Corduroy Weaving Process

Network Yarn and Twist

During air-jet loom production, the warp-directed DTY network yarn requires an additional 300 twists/m on the twisting machine to ensure that the weft-directed DTY network yarn or the network structure of DTY and spandex is fully optimized (i.e., weft elasticity is improved).

Warping Process
In the warping stage, we use a sliver warping method and particularly emphasize the importance of a one-time collective bobbin change operation.

Weaving Process Details
Given the high weft density and high weft resistance of corduroy, to ensure clear fabric texture, a smooth fabric surface, and reduce warp yarn breakage during weaving, we adopted a process route of high tension, low back beam, late shedding, and early weft insertion.

Pile Cutting and Raising (Naping) Process
Due to the high strength of polyester-nylon composite yarn, we used a double-cutting technique combined with mechanical napping during the pile cutting process to ensure that the petal-shaped composite yarn can be completely split.

Dyeing and Finishing
Disperse dyes are typically used when dyeing polyester-nylon composite yarn. However, due to the high proportion of nylon in the petal-shaped composite microfiber, using disperse dyes alone leads to uneven dyeing depth of the polyester/nylon component, which is difficult to control and thus affects colorfastness. To improve colorfastness, post-dyeing treatment is necessary. We adopted a specific treatment method: treatment at 80-100℃ using an anionic/nonionic high-temperature leveling agent and a chelating dispersant for 20 minutes, followed by thorough rinsing. This method effectively improves colorfastness.