Woven Fabric Elasticity via Segmented Weft Patterns
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Solution Overview
Problem
Existing woven fabrics that mimic knitted fabrics through weaving techniques have suboptimal elasticity and appearance, necessitating a better-performing woven fabric that replicates knitted fabric performance.
Innovation Solution
A woven fabric design featuring warp and weft yarns woven in specific patterns (6×1 and 13×1) using Ne 16/1 to Ne 32/1 ring-spun cotton warp yarns and 19/1 to 32/1 TR blended plus 40 Denier lycra weft yarns, with a dobby-type weaving loom, followed by wetting, stretching, and heat setting to achieve desired shrinkage and density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If woven fabrics use traditional weaving patterns to mimic knitted fabrics, then the fabric structure can be created through weaving, but the elasticity and appearance performance are suboptimal
Solution Approach 1:
The fabric is divided into distinct sets of weft yarns (first set and second set) with different weave patterns (6×1 and 13×1), allowing each segment to contribute differently to the overall elasticity and appearance, thereby optimizing performance without requiring a single complex pattern
Solution Approach 2:
Different regions of the fabric use different weave patterns locally - the first set of weft yarns uses 6×1 pattern while the second set uses 13×1 pattern, creating local variations in elasticity and appearance that collectively achieve superior overall performance
2Reliability
If woven fabrics use mixed yarn types (hard yarns and elastomeric yarns) in predetermined arrangement, then the fabric can achieve some stretch, but the elasticity performance remains less than optimal
Solution Approach 1:
The invention changes the weave pattern parameters from traditional single patterns to a combination of 6×1 and 13×1 patterns, and adjusts yarn density parameters (90-170 ends per inch in warp direction, 96-114 picks per inch in weft direction) to optimize elasticity performance
Solution Approach 2:
The fabric uses composite yarn construction combining TR blended yarns with 40 Denier lycra (elastomeric) yarns in the weft, creating a composite material structure that provides superior stretch and recovery properties compared to single yarn types
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 exhibits improved elasticity and appearance, resembling knitted fabrics while maintaining the look of woven denim, with consistent yarn count and shrinkage ratio across weft yarns, achieving a fabric weight of 7-9 ounces per square yard and specific density ranges.
Implementation Method 1
the plurality of weft yarns have a weft yarn density of approximately 90 picks per inch after weaving, and the plurality of weft yarns have a weft yarn density between approximately 96 ends per inch to approximately 114 ends per inch after shrinking
Data Source
AI summary
A woven fabric that includes a plurality of warp yarns and a plurality of stretch weft yarns. In one embodiment, all of the weft yarns have the same shrinkage ratio and same size of yarn count, and the repeat intersection points on the weft yarns are either 6×1 or 13×1. The weft yarns in the 6×1 pattern alternate with the weft yarns in the 13×1 pattern, with two 6×1 weft yarns followed by one 13×1 weft yarn. This results in a woven fabric that performs like a knitted fabric but with the look of woven denim when the warp yarns are indigo dyed.