METHOD FOR OBTAINING A DOUBLE WEAVE FABRIC
FIELD OF THE INVENTION
The present invention in particular relates to the method of obtaining unique finish denim fabrics
and garments.
BACKGROUND AND PRIOR ART
Denim is a classic and versatile fabric. Denim garments are produced from denim fabric. Denim fabric is generally a 3 x 1 twill woven structure where the warp yarns are indigo dyed and the weft (or filling) yarns are un-dyed cotton. It is trendy and comfortable. Denim, an indigo dyed fabric, is popular in fashion industry as with the passage of time it becomes softer and looks better as it ages.
The warp yarn (stationary) is dyed with Indigo, Ring Dyeing Process. The indigo dye is attached at the surface of yarn, leaving yarn core white. As the Indigo dye is attached at the surface of the yarns, denim fabric fade differently. A faded stylish look can be achieved due to ring dyeing of warp yarns of denim garments. Different finishing technique can be applied to Denim to take advantage of these ring dyed yarns. Denim can be hand scraped, stone washed or treated in the laundry in different ways that allow varying amount of the white cores of the indigo dyed yarn to become visible. The effects created through these treatments have made denim a popular and fashionable fabric in the clothing and textile industries. Denim looks amazing when di-stressed, but the life of garment is sacrificed. It is saved either by repair or putting a fabric patch from in-side of the garment.
Below are the few existing prior arts that are used variety of methods and process to obtain various types of textured denims for instance,

WO2016028240A1 discloses dyeing process for denim, gabardine yarns and fabrics using
vegetable organic natural dyes on continuous or semi-continuous machines based on REM
techniques.
US8615979B2 discloses method of producing a denim fabric from the yarns, comprising weaving
a fabric, wherein the weaving comprises feeding the warp yarns in a loom through a front roller and
a back roller; wherein the warps yarns are under less tension when a shed is open.
But in existing prior arts it has been observed that in order to achieve this classic denim look either
the fabric strength decreases, the dyeing methods have adverse impact on environment and also the
workers, Hence, there is a strong need of development of such a fabric in which Di-stressed look
can be achieved without repair and without hampering the life of garment.
Given the foregoing considerations, it would be advantageous to develop alternative methods for
production of indigo-dyed denim fabrics and garments with such alternative methods providing
improved consistency, reproducibility and predictability compared to the dyeing processes existing
today.
OBJECTS OF THE INVENTION
The present invention has been developed in response to the present state of the art, and in
particular, in response to the problems and needs in the art that have not yet been fully solved by
currently available techniques and processes.
Accordingly, the present invention has been developed to provide a novel method to obtain a double
weave fabric; in order to successfully overcoming all of the above-discussed shortcomings in the
art.

[001] The primary object of the present invention is obtain a Woven Fabric that looks like
Laminated Fabric and gives a unique di-stressed look without hole in garment and without repair
and the process thereof.
[002] Another object of the present invention is to provide a fabric with a denim look that
provides the typical effect of dis-coloration by wearing of the garment, but not by wet rubbing and
that at the same time has high resistance to structural weakening of the fabric itself.
[003] It is yet another object of the current invention to provide an environment friendly,
economical and simple method for obtaining classic look denim garment.
[004] How the foregoing objects are achieved will be clear from the following brief description. In
this context, it is clarified that the description provided is non-limiting and is only by way of
explanation. Other objects and advantages of the invention will become apparent as the foregoing
description proceeds, taken together with the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[005] In order to describe the manner in which the above-recited and other advantages and features of the invention can be obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. And that the elements of similar structure or function are generally represented by reference numerals for illustrative purposes throughout the figures. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
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Figure 1 Flow chart explaining the steps of the method to obtain the disclosed fabric. Figure 2 Illustrates Drawing Order, Design and Peg Plan.
TERMINOLOGY AND CALCULATIONS -
WP1-Warp Type 1
WP2-WarpType2
NE1= No. of ends of WP1 in Warp Sheet
NE2= No. of ends of WP2 in Warp Sheet
Bl = No. of Balls to be prepared for WP1
B2 = No. of Balls to be prepared for WP2
NEB1 = No. of Ends per Ball of WP1
NEB2 - No. of Ends per Ball of WP2
RS = Reed Space in Inch
Rl= Ratio of WP1 in Warp Sheet to Total Ends
R2= Ratio of WP2 in Warp Sheet to Total Ends
WPD - Warp density on Loom, Ends / Inch
WFD = Weft density on Loom, Picks / Inch
WF1= Weft Type 1
WF2 = WeftType2
TE-WDXRS
NE1=TEX{R1/(R1+R2)}
NE2 = TE X (R2/(R1+R2)}
NEB1-NE1/B1
NEB2 = NE2/B2
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DETAILED DESCRIPTION OF THE INVENTION
[006] This invention disclosure describes the subject matter for patenting with specificity to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. The principles described herein may be embodied in many different forms. [007] Illustrative embodiments of the invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. In the present description, persons have been described in the masculine gender for brevity. It may be clearly understood that the invention applies equally to persons of all genders. [008] The present invention discloses a method of manufacturing a Fabric that looks like laminated denim fabric and having a unique di-stressed look in garment wherein when top layer is scratched, it results no hole in garment and look is achieved without repair.
[009] In the current invention the fabric is has two (02) Warp yarns type the face fabric and back fabric, referred herein as WPl and WP2. Both the yam fabrics are ball wrapped. Generally, in a Denim Fabric, WPl is Indigo Dyed and WP2 is un-dyed, but both types of yams may be dyed in different color as well or kept un-dyed in different fabric. There are many possibilities of Colors in Dyeing. WPl and WP2 may be either of same count or different. The count range may vary from 7s Ne - 60s Ne. It can be Spun or Filament yam, Single Yam, Double yam, Elite Spun, Ring Spun, OE Spun, textured or a yam produced from any other technology. It may have 100% Natural Fiber, 100% man-made fiber or different Blends of Natural and Man-made fibers.
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[0010] In preferred embodiment WPl and WP2 are comprised of same size as that of weaver's Beam. WPl and WP2 are having NE1 and NE2 i.e is no. of ends respectively in Warp Sheet. [0011] NE1 and NE2 may vary from 2000 Ends to 12000 Ends, depending on Warp Density, reed space of Loom and their ratio in Warp Sheet. In the preferred embodiment NE1 = TE X (R1/(R1+R2)} and NE2 = TE X {R2/(R1+R2)}
[0012] The ratio of these yarns Nl and N2 may be 1:1, 2:1, 3:1, 4:1 or in different fraction. The Warp density in reed may vary from 52 End per inch to 220 Ends per inch, with pre-determined pattern of WPl and WP2. Bl is no. of Balls to be prepared in WPl and B2 is no. of Balls to be prepared in WP2. B1 and B2 may vary from 4 Balls to 24 Balls, depending on creel capacity of Ball Warping Machine. Further, in disclosed invention the preferable range of NEB 1 = NE1/B1 and NEB2 = NE2/B2.
[0013] Further, in another embodiment, WPl and WP2 ends are sized in predetermined pattern in one weaver's beam. In Drawing-in, WPl and WP2 are drawn through heald shafts in a predetermined Drawing Order. Face fabric is woven using WPl Warp Ends and Back Fabric is woven with WP2 Warp Ends. To join, both the layers, common weft is used with stitch points. Drawing Order, Design and Peg Plan is illustrated in detail in Fig. 2.
[0014] There may be various combinations of Design.WF1, WF2, WF3, ... WFn are weft yarn type. The fabric can be woven with one weft type (WF1) or can be woven with multiple weft types (WF1, WF2, WF3, ....WFn) in pre-determined weft pattern. The weft yarn may be Spun or Filament Yarn, Dyed or un-dyed, Rigid or Stretch, Core Spun Elastane or Cover Spun Elastane, Texturized, Texturized Stretch, Ring Spun, OE Spun, 100% Natural Fiber, 100% Man-made fiber or Blend of Natural and man-made fiber or any other yarn produced from different technology. The on loom weft density may vary from 40 picks per inch to 140 picks per inch. After making greige
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fabric, it is Singed, De-sized, Skewed and Sanforized. Different Finishes can be applied to the fabric to get desired performance and after wash look. The process is further explained by way of flow chart as illustrated in Fig. 1.
[0015] When a garment is stitched using this fabric and top layer of fabric is scratched with fine grinder in laundry, the actual beauty of fabric comes out. In normal fabric, when warp is scratched, only weft yarn is visible and a hole becomes visible in garment. But in this unique fabric, a fabric comes out from inside, imitating a patch look. But, it is actual a single fabric. [0016] The present invention has been described briefly with reference to some drawings and a preferred embodiment purely for the sake of understanding and not by way of any limitation and the present invention includes all legitimate developments within the scope of what has been described herein before. Since other modifications and changes varied to fit particular operating requirements and environments are apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention.
[0017] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The above are merely exemplary and illustrative of the inventive concept by, one of ordinary skill in the art in the specific embodiments described to make various modifications or additions, or a similar alternative manner, without departing from the invention. The invention, as defined in this disclosure or beyond the scope of the claims, should belong to the scope of the present invention.

I CLAIM:
1. A method of manufacturing the fabric essentially comprised of two (02) Warp yarns type namely face fabric and back fabric, referred herein as WP1 and WP2 respectively; wherein said wicking fibres or yarns and the yarns of the textile layer together form a double-weave fabric effect.
2. The method of manufacturing the fabric as claimed in claim 1, wherein No. of ends of WP1 in Warp Sheet(NE 1) and No. of ends of WP2 in Warp Sheet(NE 2) count range from 2000 Ends to 12000 Ends, depending on Warp Density, reed space of Loom and their ratio in Warp Sheet.
3. The method of manufacturing the fabric as claimed in claim 1, wherein the ratio of these yarns Nl and N2 may be 1:1,2:1,3:1,4:1 or in different fraction.
4. The method of manufacturing the fabric as claimed in claim 1, wherein the Warp density in reed may vary from 52 End per inch to 220 Ends per inch, with pre-determined pattern of WPlandWP2
5. The method of manufacturing the fabric as claimed in claim 1 wherein, no. of Balls to be prepared in WPl(Bl) and no. of Balls to be prepared in WP2(B2), may vary from 4 Balls to 24 Balls, depending on creel capacity of Ball Warping Machine.
6. The method of manufacturing the fabric as claimed in claim 1 wherein, Face fabric is woven using WP1 Warp Ends and Back Fabric is woven with WP2 Warp Ends, the fabric may be woven with one weft type (WF1) or with multiple weft types.
7. The method of manufacturing the fabric as claimed in claim 1, wherein the on loom weft density may range from 40 picks per inch to 140 picks per inch.
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8. The method of manufacturing the fabric as claimed in claim 1, wherein further processing, after making greige fabric may comprises one or more steps selected from, Singed, De-sizing, Skewing and Sanforizing.