A sheet-like down fabric based on tubular down yarn and its processing method

Abstract

This invention discloses a sheet-like down fabric based on tubular down yarn and its processing method. The processing method involves: densely coating the surface of the tubular down yarn to prevent damage to the down fibers during processing; secondly, shaping the tubular down yarn into a sheet-like material using weaving or non-woven methods; then, combining the processed sheet-like material as an inner layer with an upper surface material, or as a core layer with both upper and lower surface materials, followed by winding to prevent compression during the rolling process and to facilitate subsequent cutting and processing. The sheet-like down fabric obtained by this invention exhibits that the down is less prone to clumping, does not easily harden after use and washing, and has a smooth, soft surface and good warmth retention.

Description

[0001] This invention relates to a sheet-like down fabric based on tubular down yarn and its processing method, belonging to the field of textile material preparation technology. Background Technology

[0002] As a common winter insulation material, down has become an indispensable textile raw material. Traditional down fabric preparation usually involves filling double-layer garment pieces with down, patting it evenly, and then quilting it into geometric patterns; or quilting a grid pattern on double-layer garment pieces first, leaving channels for the down filling tubes, and then filling the grid one grid at a time. This preparation method is relatively slow and only suitable for customized products. In general, these traditional down preparation methods often result in problems such as down leakage and clumping in the finished product. Therefore, the preparation of down fabrics using woven, knitted, or non-woven methods has become the main research direction in the field of down fabric processing.

[0003] Xiao Houcheng proposed a method for preparing knitted down fabric, which includes a face layer, an inner lining layer, and a bottom layer. The inner lining layer is located on the lower surface of the face layer, and the bottom layer is located on the lower surface of the inner lining layer. The inner lining layer is a double-layer structure woven from jacquard double-sided fabric and fiber filaments. The inner lining layer has a mesh, and the mesh has cavities for filling down. A first breathable film layer is set between the face layer and the inner lining layer, and a second breathable film layer is set between the inner lining layer and the bottom layer. The down product prepared by this method is not easy to shift and has strong down-proof properties. However, knitted fabrics inevitably have problems such as easy shrinkage, pilling, and snagging. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a low-damage manufacturing and processing method for sheet down fabric based on tubular down yarn. This sheet down fabric is not easy to clump and clump after use and washing, and has a smooth surface, softness and good warmth retention. Its molded products can be directly applied to down pillows, down mattresses, down jackets, down quilts, down sleeping bags, thermal filling materials, etc.

[0005] To address the aforementioned problems, this invention provides a method for processing sheet-like down fabric based on tubular down yarn: first, the tubular down yarn is densely coated to prevent damage to the down fibers during processing; second, the tubular down yarn is shaped into a sheet material through weaving or non-woven methods; then, the processed sheet material is composited with the upper surface material as an inner layer or with the upper and lower surface materials as a core layer, and then wound up to prevent compression during the rolling process of the sheet-like down fabric and to facilitate cutting and processing in subsequent processes.

[0006] Preferably, the dense film coating is a sheet-like material that is coated on the surface of the tubular down yarn, and the sheet-like material is a film, fabric, nonwoven fabric, paper or leather.

[0007] Preferably, the weaving method is to form a sheet-like down fabric by using machine weaving, knitting, or braiding techniques to interweave tubular down yarns into a sheet, knit them together into a sheet, or braid them into a sheet.

[0008] More preferably, the tubular down yarns are interwoven with each other according to a set weaving pattern to form a sheet down fabric, or the tubular down yarns are interlocked with each other according to a set pattern to form a sheet down fabric, or the tubular down yarns are woven and wrapped with each other according to a set pattern to form a sheet down fabric.

[0009] Preferably, the nonwoven method involves using hot air to make the surface of the tubular down yarn sticky and self-adhesive, or using hot-rolled tubular down yarn to make the surface sticky and self-adhesive under the action of hot-pressed extrusion rollers, or spraying liquid or powder adhesive onto the surface of the tubular down yarn to bond it, or bonding the tubular down yarn onto a sheet; the sheet is a film, a thin fabric, a nonwoven fabric, paper, or leather.

[0010] More preferably, the tubular down yarns are arranged in parallel to form a sheet-like down fabric without weft, or arranged at a set angle to form a layered sheet-like down fabric, or arranged according to a set spatial morphology to form a sheet-like down fabric.

[0011] Preferably, the composite sheet material formed by combining the sheet material with the upper surface material or with both the upper and lower surface materials can have the upper or lower surface material removed or used as part of the material in subsequent processing.

[0012] Preferably, the upper or lower surface material is a sheet, which is a film, fabric, nonwoven fabric, paper, or leather.

[0013] The present invention also provides a sheet down fabric obtained by the above-mentioned processing method of sheet down fabric based on tubular down yarn, characterized in that the spatial morphology of the sheet down material is a planar morphology with uniform thickness, or a curved surface morphology with uniform thickness folded in space according to geometric patterns, or a morphology with uneven thickness in some areas but presenting a regular pattern overall.

[0014] The present invention also provides an application of the above-mentioned sheet-like down fabric in down jackets, down comforters, down sleeping bags, down scarves or down fabric fillings.

[0015] The sheet-like down fabric obtained by this invention is not prone to clumping or hardening after use and washing, and has a smooth surface, softness, and good warmth retention.

[0016] The principle of this invention is as follows:

[0017] First, the tubular down yarn is densely coated to prevent damage to the down fibers during processing. Second, it is wound into a sheet using weaving, knitting, or braiding methods, or formed into a sheet by bonding. Then, the processed sheet material is laminated as an inner layer with the upper surface material, or as a core layer with both the upper and lower surface materials, and then wound. This prevents compression during the rolling process of the sheet down fabric and facilitates cutting and processing in subsequent steps. The resulting sheet down fabric has down that does not easily clump, does not easily harden after use and washing, and has a smooth, soft surface and good warmth retention.

[0018] The key problem solved by this invention is to get rid of the phenomenon that down fibers in traditional down filling materials tend to clump together and become hard after use and washing.

[0019] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0020] (1) This invention innovatively designs a low-damage manufacturing and processing method and application of sheet down fabric based on tubular down yarn. The sheet material is used as an inner layer and combined with the upper surface material or as a core layer and combined with the upper and lower surface materials, and then rolled up. This can prevent the extrusion of the sheet down fabric during the rolling process and facilitate the cutting and processing in subsequent processes. It protects the down fibers and avoids the phenomenon of down leakage.

[0021] (2) The method for preparing sheet-like down fabric by the present invention is simple and solves the common problems of down leakage and clumping in previous down products;

[0022] (3) The sheet-like down fabric prepared by the present invention can be directly applied to different types of down products, with wide applications and broad prospects.

[0023] (4) The method of the present invention is simple, the prepared sheet down fabric is easy to process, and has excellent repeatability. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the sheet-like cotton down material in Example 1;

[0025] Figure 2 This is a schematic diagram of the sheet-like knitted down material in Example 2;

[0026] In the picture, 1 is down, 2 is cotton fabric, and 3 is knitted fabric. Detailed Implementation

[0027] To make the present invention more apparent and understandable, preferred embodiments are described in detail below with reference to the accompanying drawings.

[0028] Example 1

[0029] The specific steps for preparing sheet-like down fabric using a machine weaving method are as follows:

[0030] First, the tubular down yarn is densely coated with PE film. Second, the tubular down yarn passes around the back beam and stop plate on the warp-threading device of the loom, and then through the heald eye, heald frame, and reed, with three reeds inserted. The weft-introducing device guides the tubular down weft yarn into the shed formed by the opening of the tubular down warp yarn. Then, the reed and shuttle of the beat-up device push the tubular down weft yarn towards the weft, thus interweaving the tubular down warp and weft yarns to form a sheet-like cotton down material (such as...). Figure 1 (as shown); then, the processed sheet-like cotton down material is used as the core layer and combined with the upper and lower surface cotton woven fabric materials, and then wound to prepare a sheet-like down fabric woven by machine.

[0031] Example 2

[0032] This invention describes the preparation of sheet-like down fabrics using a knitting method. Taking a flat knitting machine as an example, the specific operation is as follows:

[0033] First, the tubular down yarn is densely coated with a polyamide film. Second, with the assistance of the yarn guide on the flat knitting machine, the tubular down yarn is guided onto the needle latch. As the needle retracts, the new yarn moves under the needle hook, and the old loop moves forward, completing the hooking process. As the bending cam continues to act, the old loop successively completes the closing and looping activities. Then, the old loop slides off the needle latch and contacts the new tubular down yarn inside the needle hook, completing the connection between the new yarn and the old loop. The needle retracts further, the old loop disengages, and simultaneously, the newly introduced tubular down yarn forms a new loop under the action of the needle hook. During the loop-forming and pulling process, the yarn forms a sheet-like knitted down material (such as…). Figure 2 (as shown); then, the processed sheet-like knitted down material is used as the core layer and combined with the upper surface layer of polyester warp-knitted mesh fabric material and the lower surface layer of polyester woven fabric material, and then wound to prepare sheet-like down fabric based on knitting method.

[0034] Example 3

[0035] The following are the specific steps for preparing sheet-like down fabric using a nonwoven method:

[0036] First, the tubular down yarn is densely coated with a polytetrafluoroethylene (PTFE) film. Second, under airflow, the tubular down yarn is evenly laid onto the forming curtain. Wind-blocking rollers are placed at the suction boundary of the advancing web to clamp the web and the forming curtain, controlling web adhesion. The web is then reinforced by its own thermal bonding to obtain a sheet-like down material. Next, the processed sheet-like down material is used as the core layer, combined with an upper layer of polyester warp-knitted mesh fabric and a lower layer of aluminized film, and then wound to prepare a sheet-like down fabric woven using a nonwoven method.

Claims

1. A method for processing sheet-like down fabric based on tubular down yarn, characterized in that, The tubular down yarn is densely coated to prevent damage to the down fibers during processing. Next, the tubular down yarn is shaped into a sheet material using weaving or non-woven methods. Then, the processed sheet material is composited with the upper surface material as an inner layer or with both the upper and lower surface materials as a core layer, and then wound to prevent compression during the winding process and to facilitate subsequent cutting and processing. The dense coating involves covering the surface of the tubular down yarn with a sheet material, which can be a film, fabric, non-woven fabric, paper, or leather.

2. The processing method for sheet-like down fabric based on tubular down yarn as described in claim 1, characterized in that, The aforementioned weaving method involves using machine weaving, knitting, or braiding techniques to interweave tubular down yarn into sheets, knit them into sheets, or braid them into sheets, thereby forming sheet-like down fabric.

3. The processing method for sheet-like down fabric based on tubular down yarn as described in claim 2, characterized in that, The tubular down yarns are interwoven according to a set weaving pattern to form a sheet down fabric, or the tubular down yarns are interlocked according to a set pattern to form a sheet down fabric, or the tubular down yarns are woven and wrapped together according to a set pattern to form a sheet down fabric.

4. The processing method for sheet-like down fabric based on tubular down yarn as described in claim 1, characterized in that, The nonwoven method involves making the surface of the tubular down yarn sticky under the action of hot air to form self-adhesion, or making the surface of the tubular down yarn sticky under the action of a hot extrusion roller to form self-adhesion, or spraying liquid or powder adhesive onto the surface of the tubular down yarn to bond it, or bonding the tubular down yarn onto a sheet, which can be a film, a thin fabric, a nonwoven fabric, paper, or leather.

5. The processing method for sheet-like down fabric based on tubular down yarn as described in claim 4, characterized in that, The tubular down yarns are arranged in parallel to form a sheet-like down fabric without weft, or arranged at a set angle to form a layered sheet-like down fabric, or arranged according to a set spatial morphology to form a sheet-like down fabric.

6. The processing method for sheet-like down fabric based on tubular down yarn as described in claim 1, characterized in that, The sheet material is combined with an upper surface material or with both an upper and lower surface material to form a composite sheet material, and the upper or lower surface material can be removed during subsequent processing.

7. The processing method for sheet-like down fabric based on tubular down yarn as described in claim 6, characterized in that, The upper or lower surface material is a sheet, which may be a film, fabric, nonwoven fabric, paper, or leather.

8. A sheet down fabric obtained by the processing method of sheet down fabric based on tubular down yarn according to any one of claims 1-6, characterized in that, The spatial form of the sheet-like down fabric is a planar shape with uniform thickness, or a shape with uneven thickness in some areas but a regular overall shape.

9. The use of the sheet-like down fabric as described in claim 8 in down jackets, down comforters, down sleeping bags, down scarves or down fabric fillings.

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