Ribbed Velvet Denim Fabric With Shrink-Tensioned Dense Fleece
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Solution Overview
Problem
Traditional denim fabrics suffer from inadequate insulation, fluff sparsity, and reduced strength due to aging and washing, with existing solutions like composite fabrics and double-layer designs failing to provide durable warmth and comfort.
Innovation Solution
A ribbed velvet denim fabric with two systems of warp and weft yarns, employing a plain weave for inside wefts and twill weave for outside warps and wefts, using thicker multifilament inside wefts with higher shrinkage rates to create a dense fleece layer, and incorporating polyester and polyamide composite yarns for enhanced shrinkage and stitch resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If yarns with heating effect are used as weft yarns to create far-infrared and heating functional effects, then the insulation effect is improved, but the insulation effect is not obvious after long-term use
Solution Approach 1:
The patent changes the physical parameters of the yarns by using hollow-structured yarns instead of traditional solid yarns. The hollow structure creates air pockets that provide thermal insulation, and this structural parameter change maintains its insulating properties over time without degradation of functional effects.
Solution Approach 2:
The patent employs composite material structures by combining hollow-structured yarns with traditional denim yarns in a multi-layer weave. This creates a composite fabric that integrates both the insulating properties of hollow structures and the durability of traditional denim, achieving long-lasting insulation effect.
2Length of moving object
If fluff is formed by floating long yarns being hooked and broken and pulled out, then the fluff is long, but the fluff is not dense enough and becomes very sparse after fabric stretching
Solution Approach 1:
Instead of forming fluff by pulling out long yarns from the fabric structure (traditional method), the patent inverts the approach by incorporating hollow-structured yarns that naturally protrude and form dense fluff through their structural characteristics during weaving and finishing processes, achieving both length and density.
Solution Approach 2:
The patent changes the structural parameters of the fluff-forming yarns by using hollow-structured yarns with specific dimensional characteristics. These yarns maintain their protruding fluff structure even when the fabric is stretched, preventing sparsity while maintaining density through their unique geometric parameters.
3Ease of operation
If fluff is formed by floating long yarns being hooked and broken and pulled out, then the fluff is created, but the strength of the fabric is greatly reduced
Solution Approach 1:
The patent extracts the fluff-forming function from the load-bearing yarns by using dedicated hollow-structured yarns specifically designed for fluff formation. This separates the insulation/fluff function from the structural strength function, allowing the fabric to maintain strength while achieving effective fleecing.
Solution Approach 2:
The patent uses composite material construction with different yarn types serving different functions: strong load-bearing yarns for fabric strength and hollow-structured yarns for fluff formation. This composite approach allows simultaneous achievement of high fabric strength and effective fleecing capability.
4Temperature
If a double-layer cloth structure with inside wefts and outside wefts is used to form fleecing, then the insulation is improved, but the fluff becomes sparse after stretching and the fabric strength is reduced
Solution Approach 1:
The patent segments the fabric structure into distinct functional layers with outside wefts for strength and inside wefts with hollow structures for insulation and fluff formation. This segmentation allows each layer to optimize its specific function without compromising the other, maintaining both strength and insulation after stretching.
Solution Approach 2:
The patent employs composite material construction combining traditional denim yarns for structural integrity with hollow-structured yarns for thermal insulation. This composite approach creates a multi-functional fabric that maintains both mechanical strength and thermal insulation properties even when stretched.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The fabric maintains high strength and warmth with dense, fine fluff that does not become sparse, offering improved insulation and comfort through a compact weave structure and yarn selection.
Implementation Method 1
the shrinkage rate of the outside wefts is greater than that of the inside wefts... Under the action of the outside wefts shrinking to tension the fabric
Data Source
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Figure 5~6
AI summary
Disclosed is a comfortable and warm ribbed velvet denim fabric, which belongs to the field of textiles, and includes two systems of warp yarns and two systems of weft yarns, where the warp yarns are divided into outside warps and inside warps, and the weft yarns are divided into outside wefts and inside wefts; the outside wefts and the inside wefts are interwoven with the inside warps in a manner of plain weave, the outside warps and the outside wefts are interwoven in a manner of twill weave, and the outside warps and the inside wefts are not interwoven; the inside wefts are thicker than the outside wefts; and the inside wefts are made of multifilaments, and a fleece layer is provided on the underside. Under the action of the outside wefts shrinking to tension the fabric, the outside wefts tie the interior of the fabric tight, causing the inside wefts to expand and protrude downward, which can cover the outside wefts and reduce the damage to the outside warps and the outside wefts in the process of fleecing. The plain weave structure makes a fabric bottom layer more compact, and the outside wefts pull the fabric tight, so that the fabric is higher in strength. The inside wefts are made of thicker multifilaments, combined with the plain weave structure, making fluff in the fleece layer short and abundant, fine and dense. When the fabric is stretched within a certain range, the fluff will not become significantly sparse.