Method of manufacturing fraying-free cotton elastane weft knit fabric
This invention is related to a method of manufacturing a cotton weft knit fabric that is resistant to fraying, curling, and laddering. The unique fabrication method described herein generates a cotton fabric that resists edge fraying and curling when cut. As a result of the unique manufacturing method described herein, the typical garment hemming process typically used to prevent hemming and fraying in weft knit fabric is not required.
1. A method of generating a fray-resistant and curl-resistant weft knit cotton-based blended fabric comprising:
a. providing a very fine cotton yarn with a count between 80 ne and 100 ne and a twist factor between 3.5 and 4.0;
b. providing a secondary fiber yarn with a linear mass density between 17 and 22 decitex;
c. interlock knitting said very fine cotton yarn and said secondary fiber yarn to create a blended fabric such that said very fine cotton yarn makes up between 85% and 90% by weight of said fabric and said secondary fiber yarn makes up between 10% and 15% by weight of said blended fabric; and
d. pre-setting said blended fabric at a temperature between 180° C. and 205° C.
2. The method of claim 1 wherein said very fine cotton yarn has a count of 80 ne.
3. The method of claim 2 wherein said secondary fiber yarn comprises elastane yarn.
4. The method of claim 3 wherein said elastane yarn has a linear mass density of 22 decitex.
5. The method of claim 4 wherein said very fine cotton yarn makes up 88% of said blended fabric and said secondary fiber yarn makes up 12% of said blended fabric.
6. The method of claim 5 wherein said pre-setting occurs at a temperature of 200° C.
7. The method of claim 6 wherein the curing hold time of said pre-setting is between 15 and 25 seconds.
8. The method of claim 7 wherein said blended fabric is additionally dyed and washed.
9. The method of claim 1 wherein said blended fabric has a knitting stitch length of 2.55 millimeters.
10. The method of claim 1 wherein the tension of said very fine cotton yarn is between 2 and 3 g.
11. The method of claim 1 wherein the tension of said secondary fiber is between 5 and 6 g.
12. The method of claim 1 wherein the weight of said blended fabric is between 175 and 185 grams per square meter.
13. The method of claim 1 wherein the width of said blended fabric is between 105 and 115 cm.
14. The method of claim 1 wherein said blended fabric has between 55 and 60 wales per inch.
15. The method of claim 1 wherein said blended fabric is steamed and compacted before being pre-set.
16. The method of claim 1 wherein said blended fabric is not stretched before presetting.
17. The method of claim 8 wherein said blended fabric width is 127 cm.
18. The method of claim 8 wherein said blended fabric width is 122 cm.
19. The method of claim 8 wherein said blended fabric width is 117 cm.
20. A method of generating a fray-resistant and curl-resistant weft knit cotton-based blended fabric comprising:
a. providing a very fine cotton yarn with a count between 60 ne and 100 ne and a twist factor between 3.2 and 4.0;
b. providing a secondary fiber yarn with a linear mass density between 17 and 44 decitex;
c. interlock knitting said very fine cotton yarn and said secondary fiber yarn to create a blended fabric such that said very fine cotton yarn makes up between 70% and 90% by weight of said fabric and said secondary fiber yarn makes up 10% and 30% by weight of said blended fabric; and
d. pre-setting said blended fabric at a temperature between 180° C. and 205° C.