements, such that a process, method, or product that includes a list of elements may include not only those defined elements but also other elements not expressly listed, or elements inherent to such a process, method, or product.
[0029] Similar to the interpretation in the Patent Examination Guidelines, in this application, expressions such as "greater than," "less than," and "exceeding" are understood to exclude the stated number; expressions such as "above," "below," and "within" are understood to include the stated number. Furthermore, in the description of the embodiments in this application, "multiple" means two or more (including two), and similar expressions related to "multiple" are also interpreted in this way, such as "multiple groups" and "multiple times," unless otherwise explicitly specified.
[0030] In the description of the embodiments of this application, the space-related expressions used, such as "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "vertical," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential," indicate the orientation or positional relationship based on the orientation or positional relationship shown in the specific embodiments or drawings. They are only for the purpose of describing the specific embodiments of this application or for the reader's understanding, and do not indicate or imply that the device or component referred to must have a specific position, a specific orientation, or be constructed or operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this application.
[0031] Unless otherwise expressly specified or limited, the terms "installation," "connection," "linking," "fixing," and "setting," as used in the description of the embodiments of this application, should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral setting; it can be a mechanical connection, an electrical connection, or a communication connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal connection of two components or the interaction between two components. For those skilled in the art to which this application pertains, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.
[0032] Referring to Figures 1-7, this invention provides a weaving process for a single-weave fabric, including a fabric weaving step. In this step, a first weft yarn 10 and a second weft yarn 20 are arranged on the same horizontal plane and interwoven with warp yarns 30. The first weft yarn 10 and warp yarns 30 are hydrophilic yarns with good moisture absorption and wicking capabilities; the second weft yarn 20 is a hydrophobic yarn with waterproof properties. The second weft yarn 20 and warp yarns 30 are interwoven alternately, with some of the second weft yarns 20 forming floats 201. During the interweaving process, the interweaving points of the first weft yarn 10 and warp yarns 30 around the floats 201 are made larger than the interweaving points of the second weft yarn 20 and warp yarns 30, thus squeezing the floats 201 to bulge on the back of the fabric, forming a raised area 40. By increasing the number of interweaving points of the first weft yarn 10 and warp yarns 30 around the floats 201, a tighter and more stable fabric structure can be formed, reducing quality problems caused by the loose structure of the single-weave fabric and improving product quality.
[0033] The fabric woven using the above-described fabric weaving process allows the hydrophobic raised areas 40 to contact the skin surface, preventing the first weft yarn 10 and warp yarn 30 from contacting the skin surface. This accelerates the flow of moisture from the second weft yarn 20 to the first weft yarn 10 and warp yarn 30, i.e., from the back of the single-weave fabric to the front, where it is absorbed by the hydrophilic first weft yarn 10 and warp yarn 30. The larger exposed surface area of the fabric accelerates the evaporation process, thereby reducing stuffiness and maintaining a cool and refreshing experience for a long time. Combining the above structure with the characteristics of hydrophobic and hydrophilic yarns, it is both effectively waterproof and quickly wicks away moisture, meeting the wearing needs in diverse environments and improving overall comfort.
[0034] The aforementioned single-weave fabric is formed by interlacing the first weft yarn 10 and the second weft yarn 20 with the warp yarn 30, and the method of weaving is not limited. The warp yarn 30 interlaces with the first weft yarn 10 and the second weft yarn 20 in a certain arrangement order to ensure the presence of hydrophobic yarns between the hydrophilic yarns. The interlacing of the warp yarn 30 with the first weft yarn 10 can be plain weave, twill weave, or other structures. A second weft yarn 20 is inserted during the interlacing of the warp yarn 30 with the adjacent first weft yarn 10, interlacing with the warp yarn 30 in the following arrangement order: the warp yarn 30 interlaces with the first weft yarn 10 and the second weft yarn 20 sequentially.
[0035] The aforementioned warp yarn 30 is a functional definition of the longitudinally distributed yarn in a single-weave fabric. It is a hydrophilic yarn. Other characteristics and quantity of the warp yarn 30 are not limited. Some warp yarns 30 may have different or the same characteristics as other warp yarns 30. Specifically, other characteristics of the warp yarns 30 can be selected according to requirements to give the single-weave fabric multiple functions. The aforementioned first weft yarn 10 is a functional definition of the transversely distributed yarn in a single-weave fabric. Other characteristics and quantity of the first weft yarn 10 are not limited. Some first weft yarns 10 may have different or the same characteristics as other first weft yarns 10. Specifically, other characteristics of the first weft yarn 10 can be selected according to requirements to give the single-weave fabric multiple functions. The second weft yarn 20 mentioned above is a functional definition of the yarn that is laterally distributed in the single-weave fabric. It is a hydrophobic yarn. There are no restrictions on other characteristics and quantity of the second weft yarn 20. Some second weft yarns 20 may have different or the same other characteristics as other second weft yarns 20. Specifically, other characteristics of the second weft yarn 20 can be selected according to the needs so that the single-weave fabric has multiple functions.
[0036] Other characteristics mentioned above may include, but are not limited to, the yarn's material, color, elasticity, strength, and fineness. For example, the hydrophilic yarn mentioned above could be an air-covered yarn (ACY) where polyester forms a network around spandex. This air-covered yarn provides elasticity in the warp direction to meet the elasticity requirements of sports fabrics and becomes hydrophilic after dyeing and finishing. Alternatively, the hydrophilic yarn mentioned above could be a wicking yarn with an irregular cross-section. The grooves formed between the irregularly shaped cross-section yarns can quickly wick away sweat and have a good wicking effect. Similarly, the hydrophobic yarn mentioned above could be a waterproof yarn, or a yarn that has undergone waterproofing treatment to achieve a waterproof effect.
[0037] The raised area 40 formed on the back of the single-weave fabric can be formed by a single float 201 or by multiple adjacent floats 201 together, as shown in Figure 3. That is, several floats 201 are adjacent to each other, forming the raised area 40 on the back of the single-weave fabric. The raised area 40 formed by multiple floats can collectively contact the skin surface, supporting the entire fabric, thereby improving the fabric's breathability and preventing the hydrophilic yarns in the non-raised areas 40 from sticking to the skin surface, thus enhancing overall comfort.
[0038] The shape of the aforementioned raised area 40 can be arbitrary, determined by adjusting the lengths of several floats 201. Referring to Figures 3 and 4, the raised area 40 can be rectangular, meaning that within the same raised area 40, several floats 201 have equal lengths. A rectangular raised area 40, with equal-length floats 201 within the same area, ensures that the shape and height of the floats 201 on the back of the single-weave fabric are more consistent. This provides uniform support and cushioning during wear or use, while also dispersing friction and wear, improving the fabric's durability and abrasion resistance, and extending its lifespan.
[0039] Referring to Figures 4-6, the proportions of the first weft yarn 10 and the second weft yarn 20 in the fabric can be different. Referring to Figure 3, the proportions of the first weft yarn 10 and the second weft yarn 20 in the fabric can be the same. Having the same proportions of the first weft yarn 10 and the warp yarn 30 prevents contact between the first weft yarn 10 and the warp yarn 30 and the skin. Furthermore, the second weft yarn 20, being a hydrophobic yarn, effectively prevents moisture from accumulating on the skin surface, while the first weft yarn 10, being a hydrophilic yarn, can quickly absorb moisture from the skin surface. This ensures both the fabric's absorbency and its breathability and moisture-wicking properties.
[0040] The first weft yarn 10 and the second weft yarn 20 can be randomly arranged. In some embodiments, they can be randomly arranged in a ratio of m first weft yarns 10 to n second weft yarns 20, where m and n are positive integers, and m ≥ n. The first weft yarn 10 and the second weft yarn 20 can also be arranged in a certain weft direction cyclic arrangement. In some embodiments, the first weft yarn and the second weft yarn are arranged in a weft direction cyclic arrangement of m:n, where m and n are positive integers, and m ≥ n. That is, the arrangement of the first weft yarn 10 and the second weft yarn 20 can be a weft direction cyclic arrangement of one first weft yarn 10 and one second weft yarn 20; or a weft direction cyclic arrangement of three first weft yarns 10 and one second weft yarn 20; and so on. Referring to Figure 3, taking the weft direction cyclic arrangement of three first weft yarns 10 and three second weft yarns 20 as an example, the raised area 40 is formed by three floating yarns 201 adjacent to each other, and three first weft yarns 10 are adjacent to each other between adjacent raised areas 40.
[0041] Referring to Figures 3 and 4, in practical applications, there are typically several raised areas 40 distributed on the back of the single-weave fabric. Preferably, these raised areas 40 are evenly distributed. This even distribution ensures that the single-weave fabric provides uniform support and cushioning during wear or use, preventing the hydrophilic yarns of the non-raised areas 40 from adhering to the skin surface and improving overall comfort. In some embodiments, the raised areas 40 are distributed in a grid pattern on the back of the single-weave fabric; in other embodiments, they are distributed in concentric rings. In some embodiments, the raised areas 40 are staggered on the back of the single-weave fabric.
[0042] In some embodiments, the length of the float 201 can be 1.2-1.4 mm; or the height of the float 201 protruding on the back of the single-weave fabric can be 0.4-0.5 mm. The spacing between adjacent protruding areas 40 can be 0.5-0.8 mm. The skin-contact surface of the protruding areas 40 can remain dry, and ventilation gaps are formed between the protruding areas 40 so that moisture in the single-weave fabric can be quickly conducted from the back of the single-weave fabric to the front of the single-weave fabric.
[0043] The fabric weaving process is followed by a dyeing and finishing process. This process involves the following steps: fabric preparation, pre-setting, refining, overflow dyeing, dehydration, spreading, and setting. During the overflow dyeing step, a suction and release agent is added to achieve better suction and release effects. The single-weave fabric can also undergo heat setting treatment to keep the floats 201 raised on the back side of the fabric.
[0044] Two specific embodiments are provided below to facilitate a further understanding of the weaving process of a single-weave fabric according to this application.
[0045] Example 1
[0046] The length of the float of the second weft yarn 20 is controlled to be 1.3 mm, the width of the raised area 40 (i.e., the width of several adjacent floats 201) is 0.5 mm, and the height is 0.47 mm.
[0047] 1. Machine Model: Electronic Multi-Arm Water Jet 230 - Double Jet
[0048] 2. Raw material selection:
[0049] Warp yarn: White cross-section matte 50D / 72F polyester environmentally friendly recycled low-elasticity lightweight mesh DTY-Z, the cross-section yarn has a suction and expulsion effect;
[0050] First weft yarn 10: White semi-dull 50D / 48F (PET 50% + PBT 50%) T8 high elastic lightweight mesh DTY-S twist, after dyeing and finishing, it has the effect of absorption and drainage, and can provide the elasticity required for sports fabrics;
[0051] Second weft yarn 20: White semi-dull 75D / 72F polyester waterproof yarn.
[0052] 3. Process parameters:
[0053] Total number of roots: 11250
[0054] Reed number: 17.5#
[0055] Upper fabric width: 215.8cm
[0056] 133 entries / in
[0057] Weft density: 131 lines / in
[0058] Threading heddles / reeds: 3 strands / reed, thread in sequence 1, 2, 3, 4, 5, 6.
[0059] Weft arrangement: First weft yarn 10 : Second weft yarn 20 = 3 : 1
[0060] 4. Organization Chart:
[0061] In this embodiment, the first weft yarn 10 and the warp yarn 30 are interwoven in a 2 / 1 right-hand twill weave, which has a certain appearance effect. Moreover, the twill weave is not as tight as the plain weave, which is more conducive to the evaporation of moisture, as shown in Figure 4. The second weft yarn 20 is interwoven with the warp yarn 30, as shown in Figure 5. The arrangement of the first weft yarn 10 and the second weft yarn 20 is designed to be 3:1, as shown in Figure 6.
[0062] Dyeing and finishing process:
[0063] Fabric preparation → pre-ordering → refining → overflow dyeing → dehydration → spreading → finishing;
[0064] Add an absorption and expulsion aid during the staining stage.
[0065] The woven single-weave fabric was tested according to GB / T21655.1-2023 "Evaluation of Moisture Absorption and Quick-drying Properties of Textiles - Part 1: Single Combination Test Method". Before washing, it reached Grade III for moisture absorption and quick-drying properties. According to GB / T21655.2-2019 "Evaluation of Moisture Absorption and Quick-drying Properties of Textiles - Part 2: Dynamic Moisture Transfer Method", it was washed 5 times according to GB / T8629-2017, 4N program, and hung to dry. The moisture absorption and wicking properties reached Grade 3, and the unidirectional moisture transfer index reached Grade 5. See Table 1 for details.
[0066] Table 1
[0067] Example 2
[0068] The length of the second weft yarn 20 float is controlled at 1.3mm, the cumulative float width of the second weft yarn 20 is 0.7mm, and the height is 0.47mm.
[0069] Except for the process parameters, the weft yarn arrangement of the first weft yarn 10: the second weft yarn 20 = 5:1, the machine model, raw material selection, and dyeing and finishing process are the same as in Example 1.
[0070] The woven single-direction woven fabric was tested according to GB / T21655.1-2023 "Evaluation of Moisture Absorption and Quick-drying Properties of Textiles - Part 1: Single-item combination test method". Before washing, it reached level III in moisture absorption and quick-drying properties. According to GB / T21655.2-2019 "Evaluation of Moisture Absorption and Quick-drying Properties of Textiles - Part 2: Dynamic Moisture Transfer Method", it was washed 5 times according to GB / T8629-2017, 4N program, and hung to dry. The moisture absorption and perspiration properties reached level 3, and the unidirectional moisture transfer index reached level 5. See Table 2 for details.
[0071] Table 2
[0072] It should be noted that although the above embodiments have been described herein, this does not limit the scope of patent protection of the present invention. Therefore, any changes and modifications made to the embodiments described herein based on the innovative concept of the present invention, or equivalent structural or procedural transformations made using the content of the present invention's specification and drawings, directly or indirectly applying the above technical solutions to other related technical fields, are all included within the scope of patent protection of the present invention.
Claims
1. A weaving process of a single guide weft fabric, comprising a fabric weaving process, in which a first weft yarn and a second weft yarn are arranged in the same horizontal plane to be interwoven with warp yarns, respectively; characterized in that, The first weft yarn and the warp yarn are hydrophilic yarns; the second weft yarn is a hydrophobic yarn; the second weft yarn and the warp yarn are interlaced to form a float below the warp yarn; and the interlacing point of the first weft yarn and the warp yarn on the outer periphery of the float is greater than the interlacing point of the second weft yarn and the warp yarn, so as to squeeze the float and make the float bulge on the back of the fabric to form a raised area.
2. A weaving process for a single guide shute fabric according to claim 1, characterized in that, Several of the aforementioned floats are adjacent to the back of the single-guide woven fabric to form a raised area.
3. A weaving process of a single-guide shute fabric according to claim 2, characterized in that, The raised area is rectangular, and within the same raised area, several floating lines are of equal length.
4. A weaving process of a single guide shirting fabric as claimed in claim 1, wherein, The first and second weft yarns are arranged in a weft direction cyclic pattern of m:n, where m and n are positive integers and m ≥ n.
5. A weaving process of a single guide shirting fabric as claimed in claim 1, wherein, The distance between adjacent protruding areas is 0.5-0.8 mm.
6. The weaving process of a single-weave fabric according to claim 1, characterized in that, The length of the float is 1.2-1.4 mm; or the height of the float protruding on the back of the single-guide woven fabric is 0.4-0.5 mm.
7. A weaving process of a single-guide shute fabric according to claim 1, characterized in that, The second weft yarn is a waterproof polyester yarn.
8. A weaving process of a single-guide shute fabric according to claim 1, characterized in that, The first weft yarn and warp yarn are open-wrap yarns in which polyester forms a network around spandex.
9. A weaving process of a single-guide shute fabric according to claim 1, characterized in that, The fabric weaving process is followed by a dyeing and finishing process, which involves processing the greige fabric woven in the fabric weaving process through the steps of fabric preparation, pre-setting, refining, overflow dyeing, dehydration, spreading, and final shaping. An absorption and discharge aid is added in the overflow dyeing step.