A method for manufacturing down jacket fabric

Abstract

This invention discloses a method for manufacturing down jacket fabric, comprising the following steps: First, using a winding device to wind multiple winding segments onto a core thread, with the ends of adjacent winding segments forming a groove between the core thread and the core thread; Second, using a winding device to wind an outer layer onto the multiple winding segments and the core thread, the outer layer forming a smooth section after being wound onto the winding segments, and a recessed section after being wound onto the groove; the winding device forms a first weft yarn, a first warp yarn, a second weft yarn, or a second warp yarn after winding the winding segments and the outer layer onto the core thread; Third, using a weaving device to interweave the first weft yarn and the first warp yarn to form an upper layer fabric, and interweaving the second weft yarn and the second warp yarn to form a lower layer fabric; Fourth, layering the upper and lower layers together. This invention offers good breathability, excellent down-proof performance, and is lightweight.

Description

[0001] This invention patent application is a divisional application of Chinese Patent Application No. 202111151077.5. The original application had the application number 202111151077.5 and the application date was September 29, 2021. The invention title is "A Breathable and Lightweight Down Jacket Fabric and Its Manufacturing Process". Technical Field

[0002] This invention relates to the field of fabric technology, and in particular to a method for manufacturing down jacket fabric. Background Technology

[0003] Fabrics are commonly used to make clothing. Based on their structure, characteristics, and intended use, fabrics can be categorized into various types, each with its own unique features. Down jacket fabrics typically require good wind and water repellency. Simultaneously, they must also possess a certain degree of breathability. Poor breathability prevents moisture from dissipating during wear, leading to dampness and discomfort. Furthermore, the fabric is difficult to dry after washing, causing the down to deteriorate to varying degrees under damp conditions, resulting in unpleasant odors and negatively impacting the wearer's comfort.

[0004] Traditional down jacket fabrics typically consist of an upper and lower layer, which are sewn together by multiple seams to create several independent compartments, each filled with down. However, traditional down jacket fabrics are not very breathable, and because the upper and lower layers are sewn together, down can sometimes escape through the seams, resulting in inadequate down-proof performance. Summary of the Invention

[0005] The present invention aims to at least partially solve one of the technical problems in the aforementioned technologies. Therefore, the object of the present invention is to provide a method for manufacturing down jacket fabric that has good breathability, good down-proof effect, and is lightweight.

[0006] To achieve the above objectives, this invention provides a method for manufacturing down jacket fabric, comprising the following steps;

[0007] First, multiple winding segments are wound onto the core wire using a winding device, and a groove is formed between the close ends of two adjacent winding segments and the core wire.

[0008] Second, a winding device is used to wind the outer wire onto multiple winding segments and the core wire. After the outer wire is wound onto the winding segments, it forms a smooth section. After the outer wire is wound onto the groove, it forms a concave section. After the winding device winds the winding segments and the outer wire onto the core wire, it forms the first weft yarn, the first warp yarn, the second weft yarn, or the second warp yarn.

[0009] Third, the first weft yarn and the first warp yarn are interwoven using textile equipment to form the upper fabric, and the second weft yarn and the second warp yarn are interwoven to form the lower fabric.

[0010] Fourth, the upper and lower fabrics are layered together, and the connecting thread is passed through the first and second ventilation holes under the action of the yarn lifting device to form multiple cavities for holding down.

[0011] The diameter of the core wire is four to seven times the diameter of the winding segment; the diameter of the core wire is three to six times the diameter of the outer sheath; after the outer sheath is wound around the winding segment and the groove, the length of the smooth section is six to eight times the length of the concave section.

[0012] According to an embodiment of the present invention, a method for manufacturing down jacket fabric involves interlacing a first weft yarn with a first warp yarn to form multiple first breathable perforations, and interlacing a second weft yarn with a second warp yarn to form multiple second breathable perforations. Connecting threads then pass through the first and second breathable perforations, thereby connecting the upper and lower layers of fabric together. Adjacent connecting threads, the upper and lower layers of fabric together form a receiving cavity that can accommodate down. Because the connecting threads pass through the first and second breathable perforations, the upper and lower layers of fabric do not need to be sewn together after fabrication, eliminating seams and preventing down from escaping through them. The small apertures of the first and second breathable perforations prevent down from escaping. The first and second breathable perforations reduce the overall weight, resulting in a lighter overall mass, while also facilitating ventilation. Therefore, the present invention offers good breathability, excellent down-proof performance, and a lightweight design.

[0013] In addition, the method for manufacturing down jacket fabric according to the above embodiments of the present invention may also have the following additional technical features:

[0014] Furthermore, the core wire is made of polyurethane fiber, while the winding segment and outer sheath are made of cotton fiber.

[0015] Furthermore, the winding direction of the outer wire is opposite to the winding direction of the winding segment. Attached Figure Description

[0016] Figure 1 A schematic diagram of the structure of a breathable and lightweight down jacket fabric according to an embodiment of the present invention;

[0017] Figure 2 A cross-sectional view of a breathable and lightweight down jacket fabric according to an embodiment of the present invention;

[0018] Figure 3 This is a schematic diagram showing the connection between the core wire and the winding segment according to an embodiment of the present invention;

[0019] Figure 4 This is a schematic diagram showing the connection between the wound wire segment and the outer wire according to an embodiment of the present invention;

[0020] Figure 5 This is a schematic diagram of the structure of an upper layer fabric according to an embodiment of the present invention;

[0021] Figure 6 This is a schematic diagram of the structure of another upper layer fabric according to an embodiment of the present invention;

[0022] Figure 7 This is a schematic diagram of the structure of a lower layer fabric according to an embodiment of the present invention;

[0023] Figure 8 This is a schematic diagram of the structure of another lower layer fabric according to an embodiment of the present invention.

[0024] Label Explanation

[0025] Upper fabric 1 First warp 11

[0026] First weft yarn 12 First breathable perforation 13

[0027] Lower layer fabric 2, Second warp 21

[0028] Second weft yarn 22 Second breathable perforation 23

[0029] Connecting line 3 Receiving cavity 4

[0030] Core wire 5, winding segment 51

[0031] Outer band 52, gentle section 521

[0032] Recessed section 522, groove 53. Detailed Implementation

[0033] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0034] like Figures 1 to 8 As shown, an embodiment of the present invention provides a breathable and lightweight down jacket fabric, including an upper fabric 1, a lower fabric 2, and connecting lines 3; the upper fabric 1 includes multiple first warp yarns 11 and multiple first weft yarns 12 interwoven with the multiple first warp yarns 11, and the multiple first weft yarns 12 interwoven with the multiple first warp yarns 11 form multiple first breathable perforations 13.

[0035] The lower fabric 2 includes multiple second warp yarns 21 and multiple second weft yarns 22 interwoven with the multiple second warp yarns 21. After the multiple second weft yarns 22 interweave with the multiple second warp yarns 21, multiple second breathable perforations 23 are formed.

[0036] The connecting line 3 passes through the first breathable perforation 13 and the second breathable perforation 23 to connect the upper fabric 1 and the lower fabric 2 together. Multiple connecting lines 3 are provided. After multiple connecting lines 3 pass through the upper fabric 1 and the lower fabric 2, adjacent connecting lines 3, the upper fabric 1 and the lower fabric 2 together form a receiving cavity 4 for receiving down.

[0037] During the fabric manufacturing process, the first weft yarn 12 and the first warp yarn 11 interweave to form multiple first ventilation holes 13, and the second weft yarn 22 and the second warp yarn 21 interweave to form multiple second ventilation holes 23. Then, connecting lines 3 pass through the first and second ventilation holes 13 and 23, thereby connecting the upper fabric 1 and the lower fabric 2 together. Adjacent connecting lines 3, the upper fabric 1, and the lower fabric 2 together form a receiving cavity 4, which can accommodate down. Because the connecting lines 3 pass through the first and second ventilation holes 13 and 23, the upper fabric 1 and lower fabric 2 do not need to be sewn together after fabrication, eliminating seams and preventing down from leaking out. The apertures of the first and second ventilation holes 13 and 23 are very small, preventing down from escaping through them. The first breathable perforation 13 and the second breathable perforation 23 reduce the overall weight, making the overall mass lighter. At the same time, the first breathable perforation 13 and the second breathable perforation 23 facilitate ventilation. Therefore, the present invention has good breathability, good downproof effect, and light weight.

[0038] like Figure 5 As shown, as an example, the first warp yarn 11 includes a core yarn 5, a winding segment 51, and an outer wrapping yarn 52. The winding segment 51 is configured as multiple strands, and each winding segment 51 is wound around the core yarn 5. The ends of two adjacent winding segments 51 that are close to each other form a groove 53 between them and the core yarn 5. The outer wrapping yarn 52 is wound around the winding segment 51 and the groove 53. After the outer wrapping yarn 52 is wound around the winding segment 51, it forms a smooth section 521. After the outer wrapping yarn 52 is wound around the groove 53, it forms a recessed section 522. After multiple first warp yarns 11 are interwoven with multiple first weft yarns 12, the outer sides of two adjacent first weft yarns 12 and the recessed sections 522 of two adjacent first warp yarns 11 form the first breathable perforation 13.

[0039] Multiple winding segments 51 can be wound onto the core wire 5 using a winding device, such that the ends of two adjacent winding segments 51 that are close to each other form a groove 53 between the core wire 5. Then, an outer sheath wire 52 is wound onto the winding segments 51 and the groove 53 using the winding device. The winding device is prior art and will not be described in detail here.

[0040] In other words, in the upper fabric 1, a special first warp yarn 11 is interwoven with a regular first weft yarn 12 to form an upper fabric 1 with a first breathable perforation 13. The first breathable perforation 13 of the upper fabric 1 is roughly elongated and can be passed through by the connecting line 3. The elongated shape of the first breathable perforation 13 makes the friction between the connecting line 3 and the first breathable perforation 13 greater after the connecting line 3 passes through, making it less likely for the connecting line 3 to shift, thereby improving the strength of the fabric. The cross-section of the connecting line 3 can be rectangular to facilitate passing through the first breathable perforation 13.

[0041] like Figure 6 As shown, as another example, both the first warp yarn 11 and the first weft yarn 12 include a core yarn 5, a winding segment 51, and an outer wrapping yarn 52. The winding segment 51 is configured as multiple strands, and each winding segment 51 is wound around the core yarn 5. The ends of two adjacent winding segments 51 that are close to each other form a groove 53 between them and the core yarn 5. The outer wrapping yarn 52 is wound around the winding segment 51 and the groove 53. After the outer wrapping yarn 52 is wound around the winding segment 51, it forms a smooth section 521. After the outer wrapping yarn 52 is wound around the groove 53, it forms a recessed section 522. After multiple first warp yarns 11 and multiple first weft yarns 12 interweave, the recessed sections of two adjacent first weft yarns 12 and the recessed sections of two adjacent first warp yarns 11 form the first breathable perforation 13.

[0042] In other words, in the upper fabric 1, special first warp yarns 11 are interwoven to form an upper fabric 1 with a first breathable perforation 13. The first breathable perforation 13 of the upper fabric 1 is approximately square, allowing the connecting thread 3 to pass through. The square first breathable perforation 13 has a large aperture, facilitating the passage of the connecting thread 3, whose cross-section can be circular. The first breathable perforation 13 is formed by four recessed sections 522, consisting of recessed sections 522 of the two first weft yarns 12 and the two first warp yarns 11, resulting in a large aperture for the connecting thread 3 to pass through. It should be noted that in this example, the first breathable perforation 13 is relatively small compared to the down, and the down will not come out of the first breathable perforation 13.

[0043] like Figure 7As shown in another example, the second warp yarn 21 includes a core yarn 5, a winding segment 51, and an outer wrapping yarn 52. The winding segment 51 is configured as multiple strands, and each winding segment 51 is wound around the core yarn 5. The ends of two adjacent winding segments 51 that are close to each other form a groove 53 between them and the core yarn 5. The outer wrapping yarn 52 is wound around the winding segment 51 and the groove 53. After the outer wrapping yarn 52 is wound around the winding segment 51, it forms a smooth section 521. After the outer wrapping yarn 52 is wound around the groove 53, it forms a recessed section 522. After multiple second warp yarns 21 are interwoven with multiple second weft yarns 22, the outer sides of two adjacent second weft yarns 22 and the recessed sections 522 of two adjacent second warp yarns 21 form the second ventilation perforation 23.

[0044] In other words, in the lower layer fabric 2, a special second warp yarn 21 is interwoven with a regular second weft yarn 22 to form a lower layer fabric 2 with a second breathable perforation 23. The second breathable perforation 23 of this lower layer fabric 2 is roughly elongated and can be passed through by the connecting thread 3. The elongated shape of the second breathable perforation 23 increases the friction between the connecting thread 3 and the second breathable perforation 23 after the connecting thread 3 passes through, making it less likely for the connecting thread 3 to shift, thereby improving the strength of the fabric.

[0045] like Figure 8 As shown in another example, the second warp yarn 21 and the second weft yarn 22 both include a core yarn 5, a winding segment 51, and an outer wrapping yarn 52. The winding segment 51 is configured as multiple strands, and each winding segment 51 is wound around the core yarn 5. The ends of two adjacent winding segments 51 that are close to each other form a groove 53 between them and the core yarn 5. The outer wrapping yarn 52 is wound around the winding segment 51 and the groove 52. After the outer wrapping yarn 52 is wound around the winding segment 51, it forms a smooth section 521. After the outer wrapping yarn 52 is wound around the groove 53, it forms a recessed section 522. After multiple second warp yarns 21 and multiple second weft yarns 22 interweave, the recessed sections 522 of two adjacent second weft yarns 22 and the recessed sections 522 of two adjacent second warp yarns 21 form the second breathable perforation 23.

[0046] In other words, in the lower layer fabric 2, special second warp yarns 21 are interwoven with other special second warp yarns 21 to form a lower layer fabric 2 with second breathable perforations 23. The second breathable perforations 23 of this lower layer fabric 2 are approximately square, allowing the connecting thread 3 to pass through. The square second breathable perforation 23 has a relatively large aperture, facilitating the passage of the connecting thread 3. This second breathable perforation 23 is formed by four recessed sections 522, consisting of recessed sections 522 of the two second weft yarns 22 and the two second warp yarns 21, resulting in a relatively large aperture for the connecting thread 3 to pass through. It should be noted that in this example, the second breathable perforation 23 is relatively small compared to the down, and the down will not leak out through the second breathable perforation 23.

[0047] In this example, the first ventilation perforation 13 and the second ventilation perforation 23 are arranged side by side. A connecting line 3 can be inserted every few rows. However, the first ventilation perforation 13 and the second ventilation perforation 23 between two adjacent connecting lines 3 are not inserted by the connecting line 3. The first ventilation perforation 13 and the second ventilation perforation 23 between two adjacent connecting lines 3 are used for ventilation, which makes the down jacket have excellent overall breathability, making it easy for moisture to dissipate during wear and easy to dry after washing.

[0048] In summary, the upper fabric 1 may include, for example: Figure 5 and Figure 6 Two types, the lower layer fabric 2 may include, for example Figure 7 and Figure 8 There are two types, which allow for the combination of the upper fabric 1 and the lower fabric 2 in various ways. For example... Figure 5 The upper fabric 1 and Figure 7 The lower layer fabric 2 is connected via connecting line 3; such as Figure 5 The upper fabric 1 and Figure 8 The lower layer fabric 2 is connected via connecting line 3; such as Figure 6 The upper fabric 1 and Figure 7 The lower layer fabric 2 is connected via connecting line 3, such as Figure 6 The upper fabric 1 and Figure 8 The lower layer fabric 2 is connected via connecting line 3. Thus, there are four possible connection methods, allowing for selection of different methods to meet various needs.

[0049] In some examples, the diameter of the core wire 5 is four to seven times the diameter of the winding segment 51. For example... Figure 3 As shown, in this example, the diameter of the core wire 5 is six times the diameter of the winding segment 51. Thus, after multiple winding segments 51 are wound around the core wire 5, the depth of the groove 53 formed is relatively small compared to the diameter of the core wire 5. This makes the depth of the recessed segment 522 formed after the outer wire 52 is wound more reasonable, and the diameters of the first ventilated perforation 13 and the second ventilated perforation 23 formed are moderate.

[0050] In this example, the diameter of core wire 5 is three to six times the diameter of outer sheath wire 52. For example... Figure 4 As shown, in this example, the diameter of the core wire 5 is five times the diameter of the outer sheath wire 52. Thus, after the outer sheath wire 52 is wound around the groove 53 and the winding segment 51, the diameters of the first ventilation hole 13 and the second ventilation hole 23 formed are moderate. At the same time, this makes the strength of the formed first weft yarn 12, first warp yarn 11, second weft yarn 22 or second warp yarn 21 greater.

[0051] In this example, after the outer wire 52 is wound around the winding segment 51 and the groove 53, the length of the smooth section 521 is six to eight times the length of the recessed section 522. For example... Figure 4As shown, in this example, the length of the smooth section 521 is seven times the length of the concave section 522. This makes the smooth section 521 longer, resulting in a reasonable distribution of the first breathable perforation 13 and the second breathable perforation 23 in the upper fabric 1 or the lower fabric 2, and good overall breathability.

[0052] In this example, by setting a smooth section 521, after the first weft yarn 12 and the first warp yarn 11 interweave, and after the second weft yarn 22 and the second warp yarn 21 interweave, the smooth sections 521 in the fabric formed can abut against each other, and the loops on the outer wall of the smooth section 521 can squeeze and restrain each other, thereby increasing the friction and making the overall strength of the fabric greater.

[0053] In some examples, the core yarn 5 is made of polyurethane fiber, and the winding segment 51 and the outer sheath 52 are made of cotton fiber. The polyurethane fiber core yarn 5 provides better elasticity for the first weft yarn 12, the first warp yarn 11, the second weft yarn 22, or the second warp yarn 21, while the cotton fiber winding segment 51 and the outer sheath 52 provide better insulation for the first weft yarn 12, the first warp yarn 11, the second weft yarn 22, or the second warp yarn 21.

[0054] To enhance the strength of the first weft yarn 12, the first warp yarn 11, the second weft yarn 22, or the second warp yarn 21, the winding direction of the outer wrapping yarn 52 is opposite to that of the winding segment 51. For example, the outer wrapping yarn 52 can be wound clockwise, while the winding segment 51 can be wound counterclockwise. This winding significantly increases the strength of the formed first weft yarn 12, the first warp yarn 11, the second weft yarn 22, or the second warp yarn 21, thereby strengthening the upper fabric 1 and the lower fabric 2. Of course, in this example, the winding direction of the outer wrapping yarn 52 can also be the same as that of the winding segment 51.

[0055] In some examples, the diameter of the connecting line 3 is equal to or slightly larger than the minimum diameter of the first breathable perforation 13 and the second breathable perforation 23, so that after the connecting line 3 passes through the first breathable perforation 13 and the second breathable perforation 23, the connection between the connecting line 3 and the upper fabric 1 and the lower fabric 2 is relatively tight. The connecting line 3 is preferably a high-strength line.

[0056] The present invention also proposes a method for manufacturing down jacket fabric, comprising the following steps;

[0057] First, a winding device is used to wind multiple winding segments 51 onto the core wire 5, and a groove 53 is formed between the ends of two adjacent winding segments 51 that are close to each other and the core wire 5.

[0058] Second, a winding device is used to wind the outer wire 52 onto multiple winding segments 51 and the core wire 5. After the outer wire 52 is wound onto the winding segments 51, it forms a smooth section 521. After the outer wire 52 is wound onto the groove 53, it forms a recessed section 522. After the winding device winds the winding segments 51 and the outer wire 52 onto the core wire 5, it forms the first weft yarn 12, the first warp yarn 11, the second weft yarn 22, and the second warp yarn 21.

[0059] Third, the first weft yarn 12 and the first warp yarn 11 are interwoven using textile equipment to form the upper fabric 1, and the second weft yarn 22 and the second warp yarn 21 are interwoven to form the lower fabric 2.

[0060] Fourth, the upper fabric 1 and the lower fabric 2 are stacked together, and the connecting line 3 is passed through the first ventilation hole 13 and the second ventilation hole 23 under the action of the yarn lifting device to form multiple receiving cavities 4 for containing down.

[0061] In this example, the winding device is prior art. The winding device can fix the core wire 5 and wind the yarn around the core wire 5. For example, the winding segment 51 can be wound around the core wire 5, and the outer sheath 52 can be wound around the winding segment 51. The winding device is prior art and will not be described in detail here. The textile equipment can interweave the weft yarn and warp yarn, and the yarn lifting device can lift the yarn. The textile equipment and the yarn lifting device are prior art and will not be described in detail here.

[0062] In this example, after the connecting line 3 passes through the first ventilation perforation 13 and the second ventilation perforation 23, there is no seam, meaning that the down does not leak out through any seam. The upper fabric 1 and the lower fabric 2 are independent of each other, and the fabric of the upper fabric 1 can be different from that of the lower fabric 2. After the upper fabric 1 and the lower fabric 2 are made, the fabrics can be further processed to improve their respective properties.

[0063] The above embodiments and figures are not intended to limit the product form and style of the present invention. Any appropriate changes or modifications made by those skilled in the art should be considered as not departing from the patent scope of the present invention.

Claims

1. A method of manufacturing a down jacket fabric, characterized by: The method comprises the following steps. I. winding a plurality of winding wire segments on a core wire by using a winding device, and forming a groove between the core wire and the end portions of the adjacent two winding wire segments which are close to each other; II. winding a wrapping wire on the plurality of winding wire segments and the core wire by using the winding device, the wrapping wire forming a flat segment on the winding wire segments and a recessed segment on the groove after being wound on the winding wire segments; the winding device winding the winding wire segments and the wrapping wire on the core wire to form a first weft yarn, a first warp yarn, a second weft yarn or a second warp yarn; III. interweaving the first weft yarn and the first warp yarn by using a textile device to form an upper layer of fabric, and interweaving the second weft yarn and the second warp yarn to form a lower layer of fabric; the first weft yarn and the first warp yarn interweaving to form a plurality of first breathable perforations, and the second weft yarn and the second warp yarn interweaving to form a plurality of second breathable perforations; IV. stacking the upper layer of fabric and the lower layer of fabric together, and passing the connecting wire through the first breathable perforations and the second breathable perforations under the action of a yarn lifting device to form a plurality of accommodation cavities for accommodating down. The diameter of the core wire is four to seven times the diameter of the winding wire segment; the diameter of the core wire is three to six times the diameter of the wrapping wire; and the length of the flat segment is six to eight times the length of the recessed segment after the wrapping wire is wound on the winding wire segment and the groove.

2. The method of manufacturing a down jacket fabric according to claim 1, wherein: The core wire is made of polyurethane fiber, and the winding wire segment and the wrapping wire are made of cotton fiber.

3. The method of manufacturing a down jacket fabric according to claim 1, wherein: The wrapping direction of the wrapping wire is opposite to the winding direction of the winding wire segment.

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