Fabric structure

Abstract

The present application proposes a fabric structure comprising: a first layer having a first needling density; a second layer underlying the first layer and having a second needling density, the second needling density being less than the first needling density; a third layer underlying the second layer; the sewing structure is used for sewing and fixing the first layer, the second layer and the third layer; and a ventilation groove structure, the first layer and / or the third layer having an outward convex portion and an inward concave portion in a cross section thereof.

Description

Fabric structure Technical Field

[0001] The present application relates to a fabric structure. Specifically, the present application relates to a fabric with a breathable groove structure. Background Art

[0002] With the development of synthetic materials and manufacturing technologies, insulation materials that offer at least one of the following functions—thermal insulation, sound insulation, and filtration—have become widely used in a wide range of products. For example, depending on their properties, insulation materials can be applied to, but are not limited to, the following products and / or fields: winter protection products, industrial / architectural insulation, and sound insulation.

[0003] The current production method for fabrics used in commercially available insulation materials involves spraying a chemical resin onto a fiber web or a blend of hot melt cotton. The material is then placed in a large, high-temperature drying oven to dry and set the resin. This production method requires a large amount of chemical resin and consumes significant amounts of fuel to power boilers or burners to achieve the high-temperature drying requirements. Furthermore, this manufacturing process generates significant amounts of carbon dioxide, exhaust gas, and wastewater pollution. Such high temperatures and polluted environments pose health risks to production workers.

[0004] Summary of the Invention

[0005] In light of the numerous issues arising from the aforementioned related production technologies, the inventors of this application have proposed a fabric with a breathable groove structure and a method for its manufacture. This method eliminates the need for chemical resins and large, high-temperature drying ovens, eliminating the drying process required for resins and heat-melting cotton. It also combines the advantages of various long-fiber nonwovens, short-fiber or long-fiber filaments, and film materials. As a result, the fabric of this application offers multifunctionality and breathability, achieving the environmental goals of being resin-free, energy-efficient, and achieving zero carbon emissions.

[0006] The present application relates to a fabric structure, comprising: a first layer, comprising first fibers and having a first needle punching density; a second layer, located below the first layer, comprising second fibers and having a second needle punching density, wherein the second needle punching density is less than the first needle punching density; a third layer, located below the second layer, for strengthening the isolation of the fabric; and a stitching structure for stitching and fixing the first layer, the second layer and the third layer.

[0007] Optionally, it also includes:

[0008] The ventilation groove structure comprises a first layer having a first set of outward convex portions and a first set of inward concave portions in a cross section thereof, and a third layer having a second set of outward convex portions and a second set of inward concave portions.

[0009] Optionally, the first group of outward convex portions have a same first width, the first group of inward concave portions have a same second width, the second group of outward convex portions have a same third width, and the second group of inward concave portions have a same fourth width.

[0010] Optionally, the first width is equal to the third width, and the second width is equal to the fourth width.

[0011] Optionally, the first width is not equal to the third width, and the second width is not equal to the fourth width.

[0012] Optionally, the first group of outward protrusions have different widths, and the second group of outward protrusions have different widths.

[0013] Optionally, the linear density of the first fiber is 0.5 dtex-15 dtex, and the linear density of the second fiber is 0.5 dtex-15 dtex.

[0014] Optionally, the second layer is combined with the first layer at the second needling density.

[0015] Optionally, it also includes:

[0016] The ventilation groove structure, in the cross section of the ventilation groove structure, the first layer or the third layer has a first group of outward convex portions and a first group of inward concave portions.

[0017] Optionally, the first group of outwardly facing protrusions have the same first width, and the first group of inwardly facing concave portions have the same second width.

[0018] Optionally, the first group of outward protrusions have different widths.

[0019] Optionally, the first layer has the first group of outwardly facing convex portions and the first group of inwardly facing concave portions, and the fabric structure further comprises:

[0020] a fourth layer located below the third layer, the fourth layer comprising the first fibers and having the first needle punching density;

[0021] a fifth layer located below the fourth layer, the fifth layer comprising the second fibers and having the second needle punching density;

[0022] a sixth layer, located below the fifth layer, for reinforcing the insulation of the fabric; and

[0023] The second suturing structure is used to sew and fix the fourth layer, the fifth layer and the sixth layer.

[0024] Wherein, in the cross section of the breathable groove structure, the sixth layer has a second set of outward convex portions and a second set of inward concave portions.

[0025] Optionally, the first layer has the first group of outwardly facing convex portions and the first group of inwardly facing concave portions, and the fabric structure further comprises:

[0026] a fourth layer, located below the third layer, for reinforcing the isolation of the fabric;

[0027] a fifth layer located below the fourth layer, the fifth layer comprising the second fibers and having the second needle punching density;

[0028] a sixth layer located below the fifth layer, the sixth layer comprising the first fibers and having the first needle punching density; and

[0029] The second suturing structure is used to sew and fix the fourth layer, the fifth layer and the sixth layer.

[0030] Wherein, in the cross section of the breathable groove structure, the sixth layer has a second set of outward convex portions and a second set of inward concave portions.

[0031] Optionally, the third layer has the first group of outwardly facing convex portions and the first group of inwardly facing concave portions, and the fabric structure further comprises:

[0032] a fourth layer positioned above the first layer, the fourth layer comprising the first fibers and having the first needle punch density;

[0033] a fifth layer located above the fourth layer, the fifth layer comprising the second fibers and having the second needle punching density;

[0034] a sixth layer, located above the fifth layer, for reinforcing the insulation of the fabric; and

[0035] The second suturing structure is used to sew and fix the fourth layer, the fifth layer and the sixth layer.

[0036] Wherein, in the cross section of the breathable groove structure, the sixth layer has a second set of outward convex portions and a second set of inward concave portions.

[0037] Optionally, the first group of outward convex portions have a same first width, the first group of inward concave portions have a same second width, the second group of outward convex portions have a same third width, and the second group of inward concave portions have a same fourth width.

[0038] Optionally, the first width is equal to the third width, and the second width is equal to the fourth width.

[0039] Optionally, the linear density of the first fiber is 0.5 dtex-15 dtex, and the linear density of the second fiber is 0.5 dtex-15 dtex.

[0040] Optionally, the second layer is combined with the first layer at the second needling density.

[0041] Optionally, the second layer is combined with the first layer at the second needling density, and the fifth layer is combined with the fourth layer at the second needling density.

[0042] Optionally, the second layer is combined with the first layer at the second needling density, and the sixth layer is combined with the fifth layer at the second needling density. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] These and other features of the disclosed embodiments will be described in detail below with reference to the relevant drawings. According to some embodiments of the present application:

[0044] FIG1 is a flow chart showing a method for manufacturing a breathable fabric;

[0045] FIG2 shows a schematic cross-sectional view of the fabric;

[0046] FIG3 shows a schematic cross-sectional view of a fabric having a stitched structure;

[0047] FIG4 is a schematic cross-sectional view of a fabric having a breathable groove structure;

[0048] Figures 5(a) to 5(d) are cross-sectional views showing the upper and lower needle plates of the same forward / reverse needle rolling machine;

[0049] 6( a ) to 6 ( d ) are schematic cross-sectional views of single-layer fabrics having different groove configurations;

[0050] 7( a ) to 7 ( b ) are schematic cross-sectional views showing different double-layer fabrics having groove structures; and

[0051] FIG8 is a schematic top view showing a fabric having a stitched structure and a groove structure.

[0052] Figure numerals: 200: fabric 202: first layer 204: second layer 206: third layer 300: fabric 302: stitching structure 400: breathable groove structure 402: outward convex portion 404: inward concave portion 406: raw edge 600-630: breathable groove structure 800: fabric 800 810: stitching structure 820: outward convex portion 830: inward concave portion 832: edge 840: needle-punched hole D: spacing W, W1, W2: width DETAILED DESCRIPTION

[0053] In the following description, several specific details are set forth to provide a thorough understanding of the embodiments described. The embodiments disclosed herein may be practiced without some or all of these specific details. In other instances, detailed descriptions of related art processing operations are omitted to avoid unnecessarily obscuring the disclosed embodiments. Although specific examples are used to illustrate the disclosed embodiments, it should be understood that they are not intended to limit the disclosed embodiments.

[0054] FIG1 shows a method for manufacturing a breathable fabric according to the present invention, which will be further described below with reference to FIG2-7.

[0055] 2 shows a schematic diagram of a fabric 200 according to an embodiment of the present application. The fabric 200 includes a first layer 202, a second layer 204, and a third layer 206.

[0056] First, in step 102 of the manufacturing method of FIG. 1 , a first fiber having a predetermined fiber specification and weight is formed into a fiber web, and then the fiber web is needled on one side with high density, for example, 50-300 needles / cm, by a needle rolling mill. 2 High-density needle punching can increase the effect of mutual entanglement between fibers, so that the originally fluffy and weak fiber web is entangled together, thereby producing a compact, solid, thin and flat first layer 202 with structural strength.

[0057] In one embodiment, the first fibers may be PP / PET staple fibers, having a linear density of 0.5 dtex to 15 dtex (dtex) and a length of 31 to 100 mm. The fiber web may have a weight of 40 to 160 gsm (grams per square meter). In an alternative embodiment, the linear density of the PP / PET staple fibers is 0.5 dtex to 7 dtex.

[0058] In step 104 of the manufacturing method, the second fiber having a predetermined fiber specification and weight is formed into a fiber web, and then passed through a reverse needle rolling mill for reverse single-sided low-density needle rolling (i.e., needle punching) (e.g., 3-50 needles / cm 2 Needling density) or no needling is performed. Because the needling density is low or zero, the fibers are less likely to tangle with each other. This creates a fluffy, elastic, and supportive second layer 204, which increases the air volume. In another embodiment, the second fibers are formed into a web, then stacked with the first layer 202 and then needled at a low density using a reverse needle mill. In this case, the second layer and the first layer are bonded at a low needling density.

[0059] In one embodiment, the second fiber can be made of PP / PET staple fiber / filament, with a linear density of 0.5 dtex to 15 dtex and a length of 31 mm to unlimited length. The fiber web can have a weight of 10 to 300 gsm. In an alternative embodiment, the fiber has a linear density of 3 dtex to 15 dtex.

[0060] The first layer has a high needle-punch density, providing high structural strength and insulation. The second layer has a low needle-punch density, retaining the fiber's bulk, resilience, and support, while also increasing air volume and providing thermal insulation. Therefore, when the first and second layers are combined, they create a multifunctional combination of advantages.

[0061] In addition, the first layer and / or the second layer can be mixed with other different fiber materials to create more functional combination advantages. For example, the mixed fibers can include hollow fibers, elastic fibers, recycled fibers, bicomponent fibers, polylactic acid fibers, natural fibers, etc.

[0062] In step 106 of the manufacturing method, the first layer 202, second layer 204, and third layer 206 are sewn together to form a fabric 300 having a sewn structure 302 (as shown in FIG3). The third layer serves to enhance the fabric's insulation (e.g., air and moisture isolation), thermal insulation, and fiber linting resistance. This method allows the spaces between the layers to freely move within the fixed space. During dynamic operation, the fiber layers vibrate, causing them to flutter freely, thereby increasing air flow and providing heat dissipation. During static operation, the fiber layers cease movement, allowing each layer to naturally wrinkle or expand, resulting in a naturally fluffier structure and increased airflow and thermal insulation. This increases the fabric's flexibility and improves its stiffness. Conventional insulation materials, on the other hand, fix the fibers into a single sheet-like structure and therefore cannot achieve the desired effects of the present invention.

[0063] In one embodiment, the material of the third layer may be PP meltblown non-woven fabric, and the weight may be 10-100gsm. In other embodiments, the material of the third layer may be PP / PET spunbond non-woven fabric, waterproof film, metal coating, etc. In one embodiment, the stitching structure is formed by continuous ultrasonic point stitching and has a double diamond checkered wheel pattern. In other embodiments, stitching and fixing can be performed by hot pressing wheels or high frequency. In other embodiments, the stitching structure may have a dotted geometric figure or an even pattern. In addition, when stitching and fixing, a fourth layer may be optionally added next to the first layer to strengthen the protection of the first layer. The material of the fourth layer may be non-woven fabric, such as long-fiber non-woven fabric, and the weight may be 9-20gsm.

[0064] Returning to Figure 1 , in step 108 , the stitched fabric (e.g., fabric 300 in Figure 3 ) is passed through a needle-pressing machine to create a breathable groove structure. In one example, the stitched fabric is passed through a single-sided needle-pressing machine, where needles are arranged on either the upper or lower needle plate at a desired spacing to create a single-sided breathable groove structure 400 (as shown in Figure 4 ) in the fabric's cross-section. The breathable groove structure 400 includes outwardly facing protrusions 402 and inwardly facing recesses 404 . Needling intertwines and secures the fibers of the first, second, and third layers at intervals, forming inwardly facing recesses toward the interior of the fabric and creating numerous needle-punched holes in these recesses. Therefore, these inwardly facing recesses enhance the fabric's breathability. Needling in the inwardly facing recesses 404 causes fibers from the first layer to enter the second and third layers, creating burrs 406 on the outside of the first and third layers. The outward-facing convex portions that are not needle-punched maintain a certain fiber bulk and thickness, achieving a thermal insulation effect. Controlling the needling density can adjust the groove depth and air permeability. The higher the needling density, the thinner and more solid the fiber layer will be, and the more numerous and larger the needle-punched holes will be, resulting in better air permeability. In the embodiment of Figure 4, the first layer 202 has an outward-facing convex portion and an inward-facing concave portion, and the third layer remains roughly flat. In another embodiment, the third layer can have an outward-facing convex portion and an inward-facing concave portion, while the first layer remains roughly flat. The resulting fabric has a total weight of approximately 60-400 gsm and a thickness of approximately 3-30 mm.

[0065] In another example, a stitched fabric layer can be run through a forward / backward needle pressing machine, where needles are arranged on the upper and lower needle plates at the desired spacing to create a double-sided breathable groove structure in the fabric's cross-section. Unlike conventional needle plate arrangements, the needle holes in the force guide and stripping guide plates of this needle pressing machine are of different sizes and positions. This requires a specially designed, high-density upper and lower needle plates and guide mechanism to create the breathable grooves. This double-sided groove structure enhances the fabric's structural strength, stretchability, and flexibility, as well as the air circulation and reflection within the grooves. This improves the stiffness and lack of flexibility of traditional heavy cotton layers.

[0066] When using the same forward / backward needle rolling machine, depending on the product requirements, the upper and lower needle plates can be arranged with the same width W and the same spacing D (as shown in Figure 5(a)), thereby forming inward-facing concave portions of the same width on both sides (as shown in the ventilation groove structure 600 in Figure 6(a)). This ensures roughly the same ventilation effect on both sides of the fabric. Alternatively, the upper and lower needle plates can be arranged with different widths and spacings (as shown in Figures 5(b) or 5(c)), thereby forming inward-facing concave portions of different widths on both sides (as shown in the ventilation groove structure 610 in Figure 6(b) or the ventilation groove structure 620 in Figure 6(c)). This ensures different ventilation effects on both sides of the fabric, with one side retaining warmth while the other side provides better ventilation and heat dissipation. Alternatively, the upper and lower needle plates can be arranged with the same width but different spacings (as shown in Figure 5(d)), thereby forming outward-facing convex portions of different widths (as shown in the ventilation groove structure 630 in Figure 6(d)). According to the ventilation requirements, the groove structure can be designed to have various widths, so that there are more inward concave parts in some parts and better ventilation, while there are fewer inward concave parts in other parts and better thermal insulation effect.

[0067] The depth of the inward concave portion will vary depending on the needle density, fiber thickness and material. As an example, the width of the inward concave portion of the breathable groove structure can be 2.5-100mm, the width of the outward convex portion can be 5-300mm, and the needle density can be 10-200 needles / cm 2 The above parameters can be adjusted according to needs.

[0068] In another example, two layers of stitched fabric (e.g., fabric 300) can be stacked one on top of the other and then run through a forward / backward needle pressing machine. Similarly, needles can be arranged on the upper and lower needle plates according to the desired spacing to create a double-sided breathable groove structure in the cross-section of the double-layer fabric. In yet another example, two layers of stitched fabric can be stacked one on top of the other and then run through a single-sided needle pressing machine to create a single-sided breathable groove structure in the cross-section of the double-layer fabric.

[0069] Two layers of stitched fabric (e.g., an upper fabric and a lower fabric) can be stacked in various combinations depending on the product's requirements. In one embodiment, the third layer of the upper fabric (e.g., 206) is stacked on top of the first layer of the lower fabric (e.g., 202) and then passed through a forward / backward needle rolling mill for production, thereby forming a double-layer fabric with a double-sided breathable groove structure, as shown in FIG7( a ). In another embodiment, the third layer of the upper fabric (e.g., 206) is stacked on top of the third layer of the lower fabric (e.g., 206) and then passed through a forward / backward needle rolling mill for production, thereby forming a double-layer fabric with a double-sided breathable groove structure, as shown in FIG7( b ). Similarly, the first layer of the upper fabric (e.g., 202) can be stacked on top of the first layer of the lower fabric (e.g., 202) and then produced. In yet another embodiment, the upper and lower fabrics can be stacked and then passed through a single-sided needle rolling mill to form a double-layer fabric with a single-sided groove structure. The total weight of the double-layer fabric formed is, for example, 120-800 gsm, and the thickness is, for example, 6-60 mm.

[0070] In addition, double-layer fabrics can be made of different material / specifications / weight combinations to provide diverse applications, options, designs or functions, and have the advantages of low cost and environmental protection.

[0071] FIG8 illustrates a top view of a fabric 800 having a breathable groove structure. The fabric 800 includes a stitched structure 810 having a double diamond checkered pattern. The fabric 800 also includes a breathable groove structure comprising an outwardly convex portion 820 and a straight inwardly concave portion 830. The inwardly concave portion has two or more needle-punched holes (schematically indicated as 840) to increase the breathability of the fabric. The size, number, and arrangement of the needle-punched holes are not limited to those shown in the figure. In the embodiment illustrated in FIG8 , the width W1 of the straight inwardly concave portion is 10 mm, the width W2 of the outwardly convex portion is 40 mm, and the widths of the double diamond grid (the diagonal lengths of the diamonds) are 30 mm and 50 mm, respectively. However, the present application is not limited thereto and can be modified as needed. In an embodiment using double-layer fabric, if necessary, continuous dot-shaped double straight line sutures (for example, by ultrasonic sutures) can be added to the edge 832 of the inward recess 830, and then breathable grooves can be processed to strengthen the fixation of the double-layer fabric.

[0072] Although the above embodiments have been described in detail for purposes of clarity of understanding, it will be apparent that certain changes and modifications may be implemented within the scope of the appended claims. It should be noted that there are many alternative ways to implement the processing methods of the present embodiments. Therefore, the present embodiments should be considered as illustrative rather than restrictive, and the present embodiments should not be limited to the details set forth herein.

Claims

1. A fabric structure comprising: a first layer comprising first fibers and having a first needle punch density; a second layer located below the first layer, the second layer comprising second fibers and having a second needle punch density, the second needle punch density being less than the first needle punch density; The third layer is located below the second layer and is used to strengthen the isolation of the fabric; and The suturing structure is used to sew and fix the first layer, the second layer and the third layer.

2. The fabric structure according to claim 1, wherein: Also includes: The ventilation groove structure comprises a first layer having a first set of outward convex portions and a first set of inward concave portions in a cross section thereof, and a third layer having a second set of outward convex portions and a second set of inward concave portions.

3. The fabric structure according to claim 2, wherein: The first group of outwardly convex portions have a same first width, the first group of inwardly concave portions have a same second width, the second group of outwardly convex portions have a same third width, and the second group of inwardly concave portions have a same fourth width.

4. The fabric structure according to claim 3, wherein: The first width is equal to the third width, and the second width is equal to the fourth width.

5. The fabric structure according to claim 3, wherein: The first width is not equal to the third width, and the second width is not equal to the fourth width.

6. The fabric structure according to claim 2, wherein: The first group of outwardly facing protrusions have different widths, and the second group of outwardly facing protrusions have different widths.

7. The fabric structure according to any one of claims 1 to 6, wherein: The linear density of the first fibers is 0.5 dtex-15 dtex, and the linear density of the second fibers is 0.5 dtex-15 dtex.

8. The fabric structure according to any one of claims 1 to 6, wherein: The second layer is bonded to the first layer at the second needling density.

9. The fabric structure of claim 1 , further comprising: The ventilation groove structure, in the cross section of the ventilation groove structure, the first layer or the first layer The third layer has a first set of outward convex portions and a first set of inward concave portions.

10. The fabric structure of claim 9, wherein: The first group of outwardly facing protrusions have a same first width, and the first group of inwardly facing concave portions have a same second width.

11. The fabric structure of claim 9, wherein: The first group of outwardly facing protrusions have different widths.

12. The fabric structure of claim 9, wherein: The first layer has the first set of outwardly facing convex portions and the first set of inwardly facing concave portions, and the fabric structure further comprises: a fourth layer located below the third layer, the fourth layer comprising the first fibers and having the first needle punching density; a fifth layer located below the fourth layer, the fifth layer comprising the second fibers and having the second needle punching density; a sixth layer, located below the fifth layer, for reinforcing the insulation of the fabric; and The second suturing structure is used to sew and fix the fourth layer, the fifth layer and the sixth layer. Wherein, in the cross section of the breathable groove structure, the sixth layer has a second set of outward convex portions and a second set of inward concave portions.

13. The fabric structure of claim 9, wherein: The first layer has the first set of outwardly facing convex portions and the first set of inwardly facing concave portions, and the fabric structure further comprises: a fourth layer, located below the third layer, for reinforcing the isolation of the fabric; a fifth layer located below the fourth layer, the fifth layer comprising the second fibers and having the second needle punching density; a sixth layer located below the fifth layer, the sixth layer comprising the first fibers and having the first needle punching density; and The second suturing structure is used to sew and fix the fourth layer, the fifth layer and the sixth layer. Wherein, in the cross section of the breathable groove structure, the sixth layer has a second set of outward convex portions and a second set of inward concave portions.

14. The fabric structure of claim 9, wherein: The third layer has the first set of outwardly facing convex portions and the first set of inwardly facing concave portions, and the fabric structure further comprises: a fourth layer positioned above the first layer, the fourth layer comprising the first fibers and having the first needle punch density; a fifth layer located above the fourth layer, the fifth layer comprising the second fibers and having the second needle punching density; a sixth layer, located above the fifth layer, for reinforcing the insulation of the fabric; and The second suturing structure is used to sew and fix the fourth layer, the fifth layer and the sixth layer. Wherein, in the cross section of the breathable groove structure, the sixth layer has a second set of outward convex portions and a second set of inward concave portions.

15. The fabric structure according to any one of claims 12 to 14, wherein: The first group of outwardly convex portions have a same first width, the first group of inwardly concave portions have a same second width, the second group of outwardly convex portions have a same third width, and the second group of inwardly concave portions have a same fourth width.

16. The fabric structure of claim 15, wherein: The first width is equal to the third width, and the second width is equal to the fourth width.

17. The fabric structure according to any one of claims 9 to 14, wherein: The linear density of the first fibers is 0.5 dtex-15 dtex, and the linear density of the second fibers is 0.5 dtex-15 dtex.

18. The fabric structure according to any one of claims 9 to 11, wherein: The second layer is bonded to the first layer at the second needling density.

19. The fabric structure according to claim 12 or 14, wherein: The second layer is combined with the first layer at the second needling density, and the fifth layer is combined with the fourth layer at the second needling density.

20. The fabric structure of claim 13, wherein: The second layer is combined with the first layer at the second needling density, and the sixth layer is combined with the fifth layer at the second needling density.

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