Multi-filament Polyester Warp and Cotton Weft Fabric Design

The patent uses a composite yarn structure where cotton fibers are blended with synthetic fibers (polyester or nylon) in the warp yarns. This composite structure combines the softness and comfort of cotton with the strength and abrasion resistance of synthetic fibers, eliminating the need for additional sizing processes while maintaining fabric softness and improving warp strength.

The patent merges the dyeing operations by using warp beams that are pre-colored in different shades. Instead of separate dyeing processes for warps and wefts, the invention combines the color application step into the yarn preparation phase, allowing unique design effects to be achieved through the arrangement and interlacing of pre-colored yarns during weaving, thereby significantly reducing production time.

The patent addresses shrinkage stability by carefully selecting and matching the specifications of cotton and polyester fibers, including their denier, twist, and pre-shrinking treatment. By adjusting these parameters and using proper weaving tension control, the invention achieves a balanced fabric structure where the different shrinkage ratios of cotton and polyester are minimized, maintaining dimensional stability while preserving the strength benefits of the blend.

The patent employs composite yarns in the warp section where cotton fibers are intertwined with synthetic fibers (polyester or nylon). This composite structure provides the abrasion resistance needed for durable weaving while maintaining the softness characteristic of cotton. The synthetic component acts as a reinforcement that protects the cotton fibers from wear during the weaving process, eliminating the need for additional sizing treatments.