Woven fabric and method of making same

Abstract

A method of weaving a woven fabric comprising weaving a first plurality of weft yarns through a plurality of warm yarns in a 6×1 pattern, and weaving a second plurality of weft yarns through the plurality of warp yarns in a 13×1 pattern. 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.

1 . A method of weaving a fabric comprising:
 weaving a first plurality of weft yarns through a plurality of warp yarns in a 6×1 pattern; and   weaving a second plurality of weft yarns through the plurality of warp yarns in a 13×1 pattern.   
     
     
         2 . The method of  claim 1 , wherein the first plurality of weft yarns and the second plurality of weft yarns are arranged in a repeating pattern. 
     
     
         3 . The method of  claim 2 , wherein the repeating pattern comprises two weft yarns woven in the 6×1 pattern followed by one weft yarn woven in the 13×1 pattern. 
     
     
         4 . The method of  claim 1 , wherein:
 the plurality of warp yarns comprises Ne 16/1 to Ne 32/1 ring-spun, 100-percent cotton, indigo-dyed yarns; and   the first and second pluralities of weft yarns comprise 19/1 to 32/1 TR blended plus 40 Denier lycra spun yarn.   
     
     
         5 . The method of  claim 1 , wherein:
 the plurality of warp yarns has a warp yarn density of approximately 90 ends per inch after weaving; and   the plurality of warp yarns has a warp yarn density from approximately 110 ends per inch to approximately 170 ends per inch after shrinking.   
     
     
         6 . The method of  claim 1 , wherein:
 the first and second pluralities of weft yarns have a weft yarn density of approximately 90 picks per inch after weaving; and   the first and second pluralities of weft yarns have a weft yarn density from approximately 96 ends per inch to approximately 114 ends per inch after shrinking.   
     
     
         7 . The method of  claim 1 , wherein:
 the plurality of warp yarns has a thickness from 16S to 32S; and   the first and second pluralities of weft yarns have a thickness from 19S to 32S.   
     
     
         8 . The method of  claim 1 , wherein a yarn count of the weft yarns in the first plurality of weft yarns under a particular tension is the same as a yarn count of the weft yarns in the second plurality of weft yarns under the same tension. 
     
     
         9 . The method of  claim 1 , wherein the first and second pluralities of weft yarns are woven through the plurality of warp yarns using a dobby-type weaving loom having a weft selection system. 
     
     
         10 . The method of  claim 1  further comprising:
 wetting the fabric; and 
 stretching the fabric in a warp direction to allow the fabric to shrink in a weft direction. 
 
     
     
         11 . The method of  claim 1  further comprising heat setting the fabric. 
     
     
         12 . A woven fabric prepared by a process comprising:
 weaving a first plurality of weft yarns through a plurality of warp yarns in a 6×1 pattern; and   weaving a second plurality of weft yarns through the plurality of warp yarns in a 13×1 pattern.   
     
     
         13 . The woven fabric of  claim 1 , wherein the first plurality of weft yarns and the second plurality of weft yarns are arranged in a repeating pattern. 
     
     
         14 . The woven fabric of  claim 2 , wherein the repeating pattern comprises two weft yarns woven in the 6×1 pattern followed by one weft yarn woven in the 13×1 pattern. 
     
     
         15 . The woven fabric of  claim 1 , wherein:
 the plurality of warp yarns comprises Ne 16/1 to Ne 32/1 ring-spun, 100-percent cotton, indigo-dyed yarns; and   the first and second pluralities of weft yarns comprise 19/1 to 32/1 TR blended plus 40 Denier lycra spun yarn.   
     
     
         16 . The woven fabric of  claim 1 , wherein:
 the plurality of warp yarns has a warp yarn density of approximately 90 ends per inch after weaving; and   the plurality of warp yarns has a warp yarn density from approximately 110 ends per inch to approximately 170 ends per inch after shrinking.   
     
     
         17 . The woven fabric of  claim 1 , wherein:
 the first and second pluralities of weft yarns has a weft yarn density of approximately 90 picks per inch after weaving; and   the first and second pluralities of weft yarns have a weft yarn density from approximately 96 ends per inch to approximately 114 ends per inch after shrinking.   
     
     
         18 . The woven fabric of  claim 1 , wherein:
 the plurality of warp yarns has a thickness from 16S to 32S; and   the first and second pluralities of weft yarns have a thickness from 19S to 32S.   
     
     
         19 . The woven fabric of  claim 1 , wherein a yarn count of the weft yarns in the first plurality of weft yarns under a particular tension is the same as a yarn count of the weft yarns in the second plurality of weft yarns under the same tension. 
     
     
         20 . The woven fabric of  claim 1 , wherein the first and second pluralities of weft yarns are woven through the plurality of warp yarns using a dobby-type weaving loom having a weft selection system. 
     
     
         21 . The woven fabric of  claim 1 , wherein the process further comprises:
 wetting the woven fabric; and   stretching the woven fabric in a warp direction to allow the woven fabric to shrink in a weft direction.   
     
     
         22 . The woven fabric of  claim 1 , wherein the process further comprises heat setting the woven fabric.