Cotton denim fabric with a low twist and method of making thereof
A cotton denim fabrics and method of making denim fabrics that are soft, smooth, bright and include a low twist multiple, a sizing at the surface of the yarn with a viscosity such that the sizing remains substantially at the surface of the yarn, and a dyed cored wherein an indigo dye penetrates deeply into the core.
1. A low twist, combed, indigo yarn wherein the yarn is a two-ply yarn, comprising:
a first yarn and a second yarn,
wherein:
the first yarn comprises a first yarn count of 7.5/1 Ne; and
the second yarn comprises a second yarn count of 10/1 Ne: and
the first yarn and second yarn comprising:
a twist multiple between 2.0 and 3.4, inclusive;
a sizing at the surface of the yarn; and
a dyed core wherein an indigo dye penetrates deeply into the core,
wherein the sizing remains substantially at the surface of the yarn.
2. A method of producing a low twist, combed indigo yarn, the method comprising:
providing combed cotton fibers
spinning the cotton fibers to produce yarns having a twist multiple between 2.0 and 3.4, inclusive;
dying the yarns, wherein an indigo dye penetrates deeply into the core to produce a dyed core;
sizing the yarns using a sizing with a viscosity of sizing chemicals that is such as to keep the sizing substantially at the surface of the yarn; and
squeezing the yarns after sizing at a pressure between 15 KN and 21 KN, inclusive to keep the sizing chemicals at the surface of the yarn.
3. The method according to claim 2 , wherein
the spinning comprises producing a yarn with a yarn count of 20/1 Ne.
4. The method according to claim 2 , wherein
the spinning comprises producing a yarn with a yarn count of 14/1 Ne.
5. A method of producing a denim fabric from a low twist, combed, indigo yarn, the method comprising:
weaving a denim 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, and
wherein an angle between the front roller and the back roller is between 1.8 and 2.8 degrees, inclusive,
wherein the yarn comprises:
a twist multiple between 2.0 and 3.4, inclusive;
a sizing at the surface of the yarn; and
a dyed core wherein an indigo dye penetrates deeply into the core,
wherein the sizing remains substantially at the surface of the yarn.
6. The method according to claim 5 , wherein the angle between the front roller and the back roller is approximately 2 degrees.
7. A denim fabric comprising a low twist, combed, indigo yarn, said denim comprising:
yarn having a twist multiple between 2.0 and 3.4, inclusive;
a sizing at the surface of the yarn, and
dyed yarn having a dyed yarn core wherein an indigo dye penetrates into the yarn core;
and wherein the sizing is kept substantially at the surface of the yarn.
8. The denim fabric comprising a low twist, combed, indigo yarn according to claim 7 , wherein
the yarn comprises a yarn count of 20/1 Ne.
9. The denim fabric comprising a low twist, combed, indigo yarn according to claim 7 , wherein
the yarn comprises a yarn count of 14/1 Ne.
10. The denim fabric comprising a low twist, combed, indigo yarn according to claim 7 , wherein the yarn is a two-ply yarn, comprising:
a first yarn and a second yarn,
wherein:
the first yarn comprises a first yarn count of 7.5/1 Ne; and
the second yarn comprises a second yarn count of 10/1 N.