fabric science - Free Download PDF (2022)

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j . j . p i z zu to’s

FABRIC SCIENCE tenth edition

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j . j . p i z z u to’s

FABRIC SCIENCE tenth edition

Allen C. Cohen Fashion Institute of Technology New York, NY

Ingrid Johnson Fashion Institute of Technology New York, NY

FAIRCHILD BOOKS New York

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Executive Editor: Assistant Acquisitions Editor: Assistant Art Director: Production Director: Senior Production Editor: Copyeditor: Ancillaries Editor: Executive Director & General Manager: Associate Director of Sales: Cover Design: Cover Art: Text Design: Page Layout: Photo Research: Illustrations:

Olga T. Kontzias Amanda Breccia Sarah Silberg Ginger Hillman Elizabeth Marotta Precision Graphics Noah Schwartzberg Michael Schluter Melanie Sankel Erin Fitzsimmons TK TronvigKuypers Precision Graphics Sarah Silberg TK

Copyright © 2012 Fairchild Books, a Division of Condé Nast Publications. All rights reserved. No part of this book covered by the copyright hereon may be reproduced or used in any form or by any means—graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems—without written permission of the publisher. Library of Congress Catalog Card Number: TK ISBN: 978-1-60901-380-6 GST R 133004424 Printed in TK TPXX CHXX

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CONTENTS

Preface xv Acknowledgments xvii

1 2 3 4 5 6 7 8 9 10 11

The Textile Industry 3 Fiber Characteristics 19 Natural and Manufactured Fibers 35 Yarns and Sewing Threads 67 Woven Fabrics 89

2 1 13 14 15 16 17

Knitted Fabrics 119

Care and Renovation of Textiles 237 Unique Fabrications and Innovations 249 Textiles for Interiors 273 Determining Fabric Quality 307 Guide to Fabric Selection 341 Textile Laws, Regulations, and Trade Agreements 351

Other Types of Textiles 147

Textile Trade and Professional Associations 361

Textile Dyeing 163

Bibliography 363

Textile Printing 181

Credits

Textile Finishing 199

Index 369

367

Textiles and the Environment 221

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EXTENDED CONTENTS

Preface

Secondary Sources of Fabrics 8

xv

Acknowledgments

Jobbers 8 Retail Stores 9 Overseas Agents

xvii

1 The Textile Industry 3

9

The Domestic and Import Textile Industries 9

Objectives 3

The Domestic Textile Industry 9 The Textile Import Industry 10

Key Terms Related to Textiles 3 International Trade 4

Buying and Selling Fabric 10

General Fields of Textile Products 5

Private Label and Exclusive Brands

The Major Textile Production Segments 5

11

Market and Production Planning 12

Table 1.1: Fabric End-Use Groupings 6

Seasons 12

Fibers 6 Yarns 6 Fabrics 6 Dyeing and Printing 7 Finishing 7

The Environment 13 Fair Trade 13 Textile Connection: Sustainability 14 Trade Shows 14

Textile Put-Up 7

Textile Careers 14

Primary Sources of Fabrics 7

Table 1.2: Textile Careers

Mills 7 Converters 8 Importers 8

15

Speaking of Textiles 15 Study Questions

16

The Textile Industry: Fabric Science Swatch Kit Assignment 17 PubQ: Reorder these entries as “Fabric Science Swatch Kit Assignment: The Textile Industry”?

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2 Fiber Characteristics 19

3 Natural and Manufactured

Objectives 19

Fibers 35

Key Terms Related to Textiles 19

Objectives 35

Fiber Sources 20

Key Terms Related to Textiles 35 Natural Fibers 36

Natural Fibers 20 Manufactured Fibers 20

Cotton

Fiber Structure 21

Table 3.1: Comparison Chart of the Most Commonly Used Natural Fibers 36

Physical Attributes 21 Chemical Composition and Molecular Formation 24

Flax 37 Silk 38 Wool 39 Other Natural Fibers 40 The Environment 42

Fiber Performance Properties 24 Table 2.1: Categories of Fiber Performance Properties 25 Abrasion Resistance 25 Absorbency 25 Chemical Effects 26 Cover 26 Elasticity 26 Environmental Conditions Flammability 26 Flexibility 26 Hand 27 Luster 27 Pilling 27 Resiliency 27 Specific Gravity 27 Static Electricity 27 Strength 28 Thermoplasticity 28

Micron System 42 Manufactured Fibers 42 Generic Names 43 Table 3.3: The FTC Recognizes the Following Generic Names and Generic Fiber Subclasses of Manufactured Fibers 43

26

Table 3.4: Comparison Chart of the Most Commonly Used Manufactured Fibers 43 Marketing of Manufactured Fibers

Acetate 45 Acrylic 46 Lyocell 46 Nylon 46 Olefin 47 Lastol 48 PLA 48 Polyester 48 Elasterell-p 49 Rayon 50 HWM Rayon 50 Spandex 50 Properties of Major Textile Fibers Microfibers 51

Identification of Textile Fibers 29 Determining Fiber Identification 29 Other Fiber Identification Tests 30 Table 2.2: Burning Characteristics of Textile Fibers 31 Table 2.3: Chemical Solubility Test for Textile Fibers 32 33

51

Table 3.5: Properties of Major Textile Fibers 52

Fiber Characteristics: Fabric Science Swatch Kit Assignment 33

Nanotechnology 53 Nano Innovation 54

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Descriptions of Principal Manufactured Fibers 45

29

Study Questions

42

Table 3.2: Diameters of Various Fibers

Textile Connection: Maintaining a Selling Price 28 Wicking

36

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Comparison of Spun and Filament Yarn Properties 70 Uses of Spun and Filament Yarns 71

Secondary Manufactured Fibers for Consumer Use 54 Textile Connection: Rayon Fiber 55

Yarn Twist 71

Bamboo Rayon 56 Glass 56 Metallic 56 Modacrylic 57 Triacetate 57

Twist Direction

Carded and Combed Cotton Yarns 72 Tow and Line Linen Yarns 72 Woolen and Worsted Yarns 72

Secondary Manufactured Fibers for Industrial Applications 58

Single and Ply Yarns 73 Yarn Spinning 74

Anidex 58 Aramid 58 Azlon 58 Lastrile 58 Melamine 58 Novoloid 59 Nytril 59 PBI 59 Rubber 59 Saran 59 Sulfar 60 Vinal 60 Vinyon 60

Yarn Pilling 75 Blends and Mixtures 75 Special Types of Yarns 76 Textured Yarns 76 Stretch Yarns 78 High-Bulk Yarns 79 Novelty Yarns 79 Chenille Yarns 80 Metallic Yarns 80 Yarn Numbering Systems 81 The Denier System 81 The Yarn Count System The Tex System 82

Carbon Fibers 60 Fluorocarbon Fibers 60 Heterogeneous Fibers 60 Fiber Innovation 62

81

Table 4.2: Yarn Number Conversions

83

Sewing Threads 83

Table 3.6: Fiber Names in Other Languages 63

Fibers Used for Threads 83 Types of Threads 84 Thread Finishes 84 Thread Sizes 84 Important Factors in Thread Selection 84 Important Thread Factors That Govern Seam Appearance 84

Table 3.7: International Abbreviations for Designating Fibers in Yarns 64 64

Natural and Manufactured Fibers: Fabric Science Swatch Kit Assignment 65

Table 4.3: Comparison of Sewing Thread Types 84

4 Yarns and Sewing Threads 67

Table 4.4: Thread Finishes and Their Uses

Objectives 67

85

Table 4.5: Sewing Applications by Thread Size 85

Key Terms Related to Textiles 67 Spun and Filament Yarns 68 Identifying Spun and Filament Yarns Monofilament, Multifilament, and Microfilament Yarns 69

Textile Connection: Tassel

69

Study Questions

86

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Yarns and Sewing Threads: Fabric Science Swatch Kit Assignment 86

E X T E N D E D

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Table 4.1: Comparison of Stretch Yarns

Other Generic Fiber Categories 60

Study Questions

71

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5 Woven Fabrics 89

Study Questions

Woven Fabrics: Fabric Science Swatch Kit Assignment 117

Objectives 89 Key Terms Related to Textiles 89

6 Knitted Fabrics 119

The Loom 90 Types of Looms 91 Loom Production 93

Objectives 119 Key Terms Related to Textiles 119

Fabric Features 93

The Knitting Industry 120

The Selvage 93 Identifying Warp Yarns and Filling Yarns 94 Face and Back 95 Top and Bottom 95 Yarns Per Inch: A Measure of Fabric Quality 96

General Knitting Fabric Terms 121 Wales 121 Courses 121 Face and Back

Circular and Flat Machines Knitting Needles 123 Cut and Gauge 124

97

Knit Stitch 126 Purl Stitch 126 Miss Stitch 126 Tuck Stitch 126

Twill Weave 99 Satin Weave 101 Which Weave Makes the Strongest Fabric? 102

Knit Fabric Classifications 127 Knit Fabric Names 128 Weft Knitting 128

Special Fabric Weaves 103

Woven Designs

122

Types of Knitting Stitches 126

Table 5.1: Comparison of Basic Weave Properties 97

Leno Weave 103 Pile Weaves 103 Double Cloth and Variations

122

Machine Nomenclature 122

97

Basic Fabric Weaves 97 Plain Weave

121

Textile Connection: Knitwear

Determining the Weave of a Fabric 96 Weave Floats

117

Table 6.1: Comparison of Jersey, Rib, and Purl Fabrics 129

106

Seamless Knitting 135 Warp Knitting 135

106

Dobby Pattern 106 Jacquard Pattern 106 Clip-Spot Pattern 107 Color-and-Weave Effect 107

Table 6.2: Comparison of Weft Knits and Warp Knits 135 Laid-in Yarn Fabrics 139 Narrow Knitted Fabrics

Technology Advancements 107

139

Factors Affecting the Cost of Woven Fabrics 108

Important Differences Between Knitted and Woven Fabrics 140

New Developments 108

The Effect of Fabric Construction (Wales and Courses per Inch) on Knitted Fabric Properties 141

Classic Woven Fabrics 108 Textile Connection

110

Glossary of Defects in Knit Fabrics

Changing the Fabric 111

Glossary of Classic Knit Fabrics

Table 5.2: Woven Fabrics by Common Characteristics 111 Glossary of Classic Woven Fabrics

Study Questions

141

141

144

Knitted Fabrics: Fabric Science Swatch Kit Assignment 145

112

E X T E N D E D

C O N T E N T S

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7 Other Types of Textiles 147

Metamerism 169 When Dyeing Is Done 169

Objectives 147

Stock Dyeing 170 Top Dyeing 170

Key Terms Related to Textiles 147 Nonwoven Fabrics 148 Background

Table 8.2: Comparison of Dyeing in Various Stages 170

148

Table 7.1: End Uses of Nonwoven Fabrics 148

Yarn Dyeing 171 Piece Dyeing 171 Continuous Dyeing 173 Garment Dyeing 173

Durable and Disposable Nonwoven Fabrics 149 Manufacturing Nonwovens 149 Fusible Nonwovens 151 Hybrid Products 151 Nonwoven Wipes 152 Trade Shows and Associations 152 The Environment 153

Special Dyeing Effects 173 Cross-Dyeing 173 Table 8.3: Classical Woven Fabrics with Colored Effects Created by Dyeing of Yarns 174

Felt 153

Union Dyeing 174 Tone-On-Tone Effects

Bonded and Laminated Materials 153 Bonded Fabrics 153 Laminated Fabrics 154

Pigment Coloring 174 Solution Dyeing 175

Quilted Material 155

Colorfastness 175

Stitch Bonding 156

Textile Connection: Bleeding Madras 176

Lace Fabrics 156

New Developments 176

Embroidery 157 Textile Connection: Appliqué

The Environment 176

158

Glossary of Imperfections of Dyed Fabrics

Tufted Fabrics 159 Study Questions

174

Study Questions

160

177

178

Textile Dyeing: Fabric Science Swatch Kit Assignment 179

Other Types of Textiles: Fabric Science Swatch Kit Assignment 161

9 Textile Printing 181

8 Textile Dyeing 163

Objectives 181

Objectives 163

Key Terms Related to Textiles 181

Key Terms Related to Textiles 163

Methods of Printing 183

Dyes and Pigments 165

Screen-Printing 183 Hand-Screen Printing

Conventional, or Aqueous, Dyeing 165 Textile Connection: A Colonial Dyer

166

183

Textile Connection: A Printed Mark 183

Classes of Dyes 166

Automatic Screen Printing 184 Rotary-Screen Printing 184 Roller Printing 185 Setting the Color in Screen and Roller Printing 186 Heat-Transfer Printing 186

Color Formulations and Matching Shades 166 Table 8.1: Major Dye Classes and their Fastness Properties 167 Computer Shade Matching and ComputerControlled Dyeing 168 E X T E N D E D

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Advancements in the Print Industry 187 Digital Printing

Table 10.1: Summary of Textile Finishes

188

Fragrances 204 Fulling 204 Mercerization 204 Napping and Sueding 205 Plissé 205 Shearing 206 Softening 206 Stiffening 206 Stone Washing, Acid Washing, and Cellulase 206

The Environment 188 Color Features of Printed Fabrics 189 Colorfastness 189 Wet-on-Dry and Wet-on-Wet Effects 189 Halftone 189 Strike-Off and Color Matching in Printed Fabrics 189 Which Method of Printing is Best? 189

Functional Finishes 207

Table 9.1: Comparison of Printing Methods 190

Antimicrobial Finishes 207 Antistatic Finishes 208 Crease-Resistant Finishes 208 Durable Press 208 Resin Treatment and Curing 208 Flame-Resistant Finishes 210 Mothproof Finishes 210 Shrinkage-Control Finishes 210

Basic Types of Prints 191 Direct Prints 191 Discharge Prints 191 Resist Prints 191 Pigment Prints 191 Special Types of Prints 192 Blotch Prints

192

Table 10.2: Shrinkage Control Methods

Table 9.2: Comparison of Wet (Dye) Prints, Dry (Pigment) Prints, and Heat-Transfer Prints 192

Nonaqueous Finishing 214 Final Fabric Drying 215 Plasma Processing 215

Glossary of Imperfections on Printed Fabric

Nanotechnology 215

195

The Environment 216

196

Textile Connection: The Changing Fabric

Textile Printing: Fabric Science Swatch Kit Assignment 197

Glossary of Finishing Imperfections Study Questions

Objectives 199

217

218

11 Textiles and the

Key Terms Related to Textiles 199

Environment 221

Classification of Finishes 200 Pretreatment Processes 200

Objectives 221

Textile Connection: The Origin of Bleaching 201

Key Terms Related to Textiles 221 Green Product Characteristics 222

Resins 202

Renewable 223 Resource Conservation Energy Saving 224

Aesthetic Finishes 202 202 E X T E N D E D

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Textile Finishing: Fabric Science Swatch Kit Assignment 219

10 Textile Finishing 199

Calendering

211

Soil-Release Finishes 212 Ultraviolet-Absorbent Finish 212 Water Repellents 212 Waterproof-Coated Fabrics 214

Flock Prints 193 Flocking 194 Warp Prints 194 Burn-Out Prints 194 Duplex Prints 194 Engineered Prints 194 Study Questions

202

224

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Nonhazardous 224 Recycling 224 Worker Assessment 225 Cost Consideration 226

Claiming Damages 246 The Environment 246 Study Questions

Textile Connection: Corporate Responsibility 226

13 Unique Fabrications and

Eco-Friendly Textiles 226

Innovations 249

Fibers 226 Yarns and Fabrics 228 Dyeing and Printing 228 Finishing 229 Care of Products 230 Recycling Programs 231

Objectives 249 Key Terms Related to Textiles 249 Fabrics with Special Features 250 Moisture Transport 250 Table 13.1: Examples of Moisture Transport/ Comfort Cooling Textiles 251

Eco-Fashion 232 Product Visibility 232

Waterproof Breathable Fabrics 252 Thermal Insulation 253

Organizations 233 Organic Standards

233

Table 13.2: Examples of Water Resistant and Waterproof, Breathable Fabrics 253

Government Regulations 234 Table 11.1: Sustainability Criteria Study Questions

247

234

Thermal Comfort 255

235

Clo Values

255

Nanotechnology 256

12 Care and Renovation

Electrotextiles 256 Phase-Change Materials 257

of Textiles 237

Ultrasonic Sound Technology 257

Objectives 237

Textile Connection: Textiles in the Car

Key Terms Related to Textiles 237

258

Industrial Fabrics 258

Soil Types 238

Table 13.3: Industrial Technical Fabrics Market (Illustrates the Wide Range of Uses and Products) 259

Laundering 238 Table 12.1: Stain Removal Guide for Washable Fabrics 239

Specialty Fibers 259 Protective Garments 260 Geotextiles 260 Biotechnology 261 Narrow Fabrics 261 Reflective Safety Apparel 261 Retroglo® Yarn 261 Growth 262 Trade Association 262

Dry-Cleaning 242 Dry-Cleaning Solvents 243 Spotting 243 Water-Repellent Garments 243 Cautions in Dry Cleaning 243 Home Solvent Cleaning 244 Dry Cleaning Versus Laundering 244 Textile Connection: Challenging the Dry Cleaners 244

Plastic, Leather, and Fur 262 Plastic 262 Leather 264 Fur 267 Study Questions 271

Professional Wet Cleaning 245 Ultrasonic Washing of Textiles 245 Trade Associations 245 Trade Shows 245 E X T E N D E D

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14 Textiles for Interiors 273

Table 14.7: Carpet Traffic Ratings Carpet Soiling 294 Carpet Maintenance 295 Methods of Cleaning 295

Objectives 273 Key Terms Related to Textiles 273 Interiors Product Classifications 274

Table 14.8: Removal of Spots and Stains from Nylon Fibers 296

Decorative Fabrics 274 Soft Floor Coverings 274

The Environment 297

Table 14.1: Widely Used Interiors Fabrics Manufactured Products

275

Window Fabrics 297

276

How Fiber Properties Affect Window Fabrics 297

Residential and Commercial Interiors 277

Table 14.9: Fiber Resistance to Ultraviolet Degradation 297

Table 14.2: The Association for Contract Textiles Performance Guidelines 278

How Yarn and Fabric Construction Affect Window Fabrics 298 How Dyes and Prints Affect Window Fabrics 298 Fabric Finishing for Window Fabrics 298 Drapery-Lining Material 299

Interior Decorators and Interior Designers 278 Flammability 278 Upholstery 279 Upholstery Fabric on Furniture

280

Wall and Ceiling Coverings 299

Table 14.3: Examples of Standard Performance Specifications for Woven Upholstery Fabrics 280

Manufactured Products 299 Bath Products 299 Bedding Products 301

Table 14.4: Upholstery Fabrics In-Use Application Terms 281

Textile Connection: Canopy Bed

Flame Resistance of Upholstered Fabrics 283

Textile Tabletop Products Study Questions

Filling and Padding of Upholstered Furniture 283 Care and Maintenance of Upholstery Fabrics 284 The Environment 284 Table 14.5: Upholstery Cleaning Codes

303

303

Hospitality Industry 304

Textile Connection: Ottoman 283

305

15 Determining Fabric Quality 307 Objectives 307

284

Key Terms Related to Textiles 307

Carpet 285

Basic Fabric Measurements 308

Table 14.6: Factors to Consider When Evaluating Carpet Quality 286

Textile Connection: See-Through Fabric 308

How Carpets Are Made 286 Other Methods of Manufacturing Carpets 288 Types of Carpet Pile 288 Carpet Construction Terms 290 Fibers, Yarns, Dyeing, Printing, and Finishing for Carpets 291 Carpet Underlay 293 Carpet Flammability 293 Traffic Classifications 294

How to Use the Pick Glass 308 Fabric Count 308 Determining Yarn-Twist Direction 310 Dimensional Properties of Fabric 311 Weight of Fabric 312 Table 15.1: Range of Fabric Weights 312 Table 15.2: Metric-English Conversions

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Weave Layout 314 Analyzing the Weave 315 Analyzing the Color Effect 316

E X T E N D E D

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17 Textile Laws, Regulations, and

Fabric Performance Testing 316 Textile Standards and Specifications 317 Environmental Standards 318 Textile Testing Laboratories 319 Relationship Between Laboratory Tests and Usage 319 Types of Test Methods 319

Trade Agreements 351 Objectives 351 Key Terms Related to Textiles 351

Textile Fiber Products Identification Act 352 Wool Products Labeling Act 354

Table 15.3: Common Textile Tests 320

Flammable Fabrics Act 354

Fabric Strength Tests 321 Surface-Friction Tests 323 Appearance Tests 325 Functional Tests 327

Flammability Standards

Textile Connection: Triangle Shirtwaist Factory Fire 355

Understanding Color 331

Care Labeling of Textile Wearing Apparel 356

Color Specifications 331 Colorfastness Tests 332

Exemptions 356 Care Labeling Contents 356 Basis for Care Information 357 Glossary of Standard Terms 357 Care Labeling Symbols 357 Responsibility of Industry and Care Labeling 358

Performance Standards and Their Application 336 Table 15.4: American Society for Testing and Materials (ASTM) Standard Performance Specifications for Fabrics and Selected End Uses 337 Study Questions

355

International Textile Regulations and Trade Agreements 358

338

International Regulations Trade Agreements 358

16 Guide to Fabric Selection 341

Study Questions

Objectives 341

358

360

Key Terms Related to Textiles 341 Examining for Aesthetics 342

Textile Trade and Professional Associations 361

Examining for Suitability 342 Textile Connection: Fashion Influences

342

Bibliography

Examining for Durability and Serviceability 344

Credits Index

Applying Fabric Selection Guidelines 344

363

367 369

Fiber Content 344 Yarn Properties 344 Fabric Properties 345 Dye and Print Properties 347 Finish Properties 348 Carpet Floor Coverings 348 The Environment 348 Fabric Selection 349

E X T E N D E D

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j . j . p i z zu to’s

FABRIC SCIENCE tenth edition

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chapter four

YARNS AND SEWING THREADS

Objectives u

u

u u

To understand that the type of yarn used has an important effect on the properties of fabric. To know the distinctions between the various yarn types as well as their properties and end-use applications. To understand the systems for determining yarn sizes. To be able to know the types, uses, and optimum applications of sewing threads.

Use fabrics in the Yarns section of the Fabric Science Swatch Kit for this chapter. Swatches 16 through 27 focus on various Yarns.

Key Terms Related to Textiles air-jet bare elastic yarn blended yarn bulk-textured carded chenille yarn combed core-spun yarn cotton count system covered elastic yarn crepe-filament crepe twist denier false twist

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monofilaments multifilaments novelty yarn open-ended spun ply ring spinning ring-spun run set-textured sewing thread single soft twist spun yarn stretch-textured

filament yarn gear crimping hard twist high-bulk or hi-bulk yarn knife-edge knit-deknit lea line linen metallic yarn metric yarn count microdenier microfibers microfilament mixture

67

tex system textured yarn thread size tow linen turns-per-inch or TPI turns-per-meter or TPM turbo-bulk yarn woolen worsted worsted count system yarn count yarn number or size yarn numbering system

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T

he formation of yarns is the next major step in the development of textile products. The simple process of making yarn predates recorded history. Cave dwellers used hair fiber from animals that were twisted into coarse yarn for ropes and nets. Eventually they refined their techniques to make yarn capable of being intertwined to produce crude fabrics. While seemingly unimportant, this invention, along with the inventions of fire and the wheel, is considered a major milestone of the world’s civilization. The ability to create a yarn, and to subsequently interlace the yarn (weaving) freed primitive humans to leave their caves in an expanded search for food, and eventually to migrate to other regions. The invention of spinning was so profound and yet so simple that the principle of making yarn, by twisting fiber while simultaneously pulling or drawing it out, has remained unchanged throughout the ages and continues to this day. Yarns are by definition groups of fibers twisted together to form a continuous strand. All textile fabrics, except for a few, such as felt (p. 153) and nonwoven fabrics (p. 148), are produced from yarns. The yarns are interlaced (woven), interlooped (knitted), or combined in other ways to form a textile fabric. There are many types of yarns, some lustrous, some dull, some smooth, some rough, some thinner than human hair, some thick and bulky. Two fabrics each made from the same fiber (e.g., polyester) and each woven in the same weave (e.g., plain weave; p. 97) may be substantially different from one another in appearance, durability, and cleanability due to the yarn differences in each of the fabrics.

(a)

twisted spun yarn

(b)

Spun and Filament Yarns

untwisted spun yarn

Yarns are classified into two main categories: spun and filament. Spun yarns are composed of relatively short lengths of fiber twisted or spun so that they hold together. The short lengths of fiber (measured in inches) are called staple fibers. Staple fibers are made into yarn by mechanical processes that first make the fibers more or less parallel, and then alternately pull and twist them. High twist is necessary to press the fibers together to give strength to the resulting yarn. It is important that staple fibers possess sufficient surface friction to adhere to each other. Filament yarns are composed of continuous strands of fiber that may be miles (kilometers) long. These yarns are produced directly from a spinnerette (see p. 20) or from a silk cocoon (see p. 39). Because filament yarns,

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twisted filament yarn

untwisted flament yarn

Figure 4.1 Twisted (a) and untwisted (b) spun and filament yarns.

unlike spun yarns, contain fibers of infinite length, they do not need to be highly twisted. Most filament yarns are of low twist (enough to hold the fibers together) to provide a smooth, lustrous surface. However, filament yarns may be tightly twisted, thus producing special effects such as crepe. (See Figure 4.1.)

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Identifying Spun and Filament Yarns

the yarn-spinning business or are a branch or department of a weaving mill or vertically integrated textile producing company.

Spun yarns may be identified by untwisting the yarn so that all fibers are parallel and by then pulling slightly, so the yarn simply comes apart without breaking. When a filament yarn is untwisted and pulled, the fibers remain parallel and the yarn does not come apart. Spun yarns composed of longer fibers are stronger, more uniform, and more lustrous than similar spun yarns made from shorter fibers. Long-staple cotton, for example, is cotton fiber of longer-than-average length and commands premium prices on cotton commodity markets. Filament yarns are composed only of manufactured fibers or silk. Spun yarns, however, may consist of both natural and manufactured fibers. In the latter instance, the long strands of fiber extruded from a spinnerette are chopped into short fiber lengths (staple) and later processed into spun yarns (see p. 21). These yarns are called spun nylon, spun polyester, or spun whatever the generic fiber composition. Manufactured yarns are made and marketed by chemical fiber producers. Spun yarns are made by yarnspinning mills that are either engaged exclusively in

Monofilament, Multifilament, and Microfilament Yarns Filament yarns may be composed of one single filament or of many filaments, and are known as monofilaments or multifilaments, respectively. (See Figure 4.2.) Both have the same fundamental properties, governed by the fiber composition of the yarn. An important physical difference is that a monofilament yarn of a given diameter is stiffer and less flexible than a multifilament yarn of the same diameter. And given two multifilament yarns of equal diameter (or equal denier, see p. 81), the yarn composed of fewer, but coarser, filaments is stiffer and less flexible than the yarn consisting of a higher number of finer filaments. Supple, soft fabrics, such as lining fabrics, are typically made from yarns composed of a large number of fine filaments. The large number gives the appropriate string of coverage and the fine filament offers greater flexibility.

Figure 4.2 Fabrics made of filament yarns may be found in many end uses, including royal wedding gowns. Y A R N S

A N D

S E W I N G

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standard yarn 2.0 dpf

microdenier yarn 1.0 dpf

microdenier yarn 0.5 dpf

Figure 4.3 Assume the three yarns are the same size, e.g. 80 d. The yarn on the left at 2 dpf would have 40 filaments. The yarn in the center at 1 dpf would have 80 filaments. The yarn on the right at .5 dpf would have 160 filaments. Thus, although the three yarns are of the same size, as the fibers get thinner (lower denier per filament) there is a higher filament count in the yarn.

Technological developments in manufactured fiber processes have made possible the generation of fibers such as nylon, polyester, lyocell and others to be produced in diameters finer than silk (microfilament) (Figure 4.3). These fine fibers are called microfibers, and are also known as microdenier. The name also applies to the yarns made from them (see p. 81 for an explanation of denier). Microfibers are used as multifilament yarns in flat or textured (see p. 76) configuration or are processed as staple fibers and then spun into yarn. Fabrics made from microfiber filament yarn are extremely soft and drapable and can be almost indistinguishable from silk. Spun yarns from microfibers can be blended with cotton, wool, or other fibers to produce yarns that possess much greater softness and flexibility, thus creating a more drapable or fluid fabric.

a typical spun-yarn fabric, is less smooth and somewhat duller with a slight surface fuzz that is characteristic of spun yarns. A filament yarn viewed against light shows uniform diameter and no fuzziness. Because each filament is as long as the yarn itself, there are no fiber ends protruding from the yarn surface as in spun yarns. This uniformity and smoothness in filament yarns is the main reason for their greater luster and smoother surface. The smooth surface of the filament yarns can sometimes be disadvantageous, causing yarns to slip and slide easily within a fabric. Excess stress on a seam, for example, may cause slipping of yarns and opening of a seam without the actual breakage of thread. This is more likely to occur in fabrics of low construction, fabrics with a low number of yarns per square inch (see p. 96) or where improper seam allowance is taken in sewing. The test described on page 324 should be used to determine the suitability of a filament yarn fabric for yarn and seam slippage. When a spun yarn is broken, some fibers break and others just slide away from each other. When a filament yarn is broken, every filament in the yarn breaks. Thus, filament yarns are stronger than spun yarns of the same diameter and fiber type because it requires more force to break yarn if all the fibers break than if only some fibers break while others slip apart. More twist in a spun yarn increases its strength by increasing the pressure exerted on the fibers. This results in reduced fiber slippage when force is exerted on the yarn. Up to a certain point, the more twist in a yarn, the stronger it is. After that point, the extra twist begins to cause the fibers to cut into each other and the yarn strength decreases. This happens because the fiber direction and thus the yarn’s strength is no longer in a spiral direction but has been forced into more of a horizontal steplike direction.

Comparison of Spun and Filament Yarn Properties There are a variety of properties used to compare and contrast spun and filament yarns. The three most important are yarn uniformity, yarn smoothness and luster, and yarn strength. In general, filament yarns are more uniform in diameter than spun yarns, although these differences are not visible to the naked eye. In filament yarns, the same number of filaments are present at every point along the yarn. A multifilament yarn composed of 40 filaments has 40 filaments along its entire length. This is not the case with spun yarns, where, for example, at one point there may be 40 fibers, at another, 43, and at still another, 37. Filament yarns are generally smoother and more lustrous than spun yarns. Satin, a familiar filamentyarn fabric, is smooth and lustrous, whereas sheeting,

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Uses of Spun and Filament Yarns Some fabrics are made only of spun yarns, some of only filament yarns, and others of a combination of spun and filament yarns. Each type of yarn is best for certain uses. Spun yarns may provide warmth, softness, and lightness of weight and are, for example, ideal in fabrics for T-shirts, sweaters, and blankets. Filament yarns are better for items where smoothness and luster are desired because the yarns are finer, more uniform in diameter, and lustrous. Filament yarn fabrics can offer a smooth, uniform surface. They are used in linings because their smoothness makes it easier to slide into and out of garments. They are also used for the outer shell of ski jackets, in a tightly packed construction, to resist the penetration of wind.

Figure 4.4 A crepe yarn kinks when slackened because of the high twist.

Yarn Twist Yarns are made by twisting together parallel or nearly parallel fibers. The amount of twist in a yarn is designated as the turns-per-inch (2.54 centimeters), or TPI, of the yarns. The TPI in a yarn has an important bearing on the appearance and durability of the yarn and the fabric that will be made from it. Spun yarns with relatively low twist (from 2 to 12 TPI) are frequently called soft-twist yarns because the yarn is softer, fluffier, and more flexible. They are not as strong as spun yarns with high twist. Knitting yarns are usually soft twist. Spun yarns with relatively high TPI (20 to 30 TPI) are called hard-twist yarns. The higher twist causes them to be smoother, firmer, and kinkier than spun yarns with low twist. They are also stronger. Filament yarns usually have very low twist (½ to 1 TPI). Twist in filament yarns does not increase strength but merely serves to keep the filaments in the yarn together. Some filament yarns are purposely made with high twist to produce a pebbly, harsh surface effect. These yarns are called crepe-filament yarns and the twist is referred to as crepe twist. (See Figure 4.4.)

Figure 4.5 S- and Z-twist yarns.

Twist Direction

properties such as strength and abrasion resistance. S- and Z-twist are important to the fabric designer and stylist because the direction of the twist affects the surface appearance of fabrics. Crepe fabrics are sometimes made by combining S- and Z-twist yarns to produce the balanced, pebbly effect on the fabric surface. Yarns for the towel business typically are made of cotton, twisted in a Z direction with a high TPI. This results in a final product that is relatively hard. Twistless

In addition to the amount of twist in a yarn, the direction of the twist is also designated. As shown in Figure 4.5, there are two types of yarn twist: S and Z. In an S-twist yarn, the spirals run upward to the left, corresponding to the direction of the diagonal part of the letter S. In a Z-twist yarn, the spirals run upward to the right, similar to the diagonal part of the letter Z. Yarn-twist direction is not an element of quality because it does not affect Y A R N S

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Tow and Line Linen Yarns

cotton or Zero Twist cotton has been used in the luxury towel industry to market terrycloth that is noticeably softer. Zero Twist is accomplished by plying a PVA (polyvinyl alcohol) yarn around the cotton yarn in the opposite direction (S direction) thus untwisting the cotton yarn. The PVA holds the cotton yarn together as it makes the pile in the terrycloth as it is woven (see p. 105). After the fabric is formed, the PVA is removed in the finishing process. The resultant towel offers consumers a very soft hand with excellent absorption.

Linen yarns are classified into two types called tow and line. Tow linen yarn is composed of short fibers and is irregular and rather coarse in texture. Tow linen is used for coarser types of linen fabrics found in sports jackets and trousers. Line linen is composed of long fibers averaging about 15 inches (38.1 centimeters) in length. Line linen yarns are smooth and fine and are used for fabrics such as fine table linens and tissue-weight blouses.

Carded and Combed Cotton Yarns

Woolen and Worsted Yarns There are two types of wool or wool-blend fabrics: woolens, made of carded yarns, and worsteds, made of combed yarns.1 A woolen yarn is fuzzier, has a more uneven diameter, is bulkier, and has a wider range of fiber length (including short fibers) than a worsted yarn. Worsted yarn is smooth with little fuzz, has an even diameter, and is more tightly twisted and firmer than woolen yarn. (See Figure 4.6.)

Carded and combed refer to the methods used to make cotton and cotton-blend spun yarns as well as to the designation of fabrics made from such yarns. A broadcloth fabric used as shirting fabric, for example, may be carded broadcloth or combed broadcloth, depending on the yarn used. All staple fibers have to be carded to help clean and disentangle them. For less costly fabrics, the fiber is carded and formed into a thick rope of loose fiber called sliver. The sliver is made into yarn by drawing and spinning. For finer fabrics, the carded cotton in the form of sliver goes to the combing unit, which further cleans the fibers and puts them in parallel position. Combing also removes short fibers. The comb delivers a loose sliver of parallel, long fibers called combed sliver, which is used to make the spun yarns, known as combed yarns. A combed yarn thus has longer fibers, fibers in more parallel position, fibers of more uniform length, fewer speck and dirt impurities, and more uniformity of diameter than a yarn that is not combed. Fabrics of combed yarn look better, feel smoother, and are stronger and more expensive than comparable fabrics of carded yarn. Fine, lightweight yarns need to be combed because long fibers are required for proper strength. They may be found in fine shirting and luxury sheeting. For some fabrics, combed yarns are not only unnecessary, but also less desirable than carded yarns. A napped fabric, such as cotton flannel, should be made from shorter fibers to create a fuzzier surface. (See p. 205.) Denim and terry cloth are two fabrics typically made exclusively of carded yarns. This gives denim the natural, rugged look consumers recognize. The fuzzy, soft bulkiness of carding helps terry cloth remove moisture.

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1. Wool fibers are first carded and then combed as part of the worsted yarn-manufacturing process. Combed sliver of wool is called top.

a

b

Figure 4.6 (a) Woolen and (b) worsted yarns.

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Fabrics made from worsted yarn are not necessarily better than fabrics made from woolen yarn. Each kind of yarn is suitable for a specific type of fabric. Tweed is an example of a woolen fabric; gabardine is an example of a worsted fabric. There are expensive woolens as well as expensive worsteds. The following are additional facts about woolen and worsted yarns: u

Fabrics of woolen yarn are more important in heavy winter coatings, ski sweaters, and blankets because woolens generally provide better insulation than worsteds. The fuzziness and soft bulkiness of woolen yarns provide the dead air spaces needed for better insulation.

u

Because worsted yarns are more tightly twisted than woolen yarns, fabrics of worsted yarn are usually firmer and denser than fabrics of woolen yarn. The more tightly twisted yarns help worsted to hold its pressed creases and generally to better keep its shape between cleanings than fabrics made of woolen yarn.

u

a

Figure 4.7 (a) Single spun and (b) ply yarns.

Fabrics made from worsted yarn usually show the yarns and weave clearly and sharply on the face of the fabric. Fabrics made from woolen yarns, on the other hand, may have a napped surface or look like the surface of felt.

together, and so forth. Most ply yarns used in clothing are two-ply. Little is gained by using yarns of higher ply. If a yarn is not ply, it is referred to as single, never single-ply. Advertisements of two-ply worsted suiting and of 2 × 2 broadcloth shirts aim to indicate quality. 2 × 2 broadcloth shirts have two-ply yarns in both warp and filling. In a 2 × 1 broadcloth, the warp is two-ply and the filling is single. In a ply yarn, two or more finer yarns are usually twisted to produce the same thickness as a single yarn, but with many additional benefits. In spun yarns, each fiber can wind more times around a thinner yarn and so hold more firmly. In plying the finer-spun yarns, more twist is added, holding the fibers more firmly in place and making the yarn stronger. Spun yarns are not perfectly even in diameter. By twisting together two or more yarns, the thin, weaker spots are reinforced. Thus, plying improves spun yarns because the fibers cannot slip as easily, the yarns are stronger, the yarn diameter is more uniform, and there is a reduced tendency to pill. Most single yarns have a Z twist. When plied with another single yarn, an S twist is used. Open end yarns (see p. 74) always have a Z twist. Ring spun (see p. 74) and air-jet (see p. 74) usually have a Z twist, but the system can produce S twist if modified.

Worsted fabrics, such as gabardine and serge used in trousers and suiting, tend to develop a shine with wear. Because the yarns are very smooth and tightly twisted, pressure on the fabric (e.g., from sitting) and rubbing tend to flatten the yarns and produce the luster. A popular suiting fabric known as unfinished worsted is given a light napping and fulling finish, which tends to cover up the yarns (see p. 205). Thus the appearance of the yarns and the weave are more subdued and the shine problem is eliminated or greatly reduced. (Unfinished worsted is a misnomer because the fabric is, in fact, given extra finishing treatments.)

Single and Ply Yarns Yarns are also categorized as single or ply. When a ply yarn is untwisted, it separates into two or more finer yarns. As shown in Figure 4.7, when a single spun yarn is untwisted, it comes apart. Ply yarn, therefore, may be defined as two or more single yarns twisted together to form one new yarn. Two-ply yarns are two singles twisted together, three-ply are three singles twisted

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In filament yarn, the diameter is uniform and the filaments cannot slip when the yarn is pulled. Twist is not needed to hold the filaments in place. For these reasons, plying does not improve filament yarns as it does spun yarns. However, plying of filament yarns can be done to produce unique effects on novelty yarns and metallic yarns (see p. 80). Ply yarns require better-quality fiber, more labor, and special machinery. Because of this expense, ply yarns are more costly than singles. Thus, most fabrics are made of single yarns.

Products made from ring spun yarns are advertised to promote their quality and are found in t-shirts, hosiery, sheets, towels, and even denim, all for the luxury market. Open-end (OE) spinning is a method of producing spun yarns. It is different from conventionally spun yarn, frequently called ring-spun yarn, in that only one process from carded sliver to spun yarn is required. Substantially higher rates of production, coupled with savings in space and power requirements, are realized in OE spinning. Carded sliver is fed to the open-end spinning unit, which separates the fibers, twists them together to form the completed spun yarn, and then winds the yarn onto spools or cones. Yarns made by this process are sometimes called roto-spun yarns or turbine-spun yarns. Some advantages of OE spun yarns are better regularity and uniformity; improved abrasion resistance, especially in high-twist types; improved distribution of fibers in blends; and improved absorption, resulting in brighter shades and print-pattern definition. Two important shortcomings are that yarn strength averages 20 percent lower than conventionally spun yarns, and manufacture is limited to coarse and medium-size yarns. These yarns are more uniform, somewhat weaker, and less expensive than ring-spun yarns. Their rate of production is 10 times faster than ring spun yarns. It has a limited range for yarn sizes and is best when under Ne 20 (see p. 82). Almost all yarn produced for denim is spun with this method. End yarns are used in fabrics such as interlock, fleece, and almost all yarns used in denim for mass markets. Air-jet spinning, also known as Vortex spinning, uses compressed air to aide in the spinning process. In

Yarn Spinning Staple fibers are spun into yarns by a variety of methods. The most widely used is ring spinning where fibers are carded to bring them to a more parallel position and bundled into a loosely formed rope about one inch in diameter, known as sliver. Multiple slivers are grouped together and then drawn or pulled slightly to decrease into a smaller diameter, known as roving. Further drawing and more twist are needed to form the desired yarn size with the required turns per inch. The final yarn is then wound onto a cone or package. (See Figure 4.8.) Ring spinning can produce anything from uniform yarns to the more complex, novelty yarns. It can produce yarns in a wide range of sizes and excels in the finer counts (see p. 81). Ring spinning produces yarns with the softest hand available and are noted for making fabrics that feel soft. However, low production rates and additional steps make this a more costly process.

Figure 4.8 Yarn winding on a package at a textile plant. F A B R I C

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this system, one end of a fiber is pushed toward the center of the yarn and the other end to the outside to wind around other fibers. This process is very fast with production twice that of open-end production and 20 times faster than ring spinning. The fibers are more securely locked into the yarn, do not slide as easily as other methods, and exhibit less fuzz or hairiness along their length. However, they have less uniformity, are limited to coarse yarn sizes, and have a lower yarn strength then ring-spun yarns. Fabrics made from this yarn will exhibit fewer pills and do not show wear easily. The largest end use is for sheeting or print cloth made of cotton and polyester blended yarns (see p. 75). It is also ideal for active wear, uniforms, and sweatshirts.

A common blended yarn is cotton and polyester, which is used extensively to make fabrics for shirts and sheets. Each fiber type in the blend adds not only its favorable properties, but also its unfavorable qualities. Thus, a shirt or dress fabric composed of 50 percent polyester and 50 percent cotton is less comfortable in hot humid weather than a 100 percent cotton fabric because of the low moisture absorption of the polyester. Not all blended yarns are perfect intimate blends. In some instances, depending on manufacturing procedures, the fibers may be dispersed in a nonuniform manner, such as a side-by-side or sheath-and-core configuration (Figure 4.9). A mixture is fabric composed of two or more different types of yarn. Filament and spun yarns combined in a fabric is an example of a mixture. A fabric with acetate warp and rayon filling is another example. Fabric mixtures are used to achieve certain design and color effects, as in cross-dyeing (see p. 173). They also are used

Yarn Pilling As described on page 28, certain fibers are more likely to pill than others. The yarn construction bears importantly on whether pills will occur. Provided that the fiber is prone to pilling, pills will develop more readily on spun yarns than on filament yarns because fiber ends are already on the surface. Filament yarn fabrics form pills only when the filaments break (e.g., from wear). Short-staple, fiber-spun yarns pill more readily than long-staple spun yarns because there are more fiber ends on the surface. Soft-twist yarns pill more than hardtwist yarns because it is easier for the fiber ends to move and protrude on the surface.

yarn a

yarn b

Blends and Mixtures A blended yarn is made of two or more fiber types. Both spun yarns and filament yarns may be blended, but spun yarns are the type most widely used. Blending is usually done to combine the desirable properties of different fibers. Wool, for example, is blended with staple polyester because wool has excellent drape and polyester helps to retain shape and reduce the cost of the fabric. Polyester is stronger than wool but thinner, so a blend of the two can be lightweight. It is difficult to obtain perfectly uniform blending of fibers in a spun yarn because of differences in specific gravity, length, diameter, surface shape and texture, the moisture regain property. There is also some variation along the length of blended yarn and in composition from inside to outside. Longer fibers tend to travel toward the center and shorter fibers toward the outside of yarns. When the blending occurs in a uniform manner, it is referred to as an “intimate blend”. Y A R N S

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Figure 4.9 Blended yarns are not always perfectly blended. Yarn A, blended at the opening stage, is a true intimate blend, which is most desirable. Yarn B, blended at the roving stage, is nonuniform and is less desirable. Yarn C is a blend consisting of long and short fibers. The long fibers tend to move to the center. Outside fibers contribute to hand, abrasion resistance, and pilling; inside fibers contribute to strength and flexibility.

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to lower the cost of certain fabrics by combining lessexpensive yarns with the more costly. They can be used to add strength to a weak yarn, such as adding nylon to a metallic yarn. A mixture is sometimes referred to as a combination fabric.

a long filament rather than a short-spun fiber that snags, the likelihood of damaging the fabric is high. Textured yarns should, therefore, be avoided in such garments as children’s playwear, where hard, rough use is anticipated.

Special Types of Yarns Textured Yarns The appearance and touch of multifilament yarn can be altered from smooth, lustrous, and flat to crimped, dull, and soft (somewhat like the appearance of spun yarn). This modification yields entirely new yarn properties, which in turn provide entirely new fabric properties. The filament yarns are modified before they are woven or knitted. Because the modified yarn takes on an entirely new surface or texture, it is called textured yarn. The ability of filament yarns to be modified to give them new shape, crimp, and bulk derives from the thermoplastic nature of the fibers from which they are produced (see p. 28). The various methods for making textured yarn involve shaping the yarn to some desired configuration of crimp or bulk by setting the yarn, heating it to near its melting point, and then cooling the material. (The exception to this is the air-jet method, described on p. 74.)

Possess high stretch and/or bulk

u

Provide greater cover (opacity) than regular filament yarns

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Afford greater breathability and absorption than regular filament yarns

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Afford greater insulation than regular filament yarns

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Provide softer and drier hand than regular filament

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Provide spunlike yarn characteristics

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Are more wrinkle resistant than spun yarns or regular filament yarns

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Poor abrasion resistance

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Easy soil penetration

Bulk-Textured The most important property of bulktextured yarns is their high bulk with low or minimal stretch. A method for producing bulk-textured yarn is the stuffer-box method, which produces an increase in bulk from 200 to 300 percent and can be found in yarns used for carpets. In this process, the filaments are compressed into the confined space of a heated chamber and heat-set with a wavy, random crimp. The resultant yarn is relatively bulky, possesses some degree of stretch, and is torque-free. Torque-free means the yarn will stay flat and motionless as opposed to a yarn that has a tendency to curl around itself.

The following are unfavorable properties of textured yarns.

u

Stretch-Textured Stretch-textured yarn is made primarily from nylon and used extensively in leotards, stretch ski pants, stretch hosiery, and similar items. These yarns can be stretched from 30 to 50 percent of their relaxed length. Stretch-textured yarns are produced by several methods. The false-twist method is the most widely used technique for producing textured yarns in finer deniers. Yarns are twisted, heat-set, and untwisted in one operation. Stretch-textured yarns are also produced by the knife-edge method. This process consists of passing the filaments over a heated roll and then pulling them over a sharp edge at an acute angle. When relaxed, the filaments take the form of coiled springs, but the spiral direction reverses itself at random, which helps produce a balanced yarn. Gear crimping is a third method for producing stretch-textured yarns. This method consists of passing the filament yarn through a series of heated rollers or sets of heated gears that deform the filaments. Variations in crimp can be obtained by controlling the number of crimps per inch as well as the depth of gear deformation.

Unfavorable Properties

u

Possible growth problem

There are several methods of producing textured yarns. They are classified into three main categories: stretchtextured, bulk-textured, and set-textured type. (See Figure 4.10.)

The following are favorable properties of textured yarns.

Types of Textured Yarn

Favorable Properties u

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textured yarn

guide rollers

guide rollers

edge point

heater

heater

regular yarn

regular yarn

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b regular yarn

textured yarn

heater heated chambers

guide rollers heater regular yarn textured yarn c

d textured yarn

circular knit fabric

unraveled textured yarn heater

high pressure/ high-velocity air

textured yarn

regular yarn

e

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Figure 4.10 Methods of producing textured yarn: (a) false twist (b) knife-edge (c) stuffer box (d) gear crimping (e) high-pressure/high velocity air-jet and (f) knit-deknit.

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The air-jet method is a second way to produce bulktextured yarns. In this method, a jet of high-velocity air is directed at a multifilament yarn, which separates the fibers, forcing some filaments to form loops and turns. The result is a bulkier, less lustrous yarn. Many yarn style varieties are possible by varying the yarn types and air-jet volume. No heat is involved, so the yarns need not be thermoplastic. The knit-deknit method is a way of producing a bulky yarn that has more stretch than yarn produced using the stuffer-box or air-jet methods. The filaments are knit into a narrow-diameter tubular form. The fabric is rolled up, heat-set, and then unraveled. Set-Textured Textured yarns in the set-textured category undergo an additional heat-setting step in the texturizing process to set the yarn and eliminate or greatly minimize stretch. This is accomplished in some instances by winding previously textured stretch yarns onto spools under moderate tension, and then heatsetting the yarn a second time. The yarn then becomes set in the bulked condition with either minimal or no stretch. Textured yarns of this type, made of filament polyester fiber, can be used in many fabrics including gabardine, interlock, and crepe de chine.

Stretch Yarns Yarns that have the capability of stretching are increasingly being used in textile materials. Aside from being the traditional materials used in foundation garments and swimwear, fabrics made from yarns that stretch are being used in apparel to provide increased comfort when sitting, bending, stooping, or engaged in active sports or work activities. Stretch fabrics are generally classified into two categories: power stretch and comfort stretch. (See Figure 4.11.) Power-stretch materials are fabrics in which holding power is required, as in foundation garments, swimwear, surgical support garments, and suspenders. The yarns used for power-stretch fabrics have high elasticity and high recovery force. Comfort-stretch fabrics are designed to yield with body movement. These fabrics have low recovery force and, in most instances, the yarns from which they are made and the fabrics themselves look the same as non-stretch materials. Stretch yarns and the fabrics made from them require not only that they stretch to the extent required, but also that they return to their original dimensions on release of the stresses that cause the stretch. Fabrics that do not readily recover are inadequate for the particular end use. A pair of pants that stretches at the knee from sitting, and that remains baggy at the knee for a long F A B R I C

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Figure 4.11 Power stretch fabrics are often used for activewear.

period of time after standing, may be less desirable than a pair of pants made from rigid fabric that does not stretch in the first place. Unrecovered stretch in textile fabrics is called growth. Growth has not been completely eliminated in most stretch fabrics, but can be kept to very low, tolerable minimums in properly constructed fabrics. In general, tightly constructed fabrics recover more quickly than loosely constructed fabrics. Also, fabrics made from highdenier stretch textured yarns recover more quickly than fabrics from fine-denier stretch textured yarns. A method for determining fabric growth is given on page 328.

Types of Stretch Yarns

The following common types of stretch yarns are compared in Table 4.1: Bare Elastic Yarns B are elastic yarns are usually composed of monofilament spandex fiber. Bare elastic yarns are used in power-stretch fabrics. In general, they S C I E N C E

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Table 4.1

Comparison oF sTreTCh Yarns

Yarn Type

Stretch Fiber Component

Stretch Type

Recovery Power

Textured yarns

Nylon or polyester

Comfort

Low

Blouses, sportswear, stretch pants, hosiery, polyester men’s socks. Polyester has a tendency to pill.

Bare elastic

Spandex

Power

Moderate

Lightweight foundations, swimwear, athletic wear— gym clothing, bike shorts.

Covered elastic

Spandex or rubber

Power

High

Heavy foundations, elastic bandages, surgical stockings, athletic supporters. Rubber has higher power and recovery than spandex, but poor shelf life—it begins to decay in one year.

Core spun

Spandex

Comfort

Very low to low

Active sportswear, stretch denim.

provide softer and more gentle shape control (moderate recovery force) than covered yarns.

and low potential shrinkage. When the finished yarn is treated with boiling water or steam, the high-shrinkage fibers contract and move to the center of the yarn, forcing the low-shrinkage fibers to buckle, which forms a yarn that is greater in diameter than the original and has more loft and bulk. Some high-bulk yarns are bulked (boiled or steamed) in yarn form, and others are bulked in garment form (e.g., knitted sweaters). Fabrics made of high-bulk acrylic yarns feel soft and luxurious, and frequently have the hand and appearance of high-quality worsted. They have the disadvantage of tending to pill easily, and they should be checked carefully for conformity to current flammability regulations.

Covered Elastic Yarns Covered elastic yarns are monofilaments that are wrapped or covered with a spun or filament yarn to hide the elastomeric yarn. Covered yarns tend to be thick and heavy and are used in powerstretch fabrics. In general, they provide firmer and more powerful shape control (high recovery force) than bare elastic yarns. Core-spun Yarns Core-spun yarns have a central filament core of spandex with staple fiber that has been spun around the core. The core in the center does not appear on the yarn surface, so the hand, texture, and appearance are identical to what the spun yarn would be without the core center. Core-spun elastic yarns are used in comfort stretch fabrics because they possess very low recovery force. These yarns can be spun very fine and thus provide elasticity without the bulk usually associated with other types of stretch yarns. Stretch chino, a popular cotton sportswear fabric used for tennis shorts and other active sportswear, is made from corespun cotton yarns. Core-spun stretch yarns are the most expensive of all stretch yarns.

Novelty Yarns Novelty yarns, sometimes also called fancy yarns, are yarns that are not of uniform thickness throughout their length, but have deliberate irregularities on their surfaces (Figure 4.12). These irregularities may be knots, bumps, curls, or similar effects. The naming of novelty yarns is confusing, however. Because there is no established terminology for novelty yarns, their names are often used interchangeably. Novelty yarns, or fabrics containing novelty yarns, should never be purchased on the basis of yarn name alone, but only when accompanied by samples. Typical novelty yarns are slub, thick and thin, spiral, flock, and bouclé. (See Figure 4.13.) Novelty yarns give fabrics made from them interesting and decorative surface effects. Using novelty yarns is one means by which textile designers can create cloth with raised or nubby surface textures as distinguished from the usual flat surface of most textile materials. Fabrics made from most novelty yarns are not durable and are especially susceptible to wear from abrasion or rubbing. The parts of the yarn exposed beyond the

Textured Yarns Textured yarns are the most widely used of the comfort stretch yarns. The “ease” or “give” these yarns contribute to the fabric is a quality many consumers find attractive.

High-Bulk Yarns High-bulk, also called hi-bulk or turbo-bulk, yarns are acrylic spun yarns that are specially processed to yield lofty, bulky, and soft yarns without stretch. These yarns are produced by a unique process that involves spinning yarn by blending acrylic fibers of high Y A R N S

A N D

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Uses and Features

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seed yarn

nub yarn

slub yarn

bouclé yarn

spiral or corkscrew yarn

chenille yarn Figure 4.13 Chanel garment made of bouclé yarns.

that has first been woven especially for this purpose. This fabric is a leno-effect weave (see p. 103) and has a filling of soft, twisted yarns. After the fabric is woven, it is cut lengthwise into narrow strips, each strip becoming a chenille yarn. The crisscrossing leno warp prevents the soft filling from falling out. (See Figure 4.14.) Chenille yarns may be made from any fiber, but most commonly they are made of cotton, wool, rayon, or nylon. Chenille yarns are used in woven fabric to produce soft pilelike effects on bedspreads and other decorative fabrics. Chenille yarns have rather low resistance to abrasion, and their use should be avoided in products that will be subjected to even minimal fabric rubbing.

Figure 4.12 Popular types of novelty yarns.

surface of the substrate are particularly vulnerable to rubbing action. Novelty yarn fabrics should be avoided in applications where durability and long wear must take precedence over fabric beauty and interesting surface effects.

Chenille Yarns Chenille yarns are yarns that have a soft pile protruding from their surface. Their appearance resembles pipe cleaners without the wire. Unlike pipe cleaners, however, chenille yarns are soft, supple, and very flexible. Chenille yarns are made in an unusual manner. The yarn is made by slitting narrow lengths from 1 ⁄8 inch to 1 ⁄ inch (3.18 millimeters to 6.35 millimeters) of a fabric 4 F A B R I C

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Metallic Yarns A strip of metallic fiber (see p. 56) is also a metallic yarn. Such yarn is flat and ribbonlike rather than round or elliptical in cross-section, as are other yarns. Strips of metallic yarns are usually from 1 ⁄32 inch (0.80 millimeter) S C I E N C E

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warp yarn

filling yarn

Figure 4.14 Making chenille yarn: Filling yarns are cut between each section of warp leno.

to 1 ⁄128 inch (0.20 millimeter) wide. These yarns can be supported by loosely twisting one or more fine-filament yarns around them (e.g., two 15-denier nylon yarns). This increases its strength and abrasion resistance. Metallic yarns are mostly used for decorative rather than functional purposes; a wide range of colors and effects is available. Metallic yarns tend to be expensive. Lurex Co., Ltd. is a major metallic yarn manufacturer.

A third system known as the tex system was developed to bring all yarn numbering systems into a single system for all types of yarns.

The Denier System The denier system is the simpler of the two numbering systems. In this system, heavier and usually thicker filament yarns are designated by higher denier numbers. Very fine yarns, of 10 denier, for example, are used in sheer hosiery. The heavy, coarse yarns used in carpeting are around 2,000 denier. The denier system is called a direct system because higher denier numbers designate heavier (thicker) yarn. A 100-denier nylon filament has twice the weight of an equal length of 50-denier nylon filament. Thus the system is based on weight in grams per 9,000 meters. A 1-denier yarn is a yarn in which 9,000 meters, if weighed, would equal 1 gram. A 2-denier yarn would weigh 2 grams per 9,000 meters, and so forth. Thus the yarn has twice the thickness per unit length. Filament yarns are sold by indicating the number of filaments the yarn contains, and the twist as well as the denier size. For example, a 300-10-1 ⁄2 Z filament yarn indicates a yarn of 300 denier in size, containing 10 filaments with 1 ⁄2 TPI of Z twist. Each filament fiber in this yarn would be 30 denier. A 400-40-1 ⁄2 Z would be thicker than the 300-10-1 ⁄2 Z, but have finer filaments because each filament fiber would be a 10-denier fiber and thus finer.

Yarn Numbering Systems Yarns are bought and sold by the pound. Knitting mills, for example, purchase their yarn requirements in pounds rather than in yards. Even home knitters purchase yarns in packages sold by ounce or gram weight. Yarn numbering systems are used to express a relationship between a unit length and weight of yarns—either meters per gram or yards per pound. The relationship between unit length and weight also reflects the diameter or thickness of a yarn. This is because a yarn of low weight per unit of length would be finer (thinner) than a yarn with a higher weight per equal unit of length. However, the diameter of the yarn may vary for any given yarn number because of differences in the specific gravity of the fibers from which yarns are made, and because some yarns are highly twisted whereas others have low twist. The terms yarn numbers and yarn sizes are used interchangeably. Despite the words “yarn size,” bear in mind that the size (or number) expresses a relationship between a unit of length and weight, and only a close, but not exact, relationship to diameter or thickness. There are two main numbering systems in use: the denier system, which is used for all filament yarns, and the yarn-count system, which is used for all spun yarns. Y A R N S

A N D

In the yarn count system, the yarn count number is inversely proportional to weight. This system, therefore, is indirect. A 50-count spun yarn has twice the weight (thickness) of a 100-count spun yarn. The

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The Yarn Count System

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weight of the yarn is indirectly proportional to the yarn-count number. Cotton yarn, for example, which is used for sheer voile fabrics, may be as fine as 100 count, whereas thicker yarns used in many poplin fabrics may be a 30 count. Heavy cotton duck fabric used for truck tarps may be made of 5-count yarn.

Cotton and cotton blends

840

Spun silk and all spun 100 percent manufactured fiber yarns except acrylic

840

Worsted, worsted blends, and acrylic

560

How Spun Yarn Count Is Expressed

Linen (lea)

Woolen and woolen blends (run)

The method of expressing yarn size of spun yarns differs by the fiber content. Yarns spun on the cotton count system, for cotton and cotton blends, are designated as c.c. for cotton count. They may also be specified as Ne for Number English and cc could be replace with Nec. Cotton and cotton-blend yarns are expressed by two numbers: The first is the yarn size and the second indicates the yarn ply. For example, 50/1 means a size50 single yarn. (In oral communication, it is called a “fifty single” or “fifties yarn”.) A 70/1 is a size-70 single yarn or 70 s; 60/2 yarn is called a 60 two-ply or 60 s two. Worsted, worsted blends, and acrylic fibers are spun on the worsted count system and are designated by w.c. or New. These yarns are indicated in the reverse order from the cotton count system. For example, 1/50 (referred to as one 50 or singles 50) is a singles yarn of 50-count size. A 2/40 yarn is two size-40 yarns plied together. This yarn is called a two-40 s yarn. Woolen and woolen blends yarns are designated by the term run, or Nar such as 4-run yarn. They are rarely plied and are single yarns unless otherwise indicated. Linen yarns are expressed by the term lea, or NeL, which is used for flax, jute, hemp, and ramie fibers. They are almost never plied because the fiber length is so long that plying does not improve the yarn measurably. Thus, they are considered single yarns unless otherwise indicated. Yarns as fine as 400-lea are used to make fine lace. Spun yarns can also be expressed in the metric system. The yarn size is indicated using the term metric. For example, a 50-count metric yarn would be designated as a 50 s metric. The metric yarn-count system expresses the number of kilometers of yarn per kilogram of weight. The system is used for all spun yarns and is an indirect count method. It may be indicated by Nm and is frequently used in international markets for any spun yarn except spun cotton, which is indicated by Ne. Several classifications are used for determining yarn counts. These classifications are called yarn-count standards and are different for each fiber-spinning system. The yarn-count standard represents the number of yards in one pound of a number 1 count of that specific yarn. The following standards are in general use:

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All spun yarns (metric)

1,600 300 496.055

A number-1-count cotton has 840 yards in one pound (768 meters per 453.6 grams) of the yarn, and a number-1-count worsted has 560 yards in one pound (512 meters per 453.6 grams) of the yarn. Both are called number-1 yarns, yet each is of different weight per unit of length. Thus a 20 cotton count would be finer than a 20 worsted count because the former has 16,800 yards per pound (15,362 meters per 453.6 grams) and the latter has 11,200 yards per pound (10,214 meters per 453.6 grams). Table 4.2 provides typical yarn number and denier comparisons. When using this table, remember that a 200-denier filament yarn is of equal weight per unit of length (and approximate thickness) to a 40-count worsted yarn, a 27-count cotton yarn, a 14-count woolen (run) yarn, a 74-count linen (lea) yarn, and a 45-count metric. There are many other variations of yarn numbers used outside the United States.

Ply Yarn Counts and Singles Equivalent

Spun yarns that are plied are expressed as, for example, 40/2 (cotton type). This means that two yarns of 40/1 each have been twisted together. The thickness of the resulting ply yarn is about twice that of the original 40/1 yarn, or about the same thickness as 20/1 yarn because this is an inverse proportion system. The singles equivalent of a 50/2 is 25 count, and of a 45/3 is 15 count. Filament yarns are rarely plied because they gain little by being plied. When they are, the usual method of expressing such a yarn would be, for example, two-ply 40 denier. The singles equivalent of such a yarn would be 80 denier. Ply yarns and single-yarn equivalents are illustrated in Figure 4.15.

The Tex System The tex system is intended to replace all the existing count and denier systems with a single system for

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Table 4.2

Yarn number Conversions Denier

Fine yarns range

Medium yarns range

Coarse yarns range

Worsted

Woolen (Run)

Cotton

50*

160

106

Linen (Lea)

56

298

Tex

Metric

5.6

180

75

106

72

37

198

8.3

120

100

80

53

28

149

11.1

90

150

53

35

19

99

16.6

60

14

200

40

27

74

22.2

45

300

27

18

9.3

50

33.4

30

400

20

13

7.0

37

44.4

22.5

500

16

11

5.6

30

55.5

18

700

11.4

7.6

4.0

21

77.7

12.9

1000

8.0

5.3

2.8

15

111

9

1500

5.3

3.5

1.9

10

166

6

2000

4.0

2.7

1.4

7

222

4.5

* Much finer filament yarns, as low as 10 denier, are commonly used.

60/1

60/1

60/2

a

60/1 60/1 60/1

30/1

singles equivalent

60/3

b

100d 100d 100d

20/1

singles equivalent

100d/3-ply 300d

c

singles equivalent

designating all yarn sizes. The International Organization for Standardization (ISO) has adopted this system and it is utilized in the sewing thread business. The tex system is a direct numbering system in which higher tex numbers correspond to increasingly heavier (thicker) yarns. The tex standard uses grams per 1,000 meters. Thus, a 10 d yarn used for pantyhose would be equivalent to a 1.1 tex yarn. Decitex (dtex) is often used when referring to a very low tex number. Thus 5.6 tex would be 560 dtex.

distorted for at least the useful life of the product. How adequately a specific thread performs these tasks depends on proper thread selection for the specified fabric and seam type used. American & Efird, Inc., is a major thread manufacturer.

Fibers Used for Threads The fibers used for sewing threads are primarily cotton, nylon, polyester, and rayon. Cotton-covered polyester is the most widely used because of its relatively low cost and high versatility. The properties and characteristics of each of the fibers prevail when they are used as threads, and these properties should be considered in thread selection for specific end uses. Rayon, for example, is usually used for thread intended primarily for embroidery or decorative stitch work rather than for seaming to hold parts together.

Sewing Threads Sewing threads are special kinds of yarns that are engineered and designed to pass through a sewing machine rapidly, to form a stitch efficiently, and to function while in a sewn product without breaking or becoming Y A R N S

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Figure 4.15 Ply yarn and singles equivalents: (a) spun yarn, (b) spun yarn, and (c) filament yarn.

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Types of Threads

will determine the ease of manufacture, durability of the product, and satisfaction of the consumer. Thread size should be as fine as possible, consistent with the strength requirements of the seam. Finer threads tend to become buried below the surface of the fabric and are, therefore, subjected to less abrasion than seams with heavier thread, which are on top of the fabric. Finer threads also require smaller needles, producing less fabric distortion than heavier needles. The breaking strength of a seam (see p. 321) should be less than that of the fabric sewn. Many authorities agree that the seam should be about 60 percent of the fabric strength. This is to ensure that if excessive stress is placed on a seam, the seam, rather than the fabric, breaks. Seams are easily repairable; fabric is not. If a garment is to be washed in hot water, then its thread should have excellent resistance to color change from this medium. Also, the thread should not shrink as a result of the cleaning method.

Threads may be spun, filament, or core-spun type. Each has distinctive properties and therefore certain advantages in specific seams. A comparison of these thread types is shown in Table 4.3. All sewing threads, whether spun, filament, or core spun, are ply yarns. Sewing threads are more highly twisted and firmer than regular yarns and are often treated with special finishes or lubricants to improve sewability.

Thread Finishes Threads are produced with various finishes, such as mercerized, soft, glacé, and bonded. In addition, special finishes, which include flame-resistant and heat-resistant types (for high-speed sewing), are also produced. Table 4.4 indicates the properties and use characteristics of thread finishes.

Thread Sizes

Important Thread Factors That Govern Seam Appearance

Sizes (weight per unit length) of thread are marketed and expressed with their Tex number designation (see p. 82). An older system of specifying thread size, the ticket number system, based on denier and yarn-count systems, is still in use but is gradually being replaced in the thread industry. Table 4.5 indicates typical Tex numbers in thread applications for various sewn products.

When woven-filament yarn fabrics and/or fabrics that have been finished with resins are sewn, there is sometimes a tendency for seams to pucker and ripple rather than to lie flat and smooth. The tendency is greater in lightweight fabrics than in heavyweight materials. Some of the causes of puckering are excessive tension on sewing thread during the sewing process, displacement or movement of fabric yarn in the sewing operation, and thread shrinkage that is greater than fabric shrinkage.

Important Factors in Thread Selection Selecting the correct thread for assembly of finished goods is of critical importance. The type of thread used

Table 4.3

Comparison oF sewing Thread TYpes

Spun

Filament

Core Spun

Lower strength than filament.

Higher strength than spun; permits use of finer thread without sacrifice of seam strength.

Combines the best features of filament and spun threads.

Versatile and adaptable to a wide variety of machine adjustment conditions.

Produces neatest seams, but careful machine adjustments necessary.

Especially useful in seaming durable-press garments.*

Less likely than filament thread to cause seam pucker.

Greater possibility of seam pucker than with spun thread.

Same seam puckering tendency as spun thread.

Least costly.

Less costly than core spun, but more costly than spun thread; textured filament threads would be good for knits because they have additional stretchability.

Most costly.

* Residual resins present in permanent press garments are absorbed by the thread, causing strength loss and abrasion-resistance loss in the cotton cover of the thread. The polyester core is unaffected by the resin, thus providing continuing seam integrity.

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Table 4.4

Thread Finishes and Their uses

Type

Description

Sewing Properties and Uses

Soft

Natural cotton thread without finishes that appears somewhat fuzzy. Small amount of lubricant sometimes added to improve sewability.

Excellent sewability, lowest cost.

Mercerized

Treated cotton thread that is stronger, more lustrous, more stable (less stretch) than soft cotton thread. The finish reduces the thread loop strength.

Increased tensile strength, lustrous appearance, and brighter shades provide for better seams than soft threads. More costly than soft thread and used in premium products.

Glacé

Highly polished cotton thread that is difficult to unravel. The polish and finish are usually obtained with waxes and starches.

Strongest cotton thread. Rarely used in apparel. Used in the manufacture of shoes, luggage, canvas goods, and similar applications.

Bonded

The term applies only to threads of manufactured fibers, both filament and spun. Waxes and resins produce high polish, eliminate fuzz (on spuns), bond together filaments and plied yarn, and impart a smooth protective coating.

Increased strength and sewability compared to same thread unbonded. Apparel usage largely in heavyweight and coated-fabric sewing. Mainly used for manufacture of shoes, luggage, tents, and other heavy-duty applications.

Table 4.5

sewing appliCaTions bY Thread size

Fine Tex (18 Through 30)

Medium Tex (30 Through 60)

Heavy Tex (60 Through 105)

Extra Heavy Tex (105 Through 135)

Blouses

Aprons

Footwear

Dresses

Athletic wear

Overcoats

Lingerie

Caps

Parkas

Decorative stitching or when a bold design look is desired

Sleepwear

Coats

Protective clothing

Swimwear

Draperies

Work wear

Other light articles

Foundation garments

Luggage Golf bags

Jeans Pants Rainwear Shorts Windbreakers

Puckering of seams can frequently be reduced or eliminated through awareness of the following factors: u

Thread size. Heavyweight thread should be used for heavyweight fabrics, lightweight thread for lightweight fabrics and extra fine thread for sheer fabrics or fabrics made of microdenier yarns.

u

Direction of seam. Seams made parallel to the warp pucker most seriously, those on the filling pucker considerably less, and seams on the bias hardly pucker at all. Sometimes turning a pattern slightly off-grain results in a pucker-free seam.

u

Thread tension. Fabrics susceptible to puckering should be sewn with the lightest thread tension possible. Y A R N S

A N D

Stitches per inch. Seams with a large number of stitches per inch are more likely to pucker because more yarn displacement is occurring. Stitches per inch, therefore, should be kept at a minimum. If possible, they should be kept within a range of 8–12 stitches per inch.

u

Sewing machine adjustments. The bottom fabric and top fabric of a sewn seam should feed into the machine at the same rate if smooth seams are expected. In some instances, use of a fine-tooth sewing machine feed dog aids in uniform feeding. Sewing machine operator skills also play a major role in uniform feeding of seam components.

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u

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Textile Connection Tassel

since the 19th century. The tassel, hanging from the mortarboard, is moved from the right side to the left side upon graduation from college. The tassel also has been used as a status symbol that differentiated individuals in a group. This applied to military uniforms (rank), religious garments (positions), and colleges (level of learning). Today tassels are found on furniture, shoes, drapery, garments, and ornamental cords. Decorative knots and beads can be used to highlight the tassel.

A tassel is a grouping of parallel, even-length yarns hanging loosely from a knob. It is used primarily as an ornament and is made in varying versions in cultures throughout the world. The word tassel comes from the Latin “tassau” which refers to a clasp. In the Middle East tassels were worn as talismans (charms to ward off evil spirits). In Oxford and Cambridge University tassels were traditionally worn by undergraduates on their caps. Graduation tassels have been used in the United States

STUDY QUESTIONS 1. Explain why combed yarns are more costly than carded yarns of the same fiber content and size.

6. Rank the following five yarns from the lightest (thinnest) to the heaviest (thickest):

2. What are novelty yarns? Comment on the use of novelty yarns for fabrics to be used for children’s play wear.

a. b. c. d. e.

3. Is it easier to make spun yarn from staple fibers or filament yarn from filament fibers? Explain your answer.

40/2 cotton 2/40 worsted 70-denier nylon filament 13-run-woolen 50-lea flax

7. Explain how a sewn seam made from fine thread might actually be more serviceable than one made from heavier and stronger thread of the same fiber and type.

4. What is meant by the term “growth” with regard to fabrics made from stretch yarn? 5. What differences in performance would you expect in a jacket made from woolen yarns as compared to one made from worsted yarns?

8. Why are ply yarns more likely to be found in better, higher-priced garments than in moderate to lowercost items? Explain your answer. 9. You are launching a line of junior dresses made of micro polyester. What advantages might yarns of this fiber have over dresses with yarns of silk?

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FABRIC SCIENCE / Swatch Kit Assignment

Yarns and Sewing Threads Use the swatch kit to find examples of the following key terms. Indicate the swatch number and fabric name for each. u

Spun yarns: indicate five samples.

u

Filament yarns: indicate five samples.

u

Carded yarns: indicate five samples.

u

Combed yarns; indicate one sample.

u

Woolen yarns; indicate one sample.

u

Worsted yarns: indicate one sample.

u

Ply yarns: indicate three samples.

u

Texture yarns: indicate two samples.

u

Monofilament yarns: indicate one sample.

u

Stretch yarns: indicate three samples.

u

Novelty yarns: indicate two samples.

u

Crepe yarns: indicate one sample.

u

Blended yarns: indicate three samples.

u

Mixture: indicate three samples.

Y A R N S

A N D

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chapter five

WOVEN FABRICS

Objectives u

To convey how woven fabrics are produced.

u

To explain why woven fabrics look and perform the way they do.

u

To recognize various weaves and know their identifying characteristics.

u

To define the terminology used regarding woven fabrics.

u

To identify various well-known woven fabrics.

Use fabrics in the Woven Fabrics section of the Fabric Science Swatch Kit for this chapter. Swatches 28 through 48 focus on various Woven Fabrics.

Key Terms Related to Textiles air-jet loom back balanced twill basket weave bias bottom broken-twill weave chevron clip-spot pattern cloth roll color-and-weave effect crepe-back satin cut-pile weave fabric dobby head dobby pattern double cloth

end face filling filling-face satin filling-pile fabric float harness heddle herringbone jacquard head jacquard loom jacquard pattern jet loom left-hand twill leno weave loom

multiphase loom napped fabric off grain on grain pick pile fabric plain weave projectile loom rapier loom reed ribbed right-hand twill sateen fabric satin weave selvage shed

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shuttle shuttleless loom top twill weave uncut-pile weave fabric warp warp beam warp-face satin warp pile water-jet loom weave woven fabric woven pile fabric yarns per inch (cloth count)

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O

ver 4,000 years ago, man created fabric through the use of a crude wood-framed loom. Typically this weaving device held yarns in an upright position as they were interlaced with one another by hand. Primeval man used this to make fabric to clothe and protect. As civilization began to develop, some woven fabric was used to indicate standing within the community. Eventually, royalty and religious figures used ornately woven fabric to indicate their stature. Looms were also used to depict stories in woven fabric, some of which are now highly valued (e.g., tapestry). Centuries later, as looms became more sophisticated and yarns smoother and finer, looms were used to create some of the world’s most intricate woven fabrics. Woven fabrics are made by interlacing two sets of yarns at right angles to each other. The length-wise yarns are known as warp yarns, or ends, and the widthwise yarns are known as filling yarns, or picks. The length-wise edges of the fabric are the selvages. The selvage is usually easily distinguishable from the rest of the material. (See p. 93.) Grain indicates a direction parallel to either the warp or filling yarns. The term on grain is used if a fabric has been cut parallel to either the warp or filling yarns. A direction not parallel to either of these yarns is called off grain, or bias. Fabric cut off grain results in a skewed portion of the textile product (e.g., pants leg or drapery). Woven fabrics elongates most in a direction that is 45° to both sets of yarns. The reason for this is that there is maximum yarn bending and shifting from the pulling force being exerted. Pulling that is on grain results in only a slight yarn extension, with the least amount usually in the warp direction. Woven fabrics also have their best drape in a bias direction. This is the result of the bending and shifting of the yarns from the fabric weight. Some garments are cut on the bias (i.e., the bias direction is vertical in the garment) to obtain maximum drapability, as shown in Figure 5.1. A problem that can occur, however, is the garment may grow (i.e., increase in length) and become uneven in length when worn. Bias bindings are narrow strips of fabric cut in the bias direction used to finish the edges of seams in sewn products. This binding elongates to conform to the shape of curved seams, thus eliminating the puckering or small wrinkles that would occur if the binding were cut on grain.

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Figure 5.1 Sketch of a garment cut on the bias.

The Loom Woven fabric is produced on a loom (Figure 5.2). The following is a simplified explanation of the process utilized to produce woven fabric: u

The warp beam, located at the back of the loom is a large roller on which all the warp yarns to be used for the fabric are wound parallel to each other.

u

The warp yarns pass through the harnesses, which look like picture frames holding many thin vertical wires called heddles, each with a hole in the middle. Each warp yarn is threaded through the hole of a heddle and thus is controlled by that harness.

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heddles reed warp yarn

cloth

shuttle harnesses

warp beam

cloth roll

u

When a harness or group of harnesses is raised with others left in the down position, a V-like opening is formed. This is called the shed.

u

A filling yarn is inserted in the shed and travels across the width of the loom, passing over some warp yarns and under other warp yarns. (See Figure 5.3.)

u

The reed is a comb-like device that pushes the filling yarn in the shed into the body of the cloth.

u

The sequence in which harnesses are raised or lowered determines the weave of the fabric.

u

The woven fabric produced by the repetition of the above steps is slowly wound onto the cloth roll located in the front of the loom.

Figure 5.2 A simplified sketch of a two-harness loom.

Figure 5.3 The interlacing of warp yarns and filling yarns.

Types of Looms Production looms can be categorized several ways, such as by method of raising ends to form the shed (e.g., dobby device, or jacquard attachment—see p. 106), by number of sheds (one to make a single fabric or two to make a double fabric), or by method of inserting the filling yarn. The most significant advances in weaving are in the methods of inserting the filling yarn (Figure 5.4).

W O V E N

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Production Looms

For early looms, the insertion of the filling yarn was done by hand, with the weaver passing the filling yarn over and under different warp yarns. Later, harnesses were added to looms which allowed groups of yarns to be lifted. Also with the use of a shuttle the weaver could

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yarn package

yarn package

yarn package

The speed of a loom, and thus the loom’s productivity, is designated by the number of picks per minute (ppm) a loom can insert for a specified width. The maximum number of meters per minute (m/min.) indicates the maximum length of filling yarn that can be inserted in a minute. These measurements are critical since they control productivity or the length of time required to weave a particular length of fabric and therefore affect the cost of a fabric. Shuttleless looms available in today’s marketplace operate at speeds that produce fabric at a high rate of productivity. They are designed to function using different fiber contents, yarn counts, structures, and modifications. They must be energy efficient, quiet, and compact in space usage. They are equipped with state of the art electronics, including internet-ready touch screen terminals. Although the use of shuttle looms is very limited, they have been used to produce authentic denim for vintage looking garments.

projectile

single rapier

double rapier (yarn has been transferred)

Projectile Loom A projectile loom uses a projectile to insert the filling yarns. A projectile is a small, light gripper device (about the size of a pocketknife) that is propelled across the loom, pulling the filling yarn behind it. It can utilize a range of filling yarns and produce fabrics at a variety of widths. The range of widths usually falls within 190 centimeters (75 inches) to 540 centimeters (213 inches). It is used to produce denim and sheeting. This loom also can produce fabric up to 18 feet (5.49 meters) wide and is used for the production of carpet. Since the projectile loom drags the filling yarn across the width of the loom, a strain is placed on the filling yarn. Thus this method is not suited for weaving with weak or fragile filling yarns. This loom is ideal for fabrics to be made of medium weight to coarse or bulky yarns, as well as yarns made of hard fibers, such as jute, and fabrics to be made of metal threads. With a production of only 400 ppm and limited versatility, projectile looms are being replaced by air-jet and rapier looms.

yarn package air or water jet

air or water jet

Figure 5.4 Inserting the filling yarn for shuttleless looms.

insert the filling yarn at a greater rate. A shuttle is a wooden device with a bobbin placed inside with filling yarn wound around it. As the shuttle is projected across the loom, the filling yarn unwinds from the bobbin, leaving a trail of yarn behind. Adding power to shuttle looms mechanized the weaving process and significantly increased the rate of production yet again. Most looms used for production are shuttleless looms. These looms employ various other devices to bring the filling yarn through the shed. With shuttleless looms the yarn comes directly from cones placed at the side of the loom. Once the filling yarn is brought across the loom, the yarn is cut, often leaving a fringe at the edges of the fabric. Except for the means of transporting the yarn across the shed, the steps in the weaving process are the same. The main devices used to insert the filling yarn across the shed are referred to as projectile, rapier, jet, or multiphase.

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Rapier Loom The rapier loom uses a rapier rod or steel tape to pull the filling yarn across the loom or a double rapier where the filling yarn is transferred at the midway point from one rapier to the other. This loom is noted for a large range of patterns produced. Because the rapier rod is not in free flight as is a projectile, less strain is placed on the filling yarn. Thus fine or delicate yarns can be used. The rapier loom is used to produce high-quality wool and silk fabrics along with fine to coarse spun yarns and delicate filament yarns. It is also utilized

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to produce technical textiles, such as fabrics made of glass or high-strength fibers such as Kevlar® for air bags used in automobiles. It can insert from 900 meters (980 yards) to 1,300 meters (1,422 yards) of filling yarn per minute for fabric ranging in width from 140 centimeters (55 inches) to 280 centimeters (110 inches).

minute). It is used for the staple fabrics of basic weaves, such as plain, rib, or basic twills.

Loom Production The filling yarns are inserted at a constant rate (e.g., 650 picks per minute). However, picks per inch (ppi) is determined by the rate at which the warp yarns pass through the loom determines the picks per inch, which affects the tightness or looseness of the fabric. For example, if the warp yarns move at the rate of 5 inches per minute and the speed of the loom is 650 picks per minute, the picks per inch (ppi) of the resulting fabric is 130 ppi (650 ÷ 5 = 130). Loom production (yards produced per hour) is low and more costly when making fabrics with high picks per inch. The ends per inch of the fabric is calculated by the number of warp yarns on the warp beam. For example, if 9,000 warp yarns are wound on a warp beam to make a fabric 60 inches wide, the fabric has 150 ends per inch (9,000 ÷ 60 = 150). If the desired fabric has 160 ends per inch and is 60 inches wide, then the new warp beam must have 9,600 ends (160 × 60 = 9,600).

Jet Loom Jet looms take the filling yarn across the loom by using a high-speed jet of either air or water. The force of the air or water carries the yarn from one side to the other. Jet looms are faster than projectile or rapier looms (higher picks per minute). They cannot, however, produce as great a variety of fabrics (no heavy and bulky yarns), nor can they produce as wide a fabric (jets have less yarn-carrying power than projectiles and rapiers). Jet looms also do less damage to the warp because there is no abrasion of this yarn by the jets of air or water. This is in contrast to the projectile or rapier, which rides across the warp yarns left in the down position of the shed. With air-jet looms, the initial propulsion force is provided by a main nozzle. Relay nozzles along the shed produce additional booster jets to help carry the yarns across the loom. Air-jet looms are used for spun or filament yarn fabrics such as those found in men’s outerwear, sheeting, and denim. It has a speed of 1,000 ppm and up. Widths vary from 190 centimeters (75 inches) to 540 centimeters (213 inches). With water-jet looms, there is only a main nozzle to provide the propulsion of the filling yarn. These looms require large amounts of clean water without minerals in it to produce efficiently. Because wet fabric cannot be stored in a roll, waterjet looms are equipped with efficient drying units. These units use vacuum suction and heat to remove the water from the fabric. Water-jet looms are best suited for weaving filament yarns made of hydrophobic fibers, such as nylon, although they can handle some blends, such as polyester/cotton. These looms cannot be used with yarns made of fibers that lose strength when wet (e.g., rayon).

Fabric Features Several features are found in all woven fabrics:

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Selvage

u

Warp and filling yarns

u

Face and back

u

Top and bottom

u

Yarns per inch

Knowledge of these fabric characteristics is needed to understand fabric structure and suitability in particular uses.

The Selvage The selvage is a lengthwise edge of a fabric. It is usually between ¼ and ½ inch (.64 cm and 1.27 cm) wide and exists on both edges of the cloth. The term selvage is derived from the descriptive term self-edge (Figure 5.5a–d). The main purpose of the selvage is to ensure that the edge of the fabric will not tear when the cloth is undergoing the stresses and strains of the finishing process. (See Chapter 10.) Sheets and bath towels are two products in which the selvage is left intact as a finished edge of the fabric.

Multiphase Loom Multiphase looms offer enormous output for light to medium weight fabrics. This is accomplished with the use of multiple sheds operating separately across the loom instead of only one shed. Thus, filling yarns can be inserted one after another, similar to a wave, as they travel across the width of the loom. This system is not as versatile as other looms, but it can produce fabric at a rate of 2,800 ppm with a weft insertion rate of 5,500 meters/minute (6,015 yards/ W O V E N

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a

Figure 5.5 Various types of selvages: (a) Selvage as produced by the shuttle loom. Selvages made on a shuttleless loom such as (b) fringe, (c) leno, and (d) tucked-in selvage.

c

Various techniques are used to make the selvage area stronger than the body of the cloth, including using heavier warp yarns; more warp yarns per inch; plied warp yarns; greater twist, if spun warp yarns; and different weave. Because the selvage is usually constructed differently than the body, it is fairly easy to identify. If the selvage warp yarns are different from the body warp yarns, their shrinkage characteristics may be different. If the selvage warp yarns have greater shrinkage during the finishing process, a tight selvage occurs, resulting in the puckering of an area within several inches of the fabric edge. This is a problem when the material is unrolled on the cutting table and the cloth does not lie flat.

Selvage The warp yarns are always parallel to the selvage. Yarn sizes Usually the warp yarns are thinner, so they abrade less as they pass through the loom and rub against the various parts (e.g., heddles, reed). A fabric that contains both filament yarns and spun yarns usually has the filament yarns as the warp set.

One way to better understand the characteristics of woven fabric is to know the differences between the warp yarns and the filling yarns. Because fabric swatches are mounted with the warp yarns vertically, it must be determined which set of yarns is the warp so the mountings are correct. More importantly, garments are usually cut with the warp yarns running lengthwise, so the

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d

drapability of the fabric must be checked by the designer to ensure that it meets the garment requirements. In all cases, distinguishing warp from filling is necessary. Finally, a textile expert making a complete analysis of a cloth must be able to identify both the warp and filling yarns in order to report such information as size, amount of twist, and fiber content. The following are some of the ways warp yarns can be distinguished from filling yarns:

Identifying Warp Yarns and Filling Yarns

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Twist For the most part, spun warp yarns have more twist than spun filling yarns. Because they usually are thinner, more twist is necessary to enable them to have sufficient strength to withstand the tensions exerted on the yarns in weaving and in finishing. S C I E N C E

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which the warp yarns or the filling yarns appear more on one side than on the other shows a difference between the face and back. Fabrics with a plain weave (see p. 97) or leno weave (see p. 103) are reversible, but fabrics with a satin weave are not (see p. 101). In a satin fabric, the warp yarns predominate on the face and the filling yarns on the back so that the two sides differ greatly in appearance. Usually the shinier, smoother side is the face. An exception is antique satin in which slub filling yarns create the slightly irregular effect on the surface. Some finishes, such as napping or brushing, affect only one surface of the cloth, whereas others, such as mercerizing, penetrate the entire fabric. Napping gives a fabric an obvious face side as, for example, in a flannel material. Mercerizing, however, produces the same change on both sides, as in a broadcloth fabric; thus a reversible fabric results. In printed fabrics, the color is usually placed only on one side. Therefore, unless the fabric is very sheer, the printed side is obvious and is considered the face. Some sheer printed fabrics may appear to be reversible because the print design seems to be the same on both sides. Caution: A garment should not be made with some parts cut from one side of the fabric and other parts cut from the other side. Even though both sides of the fabric may initially appear alike, there is often a slight difference in luster or color that does not become obvious until the garment is made and worn. This difference may become significant after cleanings and wear.

Yarns per inch Usually there are more warp yarns per inch than filling yarns per inch, making the fabric stronger in the lengthwise direction. This is necessary because most of the tension exerted on the fabric in the finishing processes is in the lengthwise direction. Sometimes, however, the ends and picks per inch are equal (e.g., 80 square-print cloth) or occasionally the picks per inch is greater (e.g., soft filled sheeting). Ply yarns As discussed in Chapter 4, a plied yarn is stronger than a single yarn of the same size. Thus, the warp yarns are occasionally plied to give added strength, and the filling yarns usually remain single. Stiffness In 100 percent spun-yarn fabrics, the warp yarns are generally stiffer than the filling yarns because they usually have more twist. In 100 percent filament-yarn fabrics, the filling yarns are usually stiffer because they generally are thicker. A stiffer set of yarns usually results in less fabric drapability in that direction. Stretchability Usually there is more elongation in the width-wise direction. In most cases there are more ends per inch, so the picks usually have more crimp as they interlace (go under and over the warp yarns more frequently) to a greater degree. Stripes Most woven stripes appear in the lengthwise direction. Warp-wise woven stripes only require the appropriate color yarns to be properly grouped when the warp is made on the warp beam. When fabric is cut with the stripe in the length direction, the garment gives the wearer the illusion of more height and a leaner look. Checks and plaids are created by making stripes in both the warp direction and the filling direction.

Top and Bottom Besides having a face and a back, some fabrics have a top and a bottom on the face side. Where there is a difference, it is usually caused by the weave or the finish. In pile fabrics such as velveteen and corduroy, the pile is not perfectly erect, but lies at an angle. The color may vary from dark to light as the fabric is turned 180° on a flat surface because of the difference in the angle of light reflection. Sometimes these fabrics are used in garments where the pile lies upward in order to obtain a richer or darker color. With fabrics having an obvious top and bottom, the garment must be made with all its parts in the same top-down or bottom-down direction. A fabric with a woven or printed figure in an obviously upright position (e.g., horse, tree) can be cut in only one direction because in every piece forming the garment, the figure must be in the upright position. Printed fabrics that can only be used in one direction are called directional prints. Most fabrics, however, when resting on a flat surface with the face side up and the warp yarns vertical, have

Face and Back Fabric developers generally address issues such as quality or durability, with the yarns on the face of the fabric. Thus, fabrics have a technical face side and a technical back side. The face side has the better appearance and usually forms the outside of the garment (or other textile product). Sometimes fashion dictates the use of the back of a fabric as the outside of the garment for the particular effect desired. Fabric developers generally address quality or durability issues with the yarns on the face of the fabric. There are various reasons that the face and back of cloth appear different. The two sides of a fabric may be different because of the weave or finish. Any fabric in W O V E N

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the same appearance as when the fabric is turned so that the edge that was at the top is at the bottom. Thus, it usually does not make any difference in appearance with these fabrics if a garment is made with its parts placed from top-to-bottom or if its parts are turned 180° and placed bottom-to-top. In fact, most mass-produced apparel is cut this way to interlock patterns efficiently. Nevertheless, this could be undesirable because there may be a slight difference in color or luster that is not noticeable in a smaller piece of fabric but is obvious in the full garment.

Yarns Per Inch: A Measure of Fabric Quality

Figure 5.6 Percale sheets by Martha Stewart Collection™ for Macy’s.

The yarns per inch in a fabric is given by two numbers with an × between them. For example, 80 × 74 (pronounced “eighty-by-seventy-four”) means 80 yarns per inch in the warp and 74 yarns per inch in the filling. The first number is for warp yarns per inch and the second is for filling yarns per inch. A fabric with the same number of yarns per inch in both directions is said to be square. An 80-square print cloth has 80 ends and 80 picks per inch. The yarns per inch in the warp and in the filling is known as the fabric count, fabric density, or cloth count. Yarns per inch is a measure of fabric quality. Two broadcloths may differ in price because one has more yarns per inch. A higher number of yarns per inch gives the fabric more strength, more weight, better hand, reduced possibility of yarns shifting out of place (yarn distortion; see p. 324), and better abrasion resistance. Increasing the yarns per inch also increases the cost of the fabric. The type numbers given for sheeting are based on the number of yarns per square inch. The sum of the yarns per inch in the warp and the yarns per inch in the filling is referred to as the type number. For example, if sheeting has 100 ends and 100 picks per inch, the type number is 200 (100 plus 100). It is also referred to as 200count. For other fabrics, the value is given as 100 × 100, and not as a sum. Historically, manufacturers of sheets with a cloth count of 100 × 100 made of single yarns would indicate a 200 thread count on the package. Recently some manufacturers of sheets have counted ply yarns as two separate yarns when indicating the thread count. Thus the same sheet made of 2 ply yarns might indicate a 400 thread count. This confusion triggered a concern for the industry as well as the retailers and resulted in a

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class action suit and settlement. Thread count has long been recognized by consumers as a tool to determine quality (Figure 5.6). A contradiction in cloth count causes doubt and confusion for consumers. To learn how to determine the yarns per inch of a woven fabric, see page 309.

Determining the Weave of a Fabric Woven fabric is analyzed to determine the weave. It is done by determining the order in which the yarns interlace. Fabric is usually analyzed on the face side, but sometimes the weave may be more clearly seen on the back. To determine the weave of the fabric, every interlacing is examined to determine whether the warp yarn or the filling yarn is on the surface. The weave may be illustrated on graph paper indicating the location of the warp yarn on the surface. If the warp yarn is on the surface of the fabric, it is indicated by marking in one box on the graph paper; if the warp yarn is on the back of the fabric, the box is left empty. Refer to page 314 for further information. The vertical and horizontal rows of squares are the same size. A weave diagram only shows the order in which the yarns interlace (Figures 5.7a–c). The weave diagram does not show the relative number of yarns per inch between warp and filling, nor does it indicate the yarn size and type. Thus sheeting fabric, voile, overcoat fabric, and lining could all have the same weave diagram but entirely different appearances and end-use applications.

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Weave Floats 21

16

11

6

1

22

17

12

7

2

23

18

13

8

3

24

19

14

9

4

25

20

15

10

5

21

16

11

6

1

22

17

12

7

2

23

18

13

8

3

24

19

14

9

4

25

20

15

10

5

a

Warp yarns and filling yarns in a fabric interlace with each other. When one yarn does not interlace with the next adjacent yarn, but passes over two or more adjacent yarns, it is said to float. If a warp yarn passes over two or more adjacent filling yarns, a warp float results. When the filling yarn passes over warp yarns, a filling float occurs. Floats tend to make the fabric surface flat and increase the amount of luster. They also enable yarns to slide under each other in the fabric and are, therefore, used when fabrics of many yarns per inch are to be made. (See p. 102.) When the float is relatively long, a snagging problem frequently results. The yarn can easily catch and break on broken fingernails or other rough surfaces. Floats also weaken the fabric because they reduce the frequency with which yarns pass from one side of the fabric to the other (from the face to the back or from the back to the face). This affect can be offset by increasing the yarns per inch of the fabric.

b

Basic Fabric Weaves There are three basic weaves: plain weave, twill weave, and satin weave. All other weaves are a variation or a combination of these weaves. The type of weave used in a fabric depends on the desired appearance and performance (see Table 5.1). Such factors as luster, strength, pattern, color effect, and, most importantly, cost, are considered before the fabric weave is chosen.

Plain Weave

c

Plain weave is the simplest and the most used weave. It is found in a wide range of fabrics, from the sheerest to the heaviest. Fabrics with a plain weave are reversible unless one side is made the face by a finishing or printing process.

Figure 5.7 (a) The interlacing yarns of a satin weave; (b) the numbered squares that correspond to the interlacings of the weave; and (c) the weave on graph paper.

Table 5.1 Weave

Comparison oF basiC Weave properTies Luster

Snag Resistance

Surface Effect

Tearing Strength

Wrinkle Resistance

Plain

Poor

Good

Flat, uninteresting

Low

Poor

Twill

Fair

Good

Twill lines

Medium

Fair

Satin

Good (especially with filament yarns)

Poor if long floats

Smooth

High

Good

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More fabrics are made with plain weave than any other weave. These include such well-known fabrics as gauze and chiffon (sheer), gingham, chambray (shirting/ blouse weight), taffeta and chintz (medium weight), and burlap and canvas (heavier weight). In plain weave, each warp yarn passes alternately over one and then under one filling yarn, for the whole length of the fabric. Two adjacent warp yarns interlace exactly opposite. One warp yarn goes under the same filling yarn that the next warp yarn goes over. The third and fourth warp yarns weave the same as the first and second, respectively (see Figure 5.8a and b). As shown in Figure 5.8 each filling yarn passes alternately over one and then under one warp yarn, for the full width of the fabric. Two succeeding filling yarns weave exactly opposite. When one filling yarn passes over a warp yarn, the next filling yarn passes under the

same warp yarn. The third and fourth filling yarns weave the same as the first and second. The plain weave, therefore, makes one complete cycle on two ends and two picks. By definition, we say the repeat of this weave is on two ends and two picks. More complex weaves have larger repeats. Plain-weave fabrics require only two harnesses to weave the body of the fabric (excluding the selvage) because the weave repeats every two ends. One harness controls half the warp yarns (1, 3, 5, etc.), and the second harness controls the other warp yarns (2, 4, 6, etc.). When one harness is raised, the other is lowered, and then the sequence is reversed for the next pick. Plain-weave fabrics have firm constructions. They tend to wear well and ravel less than comparable fabrics of other weaves. Because the surface is plain, it offers a good background for printed and decorative designs. Plain-weave fabrics tend to wrinkle more than fabrics of other weaves. Frequent interlacing does not allow the yarns to move in the fabric to relieve stress from the bent fibers. A high number of interlacings also results in less bias stretch. Plain weaves usually have little surface interest unless colored yarns are used to make designs (for example, a plaid) or special yarns or finishes are used to produce texture. The tearing strength of a plain weave is lower than that of any other weave. Because this weave has no floats, when tearing a plain-weave fabric, the yarns break one at a time. When tearing other woven fabrics, however, the yarns shift and bunch together from the tearing force being exerted. The fabric tearing strength of such fabrics is higher because several yarns must be torn simultaneously instead of only one at a time.

filling yarns

plain weave

warp yarns

a

Ribbed Plain Weave

A fabric with a plain weave may have a ribbed surface. The rib is produced because the filling yarns are thicker than the warp yarns. The rib can be very pronounced, as in a bengaline or ottoman fabric; easily visible, as in a faille or poplin fabric; or less noticeable, as in a broadcloth or taffeta. The rib, however, can always be detected by running a fingernail up and down the fabric. Although rib effects are popular, they can have problems. The filling yarns that form the ribs may have been made bulky by having little twist and/or short staple fibers. Because wear occurs mainly on the top of the ribs, if the heavy filling yarns are not well protected by the set of thinner warp yarns, the fabric will not wear well because the heavy yarns will abrade quickly. Ribbed fabrics with thin warp yarns and fine ribs possess better drape and a smoother surface, and fabrics

b Figure 5.8 (a) Plain weave and (b) plain weave on graph paper.

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with large ribs possess an uneven surface and more body. Sometimes, the ribbed fabrics are also called unbalanced fabrics because the sizes of the warp and filling yarns, as well as the number of ends and picks per inch within the fabric, are greatly different from one another. Ribbed fabrics can also be made with a rib weave— a variation of a plain weave. The weave creates ribs in either the warp or filling direction when two or more yarns interlace in the same sequence. A warp rib creates a rib across the fabric in the width direction (ribs). A filling rib creates a rib in the warp or length direction (cords). Examples of ribbed fabric include grosgrain and repp, among others.

a

a

Basket Weave

A major plain-weave variation is the basket weave. Basket weaves are made by having groups of two or more warp yarns interlacing as one yarn with groups of two or more filling yarns that also interlace as one yarn. The groups of yarns interlace in plain-weave sequence. Fabrics with basket weaves are reversible unless the finish or print makes one side the face. Two well-known fabrics made with basket weave are monk’s cloth and hopsacking. The two-by-two (2 × 2) basket weave is the most common. In this weave, the warp yarns in pairs interlace in plain-weave sequence with the filling yarns in pairs. (See Figures 5.9a and b.) The weave repeats on four ends and four picks and requires two harnesses to make. Basket weave is a decorative weave. Most basketweave fabrics are made with relatively few yarns per inch and frequently with low-twist yarns to increase the weave effect. Thus, these types of fabric tend not to be durable and easily shrink when washed. They are frequently difficult to sew because the yarns can move easily; this also causes the fabric to lose its shape.

b Figure 5.9 (a) A 2 × 2 basket weave and (b) a 2 × 2 basket weave on graph paper. b

a

Twill Weave

Figure 5.10 Denim twill weave (a) back and (b) face.

Twill weaves (Figure 5.10) produce diagonal lines on the cloth. In a right-hand twill, the diagonals run upward to the right; in a left-hand twill, the lines run upward to the left. The direction of the twill on the back of the cloth is opposite to the twill line on the face. Some well-known twill weave fabrics are denim, gabardine, serge, and chino. There are many twill weaves. The simplest is a 2—1 twill (referred to as two up, one down) or a 1—2 twill (one up, two down), which repeat on three ends and three picks. (Only three harnesses are required for body of the cloth.) Most twills are made on fewer than six harnesses. W O V E N

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b

In a 3—1 twill (three up, one down), each warp yarn passes over three filling yarns and then under one filling yarn. The warp is on the face three times more than 1 the filling, forming a warp-face twill. In a — twill (one 3 up, three down), the warp passes over one filling yarn and then under three filling yarns, to produce a fillingface twill. A 2—2 twill has both warp and filling showing to the same extent on the face, and it is known as a balanced twill. A balanced fabric would have about the same size and number of warp and filling yarns per inch. F A B R I C S

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a

Most twills are either warp face or balanced. (See Figure 5.11a–c.) This produces a more obvious twill line and also a more abrasion-resistant surface. In a twill weave, every warp yarn interlaces in the same order, which may be 2—1, 2—3, 3—2, or any other sequence. However, each succeeding warp yarn starts the sequence of one or more filling yarns higher or one or more filling yarns lower. If each succeeding warp yarn to the right has the corresponding interlacing one filling yarn higher, the weave is a 45° right-hand twill (see Figure 5.12a and b). If each succeeding warp yarn to the right has a corresponding interlacing one filling yarn lower, the weave is a 45° left-hand twill. The step can also be more than one. If the corresponding interlacing on the succeeding warp yarn is two filling yarns higher or lower, a 63° twill weave is produced. Stepping up or down three filling yarns produces a 70° twill, up or down four produces a 75° twill. Most twills are 45° twills but the difference in yarn size of the warp (finer) and the filling (coarser) may cause the perception of a 63° twill (i.e., steeper twill line). A twill weave with a diagonal line greater than 45° is also referred to as a steep twill. If the diagonal line is less than 45°, it is sometimes referred to as a reclined twill. Figure 5.13 shows the different twill angles.

b

c

Figure 5.11 (a) Balanced twill 2—2; (b) warp-face twill 2—1; and (c) filling1 face twill — . 2

Important Features

Twill lines can be made more prominent by using plied yarns, high-twist yarns, twill weaves with longer floats, high yarns per inch, and yarn twist opposite to the twillline direction. Fabrics with these prominent lines (e.g., gabardine) may become flattened by wear and pressure, and thus become shiny. Twills are widely used for work clothes (e.g., denim), suiting fabrics (e.g., serge), and dress fabrics (e.g., surah). Twill weaves have fewer interlacings than plain weave, which permits more yarns per inch in the fabric and makes twills more compact, stronger, heavier, and more durable than plain- and basket-weave fabrics. In twill, the floats are short, so yarn snagging is not a problem.

a

Broken-Twill Weave

Although the twill lines usually run in one direction, sometimes a fabric combines right- and left-hand twills. This weave is called a broken-twill weave. It is made from a regular twill weave in which the twill runs in one direction (e.g., right) for a desired number of yarns, and then the direction of the twill is reversed (e.g., left) for a desired number of yarns. The pattern then repeats. A well-known broken-twill design is chevron. This design produces stripes in a zig-zag effect. Usually yarns F A B R I C

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b Figure 5.12 (a) 45° right-hand twill weave and (b) 45° right-hand twill on graph paper. S C I E N C E

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One set of yarns forms most of the face; the other set forms most of the back. In a warp-face satin, the face is predominantly warp yarns. A filling-face satin has filling yarns predominant on the face. Thus there are no balanced satins comparable to the balanced twills. (See Figures 5.15a–d.) Satin weaves are designated by the number of harnesses they require in weaving. A satin may be named a five-harness satin, or a five-shaft satin. Five is the lowest possible and also most common number of harnesses for making satin. Some seven-harness and eightharness satins are also produced, but beyond eight is not economical. For a five-harness satin there are only five interlacings in one repeat of the weave. The number of interlacings is the same as the number of harnesses used to produce the weave. The length of the floats in satin is one fewer than the number of harnesses used. The number of harnesses used is also the size of the repeat in the warp and in the filling directions. Satin is also the name of a fabric of satin weave. Satin fabric is made from filament yarns, with the warp yarns predominant on the face. Satin fabrics are smooth and lustrous for a number of reasons: lustrous filament yarns are used; the weave has few interlacings, and thus, long floats; and the face yarns are very fine and closely packed. Since the greatest luster is in the lengthwise direction (the direction of the floats of satin), garments using this fabric are made so this direction is vertical in the garment to maximize the luster. Sateen fabric is a durable cotton fabric usually with a filling-face satin weave. It is not as lustrous as satin fabric because spun yarns are used in it. Because it is also heavier, and is made with thicker yarns, it is not as drapable as satin fabric. In crepe-back satin, the warp yarns are fine and have little or no twist, and the filling yarns are highly twisted. The face of the fabric is almost entirely warp yarns, and the back is almost entirely filling yarns. Because of the high twist, the filling gives the back a crepe, or pebbly, appearance and leaves the face fairly smooth. Satin weaves produce a very even surface because of the many warp or filling floats. (Satins have the minimum number of interlacings, which are widely distributed.) Although the long floats of the yarns provide luster to the satin-weave fabrics, they are also responsible for the poor wearing quality of many of these cloths. The floats cause the yarns to be greatly exposed to abrasive forces. Also, with filament yarns common in these fabrics, the floats catch on rough surfaces and the filaments break. Thus, satin-weave fabrics are most common in

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Figure 5.13 Degree of twill angle.

Figure 5.14 Herringbone weave shown on graph paper.

in two different colors are used to accentuate these designs. Herringbone is considered a broken twill by many. It is so called because the vertical stripes of both right- and left-hand twill resemble the backbone of a herring fish. (See Figure 5.14.)

Satin Weave In a true satin weave, there is only one interlacing for each warp yarn, and only one interlacing for each filling yarn in each repeat of the weave. Also, no two interlacings ever touch or are adjacent. This means the satin weave fabrics have relatively long floats. W O V E N

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Figure 5.15 (a) Five-shaft warp-face satin weave; (b) five-shaft filling-face satin weave; (c) five-shaft warp-face satin weave on graph paper; and (d) five-shaft filling face satin weave on graph paper.

end uses that are not subject to hard wear, such as evening dresses, fine lingerie, and draperies. Under certain conditions, however, good abrasion resistance and strength can occur in satin-weave fabrics. The long floats found in this weave enable the yarns to slide under one another, thus allowing more yarns per inch than if woven with shorter floats or none at all. If the fabric is made with a very large number of yarns per inch, an extremely durable fabric results because the fiber is very dense. With yarns tightly packed, and using spun yarns, snagging is not a serious problem. Examples of several of these fabrics, which also have satisfactory drapability, are the sateen materials used for military combat uniforms frequently used for camouflage.

that does have floats. In Figure 5.16a the filling yarn is interlacing with six yarns, whereas in Figure 5.16b the filling is interlacing with eight yarns. Thus, satin-weave fabric is the strongest because it can be made with the most yarns per inch since it has the fewest interlacings.

a

Which Weave Makes the Strongest Fabric? Weaves with long floats produce the strongest fabric because these fabrics can be made with the greatest number of yarns per inch. Figure 5.16a shows the yarns at the edge of fabric with a weave that has no floats. Figure 5.16b shows the yarns at the edge of a fabric with a weave F A B R I C

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b Figure 5.16 Weave influence on maximum yarns per inch of a fabric. Notice that illustration b has fewer interlacings and therefore more yarns per inch. S C I E N C E

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Special Fabric Weaves

all wovens, plus an additional set of yarns to create the pile surface. There are two basic types of pile-weave fabrics: the warp-pile fabrics, which have an extra set of warp yarns, and the filling-pile fabrics, which have an extra set of filling yarns. When the pile yarns are cut, the resulting fabric is referred to as a cut-pile weave fabric. These yarns are cut between interlacings to form many cut ends, which point up on the surface of the cloth and form the pile. If the pile yarns are not cut, an uncut-pile weave fabric is produced. (See Figure 5.18.) Velvet is an example of a cut warp-pile weave fabric, and terry cloth is an example of an uncut warp-pile weave fabric. (See Figure 5.19.) Filling-pile weave fabrics, such as corduroy and velveteen, are always cut. A napped fabric is different from a pile fabric. Nap is a fibrous surface produced by brushing up fibers on the cloth during a textile finishing process. (See p. 205.) Extra yarns are not used to produce the surface effect. When warp yarns are removed from corduroy or velveteen fabrics, they are covered with short lengths of fibers. The same occurs with filling yarns removed from velvet. The pieces of pile yarns that were cut cling to the yarns that were removed.

Various special fabric weaves besides the basic weaves are also used. Three of the most common special weaves are leno weave, pile weave, and weaves that make a double cloth.

Leno Weave In the simplest leno weave, the warp yarns twist back and forth in pairs around each pick, firmly holding the filling yarn in the figure-eight loops formed. Because the filling yarns are firmly held in place, they cannot shift in the warp direction (Figure 5.17). However, the warp yarns can shift in the filling direction. Adhesive may be used in finishing leno fabrics to cement the yarn in place to further reduce slippage. In counting yarns per inch in leno weave, the two warp yarns that twist to form a loop for the filling count as two separate yarns. They do not form a ply yarn. These yarns twisting identify this as a leno fabric. Leno weave is especially useful for reducing yarn slippage in fabrics that require yarns spaced far apart. It has greater firmness and strength than plain weave of the same low cloth count. The construction is used in mosquito netting, sheer curtains (e.g., marquisette), and some summer apparel fabrics in open and see-through constructions. It is used for industrial purposes and as packaging for fruits and vegetables. It is also used to make chenille yarns (see p. 80).

Cut-Pile Fabrics

Cut-pile fabrics are cut on the face after the fabric is completely woven. Two methods are used for making cut-warp pile fabrics. In one method, a double cloth is woven (see p. 106) with pile yarns interlacing between and connecting the two fabrics. The completed double cloth is cut into two fabrics by cutting the interlacing warp yarns. These cut yarns form the pile for each of the resulting fabrics. In the second method, after a number of filling yarns have been inserted, a special rod with a blade at one end is interlaced instead of a filling yarn. The harnesses operate so that only pile warp yarns pass over the rod. After several more filling yarns have been

Pile Weaves Woven-pile fabrics are material with a raised hairlike or furlike surface. Two well-known fabrics with such a surface are velvet and terry cloth. The surface is produced with an extra set of yarns (warp or filling) known as pile yarns. Thus, pile fabrics have the regular warp yarns and filling yarns (called ground yarns) that are common to

Figure 5.17 Leno weave. Notice how each pair of warp yarns twists to hold the filling yarns. W O V E N

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Figure 5.18 Filling-pile weave fabric: ground filling (purple and dark blue), ground warp (brown), and pile filling (light blue).

woven beyond the rod, the rod is removed and the knife at the end of the rod cuts all warp yarns that pass over the rod. The cut yarns stand up to form the pile. The weaving continues with the insertion of the rod after weaving a few additional filling yarns and the removal of the rod after weaving a few more filling yarns. With filling cut-pile fabrics, there is no raising of yarns by wires. The pile-filling yarns are woven to float over a group of warp yarns. The pile yarns are then cut at the center of the float. The ends of the cut yarns produce the cut-pile effect. The floats in corduroy fabric are placed in lengthwise rows, and the floats in velveteen are randomly spaced. Thus, when corduroy fabric is cut, the characteristic wale or hill-and-valley effect is produced. The thickness of the wales can be varied, from narrow (used for apparel) to very wide (used for furniture fabric). When velveteen fabric is cut, an overall cutpile surface is produced. Decorative patterns and effects can be created by cutting floats selectively. Cut-pile weave fabrics are made with different heights of pile. For example, velvet has a low pile height, velour has a higher pile, and plush has still higher pile. The face of cut-pile fabrics has an up-and-down direction (top and bottom) because of the position of the pile. A garment made with the pile fabric facing downward offers a smoother surface for light and so appears more lustrous. If the pile is up, the color is richer because more of the interior of the fabric (and color) is visible. However, the fabric is less durable because the pile fibers are more exposed to rubbing forces. In cutting fabric for a garment, the pile of all pieces in the garment must lie in the same direction to produce F A B R I C

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Figure 5.19 These velvet jackets are of a warp-pile weave fabric.

a uniform effect. Velvet, a cut-pile warp fabric is especially sensitive to crushing and must be stored so that the pile is not flattened.1 Also, special care must be exercised in cleaning and refinishing velvet apparel. Pile construction affects the fabric wearability. The short lengths of cut-pile yarn may have a V shape or a W shape. The W-shape pile is more firmly held in place because it interlaces with three yarns, and the V-shape interlaces with only one yarn. Thus, the W-shape pile yarn is held more securely, preventing a bald spot from developing. The W-shape pile, however, is not as dense as the V-shape pile because the latter has two pile ends for each interlacing, and the W-shape pile has two pile ends for every three interlacings. (See Figure 5.20.) To obtain the same pile density for a W-shape pile as for a V-shape pile, 1. Yard goods of velvet are shipped and stored on special bolts that keep the layers separate to avoid crushing. S C I E N C E

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knife a b c d e Figure 5.20 Double cloth pile weaving. Knife cuts pile warp yarns to make two velvet fabrics: V pile formation (top) and W pile formation (bottom) with (a) ground warp (top); (b) ground filling (top); (c) pile warp; (d) ground warp (light blue) (bottom); and (e) ground filling (bottom).

more yarns per inch would have to be used. A denser pile can better resist crushing, gives better cover, and stands more erect, but also is more costly. At times combinations of V-shape and W-shape pile are used in the same fabric. The V-shape adds depth to the pile and the W-shape adds stability. This alternative is often utilized in the construction of wide wale corduroy. Different ground weaves are used for cut-pile fabrics. Usually the body of corduroy and velveteen fabrics are made with either a plain, rib, or twill weave. The base construction will add to the durability of the fabric. A rib or twill weave will lock in the pile more securely. A twill weave can result in a stronger fabric (more yarns per inch are possible; see p. 100), thus the twill-back pile fabrics are usually more durable than those with a plain weave ground.

Figure 5.21 Terry cloth is an example of a pile fabric, often used for towels.

end for one ground end, two pile ends for two ground ends, or some other simple arrangement. Two warp beams are used for weaving terry. On one beam, the warp yarn is tight, and on the other, the yarn is quite loose. The extra length in the loose warp yarn forms the loops in the fabric. A pile warp yarn may be almost four times longer than a ground warp yarn from the same cloth. Frieze fabric, a thick pile fabric with patterns made from its loop surface, used for upholstery, is an example of an uncut-pile weave fabric. As in cut-pile weave fabrics, a strong ground fabric with a large number of yarns per inch and a dense pile makes a durable uncut-pile material. High loops and thick, low-twist pile yarns make a more absorbent, but less durable, fabric. Towels rented at the beach frequently are scratchy and have poor absorption, but are usually very durable because of the high-twist pile yarns.

Uncut-Pile Fabrics Terry cloth is an example of a fabric with an uncut-pile weave (Figure 5.21). The fabric consists of ground warp and filling yarns plus an extra set of warp yarns for the pile, in the form of loops on the surface of the cloth. The loops are formed by having the extra warp yarns (pile yarns) raised by a wire inserted across the loom. The wire is then removed until the next set of loops is to be formed. The warp direction of terry is readily determined because the extra yarn that forms the pile is lengthwise. The weave varies so that there may be one pile W O V E N

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Sometimes the pile loops are cut in a terry cloth for decorative effect. This is then considered a cut-pile fabric.

Double Cloth and Variations A double cloth is actually two fabrics held together by a separate set of yarns. Each fabric is made using one set of warp yarns and one set of filling yarns (a total of two warp and two filling sets), with a third set of warp yarns moving back and forth between the two layers of fabrics to hold them together. All yarns are woven simultaneously to produce the double cloth. Some double cloths are specifically designed to be cut into two separate fabrics, such as velvet. Here, both of the resulting fabrics have a cut-pile surface. Other fabrics are structured to remain as one fabric, such as some tapestries. A double-cloth fabric used to make coats may be made with a solid color face and plaid back. Blankets are sometimes made in this manner. Some fabrics resemble a double-cloth construction but are made with one set each of warp and filling. The three-dimensional effect is the result of the weave forcing some of the yarns to be raised. An example of this fabric type is piqué.

Woven Designs If a fabric containing a woven design is carefully examined (using a pick glass), it is clear that the design was created by long and short floats as well as the placement of interlacings. So-called white-on-white shirtings and brocades are examples of this type of fabric. Depending on their design and how they are produced, they are known as dobby patterns, jacquard patterns, clip-spot patterns, or color and weave effects.

Figure 5.22 The design in this fabric is created by a jacquard loom.

designs exceed the capacity of harness looms, a special loom must be used. This loom usually has no harnesses, and the ends are controlled by a jacquard head located at the top of the loom. The loom is referred to as a jacquard loom because the control device was perfected in 1805 by Joseph-Marie Charles Jacquard. The jacquard head uses a computer tape to control the warp yarns, in the same way that a punched paper roller controls the keys in a player piano. The position of the holes in the tape determines the sequence in which the warp yarns are moved. Hooks and needles are used to raise and lower the warp yarns by controlling a cord attached to each heddle. Because there are no harnesses, any combination of yarns can be raised or lowered to produce the design. The jacquard loom operates more slowly than do the other, simpler looms, so the fabrics produced on this loom are more expensive. Damask, tapestry, and brocade are several fabrics commonly made with jacquard designs.

Dobby Pattern A dobby pattern is a design that contains simple geometric forms or motifs. It is made on a loom with a special harness control mechanism called a dobby head. The loom, referred to as a dobby loom, uses computercontrolled mechanisms to determine which harnesses are raised or lowered. Since up to 32 harnesses can be controlled this way, complex and expensive weaves can be produced. If more complex designs are desired, a jacquard loom must be used.

Jacquard Pattern A jacquard pattern is a design that contains very detailed, intricate motifs (Figure 5.22). Because these F A B R I C

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Clip-Spot Pattern

Wherever a warp yarn and a filling yarn interlace, a small spot of the color of the yarn passing over is seen on the face of the cloth. The sum of the colors of all the yarns interlacing on the face produces various stripes, checks, and plaids.

Woven designs can also be obtained by using extra warp yarns or filling yarns. In a clip-spot pattern, the extra yarns interlace in the fabric to make a simple design and then float until the yarns again interlace to repeat the pattern. The long floats between the patterns are often cut away and discarded. The ends of the cut yarns are easily seen on the back of the fabric. Dotted Swiss fabric has extra filling yarn, and clipspot shirting fabric contains extra warp yarn to make the design. The durability of the design (i.e., how well the extra yarns remain in the fabric) depends on the number of interlacings in the design and the closeness of the yarns in the fabric. The additional yarns do not substantially affect the strength of the fabric.

Technology Advancements From a design and production perspective, advances in technology have enabled the industry to produce a variety of woven fabrics more quickly and effectively than ever before. They have allowed the woven-fabrics industry the opportunity to offer value-added merchandise with a shortened production cycle. This quick turnaround has fueled new opportunities in the use of woven fabrics in broad applications for both the apparel and interior furnishings industries. The initial design can be made in minutes with the colored pattern shown on the computer screen. Any modifications and/or alternatives can be produced with the same ease. The images of the color monitors are very realistic, as are the designs that are reproduced by color printers. These computer-generated designs are sent directly to buyers anywhere in the world and when approved can be electronically transmitted to computeroperated loom systems at the textile mill. The application of various technologies allows the textile designer to work directly with the consumer (e.g., dress designer). Any changes in color or pattern can quickly be accomplished. The print hard copy that is finally approved usually has a remarkable similarity to the fabric to be made. The designer can choose the type of yarn (e.g., tightness of twist and thickness) as well as the surface (e.g., smooth or brushed, slightly blurred look). Equipment is now available that can scan a woven fabric and analyze the warp and filling yarns, colors, the cloth count, and the particular weave. This can be done to actual fabric samples that are as complex as multifaceted dobby patterns found in upholstery and men’s suiting. The fabrics can be shown as a three-dimensional object. Thus the effects of changing in yarns, fabric construction (ypi), and finish can be viewed. Also both sides of the material can be seen. The garment designer can also use a computer system to draw the garment on the screen. When the garment is completed and approved, any pattern of fabric stored in the computer can be displayed on the garment. The garment can also be displayed on a model, with the computer simulating draping, shadowing, and

Color-and-Weave Effect A color-and-weave effect is a pattern produced in a fabric by using a certain weave and a certain arrangement of differently colored yarns in both the warp and the filling. A houndstooth pattern is a common example of a color-and-weave effect design (Figure 5.23). The houndstooth pattern shown in the chapter opening pages is made from a two-up, two-down, 45°, left-hand twill. In this example, both warp and filling have black and white yarns arranged four of one color, followed by four of the second color.

Figure 5.23 Houndstooth plaid. W O V E N

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light-pattern changes to create a realistic three-dimensional form. A printout can be produced for distribution to customers, sales personnel, or management. Technological advances have provided the opportunity for full integration of design and production of woven fabric. Technology has given the textile industry the catalyst to enhance the designer’s creativity, to suggest production alternatives when needed, and to establish accurate information regarding quick delivery of goods to a global marketplace.

The fabric yarns per inch must also be considered. A fabric with greater warp yarns or filling yarns per inch costs more than one with fewer yarns because it has greater yarn content. The more picks per inch in the fabric, the fewer yards of fabric per hour are produced. Increasing or decreasing the ends per inch usually has no effect on the production rate of the loom. The number of yarns per inch and the type of yarns used in a fabric affect the weight of the fabric. Therefore, fabric weight directly affects the cost of woven cloth. In fact, some textiles are bought and sold primarily on the basis of their weight. This is more fully discussed in Chapter 15. Other costs include those for dyeing or printing and finishing. These areas are discussed in subsequent chapters. Basic fabric types, such as broadcloth and print cloth in their various constructions, are widely sold and traded in the textile market.

Factors Affecting the Cost of Woven Fabrics The selling price of a fabric is based on the cost to produce it as well as the demand for the cloth. Fabric is bought and sold both in unfinished and finished states. The following are some of the factors that affect the cost of producing woven fabrics:

New Developments

Fiber content: The cost of fibers is based on quality as well as generic type. Pima cotton is more expensive than upland cotton because it is a betterquality fiber. Polyester is more expensive than acetate because of the higher cost of manufacturing. Antron® nylon costs more than the regular type of nylon for the same reason.

Three major concerns for the manufacturers of products are: the cost of raw materials, capital costs, and the costs of energy. Because of these concerns all industries continues to evaluate and reshape their operations and equipment. The following list presents opportunities in the weaving industry:

Yarn type: The cost of yarns is based on fiber content and the type of yarn. Novelty yarns are more expensive to produce than the regular type. High-twist spun yarns cost more than low-twist spun yarns of the same yarn size because the former take longer to produce. Thinner spun yarns are usually more expensive than thicker yarns for the same reason. Worsted yarn is more expensive than woolen yarn because additional production steps are required. Lighter-weight filament polyester yarn (lower denier) is more expensive than heavier polyester yarn composed of the same number of filament fibers because smaller spinnerette holes are used to make the lighter fibers, causing lower production rate. Ply yarn is more costly than an equivalent size single yarn because both thinner yarns and a plying process are required.

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Enhanced mill flexibility

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Quicker response to demand shifts

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Improved ability to use new fibers, yarns, and finishes

Classic Woven Fabrics This section contains a brief description of many of the classic woven fabrics (Figure 5.24). Identifying features are emphasized and a general indication of their use is also included to help the reader obtain a better mental image of the cloth. It should be noted that the following glossary of classic woven fabric names can only give the reader an approximate mental picture of the fabrics listed. As a reinforcement, it is strongly recommended that, wherever possible, the actual fabric be examined, many of which are in the Fabric Science Swatch Kit.

Construction: The weave used is an important fabric cost factor. A jacquard design costs more than a plain, twill, or satin weave because of additional preliminary and loom set-up costs, the lower production of the jacquard loom, and the relatively few jacquard looms one operator can tend. F A B R I C

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The origins of woven-fabric names are varied. Batiste, for example, was named for its French creator, Jean Batiste, a linen weaver. Denim was named after the French city in which it first appeared (fabric “de Nîmes” or “from Nîmes”). Corduroy was derived from the French cord du roi, meaning “King’s cord.” Taffeta is the modern name for the old Persian fabric name taftah. Challis originated from the Native American word shallee, meaning soft. Cheesecloth was named after its original use—to wrap cheese. Seersucker is a classic woven fabric with a puckered effect. It is created with two warp beams one on top of the other. The first is under tension while the second is not. The resultant fabric has a permanently puckered or crinkled effect, which makes the fabric, and thus the garment, appear to be less wrinkled. The name comes from a Persian word meaning milk and sugar. It should be noted that these classic woven fabric names are given primarily on the basis of the appearance and approximate weight of the fabrics (see Table 5.2). For example, poplin fabrics, although they vary somewhat, all have fine horizontal ribs and are constructed similarly with regard to yarn sizes, yarns per inch, and fabric weight. A great number of fabrics in use today do not possess classic names. They are referred to either by style numbers (e.g., Style No. 473) or by names given to them by the mill, converter, or store (e.g., “Sea Breeze” for a sheer curtain fabric or “Iron Wear” for a very durable work-clothes fabric). Sometimes fabrics are referred to by names that describe their end use, such as “shirting fabric” or “dress fabric.” Most of these fabrics are developed for a particular market and then fall out of fashion within one or two seasons. Thus, the student of textiles should not despair if he or she does not recognize various fabrics in the marketplace because there is an excellent possibility that they are of the nonclassic type. See pages 112–116 for a Glossary of Classic Woven Fabrics. It includes a list of definitions for classic fabrics with a description of each fabric’s characteristics and use.

Figure 5.24 The skirt of this dress is an example of a well-known classic woven fabric—tulle. The particular fiber content, yarn type, and fabric construction yields very fine, slightly stiff, net-like fabric.

Fabrics are referred to as classic or traditional fabrics when they have been in use for many years and are continually made in virtually the same manner by textile mills. Although originally these fabrics were either 100 percent cotton, flax, silk, or wool, now they frequently are made with yarns blended with manufactured fibers. Excessive cost or disappearing end use are two main reasons some classic fabrics have ceased to be made.

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Textile Connection A product that can be considered as one of the most successful ever produced is the denim fabric. Denim jeans became popular among young and old alike, of both sexes, in all economic and social classes, with both radical and conservative dressers, and in virtually all parts of the world. Never before has the entire world adopted a clothing fashion so unanimously.

(In the 1960s and later, many owners would use a bathtub to obtain a snug, body-conforming fit.)

Evolution of Blue Jeans Jeans moved into the 20th century, carrying their blue-collar image until the 1950s. Then a new segment of consumer was recognized—the teenager, who made jeans the uniform of American youth. Blue jeans became an anti-establishment symbol of the 1960s and the anti-war movement. Sales of blue jeans grew rapidly during this decade. In the 1970s, the impact of the counter-culture declined. Jeans became an expression of a more leisurely life. Jeans were being purchased not for sociological reasons, but for their inherent virtues— durability, comfort, value, and the non-necessity of ironing them. Jeans also embodied the new sexuality emerging in U.S. culture. The wearing of this garment spread to other countries, helped by new technologies that encouraged rapid global communications, a global transportation system, and global business services and rules of trade.

Origin The origin of denim was in Nîmes, France, where a fabric “serge de Nîmes” was developed. It was a coarse, twilled fabric made of cotton, which was very strong and durable. The sails of the Niña, Pinta, and Santa María were made from this fabric. A version for trousers was later developed, called “denim” (“de Nîmes” or “from Nîmes”). Sailors from Dung, India, wore trousers made of this fabric and hence the name “dungarees.” A century later, the trousers became known as “jeans,” the name derived from the trousers worn by sailors from Genoa. The first exclusively American denim jeans were made by a Bavarian immigrant, Levi Strauss, on the West Coast in about 1850. They were created as durable pants that could stand up to the rigors of gold mining and other outdoor activities. The only color available was blue, hence the term “blue jeans.” The denim fabric, as well as its precursors (e.g., canvas), were very stiff. They had to be washed thoroughly before they became comfortable to wear. There was some color bleeding from most of the garments, thus they had to be washed separately to prevent undesirable coloring of other garments in the wash load. Such conditions were tolerable for work clothes since this was expected from past experiences. Cowboys adopted jeans as their own. Attempting to eliminate wrinkles in their jeans, which could rub and create sores after a day of riding, they would sit in a water-filled horse trough and then ride all day in the wet jeans. The result was a pair of jeans sun baked in the form of the man’s body.

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Design Influence In the late 1970s, designers became involved in making denim jeans a fashion item. Jeans were made for women for the first time—with different proportions than those for men. Fashion designers branded their tailored jeans by “signing the back pockets of their own jeans.” The high price of these signature jeans proved of secondary importance to the strong fashion trend. The evolution of denim and blue jeans continued with the introduction of pre-washed (to soften the fabric) and pre-shrunk (for better fit) jeans. Then the pre-worn look evolved—the more worn, the better, including holes in the knees and frayed leg bottoms. To increase the worn look, abrasives, such as stones, were put in the commercial washing machines used by jean manufacturers. (This process also further softened the fabric.) This was called stone washing.

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Changing the Fabric

A unique version of the denim jean occurred in 1990 when a manufacturer fired shotguns into the garments to create holes. This took the “ripped jean” concept one step further. Periodically, the blue jean silhouette was altered to follow the trend of the times—from a straight-leg cut, to bellbottoms, to a flared silhouette, and back again to a straight leg. Blue jeans have also developed into different styles for different ages and body proportions (e.g., skinny leg, relaxed fit, boot cut, etc.) as well as for various price categories.

Table 5.2

a

Denim began to find a multitude of other end uses—denim jackets, shorts, furniture coverings, and dog beds. This diversity helped spur innovations, such as lighter weight fabrics (e.g., 10 oz.), various colors (not only blue), prints, finishes, and weaves other than the traditional twill weave (e.g., dobby). Other changes included the use of polyester/cotton blends and novelty yarns (e.g., slub) as well as the development of stretch denim.

Woven FabriCs by Common CharaCTerisTiCs

Sheer

Light

Heavy

Ribbed

Buckram Cheesecloth Chiffon Crinoline Dotted Swiss Gauze Marquisette Ninon Scrim Tulle

Batiste Calico Chambric Chambray Gingham Lawn Madras Nainsook Organdy Organza Oxford (rib weave) Percale Toile de Jouy Voile

Burlap Canvas Crash Cretonne Duck Muslina Osnaberg Sailcloth Tickingb

Bengaline Broadcloth Faille Grosgrain Ottoman Poplin Repp Taffeta

Twill

Woven Design

Brushed

Cord

Novelty Yarn

Cavalry twill Cheviot Chino Denim Drill Gabardine Jean Serge Tweed Whipcord

Brocade Brocatelle Damask Frieze Huck Matelassé Piqué Tapestry

Challis Flannel Flannelette Melton

Bedford cord Dimity

Antique satin Antique taffeta Butcher fabric Honan Pongee Shantung

Pile

Puckered

Lustrous

Miscellaneous

Corduroy Terry cloth Velvet Velveteen

Crepe (types) Plissé Seersucker

Charmeuse Chintz Foulard Habutai Peau de soie Sateen Satin Surah

Monk’s cloth Sharkskin

Also is made in lighter weight. Sometimes with woven design.

b

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Glossary of Classic Woven Fabrics Burlap: Heavy, plain-weave fabric with open construction and coarse, irregular yarns usually made of jute fiber. Used for sacks, upholstery, and wall coverings.

Antique satin: Satin fabric with slub filling yarns prominent on the dull side (back). See satin. Usually used for draperies, with the back as the exposed side. Antique taffeta: Heavy, crisp taffeta with slub filling yarns. See taffeta.

Butcher cloth: Medium-weight, plain-weave fabric with slightly irregular coarse yarns. Sometimes made from flax and called butcher linen. Most frequently made from polyester blend (e.g., polyester/ cotton). Used for apparel.

Barkcloth: Medium-weight fabric with a rough surface that resembles the bark of a tree. Used for furniture slipcovers and draperies. Batiste: Lightweight, plain-weave, soft fabric. Made primarily of cotton (blend) but can be of wool (blend). If made of wool, it is lighter than challis. Used for dresses.

Calico: Lightweight, plain-weave, cotton-type fabric, usually with bright, small print design on contrasting background. Used for blouses and dresses. Cambric: Lightweight, closely woven, plain-weave, cotton-type fabric with slight luster. Used for undersides of chairs and children’s dresses.

Bedford cord: Heavy, cotton-type fabric with prominent lengthwise raised cords on the face. Used for trousers and upholstery.

Canvas: Heavy, plain-weave, cotton-type, durable fabric. Used for tents, awnings, and industrial purposes.

Bengaline: Medium-weight, lustrous fabric with prominent crosswise ribs. Ribs are covered with filament warp yarns. Lighter, with thinner ribs, than an ottoman, but heavier, with more prominent ribs, than a faille. Used for cummerbunds and lapels of tuxedos, coats, and upholstery.

Casement cloth: Any open-constructed fabric used for draperies. Cavalry twill: Medium-weight, durable, worstedtype fabric with prominent, fancy twill lines. Used for slacks.

Broadcloth: Lightweight, plain-weave, tightly woven, thin-yarn fabric with slight crosswise rib. Made of cotton (blend) or wool (blend). If cotton type, it has a lustrous surface and resembles a lightweight poplin. Used for shirts. If a wool type, it is slightly heavier and was a one-way brushed surface. Used for dresses.

Challis: Lightweight, plain-weave, slightly brushed, supple, woolen, or cotton-type fabric, usually with a printed design. Used for dresses, scarves, and infants’ wear. Chambray: Lightweight, plain-weave, cotton-type fabric usually with colored warp and white filling yarns. Square construction (about 80 × 76) and used for shirts.

Brocade: Heavy, luxurious fabric with supplementary warp yarns or filling yarns, forming a slightly raised jacquard design. Used for apparel and decorative fabrics.

Charmeuse: Lightweight, satin-weave, silklike fabric with soft hand and very shiny face. Used for dresses and pajamas.

Brocatelle: Heavy, luxurious fabric, similar to a brocade but with the jacquard design puffed up or blistered, making it very noticeable. Also has a heavy widthwise rib. Used for draperies and furniture.

Cheesecloth: Very lightweight, plain-weave, soft, cotton-type fabric, with very open construction. Used for polishing cloths and dress costumes.

Buckram: Lightweight, plain-weave, open construction, stiff, cottonlike fabric. Has slightly more yarns per inch and stiffer than crinoline. Used for apparel interfacing and interlining, and bookbindings.

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Cheviot: Medium/heavy, rough, twill-weave fabric with fuzzy surface and uneven yarns. Similar to tweed, but more casual in appearance (suitable for rough use). Used for suiting and coats.

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Denim: Medium-weight, twill-weave, cotton-type fabric. Warp is colored and filling is white or gray. Traditional color is indigo blue, which usually begins to fade after only a few washings. Used for slacks and work clothes.

Chiffon: Lightweight, sheer, plain-weave, silklike fabric. Filament yarns are highly twisted. Used for dresses. Chino: Medium-weight, closely woven, twill-weave, cotton-type fabric with a slight shine. Used for uniforms and pants.

Dimity: Lightweight, sheer, cotton-type fabric with lengthwise cords formed by grouping several warp yarns together (rib weave). Plain-weave sections occur between the cords. Used for curtains and dresses.

Chintz: Light- to medium-weight, plain-weave, closely woven, fine, cotton-type fabric with a glazed (polished) finish. Usually printed in bright colors. Used for draperies, upholstery, and dresses.

Donegal tweed: Plain-weave tweed with colorful nub or slub yarns. See tweed.

Corduroy: Medium-weight cotton fabric with lengthwise wales produced by cutting the pile filling yarns. Used for slacks and jackets.

Dotted Swiss: Lightweight, sheer, fine-yarn fabric with small dotted areas that have been either woven (clip-spot design) or flocked (glued) to achieve the dot effect. Used for dresses and curtains.

Covert: Lightweight overcoating fabric, usually made with two shades of the same color (e.g., dark brown and medium brown). A rugged fabric with a twill weave. Either woolen or worsted-type, and used for coats, uniforms, and hunting clothing.

Drill: Medium-weight, durable, cotton-type fabric with twill weave. Similar to denim. Called khaki when dyed that particular color. Used for pockets, work clothes, and sneakers.

Crash: Medium-weight, plain-weave, coarse, cotton-type fabric with uneven yarns. Often made from flax and used for linen towels, curtains, women’s jackets, and bookbindings.

Duck: Medium- or heavyweight, plain-weave, durable, cotton-type fabric. Slightly lighter than canvas, but heavier than sailcloth. Used for apparel and industrial purposes.

Crepe: Fabric with a pebbly or crinkled surface. Obtained by using crepe (high-twist) yarns, chemicals, or weave. Used for apparel or home furnishings. Varieties include crepe-back satin, crepe de chine, and georgette.

Duchess satin: Heavy, rich-looking satin fabric. Used for wedding dresses. See satin.

Crepe de chine: Light- to medium-weight, fine crepe fabric with crepe filament yarns. See crepe.

Faille: Medium-weight, semilustrous fabric with very noticeable crosswise ribs. Used for evening dresses.

Crepe-back satin: Satin fabric with crepe surface on the dull side (back). See satin.

Faille taffeta: Taffeta with very visible crosswise ribs. See taffeta.

Cretonne: Light- to medium-weight, plain-weave, closely woven cotton-type fabric similar to an unglazed (unpolished) chintz, but not as fine quality. Usually printed with large designs. Used for draperies and slipcovers.

Flannel: Light- to medium-weight, soft cotton, or woolen-type fabric, usually brushed on both sides. Used for shirts and pajamas. Flannelette: Light- to medium-weight soft cotton-type fabric, usually brushed only on one side. Lighter weight than flannel. Used for shirts and pajamas.

Crinoline: Lightweight, plain-weave, stiff, cotton-type fabric with very open construction. Stiffer and slightly more closely woven than cheesecloth. Used for supporting hoopskirts or hem edges and interlining.

Foulard: A lightweight, filament-yarn, twill-weave fabric with a soft hand. Frequently printed with small overall design (foulard print). Similar to surah. Used for scarves, ties, and dresses.

Damask: Heavy, bright, fine-yarn fabric with a reverse jacquard design on both sides. Flatter than brocade. Used for draperies and tablecloths.

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Frieze: Heavy, thick, rough-surface pile fabric with patterns made from its raised, small loop surface. The loops are sometimes sheared to give a cut-pile effect. Ribbed effect on face. Used for upholstery.

Jean: Medium-weight, fine-yarn, cotton-type, durable fabric with slight twill lines. Lighter and finer than drill fabric. Used for slacks and skirting. The term jean now usually refers to slacks.

Gabardine: Medium-weight, fine-yarn, durable, twill-weave fabric with slight twill lines. Cotton or worsted types. Used for slacks and suits.

Lamé: A flat, lightweight fabric woven with metallic yarns that create a shiny surface. Used for dresses, blouses, and eveningwear.

Gauze: Very light, sheer, open-construction, plainweave, cotton-type fabric. Used for dresses, curtains, and bandages.

Lawn: Lightweight, fine, plain-weave, cotton-type fabric, slightly stiff. A little less sheer than voile. Used for blouses and dresses.

Georgette: Light, sheer fabric with crepe surface. Usually has the same yarns in warp and filling. See crepe.

Madras: Lightweight, usually plain-weave, carded, spun-yarn fabric, frequently made with a plaid design so that colors can bleed when fabric is washed (bleeding Madras), resulting in everchanging shades. Imported from Madras, India. Used for shirts and dresses.

Gingham: Lightweight, plain-weave, cotton-type fabric, usually with a plaid or check pattern (gingham plaid or gingham check). Used for shirts, dresses, and curtains.

Marquisette: Lightweight, sheer, open-construction fabric with leno weave. Similar to mosquito netting. Used for curtains.

Grosgrain: Heavy, closely woven lustrous fabric with pronounced crosswise ribs. Used for ribbons (narrow-width fabric), graduation gowns, and vestments in churches.

Matelassé: Medium- or heavyweight, luxurious, jacquard weave, double-cloth fabric with a blistered or quilted surface. Used for draperies, upholstery, and evening dresses.

Grospoint: Heavy, thick, rough-surface pile fabric with loop surface. Has larger loops than frieze. Used for upholstery.

Melton: Heavyweight, closely woven woolen fabric, completely fulled (i.e., felted) with nap. Used for coats and uniforms.

Habutai: Lightweight, plain-weave, spun-yarn, soft, silklike fabric.

Moiré taffeta: Taffeta with moiré or watermark design. See taffeta.

Harris tweed: Trademark for tweed fabrics from islands of the Outer Hebrides off the northern coast of Scotland. Used primarily for sport jackets.

Monk’s cloth: Heavyweight, soft, coarse, cottonlike fabric with pronounced basket weave design. Used for slipcovers and draperies.

Honan: Lightweight, plain-weave, silklike fabric with slightly uneven (thick and thin) yarns in both warp and filling. Used for blouses and dresses.

Muslin: Light- to medium-weight, plain-weave, stiff, unfinished cotton fabric with speckled effect from the “trash” content (i.e., foreign matter such as twigs and leaves not thoroughly removed during processing to cut costs). Used for designer sample garments and interfacing. When finished, the fabric is soft and used for sheets, furniture coverings, and dresses.

Hopsacking: Heavier-weight, coarse, irregular yarns made with basket weave. Resembles burlap fabric. Used to store hops, but now also used for apparel and wall hangings (when printed). Huck: Medium-weight, flat, coarse, cotton-type fabric, usually with dobby design. The spun filling yarns have low twist to add to absorbency. Used for towels.

Nainsook: Lightweight, plain-weave, cottonlike fabric, either crisp or soft. Slightly heavier than lawn. Used for blouses and infants’ wear.

Irish tweed: Tweed fabric from Ireland, usually with white warp and colored filling. See tweed.

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Poplin: Medium-weight, cotton-type fabric with fine horizontal ribs. Usually a solid color. Used for golf jackets and raincoats.

Ninon: Lightweight, plain-weave, sheer, open-construction fabric with high-twist filament yarns that give the fabric a crisp hand. Heavier than chiffon. Warp yarns grouped in twos. Used for curtains and evening wear.

Repp: Medium-weight, spun-yarn, coarse fabric with distinct horizontal ribs. Similar to poplin, but with more obvious ribs. Used for neckties, upholstery, and sportswear.

Organdy: Lightweight, plain-weave, cotton-type open-construction fabric with fine-spun yarns and a stiff finish. Used for blouses and curtains.

Sailcloth: Medium- to heavyweight, plain-weave, durable, cotton-type fabric. Slightly lighter than duck. Used for jackets, shorts, and boat sails.

Organza: Similar to organdy, except made of silk or manufactured filament fiber. Used for dresses and trimmings.

Sateen: Medium-weight, cotton-type fabric with satin weave and semi-lustrous surface. Used for slacks, work uniforms, and shoe uppers.

Osnaberg: Medium- to heavyweight, coarse, durable, plain-weave, cotton-type fabric that is unfinished. Used for industrial purposes. Ottoman: Heavy, lustrous fabric with large horizontal ribs covered by the warp yarns. Similar to bengaline but heavier. Used for upholstery, draperies, and evening dresses.

Satin: Medium-weight fabric of filament yarns. Satin weave has fine, closely woven warp yarns. Highly lustrous, smooth face and dull, rougher back. Used for fancy dresses. Varieties include antique satin, crepeback satin, duchess satin, and slipper satin.

Oxford: Lightweight, soft, cottonlike fabric with small 2 × 1 basket weave (rib weave) repeats. Fine warp and coarse filling yarns, with smooth surface. Used for shirts.

Scrim: Very lightweight, sheer, open-construction, plain-weave, cotton-type fabric. Similar to slightly stiff cheesecloth. Used for curtains and as support for nonwoven fabrics.

Panné velvet: Velvet fabric in which the surface pile is flattened in one direction. See velvet.

Seersucker: Lightweight, cotton-type, color-striped fabric. Also with permanent, length-wise, alternating, puckered-striped and flat-striped sections. Used for dresses and sport jackets.

Paper taffeta: Lightweight taffeta with a crisp finish. See taffeta.

Serge: Heavy, worsted-type, durable, solid-colored, smooth-surface fabric with twill weave. Yarns that have a higher-than-normal twist and are closely woven result in fabric becoming shiny after wear. Used for suits.

Peau de soie: Heavy, twill-weave, satin-effect, luxurious, soft, silklike fabric. Used for evening gowns. Percale: Lightweight, plain-weave, fine-yarn, combed cotton-type fabric. Used for sheets (up to 200 yarns per square inch), dresses, and blouses.

Shantung: Medium-weight, plain-weave, silklike fabric with pronounced-slub filling yarns. Heavier and more textured surface than pongee. Used for dresses.

Piqué: Medium-weight, crisp, cotton-type fabric with raised dobby design. Some patterns used are cords, waffle, and bird’s eye. Used for women’s and children’s wear, collars and cuffs, and infants’ bonnets.

Sharkskin: Medium-weight, semilustrous hardfinish, twill-weave, worsted or synthetic-type fabric. The surface resembles the skin of a shark. Used for suits and skirts.

Plissé: Lightweight, plain-weave, puckered-striped, cotton-type fabric. Slightly resembles seersucker. Used for dresses and summer pajamas.

Surah: Lightweight, silklike, lustrous, fine fabric with twill weave. Frequently printed. Used for dresses and blouses.

Pongee: Lightweight, plain-weave, silklike fabric with slight-slub filling yarns. Used for blouses and dresses.

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Toile de Jouy: Light- to medium-weight, plain weave, fine, cotton-type fabric, usually with one color-printed scenic design. Used for interior furnishings and clothing.

Taffeta: Medium-weight, plain-weave, lustrous fabric, made with filament yarns. Slight crosswise ribs. Fabric has great rustle when rubbed. Used for dresses, blouses, and women’s suits. Varieties include antique taffeta, faille taffeta, moiré taffeta, paper taffeta, and tissue taffeta.

Tulle: Very fine, slightly stiff, silky, netlike fabric. Used for wedding veils, party gowns, and trimmings.

Tapestry: Heavy, spun-yarn, ribbed fabric with colored jacquard design resulting from different-colored groupings of filling yarns (visible as stripes on fabric back). Made with two sets of warp yarns and two sets of filling yarns. Used for wall hangings, upholstery, and handbags. With hand-woven tapestry, the filling yarns used to produce the design only interlace within the perimeter of the design being cut. The yarns are left hanging fringelike on the back. With machine-made woven tapestry, these filling yarns weave from selvage to selvage.

Tweed: Medium- to heavyweight, woolen, roughtwill-weave fabric with a fuzzy surface and colored nub or slub yarns. Used for suits and coats. Varieties include Donegal tweed, Harris tweed, Irish tweed, and Scottish tweed. Velvet: Medium-weight, manufactured or silk- filament yarn fabric with cut-pile surface that stands erect. Used for dresses, suits, and interior furnishings. Velveteen: Medium-weight, cotton-type fabric with cut-pile surface that lies flat. Used for dresses and robes.

Terry cloth: Medium-weight, soft, cotton-type fabric with low-twist yarns forming surface loops. Used for towels and beach robes.

Voile: Lightweight, sheer, crisp, plain-weave, hightwist spun-yarn, cotton-type fabric with very, very fine yarns. Used for curtains and blouses.

Ticking: Heavy, strong, closely woven, cotton-type fabric, usually made with stripes or woven design. Used for mattress and pillow coverings, upholstery, and work clothes.

Whipcord: Heavy, strong cotton or worsted-type fabric with prominent, round, diagonal twill lines. Similar to heavy gabardine with a more prominent twill line. Used for riding clothes and uniforms.

Tissue faille: Lightweight faille. See faille. Tissue taffeta: Lightweight, transparent taffeta. See taffeta.

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STUDY QUESTIONS 1. Why do woven fabrics stretch more on the bias, or diagonal, direction?

8. A woven fabric with jacquard design contains long floats. What potential problems would result from this construction if the fabric is used for apparel?

2. State three reasons fabrics with the same weave can have different appearances.

9. Which of the following fabrics is lightest, assuming that each fabric is made with size 40/1 yarns? Why?

3. State two major indicators of quality in a velvet fabric.

a. b. c. d

4. Which of these two fabrics would be the more costly to produce, assuming that they are identical in all other aspects (e.g., fiber content)? Explain.

100 × 70 90 × 90 110 × 70 100 × 80

10. Compare a high-count fabric (many yarns per inch) with a similar low-count fabric, considering the following characteristics:

Fabric A: 120 × 80 Fabric B: 110 × 90

5. You are in a store and see two sheets for sale. Each is labeled “200 percale.” What differences in construction could there be between these two fabrics, even though both have the same identification?

a. b. c. d. e. f. g. h. i.

6. State three reasons one side of a woven fabric can be different from the other side. 7. Other than by dyeing or printing, indicate three ways by which a fabric woven with the plain weave may be given added surface interest.

Abrasion resistance. Cover. Drape. Flame resistance. Seam slippage. Shrinkage potential. Stability. Strength. Wind resistance.

FABRIC SCIENCE / Swatch Kit Assignment

Woven Fabrics A. For each indicate the swatch number and the fabric name. 1. Find five woven samples that have an obvious face and back. 2. Find five woven samples that are plain weave. 3. Find five woven samples that are twill weave. 4. Find three woven samples that are satin weave. B. Indicate the cloth count for the following woven samples: 1. Sample #2 4. Sample #13 2. Sample #9 5. Sample #16 3. Sample #10 C. Answer the following using carefully constructed sentences, correct spelling, and proper punctuation. 1. Why does sample #25 have nylon in the warp direction? 2. What are two ways to distinguish the warp from the filling in swatch #97? 3. What is the easiest way to distinguish the warp from the filling in sample #35? 4. What produces the ridges in sample #36? W O V E N

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