A down fabric and its manufacturing process

Abstract

This invention provides a multi-layered down fabric and its manufacturing process. The down fabric includes, from top to bottom, an outer fabric layer, a middle layer, and a lining layer. The middle layer includes a first inner lining layer, a second inner lining layer, and down filling material and a down-proof structure disposed between the first and second inner lining layers. The space between the first and second inner lining layers is divided into multiple independent down-filling zones by the down-proof structure. Each down-filling zone is filled with the down filling material. The outer fabric layer, middle fabric layer, and lining layer are sewn together by a first type of stitching around the perimeter of the down fabric. This down fabric improves upon or even eliminates the problem of down leakage through pinholes, provides better insulation, has a longer service life, is more comfortable for consumers to wear / use, and is easier to wash. The manufacturing process is simple, highly automated, and has excellent production efficiency.

Description

Technical Field

[0001] This invention relates to the field of clothing fabric technology, and in particular to a down fabric that prevents down leakage and its manufacturing process. Background Technology

[0002] With the arrival of winter, people purchase warm clothing to protect themselves from the wind and frost. In recent years, down products have become particularly popular in both the south and the north. Down products refer to comprehensive and practical products made with duck and goose feathers and down as filling material, down fabric as the filling structure, and then sewn together. Down fabric, as an important component of down products, plays a key role in the overall quality stability of down products. As a commonly used fabric in home textiles and clothing, such as down jackets and down comforters, down fabric has excellent warmth retention, loft, and elasticity. It also has advantages such as being lightweight, having good temperature and humidity regulation properties, being healthy, having good moisture absorption, and being durable, making it popular among various consumer groups.

[0003] Traditional down fabrics typically consist of two layers of fabric stacked together, with down filling the space between the outer and inner layers and then sewn together. Especially after prolonged wear and washing, down feathers are prone to escaping, a phenomenon undesirable to consumers. Furthermore, traditional fabrics offer relatively low protection; damage to the outer layer affects the down fabric's insulation and lifespan. To address these issues, the applicant conducted further research, leading to this case. Summary of the Invention

[0004] To overcome the shortcomings of existing down fabrics, such as severe down leakage and short lifespan, this invention aims to propose a down fabric that is simple to weave, has good down-proof effect, and is aesthetically pleasing, as well as its manufacturing process.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] The down fabric of the present invention adopts a multi-layer structure design, including a fabric layer, a middle layer and a lining layer arranged sequentially from top to bottom. The middle layer includes a first inner lining layer, a second inner lining layer and down filling material and a down-proof structure disposed between the first and second inner lining layers. The space between the first and second inner lining layers is divided into multiple independent down-filling areas by the down-proof structure. Each down-filling area is filled with the down filling material. The fabric layer, the middle layer and the lining layer are fixed together by sewing together with a first type of stitch around the perimeter of the down fabric.

[0007] Furthermore, the anti-down leakage structure is a strip-shaped anti-down leakage cotton strip disposed between the first and second inner lining layers. The anti-down leakage cotton strip is fixed to the first inner lining layer and the second inner lining layer of the intermediate layer, thereby dividing multiple independent down filling areas in the space between the first and second inner lining layers by the anti-down leakage cotton strip.

[0008] Furthermore, the two ends of the anti-down-leakage cotton strip are sewn to the first inner lining layer by a second type of stitching. The central areas of the fabric layer, the first inner lining layer, the second inner lining layer, and the lining layer are sewn to the third type of stitching. The side of the first inner lining layer with the anti-down-leakage cotton strip is attached to the second inner lining layer. The distribution position, distribution interval, and direction of the third type of stitching correspond one-to-one with the anti-down-leakage cotton strip.

[0009] Furthermore, the anti-down-leakage cotton strip is sewn to the second inner lining layer by a second type of stitching, and the central area of ​​the first inner lining layer, the second inner lining layer, and the lining layer is sewn to the third type of stitching. The side of the second inner lining layer with the anti-down-leakage cotton strip is attached to the first inner lining layer. The distribution interval and direction of the third type of stitching correspond one-to-one with the distribution interval and direction of the anti-down-leakage cotton strip.

[0010] Furthermore, the anti-down-leakage cotton strip includes multiple parallel diagonally arranged anti-down-leakage cotton strips and multiple parallelly arranged laterally arranged anti-down-leakage cotton strips. The diagonally arranged anti-down-leakage cotton strips and the laterally arranged anti-down-leakage cotton strips are intersected, thereby forming multiple independent diamond-shaped down-filling areas between the first and second inner lining layers.

[0011] Furthermore, the anti-down-leakage cotton strip is an anti-down-leakage cotton strip with a width between 1.0cm and 1.2cm, and the weight of the anti-down-leakage cotton strip per square meter is 20g. The upper and lower surfaces of the anti-down-leakage cotton strip are respectively provided with hot melt adhesive layers; preferably, the outer surfaces of the first, second and third type of sewing lines are coated with hot melt adhesive layers.

[0012] Furthermore, the third type of stitching includes multiple parallel diagonal stitching lines and multiple parallel lateral stitching lines, which intersect and together with the first type of stitching lines, form multiple interlaced diamond patterns on the inner surface of the down fabric.

[0013] Furthermore, the first type of stitching is 0.5cm away from the outer edge of the down fabric; the multiple diagonal stitchings are arranged in parallel at equal intervals, and the minimum interval between two adjacent diagonal stitchings is 3cm; correspondingly, the multiple diagonal stitchings are arranged in parallel at equal intervals, and the minimum interval between two adjacent diagonal stitchings is 3cm.

[0014] Furthermore, the anti-down-leakage cotton strip also includes sealing cotton strips disposed around the perimeter of the intermediate layer, the distance of the sealing cotton strips to the edge of the intermediate layer being the same as the distance from the stitches formed by the first type of stitching on the first and second inner lining layers to the edge of the first and second inner lining layers.

[0015] Furthermore, the edges of the down fabric are provided with overlock or rolled edges.

[0016] On the other hand, the present invention also provides a manufacturing process for down fabric, which includes the following steps:

[0017] 1) Cut the fabric for making the outer fabric layer, the first inner lining layer, the second inner lining layer and the lining layer, wherein the outer fabric layer, the first inner lining layer, the second inner lining layer and the lining layer are the same in shape and size;

[0018] 2) Create an intermediate layer with a fixed anti-down leakage structure;

[0019] 3) The intermediate layer is sewn to the outer fabric layer and the inner fabric layer, and multiple down filling channels are formed in the intermediate layer;

[0020] 4) Fill the down filling channels sequentially with down filling material;

[0021] 5) Seal the filling channel.

[0022] Furthermore, the anti-down leakage structure is a strip-shaped anti-down leakage cotton strip fixed between the first and second inner lining layers, and step 2) further includes the following steps:

[0023] 21) Select one of the first and second inner lining layers as the base layer for the down-proof cotton strip;

[0024] 22) Sew down-proof cotton strips on the selected base layer. The down-proof cotton strips include multiple parallel diagonal down-proof cotton strips and multiple parallel collateral down-proof cotton strips, which are arranged in a cross pattern.

[0025] Furthermore, in step 12), the two ends or the entire anti-down-leakage cotton strip is sewn onto the base layer via a second type of sewing thread.

[0026] Furthermore, step 3) further includes:

[0027] 31) The fabric layer, the first inner lining layer, the second inner lining layer and the lining layer are stacked in order from top to bottom, and the anti-down-leakage cotton strip is placed between the first inner lining layer and the second inner lining layer.

[0028] 32) The fabric layer, the middle layer and the lining layer are sewn together by the diagonal stitch in the third type of stitch, and multiple down filling channels are formed in the middle layer. The sewing position of the diagonal stitch overlaps with the setting position of the diagonal anti-down filling strip in the anti-down filling strip.

[0029] 33) Partial stitching is performed around the fabric layer, intermediate layer and lining layer by means of a first type of stitch, each down filling channel having at least one opening, and the stitching position of the first type of stitch is spaced apart from the selvage of the down fabric.

[0030] Furthermore, step 2) further includes: step 23) setting sealing strips around the first inner lining layer or the second inner lining layer; step 33) is replaced by: 33') along the setting position of the sealing strips, partially sewing around the fabric layer, middle layer and lining layer by means of a first type of stitching, leaving at least one opening for each down filling channel, and the sewing position of the first type of stitching is spaced apart from the selvage of the down fabric.

[0031] Furthermore, step 5) further includes:

[0032] 51) Seal each down filling channel by means of the first type of stitching, wherein the spacing between the first type of stitching and the selvage of the fabric is the same as the spacing between the first type of stitching and the selvage of the fabric in step 33).

[0033] 52) Continue sewing between the fabric layer, the middle layer and the lining layer by means of the downward stitch in the third type of stitch, the sewing position of the downward stitch overlaps with the setting position of the downward anti-down-leakage cotton strip in the anti-down-leakage cotton strip.

[0034] Further, step 32) is replaced by: 32') sewing the intermediate layer and the lining layer together by means of the slanted stitch in the third type of stitch, and forming multiple down filling channels in the intermediate layer, wherein the sewing position of the slanted stitch overlaps with the setting position of the slanted down-proof strip in the down-proof strip; step 52) is replaced by: 52') continuing to sew between the intermediate layer and the lining layer by means of the folded stitch in the third type of stitch, wherein the sewing position of the folded stitch overlaps with the setting position of the folded down-proof strip in the down-proof strip.

[0035] Furthermore, the manufacturing process also includes: drawing corresponding reference lines on the base layer of the anti-down-leakage cotton strip and on the fabric layer or the lining layer, respectively, and the setting direction of the anti-down-leakage cotton strip and the sewing direction of the third type of stitch are the same as the reference lines.

[0036] Furthermore, step 31) also includes fixing the overlapping fabric layer, the first inner lining layer, the second inner lining layer, and the lining layer.

[0037] Furthermore, the manufacturing process also includes: step 6) overlocking or rolling the edges around the down fabric and step 7) hot pressing the down fabric.

[0038] Compared with existing technologies, the down fabric and its manufacturing process of the present invention incorporate anti-down-leakage strips at the needle holes of the stitches, improving or even eliminating the problem of down leakage through needle holes, resulting in better insulation, longer service life, greater comfort for consumers during wear / use, and easier washing. Simultaneously, the down fabric of the present invention features structural improvements to the anti-down-leakage strips and / or the stitching. A hot-melt adhesive layer is coated on the surface of the anti-down-leakage strips in contact with the first and second inner lining layers and / or the surface of the stitching. Correspondingly, a hot-pressing process is added to the manufacturing process of the down fabric, filling the needle holes with hot-melt adhesive. This gives the down fabric of the present invention excellent anti-down-leakage performance, while also offering advantages such as simple weaving and aesthetically pleasing down products. The manufacturing process is simple, highly automated, and efficient. Attached Figure Description

[0039] The above and other objects, features, and advantages of the invention will be apparent from the following description of preferred embodiments illustrating the gist of the invention and its use, and the accompanying drawings, in which:

[0040] Figure 1 A schematic diagram of the down fabric described in this invention is shown;

[0041] Figure 2A Shown Figure 1 A schematic diagram of the layer structure of the fleece fabric shown.

[0042] Figure 2B A schematic diagram of the first inner lining layer with anti-down leakage cotton strips fixed is shown;

[0043] Figure 3 Another schematic diagram of the down fabric described in this invention is shown;

[0044] Figure 4A Shown Figure 3 A schematic diagram of the layer structure of the down fabric shown.

[0045] Figure 4B A schematic diagram of the second inner lining layer with anti-down leakage cotton strips is shown;

[0046] Figure 4C Another schematic diagram shows the second inner lining layer with anti-down-leakage cotton strips fixed in place;

[0047] Figures 5A-5H A schematic flowchart of the down fabric manufacturing process described in this invention is shown.

[0048] Figures 6A-6B This diagram illustrates another process flow of the down fabric manufacturing technique described in this invention.

[0049] [Explanation of Key Component Symbols]

[0050] Fabric layer 1

[0051] First inner liner layer 21 Second inner liner layer 22

[0052] Down filling 23

[0053] Down-proof cotton strips 24

[0054] Flip towards anti-down-leakage cotton strip 241 Press towards anti-down-leakage cotton strip 242

[0055] Horizontal anti-down leakage cotton strip 243, sealing cotton strip 244

[0056] Down filling channel 25

[0057] Down filling area 26, diamond-shaped down filling area 26'

[0058] Lining layer 3

[0059] Category 1 Line 41

[0060] Second-class vehicle line 42

[0061] Third-class vehicle line 43

[0062] 431 (left-hand stroke) 432 (right-hand stroke)

[0063] Edge copying structure 6 Detailed Implementation

[0064] The technical solutions of the down fabric and its manufacturing process described 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 a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0065] In the description of this invention, it should be understood that the terms "center," "lateral," "longitudinal," "front," "rear," "left," "right," "upper," "lower," "vertical," "horizontal," "top," "bottom," "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 for the convenience of describing this invention and simplifying the description, and do not 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 limiting the scope of protection of this invention.

[0066] like Figure 1 , 2A As shown in Figure 2B, a preferred embodiment of the down fabric of the present invention is illustrated. The down fabric has a multi-layer structure, comprising, from top to bottom, an outer fabric layer 1, an inner layer, and a lining layer 3. The inner layer includes a first inner lining layer 21, a second inner lining layer 22, and down filling material 23 and down-proof cotton strips 24 disposed between the first inner lining layer 21 and the second inner lining layer 22. The space between the first and second inner lining layers 21 and 22 is divided into multiple independent down-filling areas 26 by the down-proof cotton strips 24. Each down-filling area 26 is filled with the down filling material 23. The outer fabric layer 1, the first inner lining layer 21, the second inner lining layer 22, and the lining layer 3 have the same shape and size. When the above-mentioned fabric layers are laid in sequence, the edges of each fabric layer are also aligned with each other. The outer fabric layer 1, the inner layer, and the lining layer 3 are sewn together at their edges by a first type of stitching 41.

[0067] like Figure 1 , 2A As shown in Figure 2B, in the intermediate layer, the anti-down-leakage cotton strips 24 are arranged parallel to each other in the horizontal direction. The upper and lower surfaces of each anti-down-leakage cotton strip 24 are respectively attached and fixed to the inner side of the first inner lining layer 21 and the second inner lining layer 22, thereby dividing multiple independent down-filling areas 26 extending in the horizontal direction in the space between the first and second inner lining layers 21 and 22 by the anti-down-leakage cotton strips 24.

[0068] In such Figure 1 , 2AIn a preferred embodiment of the present invention shown in Figure 2B, the entire anti-down-dive cotton strip 24 is sewn and fixed to the first inner lining layer 21 by a second type of stitching 42. Furthermore, the central areas of the fabric layer 1, the first inner lining layer 21, the second inner lining layer 22, and the lining layer 3 are then sewn and fixed by multiple third type of stitching 43. The side of the first inner lining layer 21 where the anti-down-dive cotton strip 24 is fixed is attached to the second inner lining layer 22. The distribution position, distribution interval, and direction of the third type of stitching 43 correspond one-to-one with the anti-down-dive cotton strip 24. That is to say, the multiple third type of stitching 43 are also arranged parallel in the horizontal direction, and each third type of stitching 43 should pass through the corresponding anti-down-dive cotton strip 24 when sewing.

[0069] Figure 3 , 4A 4B illustrates another preferred embodiment of the down fabric of the present invention. In this preferred embodiment, the down fabric is the front panel of a down jacket. The front panel of the down jacket has a multi-layer structure, which includes, from top to bottom, an outer fabric layer 1, an intermediate layer, and a lining layer 3. The intermediate layer includes a first inner lining layer 21, a second inner lining layer 22, and down filling material 23 and down-proof cotton strips 24 disposed between the first inner lining layer 21 and the second inner lining layer 22. The down-proof cotton strips 24 include multiple parallel diagonally arranged diagonally arranged down-proof cotton strips 241 and multiple parallelly arranged collaterally arranged down-proof cotton strips 242. The diagonally arranged down-proof cotton strips 241 and collaterally arranged down-proof cotton strips 242 are intersected and respectively attached and fixed to the inner side of the first inner lining layer 21 and the second inner lining layer 22, thereby forming multiple independent rhomboid down filling areas 26' between the first and second inner lining layers 21 and 22. Each of the diamond-shaped down filling areas 26' is filled with the down filling material 23. The fabric layer 1, the first inner lining layer 21, the second inner lining layer 22 and the lining layer 3 are all the same in shape and size. When the above-mentioned fabric layers are laid in sequence, the edges of each fabric layer are also aligned with each other. The fabric layer 1, the middle layer and the lining layer 3 are sewn together at their edges by a first type of stitching 41.

[0070] In a preferred embodiment of the present invention, such as Figure 4B As shown, the entire anti-down-leakage cotton strip 24 is sewn and fixed to the second inner lining layer 22 via the second type of stitching 42.

[0071] Preferably, to avoid forming too many pinholes in the first inner liner layer 21 and / or the second inner liner layer 22, increasing the possibility of down leakage, such as Figure 4CAs shown, in this preferred embodiment, each of the anti-down-diving cotton strips 24, whether it is the anti-down-diving cotton strip 241 facing outward or the anti-down-diving cotton strip 242 facing inward, has only two ends that are sewn and fixed to the second inner lining layer 22 via the second type of stitching 42, while the other parts besides the two ends are only in contact with the second inner lining layer 22, but are not sewn and fixed via the second type of stitching 42.

[0072] Furthermore, such as Figure 4C As shown, to facilitate the smooth completion of the subsequent down filling process, the flared down-proof cotton strip 241 and the folded down-proof cotton strip 242 are arranged in a woven cross pattern (in other words, at some intersections, the flared down-proof cotton strip 241 is positioned below the folded down-proof cotton strip 242, while at other intersections, the flared down-proof cotton strip 241 is positioned above the folded down-proof cotton strip 242); at the same time, the intersections of the flared down-proof cotton strip 241 and the folded down-proof cotton strip 242 are sewn and fixed to the second inner lining layer 22 by a second type of stitching 42 to facilitate the smooth completion of the subsequent down filling process.

[0073] In such Figure 3 , 4A In the preferred embodiment of the down fabric shown in Figure 4B, the central areas of the fabric layer 1, the first inner lining layer 21, the second inner lining layer 22, and the lining layer 3 are sewn and fixed by a third type of stitching 43. The side of the second inner lining layer 22 where the anti-down-draining cotton strip 24 is fixed is attached to the first inner lining layer 21. The third type of stitching 43 includes multiple parallel and equally arranged diagonal stitching 431 and multiple parallel and equally arranged lateral stitching 432, which together with the first type of stitching 41 form multiple interlaced diamond patterns on the inner surface of the down fabric. The diagonal stitching 431 and the lateral stitching 432 are arranged intersectingly. The starting position, distribution interval, and direction of the diagonal stitching 431 and the lateral stitching 432 correspond one-to-one with the diagonal anti-down-draining cotton strip 241 and the lateral anti-down-draining cotton strip 242, respectively. That is to say, each of the third type of stitching 43 should pass through the corresponding anti-down-draining cotton strip 24 when sewing. The third type of stitching 43, together with the first type of stitching 41, forms a plurality of interlaced diamond-shaped grids 5 on the inner and outer surfaces of the down fabric.

[0074] In an alternative embodiment of the above-described embodiment, the third type of stitching 43 only sews and fixes the central area of ​​the first inner lining layer 21, the second inner lining layer 22, and the lining layer 3, without sewing and fixing the fabric layer 1 together. The down fabric with this structure will not form multiple interlaced diamond patterns on its outer surface, nor will the third type of stitching 43 be exposed on it, thus providing more convenience for the selection of the pattern of the fabric layer 1.

[0075] Preferably, the width of the anti-down-leakage cotton strip 24 is between 1.0cm and 1.2cm, and the weight of the anti-down-leakage cotton strip 24 per square meter is 20g.

[0076] The down fabric of this invention is made by sewing the various fabric layers together with stitching. During the sewing process, several needle holes will inevitably be formed on each fabric layer. Although the middle layer of the fabric layer is provided with anti-down leakage cotton strips 24, in order to better prevent down leakage, the upper and lower surfaces of the anti-down leakage cotton strips 24 of the down fabric of this invention are further coated with hot melt adhesive layers. After the down fabric is made, the corresponding sewing fixing points are hot-pressed to melt the hot melt adhesive layer and seal the sewing needle holes. While ensuring the anti-down leakage performance, the windproof and cold-resistant performance of the down fabric is also improved.

[0077] The hot melt adhesive layer can be one of ethylene-vinyl acetate (EVA) hot melt adhesive, polyamide hot melt adhesive, low-melting-point PE fiber, PU adhesive, or release paper.

[0078] Alternatively, the hot melt adhesive layer may be a plurality of hot melt adhesive particles disposed on the upper and lower surfaces of the anti-down-leakage cotton strip 24.

[0079] In addition to further coating the upper and lower surfaces of the down-proof cotton strip 24 with a hot melt adhesive layer, using specially made sewing thread can also achieve the effect of sealing the needle holes. In this embodiment, the first type of thread, the second type of thread, and the third type of thread all have a core-sheath structure, with the core filament made of carbon fiber filaments and the core filament covered with a hot melt adhesive layer as the sheath. The hot melt layer is a low-melting-point PE fiber layer wrapped around the core filaments. After the down fabric is made, the corresponding sewing paths or the entire down fabric is hot-pressed to melt the hot melt adhesive layer, sealing the needle holes. This ensures the down-proof performance while also improving the windproof and cold-resistant performance of the down fabric.

[0080] In a specific embodiment of the down fabric of the present invention, the distance of the first type of stitch 41 from the outer edge of the down fabric and the minimum interval between two adjacent diagonal stitches 431 or diagonal stitches 432 can be adjusted according to the actual use of the down fabric.

[0081] Preferably, the down fabric is used to make down garments, the distance between the first type of stitch 41 and the outer edge of the down fabric is 0.5cm, and the minimum interval between two adjacent diagonal stitches 431 is 3cm; and the minimum interval between two adjacent lateral stitches 432 is also 3cm.

[0082] Furthermore, to prevent down leakage from the edges of the down fabric, the anti-down leakage strip also includes sealing strips around the perimeter of the intermediate layer. The distance from the sealing strips to the edge of the intermediate layer is the same as the distance from the stitches formed by the first type of stitching 41 on the first and second inner lining layers 21 and 22 to their edges. In other words, when the first type of stitching 41 sews along the edges of the down fabric, it passes through the sealing strips sandwiched in the middle of the intermediate layer.

[0083] Furthermore, the down fabric has an overlocking structure 6 at its edge.

[0084] Alternatively, the down fabric may have a rolled edge structure.

[0085] This invention also provides a manufacturing process for down fabrics, such as... Figures 5A-5H The diagram illustrates that the manufacturing process of the down fabric includes the following steps:

[0086] 1) Cut the fabrics used to make the outer fabric layer 1, the first inner lining layer 22, the second inner lining layer 22, and the lining layer 3 into the required shapes, as shown in the figure. Figures 5A-5H In the preferred embodiment shown, the fabric layer 1, the first inner lining layer 22, the second inner lining layer 22, and the lining layer 3 are cut into the shape of the front piece of a down jacket, and the fabric layer 1, the first inner lining layer 22, the second inner lining layer 22, and the lining layer 3 are of the same shape and size (e.g., Figure 5A (as shown);

[0087] 2) Create an intermediate layer with a fixed down-proof structure. The specific steps are as follows:

[0088] 21) Select the first inner lining layer 21 as the base layer for the down-proof cotton strip, and draw reference lines with consistent spacing and slope on the first inner lining layer 21 and the fabric layer 1 respectively, such as... Figure 5B As shown, the reference lines include multiple diagonal reference lines and multiple lateral reference lines;

[0089] 22) Along the flared reference line, sew the flared anti-down-seepage cotton strip 241 using the second type of stitching 42 on the selected first inner lining layer 21. Then, along the pressed reference line, sew the pressed anti-down-seepage cotton strip 242 using the second type of stitching 42 on the first inner lining layer 21. The flared anti-down-seepage cotton strip 241 and the pressed anti-down-seepage cotton strip 242 are arranged intersectingly (e.g., ...). Figure 5C , 5D (as shown);

[0090] 3) The intermediate layer is sewn to the outer fabric layer 1 and the lining layer 3, and multiple down-filling channels 25 are formed in the intermediate layer, specifically:

[0091] 31) The fabric layer 1, the first inner lining layer 21, the second inner lining layer 22, and the lining layer 3 are stacked in a top-to-bottom order, with the side of the fabric layer 1 marked with reference lines facing outwards. The anti-down-leakage cotton strips 241 and 242 are sandwiched between the first inner lining layer 21 and the second inner lining layer 22 (e.g., ...). Figure 5E (as shown);

[0092] 32) Along the reference line drawn on the fabric layer 1, the fabric layer 1, the middle layer and the lining layer 3 are sewn together by the reference line 431 in the third type of stitching, thereby forming a plurality of down filling channels 25 in the middle layer. The sewing position of the reference line 431 overlaps with the setting position of the anti-down leakage cotton strip in the anti-down leakage cotton strip 24.

[0093] 33) Partial stitching is performed around the fabric layer 1, the middle layer, and the lining layer 3 using the first type of stitching 41 to leave at least one opening for each down filling channel 25 to facilitate the down filling operation. The stitching position of the first type of stitching 41 is spaced approximately 0.5 cm from the selvage of the down fabric to prevent unraveling during sewing (e.g., Figure 5F (As shown).

[0094] 4) Fill the down filling channels 25 with down filling material in sequence;

[0095] 5) Seal the down filling channel 25, specifically...

[0096] 51) Each filling channel 25 is sealed by the first type of stitching 41, that is, the previously unsewn portions of the fabric layer 1, intermediate layer, and lining layer 3 are sewn together by the first type of stitching 41, thereby forming a closed seam around the down fabric by the first type of stitching 41. The seam is spaced about 0.5 cm from the selvage of the down fabric to prevent unraveling during sewing (e.g., Figure 5G (as shown);

[0097] 52) Following the directional reference line drawn on the fabric layer 1, the stitching between the fabric layer 1, the middle layer, and the lining layer 3 continues using the directional stitch 432 in the third type of stitching, to form multiple staggered diamond patterns on the inner and outer surfaces of the down fabric. The stitching position of the directional stitch 432 overlaps with the position of the directional anti-down-leakage strip in the anti-down-leakage strip 24 (e.g., ...). Figure 5H (As shown).

[0098] Preferably, in order to avoid forming too many pinholes on the first inner liner 21 or the second inner liner 22, which would increase the possibility of down leakage, in an alternative step of step 22), each of the down-proof cotton strips 24, whether facing down-proof cotton strip 241 or down-proof cotton strip 242, is only fixed to the second inner liner 22 by sewing two ends through the second type of stitching 42, while the other parts are only in contact with the second inner liner 22, but are not fixed by sewing through the second type of stitching 42.

[0099] Furthermore, to facilitate the smooth completion of the subsequent down filling process, the flared down-proof cotton strip 241 and the folded down-proof cotton strip 242 are arranged in a woven cross pattern (in other words, when setting the flared down-proof cotton strip 241, its position relative to the flared down-proof cotton strip 242 is not exactly the same; at some of the intersection points, the flared down-proof cotton strip 241 is located below the folded down-proof cotton strip 242, while at other intersection points, the flared down-proof cotton strip 241 is located above the folded down-proof cotton strip 242); at the same time, in step 22), the intersection points of the flared down-proof cotton strip 241 and the folded down-proof cotton strip 242 are also sewn and fixed to the second inner lining layer 22 by the second type of stitching 42.

[0100] Furthermore, as consumers' living standards continue to improve, their requirements for down products are no longer limited to warmth, breathability, and down-proofness. Consumers are placing higher demands on the design and aesthetics of related products, which has prompted manufacturers and product design teams to continuously improve upon existing technologies. Another preferred embodiment of the down fabric manufacturing process described in this invention arose from this market demand environment.

[0101] Specifically, step 32) in the manufacturing process of the down fabric described above is replaced by: 32') sewing the middle layer and the lining layer 3 together by means of the slanted stitch 431 in the third type of stitching, and forming multiple down filling channels 25 in the middle layer, wherein the sewing position of the slanted stitch 431 overlaps with the setting position of the slanted anti-down-draining cotton strip in the anti-down-draining cotton strip 24; step 51) is replaced by: 51') continuing to sew between the middle layer and the lining layer 3 by means of the folded stitch 432 in the third type of stitching, wherein the sewing position of the folded stitch 432 overlaps with the setting position of the folded anti-down-draining cotton strip in the anti-down-draining cotton strip 24.

[0102] The down fabric produced by the above-described preferred embodiment has a central area of ​​fabric layer 1 that is not sewn to other layers. In this way, multiple third-type sewing lines will not appear on the outer surface of the down fabric. Designers can choose fabrics with various patterns as fabric layer 1, so that down products made from the down fabric of the present invention can have more styles and be more fashionable.

[0103] In addition, when sewing the down fabric, selecting suitable needles and thread can also prevent down leakage to some extent. In the manufacturing process of the down fabric of this invention, the inventors selected needles and thread based on the principle of fine needles and thick thread. Specifically, using fine, pointed needles reduces the contact area with each layer of fabric during sewing, resulting in smaller needle holes; thick thread is then used to plug the needle holes to prevent down feathers from leaking out. At the same time, the needle moves up and down very frequently during sewing, and overheating or damage to the needle can also lead to larger needle holes. Therefore, technicians need to constantly monitor the condition of the needles during operation and change them frequently (usually every 4 hours) to avoid enlarged needle holes caused by overheating or damage to the needles.

[0104] Specifically, in the manufacturing process of the down fabric described in this invention, a German Blue Lion model "DBx1SF" sewing machine needle with a size of "SIZE: 8" is selected for stitching. Its slender needle body extends to the upper part of the needle and does not have a thickened design, minimizing damage to the layers of fabric. The first, second, and third types of thread use polyester filament yarn with a Tex 24 count, which is uniformly smooth, improving lubrication and reducing sliding friction.

[0105] Alternatively, the needle can also be a Japanese organ needle "DBx1 KN" in size "65 / 9".

[0106] The requirements for needles are also quite high. It is recommended to use Blue Lion or Accordion brand needles. Follow three principles: fine needles, pointed tips, and frequent needle changes. The principle of fine needles and thick threads is used. The fine needle and pointed tip reduce the contact area between the needle and the fabric during sewing, resulting in a smaller needle hole. The thick thread is used to block the needle hole and prevent lint from coming out. The needle moves up and down very frequently during sewing. By changing needles frequently, the problem of needle holes becoming larger due to needle overheating and damage can be reduced.

[0107] Alternatively, the down fabric of the present invention can also be manufactured by the following steps:

[0108] 1) Cut the fabric for making the outer fabric layer 1, the first inner lining layer 22, the second inner lining layer 22 and the lining layer 3. The outer fabric layer 1, the first inner lining layer 22 and the second inner lining layer 22 and the lining layer 3 are the same in shape and size.

[0109] 2) Create an intermediate layer with a fixed down-proof structure. The specific steps are as follows:

[0110] 21”) Select the first inner lining layer 21 as the base layer of the anti-down leakage cotton strip, and draw multiple horizontal reference lines on the first inner lining layer 21 and the lining layer 3 respectively;

[0111] 22”) Along the horizontal reference line, a horizontal anti-down-leakage cotton strip 243 is sewn on the selected second inner lining layer 22 using a second type of stitching 42. The entire horizontal anti-down-leakage cotton strip 243 is fixed to the second inner lining layer 22 by sewing with the second type of stitching 42 (e.g., Figure 6A (as shown);

[0112] 23”) A sealing strip 244 with a closed path is provided around the first inner liner layer 21. The sealing strip is fixed by sewing with second type of stitching 42. The second type of stitching 42 is spaced 0.5 cm away from the edge of the first inner liner layer 21 (e.g., Figure 6B (As shown)

[0113] 3) The intermediate layer is sewn to the outer fabric layer 1 and the lining layer 3, and multiple down-filling channels 25 are formed in the intermediate layer, specifically:

[0114] 31”) The fabric layer 1, the first inner lining layer 21, the second inner lining layer 22 and the lining layer 3 are stacked in order from top to bottom. The stacked fabric layer 1, the first inner lining layer 21, the second inner lining layer 22 and the lining layer 3 are fixed. The side of the lining layer 3 with the reference line is facing outward. The horizontal anti-down-leakage cotton strip 242 and the sealing anti-down-leakage cotton strip 243 are sandwiched between the first inner lining layer 21 and the second inner lining layer 22.

[0115] 32”) Along the horizontal reference line drawn on the lining layer 3, the middle layer and the lining layer 3 are sewn together by the third type of stitching, thereby forming multiple horizontal down filling channels in the middle layer. The sewing position of the horizontal stitching overlaps with the setting position of the horizontal down-proof strip 243. That is to say, each of the third type of stitching 43 should pass through the corresponding horizontal down-proof strip 243 when sewing.

[0116] 33”) Along the setting position of the sealing cotton strip, partial sewing is carried out around the fabric layer 1, the middle layer and the lining layer 3 by means of the first type of stitch 41, so as to leave at least one opening for each down filling channel 25 to facilitate down filling operation. The sewing position of the first type of stitch 41 is about 0.5cm away from the edge of the down fabric to prevent the thread from coming loose during sewing. The first type of stitch 41 should pass through the corresponding sealing anti-down cotton strip when sewing.

[0117] 4) Fill the down filling channels 25 with down filling material in sequence;

[0118] 5”) Each down filling channel 25 is sealed by the first type of stitching 41, that is, the parts that were not previously sewn are sewn around the fabric layer 1, the middle layer and the lining layer 3 by the first type of stitching 41, thereby forming a closed stitch line sewn by the first type of stitching 41 around the down fabric. The stitch line has a gap of about 0.5cm between it and the selvage of the down fabric to prevent the thread from coming loose during sewing.

[0119] 6) Overlock or roll the edges around the down fabric;

[0120] 7) Apply heat to the down fabric.

[0121] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them; although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications can still be made to the specific implementation of the present invention or equivalent substitutions can be made to some technical features without departing from the spirit of the technical solutions of the present invention, and all such modifications and substitutions should be covered within the scope of the technical solutions claimed in the present invention.

Claims

1. A down fabric, characterized in that, The down fabric adopts a multi-layer structure design, including a fabric layer (1), a middle layer, and a lining layer (3) arranged sequentially from top to bottom. The middle layer includes a first inner lining layer (21), a second inner lining layer (22), down filling material (23) disposed between the first and second inner lining layers (21, 22), and multiple strip-shaped anti-down-leakage cotton strips (24). The upper and lower surfaces of the anti-down-leakage cotton strips (24) are respectively provided with hot melt adhesive layers. The space between the first and second inner lining layers (21, 22) is divided into multiple independent down-filling areas (26) by the multiple strip-shaped anti-down-leakage cotton strips (24). Each down-filling area (26) is filled with the down filling material. The fabric layer (1), middle layer, and lining layer (3) are arranged sequentially from top to bottom. The interlayer and lining layer (3) are sewn together by a first type of sewing thread (41) that is sewn around the perimeter of the down fabric. Both ends of all the down-proof cotton strips (24) are sewn to the same inner lining layer by a second type of sewing thread (42). In the central area of ​​the down fabric, a third type of sewing thread (43) is used to sew along each down-proof cotton strip, thereby sewing together the first inner lining layer (21), the down-proof cotton strips (24), the second inner lining layer (22), and the lining layer (3). The upper and lower surfaces of the down-proof cotton strips (24) are respectively bonded to the inner surfaces of the first inner lining layer (21) and the second inner lining layer (22) by a hot pressing process.

2. The down fabric as described in claim 1, characterized in that, The hot melt adhesive layer is one of ethylene-vinyl acetate hot melt adhesive, polyamide hot melt adhesive, low-melting-point PE fiber, PU adhesive, or release paper; the first type of thread, the second type of thread, and the third type of thread are all core-sheath structures, with the core filament made of carbon fiber filaments and the core filament covered with a hot melt adhesive layer as a sheath layer, which is a low-melting-point PE fiber layer.

3. The down fabric as described in claim 1 or 2, characterized in that, The entire anti-down-drilling cotton strip (24) and the second inner lining layer (22) are sewn together by a second type of stitch (42). The anti-down-drilling cotton strip (24) is an anti-down-drilling cotton strip (24) with a width between 1.0cm and 1.2cm. The weight of the anti-down-drilling cotton strip (24) per square meter is 20g.

4. The down fabric as described in claim 1 or 2, characterized in that, The anti-down-diving cotton strip (24) includes multiple parallel anti-down-diving cotton strips (241) arranged in a slanted direction and multiple parallel anti-down-diving cotton strips (242) arranged in a woven cross arrangement, thereby forming multiple independent rhomboid down-filling areas (26') between the first and second inner lining layers (21, 22).

5. The down fabric as described in claim 4, characterized in that, Both ends of all the anti-down-drilling cotton strips are sewn to the same inner lining layer by the second type of stitching (42), and at each intersection of the flared anti-down-drilling cotton strip (241) and the folded anti-down-drilling cotton strip (242), the flared anti-down-drilling cotton strip (241) and the folded anti-down-drilling cotton strip (242) are sewn to the same inner lining layer by the second type of stitching (42).

6. The down fabric as described in claim 4, characterized in that, The third type of stitching (43) includes multiple parallel diagonal stitching (431) and multiple parallel lateral stitching (432). The diagonal stitching (431) and lateral stitching (432) are intersected and together with the first type of stitching (41), they form multiple interlaced diamond patterns on the inner surface of the down fabric.

7. The down fabric as described in claim 6, characterized in that, The first type of stitch (41) is 0.5cm away from the outer edge of the down fabric; the multiple diagonal stitches (431) are arranged in parallel at equal intervals, and the minimum interval between two adjacent diagonal stitches (431) is 3cm; correspondingly, the multiple parallel stitches (432) are arranged in parallel at equal intervals, and the minimum interval between two adjacent parallel stitches (432) is 3cm.

8. The down fabric as described in claim 1, characterized in that, The anti-down-diving cotton strip also includes a sealing cotton strip disposed around the middle layer. The distance from the sealing cotton strip to the edge of the middle layer is the same as the distance from the stitches formed by the first type of stitch (41) on the first and second inner lining layers (21, 22) to the edges of the first and second inner lining layers (21, 22).

9. The down fabric as described in claim 1, characterized in that, The down fabric has an overlock or rolled edge structure.

10. A manufacturing process for producing the down fabric as described in any one of claims 1-9, characterized in that, Includes the following steps: 1) Cut the fabric for making the fabric layer (1), the first inner lining layer (21), the second inner lining layer (22) and the lining layer (3), wherein the fabric layer (1), the first inner lining layer (21), the second inner lining layer (22) and the lining layer (3) are the same in shape and size; 2) Make an intermediate layer with the anti-down-drilling cotton strip fixed in place. Select one of the first and second inner lining layers (21, 22) as the base layer of the anti-down-drilling cotton strip. Use the second type of sewing thread (42) to sew the two ends of the anti-down-drilling cotton strip (24) to the selected base layer. 3) In the central area of ​​the down fabric, a third type of sewing thread (43) is used to sew along each of the down-proof cotton strips to fix the first inner lining layer (21), the down-proof cotton strips (24), the second inner lining layer (22), and the lining layer (3) to form a plurality of down-filling channels (25) in the middle layer. A first type of sewing thread (41) is used to partially sew around the fabric layer (1), the middle layer, and the lining layer (3). Each down-filling channel (25) has at least one opening. The sewing position of the first type of sewing thread (41) is spaced from the selvage of the down fabric. 4) Fill the down filling channel (25) with down filling material in sequence; 5) Seal the filling channel (25); 6) Overlock or roll the edges around the down fabric; and 7) The down fabric is hot-pressed.

11. The manufacturing process of down fabric as described in claim 10, characterized in that, The anti-down-diving cotton strip (24) includes multiple parallel diagonal anti-down-diving cotton strips and multiple parallel collateral anti-down-diving cotton strips. The diagonal and collateral anti-down-diving cotton strips are arranged in a woven pattern. At the intersection of the diagonal and collateral anti-down-diving cotton strips (241) and the collateral anti-down-diving cotton strips (242), the corresponding diagonal and collateral anti-down-diving cotton strips (241) are sewn onto the base layer of the anti-down-diving cotton strip using a second type of stitching (42).

12. The manufacturing process of down fabric as described in claim 11, characterized in that, Step 3) further includes: 31) The fabric layer (1), the first inner lining layer (21), the second inner lining layer (22) and the lining layer (3) are stacked in order from top to bottom, and the anti-down-diving cotton strips in the flared direction and the anti-down-diving cotton strips in the downward direction are woven and cross-laid between the first inner lining layer (21) and the second inner lining layer (22). 32) Using the slanted stitch (431) of the third type of stitching thread, the first inner lining layer (21), the slanted anti-down-draining cotton strip (241), the second inner lining layer (22) and the lining layer (3) are stitched together to form a plurality of down-filling channels (25) in the middle layer. 33) Partial stitching is performed around the fabric layer (1), the middle layer and the lining layer (3) by means of a first type of stitch (41), each down filling channel (25) having at least one opening, and the stitching position of the first type of stitch (41) is spaced from the selvage of the down fabric. Step 5) further includes: 51) Each filling channel (25) is sealed by the first type of stitch (41), the spacing between the first type of stitch (41) and the selvage of the fabric is the same as the spacing between the first type of stitch (41) and the selvage of the fabric in step 33). 52) Using the lateral stitch (432) of the third type of stitching, sew along each of the lateral down-proof strips (242) to secure the first inner lining layer (21), the lateral down-proof strips (242), the second inner lining layer (22), and the lining layer (3) to divide each of the down-filling channels (25) into multiple independent diamond-shaped down-filling areas (26).

13. The manufacturing process of down fabric as described in claim 12, characterized in that, Step 2) further includes: setting a sealing cotton strip around the first inner lining layer (21) or the second inner lining layer (22); Step 33) is replaced by: 33') along the setting position of the sealing cotton strip, by means of a first type of stitching (41) partially sewing around the fabric layer (1), the middle layer and the lining layer (3), leaving at least one opening for each down filling channel (25), and the sewing position of the first type of stitching (41) is spaced from the selvage of the down fabric.

14. The manufacturing process of down fabric as described in claim 12, characterized in that, Step 32) is replaced by: 32') using the slanted stitch (431) of the third type of stitching to sew along each of the slanted anti-down-draining cotton strips (241) to sew together the fabric layer (1), the first inner lining layer (21), the slanted anti-down-draining cotton strips (241), the second inner lining layer (22) and the lining layer (3) to form a plurality of down-filling channels (25) in the intermediate layer; Step 52) is replaced by: 52') using the folded stitch (432) of the third type of stitching to sew along each of the folded anti-down-draining cotton strips (242) to sew together the fabric layer (1), the first inner lining layer (21), the folded anti-down-draining cotton strips (242), the second inner lining layer (22) and the lining layer (3) to sew together each of the down-filling channels (25) to divide each of the down-filling channels (25) into a plurality of independent diamond-shaped down-filling areas (26').

15. The manufacturing process of down fabric as described in claim 10, characterized in that, The manufacturing process also includes: drawing corresponding reference lines on the base layer of the anti-down-diving cotton strip and on the fabric layer (1) or the lining layer (3), and the setting direction of the anti-down-diving cotton strip (24) and the sewing direction of the third type of stitch are the same as the reference lines.

16. The manufacturing process of down fabric as described in claim 12, characterized in that, Step 31) further includes fixing the overlapping fabric layer (1), the first inner lining layer (21), the second inner lining layer (22) and the lining layer (3).

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