What Exactly is Corduroy Fabric?
Corduroy is a strong and long-lasting fabric known for its distinctive ridged texture. It can be made from various materials, allowing for a range of different feels and finishes. The most recognizable feature of corduroy is its unique ribbed design, which can be woven in different widths to create a variety of styles.
Although corduroy is often made with cotton, it can also be woven using blends of cotton and polyester, or even entirely with polyester. In some cases, wool is used to make corduroy, but the ridges on wool corduroy are less pronounced than those made from other materials. Manufacturers can dye corduroy in a vast array of colors, and a specific dyeing technique can create an uneven fading effect that adds a visually appealing touch.
Technical Details of Corduroy Fabric
Corduroy fabric is made from three different yarns that are woven together. The first two yarns create either a plain or twill weave pattern. The third yarn is then inserted into this weave in the filling direction, forming "floats" that stretch across at least four of the warp yarns.
Textile manufacturers then use blades to cut the float yarns, creating the characteristic ridges of piled fabric on the surface. These ridges, known as "wales," can vary greatly in width. The "wale number" of corduroy fabric refers to how many wales are present in one inch of the fabric. Typically, standard corduroy fabric features around 11-12 wales per inch.
A lower wale number means the wales on corduroy fabric will be thicker and more pronounced. Conversely, a higher wale number results in thinner wales that are packed closer together.
The History of Corduroy Fabric
Fabric historians trace the origins of corduroy back to an ancient Egyptian fabric known as fustian, which dates back to around 200 AD. While fustian also features raised ridges similar to corduroy, it is much rougher and less tightly woven compared to the corduroy we know today.
Modern corduroy was developed by textile manufacturers in England during the 18th century. The origin of the fabric's name is still debated. One popular theory suggests that "corduroy" comes from the French phrase "corde du roi," meaning "cord of the king," implying that it was worn by French nobility. However, there is no historical evidence to support this theory.
It is more plausible that British textile manufacturers derived the name "corduroy" from "kings-cordes," a term that was used in the early 19th century. Another possibility is that the name originated from the British surname Corderoy.
Regardless of its name, corduroy gained widespread popularity across all levels of British society in the 1700s. However, by the 19th century, velvet had overtaken corduroy as the preferred fabric for the elite, leading to corduroy being referred to derisively as the “poor man’s velvet.”
Corduroy in the 20th Century
Corduroy saw a revival in popularity during World War I, briefly becoming the fabric of choice for infantry uniforms and school attire of the time. It continued to be fairly popular throughout the first half of the 20th century but fell out of fashion in the 1950s.
In the 1970s, corduroy experienced a major revival in Western culture, gaining renewed popularity thanks to bands like the Grateful Dead. Often seen as a nostalgic nod to early 20th-century working-class style or simply appreciated for its distinctive colors and textures, corduroy quickly became a defining fabric of the era.
Corduroy in Modern Times
Corduroy has experienced several cycles of popularity over the years. Although it may not be as trendy as it once was, it remains a favored fabric for its durability and versatility, especially for couches/ sofas, pants, jackets, and children's clothing. While synthetic fibers were commonly used in corduroy production throughout the 20th century, there has been a recent trend towards natural textiles. This renewed interest has led to a rise in the popularity of all-cotton and all-wool corduroy fabrics.
How is Corduroy Fabric Produced?
The process of making corduroy can differ based on the materials used. Natural fibers like cotton and wool come from plants and animals, respectively. In contrast, synthetic fibers such as polyester and rayon are manufactured in factories. Each type of material follows its own specific production process to create the distinctive corduroy fabric.
Once textile manufacturers have obtained the yarns needed, the production of corduroy fabric generally follows a standard set of steps:
1. Weaving
Corduroy fabric is primarily woven using a plain weave, where weft threads alternate over and under warp threads. Although less common, a twill weave can also be used. After completing the main weave, manufacturers introduce a "pile thread." This thread is cut to create the distinctive ridges of corduroy.
2. Gluing
Glue is applied to the back of the woven fabric to secure the pile yarns and prevent them from pulling through during the cutting process. This adhesive is later removed as part of the production process.
3. Cutting the Pile Yarn
Next, textile manufacturers use an industrial cutter to sever the pile yarn. The cut yarn is then brushed and singed to create soft, even ridges on the fabric.
4. Dyeing
Textile manufacturers often use pigment dyeing to create a unique, irregular pattern on the finished corduroy fabric. This dyeing technique enhances the pattern over time, especially with washing, highlighting one of corduroy's most attractive features.
How is Corduroy Fabric Utilized?
Historically, corduroy was used for a wide range of items, including workwear, military uniforms, hats, and upholstery. While its popularity has declined, corduroy is now primarily used for garments such as pants, jackets, and casual wear, reflecting its enduring versatility despite a narrower scope of applications.
Today, corduroy is mainly used for producing overalls (or dungarees), pants, and jackets. Although corduroy trousers may not have the same cult status they did in the 1970s, they remain a stylish and enduring choice for many.
Beyond clothing, corduroy is used by furniture and accessory makers for chair and couch coverings, as well as decorative cushions. Although corduroy was once a popular choice for automobile upholstery starting in the 1910s, it has since been replaced by more durable materials in cars. However, you might still find this distinctive ridged fabric on the couch in a friend’s home.
Where is Corduroy Fabric Made?
China is the leading global producer of textiles, including corduroy fabric. Although India is the top producer of cotton and other countries dominate the wool market, China stands out for producing the highest number of finished garments annually.
Given its leading position in the textile industry, China is probably the top producer of corduroy fabric and finished corduroy garments globally. However, Indian textile manufacturer Sintex asserts that it is Asia's largest corduroy producer. While China may produce the most corduroy overall, India could be home to the world’s largest corduroy manufacturer.
What is the Cost of Corduroy Fabric?
Corduroy typically costs more than fabrics with similar materials due to its more complex production process. However, advancements in technology have significantly reduced the time required to manufacture corduroy, making the price difference relatively small. On average, corduroy fabric is about 10-20% more expensive than plain-weave fabric made from the same fibers.
What Are the Different Types of Corduroy Fabric?
Corduroy fabric comes in several distinct subtypes, each with unique characteristics. Additionally, there is a related type of corded fabric that is not technically corduroy but worth noting:
1. Standard Corduroy
Standard corduroy fabric typically features 11 wales per inch. However, fabric with anywhere from 8 to 13 wales per inch is generally classified as standard corduroy as well.
2. Elephant Cord
Elephant cord, named for the large folds resembling an elephant’s skin, features very thick and prominent cords. This type of corduroy fabric usually has a wale number ranging from 1.5 to 6.
3. Pinwale Corduroy
In contrast to elephant cord, pinwale corduroy has many tiny ridges packed into each square inch. The finest pinwale corduroy can have up to 21 wales per inch, creating a very delicate and subtle texture.
4. Pigment-Dyed Corduroy
Pigment-dyed corduroy undergoes a special dyeing process that creates a mottled effect, which becomes more pronounced with each wash. This technique is commonly used for most types of corduroy fabric.
5. Spandex Corduroy
Spandex can be blended with cotton, polyester, or wool corduroy to create a stretchy version of the fabric. This type of corduroy is often used in children's clothing, providing additional flexibility and comfort.
6. Bedford Cord
Bedford cord is an American fabric that shares a similar weave with corduroy but differs in its pile. In Bedford cord, the pile yarns are left uncut, which results in less pronounced ridges compared to traditional corduroy.
How Does Corduroy Fabric Affect the Environment?
The environmental impact of corduroy fabric largely depends on the fibers used in its production. Synthetic fibers tend to be more harmful to the environment due to their non-biodegradable nature. However, natural fibers, while generally considered more eco-friendly, can still have negative environmental effects depending on their production methods.
The production of synthetic fibers like polyester involves industrial processes that generate substantial chemical waste. Additionally, synthetic fibers are not biodegradable and contribute to environmental pollution by releasing pollutants into water systems with every wash.
Among natural fibers used in corduroy, cotton poses the most significant environmental challenges. Cotton cultivation often involves the use of chemical pesticides and fertilizers, which can harm local ecosystems. Despite this, cotton is biodegradable and does not contribute to microfiber pollution, unlike synthetic fibers.
Wool is considered one of the most sustainable textile fibers. Unlike cotton, wool production does not rely on chemical cultivation agents. Although waste from wool-producing animals can pose challenges, wool is biodegradable and recyclable, making it a more eco-friendly choice.
Certifications for Corduroy Fabric
Corduroy fabric can qualify for various certifications based on its fiber content. Non-recycled synthetic textiles may receive International Organization for Standardization (ISO) certification. Wool corduroy products might be certified by organizations like Woolmark, while those made with American Pima cotton can obtain certification from the American Supima Association (ASA).
Conclusion
Corduroy fabric has evolved significantly since its early days, offering a blend of durability and style that remains appealing today. Its unique ribbed texture, created through a meticulous weaving and cutting process, provides both aesthetic and practical benefits. Whether made from cotton, polyester, or blends, corduroy fabric's versatility has made it a staple in fashion and furnishings.
Historically, corduroy has seen periods of decline and resurgence, reflecting broader fashion trends and societal changes. From its ancient origins to its modern iterations, corduroy's adaptability is a testament to its enduring appeal. Despite shifting trends, corduroy continues to be valued for its distinct look and comfort, making it a popular choice for everything from casual wear to home decor.
In contemporary times, corduroy remains relevant, particularly in upholstery and garments. Its various types, including pinwale and elephant cord, cater to different preferences and needs, offering options for both subtle and bold statements. As we continue to seek both style and functionality, corduroy fabric stands out for its blend of tradition and innovation.
For those looking to add a touch of classic style to their home, consider exploring the offerings at Corduroy Depot. As your #1 source for corduroy couches and sofas, Corduroy Depot combines style and affordability, ensuring you find the perfect couch without compromise. Embrace the blend of elegance and comfort with Corduroy Depot and transform your living space today!