Integrally-woven cold-spot-free convection-proof down jacket fabric and preparation method thereof

Abstract

The invention discloses an integrally woven cold-spot-free anti-convection down jacket fabric and a preparation method, the fabric comprises five layers of symmetrical tissues, namely a surface layer, a first inner layer, a middle layer, a second inner layer and an inner layer; the surface layer adopts a windproof high-density plain weave, and the inner layer adopts a down-proof high-density plain weave; the material of the middle layer penetrates through the five layers of tissues, and a plurality of strip-shaped down filling cavities are respectively formed in the first inner layer and the second inner layer through interval weaving. The method for preparing the integrally woven cold-spot-free convection-proof down jacket fabric is simple and convenient, and the obtained fabric integrates the layering functions that the surface layer is windproof, the first inner layer and the second inner layer are downproof, and the middle layer is highly fluffy.

Description

Technical Field

[0001] This invention relates to the field of functional textile fabric technology, and in particular to an integrally woven, cold-spot-free, anti-convection down jacket fabric and its preparation method. Background Technology

[0002] Traditional down jackets use a double-layer fabric stitched together for down filling. This classic structure has three major drawbacks in practical use: (1) The seam creates a non-down area, resulting in uneven warmth and the needle holes are prone to letting down through; (2) The distribution of down depends on the sewn baffles and is limited by the size of the down bale. The amount of still air is low, and the warmth retention effect is limited. (3) Fabric pores can easily cause air convection and heat loss, reducing the heat retention effect.

[0003] Existing improved processes, such as coating finishing, can enhance down-proofness, but they sacrifice breathability and softness. Summary of the Invention

[0004] Objective: In order to overcome the shortcomings of the existing technology, the present invention provides an integrated woven down jacket fabric with no cold spots and a method for preparing it, which eliminates down leakage and thermal bridging effects caused by sewing needle holes, blocks the air convection channels in the down cavity, and realizes the integrated layered functions of windproof surface layer, down leakage prevention inner layer, and high loft middle layer.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0006] In a first aspect, the present invention provides an integrally woven down jacket fabric with no cold spots and anti-convection, the fabric comprising a symmetrical five-layer structure, namely a face layer, a first inner layer, a middle layer, a second inner layer, and an inner layer; the face layer adopts a windproof high-density plain weave, and the inner layer adopts an anti-down-leakage high-density plain weave; the material of the middle layer runs through the five layers, and through interval weaving, multiple continuous strip-shaped down-filling cavities are formed at the first inner layer and the second inner layer respectively.

[0007] The middle layer material runs through five layers of fabric, forming multiple continuous strip-shaped down filling cavities between the two inner layers. This eliminates the need for separate quilting to separate the down filling cavities, thus preventing down leakage and thermal bridging caused by sewing needle holes and achieving uniform warmth of the entire fabric. The strip-shaped down filling cavities are integrally molded, blocking the air convection channels inside the down cavity.

[0008] In some embodiments, the surface material is made of 20D fine denier polyester filament with a warp density of 580-620 threads / 10cm and a weft density of 550-580 threads / 10cm.

[0009] In some embodiments, the width of a single cavity of the strip-shaped down filling cavity is 5-15 cm, and the distance between the cavity walls is 0.3-0.5 cm.

[0010] In some embodiments, the first inner layer and the second inner layer are made of 2 / 2 twill weave.

[0011] In some embodiments, the intermediate layer material is a blend of 0.8-1.2D ultrafine denier nylon and polyester yarn; and adopts a 2 / 1 twill weave.

[0012] In some embodiments, the inner layer material is made of 20D fine denier polyester filament with a warp density of 580-620 threads / 10cm and a weft density of 550-580 threads / 10cm.

[0013] In a second aspect, the present invention provides a method for preparing a one-piece woven, cold-spot-free, anti-convection down jacket fabric as described in the first aspect, comprising: On a double shed loom, a layered weft insertion process is used to simultaneously weave the warp and weft systems, with a pre-reserved filling opening; Down is injected into the filling port through the down injection tube integrated into the loom; After filling with down and sealing the opening, overlock the excess fabric.

[0014] In some embodiments, the warp system includes inner warp yarns, middle warp yarns, and surface warp yarns, and the weft system includes inner weft yarns, middle weft yarns, and surface weft yarns; the middle warp yarns run through the five layers of fabric in a 2 / 1 twill pattern.

[0015] In some embodiments, the strip-shaped down-filling cavity formed by the outer layer and the first inner layer and the strip-shaped down-filling cavity formed by the second inner layer and the inner layer are stably superimposed based on the knot weaving of the intermediate layer warp yarns; Alternatively, the strip-shaped filling cavity formed by the first inner layer and the middle layer and the strip-shaped filling cavity formed by the second inner layer and the middle layer are stably superimposed based on the knot weaving of the warp yarns of the middle layer.

[0016] In some embodiments, the method further includes treating the intermediate layer with SiO2 sol, wherein the SiO2 sol has the following formulation: molar ratio of EtOH:TEOS = 14-16, molar ratio of H2O:TEOS = 7-9, and pH = 1.4-1.6.

[0017] SiO2 sol is embedded in the fiber gaps rather than forming a film on the surface, maintaining the fabric's flexibility and bending stiffness ≤3.5mN·cm.

[0018] This invention employs an integrated design for weaving down jacket fabric, which, compared to traditional stitching weaving, offers the following advantages and benefits: (1) Multiple strip-shaped down-filled cavities are formed at the first inner layer and the second inner layer, which divide the airflow, block the air convection channels in the cavity, and improve the heat preservation performance; (2) The intermediate layer fabric was treated with SiO2 sol to block the micropores with a pore size ≤40 μm in the fabric and reduce air convection; (3) The fabric is woven as a whole, eliminating pinholes; the blended yarn of ultra-fine denier nylon and polyester is used as the middle layer and is treated with SiO2 sol, which doubles the barrier to prevent down from coming out of the fabric gaps and reduces the down leakage rate. (4) The strip-shaped down filling cavity optimizes the down distribution, and the down loft is ≥850 cm. 3 / g, the clo value of the fabric increased by 0.4-1.5 clo; (5) The areal density of the fabric is ≤180 g / m³ 2 It reduces weight by 25% compared to traditional down fabrics, achieving both warmth and lightweight design. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this disclosure or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this disclosure. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the structure of a five-layer fabric for an integrated, cold-point-free, anti-convection down jacket, as described in an embodiment of the present invention. In the figure, A is a schematic diagram of the structure in which the strip-shaped down filling cavity formed by the outer layer and the first inner layer is woven in an alternating manner with the strip-shaped down filling cavity formed by the second inner layer and the inner layer. In the figure, B is a schematic diagram of the structure in which the strip-shaped down filling cavity formed by the first inner layer and the middle layer is woven in an alternating manner with the strip-shaped down filling cavity formed by the second inner layer and the middle layer.

[0021] Figure 2 This is a cross-sectional schematic diagram of the five-layer structure of the integrated woven down jacket fabric with no cold spots and anti-convection in an embodiment of the present invention; Figure A is a cross-sectional schematic diagram of the strip-shaped down filling cavity formed by the outer layer and the first inner layer and the strip-shaped down filling cavity formed by the second inner layer and the inner layer being woven in an integrated manner; Figure B is a cross-sectional schematic diagram of the strip-shaped down filling cavity formed by the first inner layer and the middle layer and the strip-shaped down filling cavity formed by the second inner layer and the middle layer being woven in an integrated manner.

[0022] Figure 3 This is a schematic diagram of the integrated weaving process for a down jacket fabric with no cold spots and anti-convection properties, as described in an embodiment of the present invention.

[0023] In the diagram: 1. Top layer, 2. First inner layer, 21. First strip-shaped filling cavity, 3. Middle layer, 4. Second inner layer, 41. Second strip-shaped filling cavity, 5. Inner layer. Detailed Implementation

[0024] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use.

[0025] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may include different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0026] Example 1:

[0027] This embodiment provides a one-piece woven down jacket fabric with no cold spots and anti-convection. The fabric includes a symmetrical five-layer structure, namely, a face layer 1, a first inner layer 2, a middle layer 3, a second inner layer 4, and an inner layer 5. The face layer 1 adopts a windproof high-density plain weave, and the inner layer 5 adopts a down-proof high-density plain weave.

[0028] like Figure 1 China A and Figure 2 As shown in Figure A, the material of the intermediate layer 3 penetrates through five layers of fabric. Multiple continuous first strip-shaped filling cavities 21 are formed at the first inner layer 2 through the intermittent weaving of the outer layer 1, the first inner layer 2, the second inner layer 4, and the inner layer 5. Multiple continuous second strip-shaped filling cavities 41 are formed at the second inner layer 4. The first strip-shaped filling cavities 21 and the second strip-shaped filling cavities 41 form a stable superposition state based on the knot weaving of the intermediate layer warp yarns.

[0029] The surface layer 1 is made of 20D fine denier polyester filament with a warp density of 600 threads / 10cm and a weft density of 550 threads / 10cm.

[0030] The width of the first strip-shaped filling cavity 21 and the second strip-shaped filling cavity 41 is 12 cm, and the distance between the cavity walls is 0.5 cm.

[0031] The first inner layer 2 and the second inner layer 4 are made of 2 / 2 twill weave.

[0032] The middle layer 3 is made of a blend of 0.8D ultrafine denier nylon and polyester yarn; it adopts a 2 / 1 twill weave.

[0033] The inner layer 5 is made of 20D fine denier polyester filament with a warp density of 590 threads / 10cm and a weft density of 580 threads / 10cm.

[0034] Example 2:

[0035] This embodiment provides a one-piece woven down jacket fabric with no cold spots and anti-convection. The fabric includes a symmetrical five-layer structure, namely, a face layer 1, a first inner layer 2, a middle layer 3, a second inner layer 4, and an inner layer 5. The face layer 1 adopts a windproof high-density plain weave, and the inner layer 5 adopts a down-proof high-density plain weave.

[0036] like Figure 1 China B and Figure 2 As shown in Figure B, the material of the intermediate layer 3 penetrates through five layers of fabric. Through the first inner layer 2 and the intermediate layer 3, and the intermediate layer 3 and the second inner layer 4, multiple continuous first strip-shaped filling cavities 21 are formed at the first inner layer 2, and multiple continuous second strip-shaped filling cavities 41 are formed at the second inner layer 4. The first strip-shaped filling cavities 21 and the second strip-shaped filling cavities 41 form a stable superposition state based on the knotted weaving of the intermediate layer warp yarns.

[0037] The surface layer 1 is made of 20D fine denier polyester filament with a warp density of 580 threads / 10cm and a weft density of 560 threads / 10cm.

[0038] The width of a single cavity of the first strip-shaped filling cavity 21 and the second strip-shaped filling cavity 41 is 7 cm, and the distance between the cavity walls is 0.4 cm.

[0039] The first inner layer 2 and the second inner layer 4 are made of 2 / 2 twill weave.

[0040] The middle layer 3 is made of a blend of 0.9D ultrafine denier nylon and polyester yarn; it adopts a 2 / 1 twill weave.

[0041] The inner layer 5 is made of 20D fine denier polyester filament, with a warp density of 600 threads / 10cm and a weft density of 570 threads / 10cm.

[0042] The performance of this one-piece woven down jacket fabric with no cold spots and anti-convection was tested and compared with that of traditional sewn fabric. The results are shown in Table 1.

[0043] Table 1 Performance test results of one-piece woven cold-spot-free anti-convection down jacket fabric and traditional stitched fabric

[0044] As shown in Table 1, the one-piece woven down jacket fabric with no cold spots and anti-convection provided in this embodiment has a clo value that is 26.7%-44.8% higher than that of traditional sewn fabrics, a down leakage rate that is reduced by more than 50%, a decrease in air permeability, and an improvement in warmth retention.

[0045] Example 3:

[0046] This embodiment provides a method for preparing a one-piece woven, cold-spot-free, anti-convection down jacket fabric, such as... Figure 3 As shown, the method includes: The intermediate layer 3 is subjected to SiO2 sol treatment. The SiO2 sol has the following formulation: molar ratio of EtOH:TEOS = 14-16, molar ratio of H2O:TEOS = 7-9, and pH = 1.4-1.6. On a double-shed loom, a layered weft insertion process is used to simultaneously weave the warp and weft systems, with a pre-reserved filling opening; Down is injected into the filling port through the down injection tube integrated into the loom; After filling with down and sealing the opening, overlock the excess fabric.

[0047] The warp system includes inner warp yarns, middle warp yarns, and surface warp yarns, and the weft system includes inner weft yarns, middle weft yarns, and surface weft yarns; the middle warp yarns run through the five layers of fabric in a 2 / 1 twill pattern.

[0048] In the description of this application, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only used to explain the relative positional relationship and movement between components in a specific orientation. If the specific orientation changes, the directional indication will also change accordingly. These terms are used only for the convenience of describing this application and for simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0049] Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0050] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art will understand the specific meaning of the above terms in this application based on the specific circumstances.

[0051] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A one-piece woven down jacket fabric with no cold spots and anti-convection properties, characterized in that, The fabric comprises a symmetrical five-layer structure, consisting of a face layer, a first inner layer, a middle layer, a second inner layer, and an inner layer. The face layer is made of a windproof high-density plain weave, and the inner layer is made of a down-proof high-density plain weave. The middle layer material runs through all five layers and is woven at intervals to form multiple continuous strip-shaped down-filling cavities in the first and second inner layers.

2. The one-piece woven down jacket fabric with no cold spots and anti-convection properties according to claim 1, characterized in that, The surface material is made of 20D fine denier polyester filament with a warp density of 580-620 threads / 10cm and a weft density of 550-580 threads / 10cm.

3. The one-piece woven down jacket fabric with no cold spots and anti-convection as described in claim 1, characterized in that, The width of a single cavity in the strip-shaped filling cavity is 5-15 cm, and the distance between the cavity walls is 0.3-0.5 cm.

4. The one-piece woven down jacket fabric with no cold spots and anti-convection properties according to claim 1, characterized in that, The first inner layer and the second inner layer are made of 2 / 2 twill weave.

5. The one-piece woven down jacket fabric with no cold spots and anti-convection properties according to claim 1, characterized in that, The intermediate layer material is a blend of 0.8-1.2D ultrafine denier nylon and polyester yarn; it adopts a 2 / 1 twill weave.

6. The one-piece woven down jacket fabric with no cold spots and anti-convection as described in claim 1, characterized in that, The inner layer material is made of 20D fine denier polyester filament with a warp density of 580-620 threads / 10cm and a weft density of 550-580 threads / 10cm.

7. The method for preparing the one-piece woven, cold-spot-free, anti-convection down jacket fabric as described in any one of claims 1-6, characterized in that, include: On a double-shed loom, a layered weft insertion process is used to simultaneously weave the warp and weft systems, with a pre-reserved filling opening; Down is injected into the filling port through the down injection tube integrated into the loom; After filling with down and sealing the opening, overlock the excess fabric.

8. The method for preparing the one-piece woven, cold-spot-free, anti-convection down jacket fabric according to claim 7, characterized in that, The warp system includes inner warp yarns, middle warp yarns, and surface warp yarns, and the weft system includes inner weft yarns, middle weft yarns, and surface weft yarns; the middle warp yarns run through the five layers of fabric in a 2 / 1 twill pattern.

9. The method for preparing the one-piece woven, cold-spot-free, anti-convection down jacket fabric according to claim 7, characterized in that, The strip-shaped down-filling cavity formed by the outer layer and the first inner layer, and the strip-shaped down-filling cavity formed by the second inner layer and the inner layer, form a stable superposition state based on the knot weaving of the warp yarns in the middle layer; Alternatively, the strip-shaped filling cavity formed by the first inner layer and the middle layer and the strip-shaped filling cavity formed by the second inner layer and the middle layer are stably superimposed based on the knot weaving of the warp yarns of the middle layer.

10. The method for preparing the one-piece woven, cold-spot-free, anti-convection down jacket fabric according to claim 7, characterized in that, The method further includes treating the intermediate layer with SiO2 sol, wherein the SiO2 sol has the following formulation: molar ratio of EtOH:TEOS = 14-16, molar ratio of H2O:TEOS = 7-9, and pH = 1.4-1.6.

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