Integrally woven and formed partitioned breathable quilt and manufacturing method

Abstract

The invention relates to the technical field of fabric processing, and particularly discloses an integrally woven and formed partitioned breathable quilt which comprises a three-layer woven fabric composed of an upper fabric layer, a lower fabric layer and a connecting layer. The connecting layer is arranged in a manner that binding warp yarns penetrate through the upper fabric layer and the lower fabric layer, and the three layers of woven fabrics are divided into a warm-keeping area and a breathable area; by means of the innovative structural design of three-layer tatting and partitioned binding, the quilt has the excellent warm keeping performance and the excellent air permeability at the same time; the warm-keeping area can effectively lock heat, and the requirement of a human body for warmth is met; the breathable areas can achieve efficient breathability and avoid stuffiness, distribution of the breathable areas and the warm-keeping areas can accurately meet the requirements of different parts such as the shoulders, the neck and the feet of the human body, the problems that warm keeping and breathability of a traditional quilt are difficult to consider, and zoned regulation cannot be achieved are thoroughly solved, and the use comfort level is greatly improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of fabric processing, in particular to an integrally woven and formed zoned breathable quilt and a manufacturing method thereof. BACKGROUND

[0002] With the improvement of modern living standards, people's requirements for sleep quality are increasing, and the quilt, as a key home textile product to ensure high-quality sleep, needs to meet the core needs of warmth and dryness, lightness and breathability. However, there are many defects in the design and manufacturing process of traditional quilts that are difficult to overcome.

[0003] To achieve better warmth, traditional quilts usually rely on filling a large amount of warm-keeping materials (such as down, chemical fibers, etc.), but this approach can significantly weaken the breathability of the quilt, leading to a stuffy feeling when used, and making it difficult to maintain a dry sleep environment; The existing market for improved quilts on breathability mostly use the basic process of "filling materials and quilting forming", and then through later splicing or quilting mesh fabric to enhance the local breathability, such process not only complex and tedious, but also increases the redundancy of the production process, significantly increasing the production cost; In addition, the traditional quilt lacks targeted design of warmth and breathability, and cannot be adjusted according to the different needs of different parts of the human body (such as shoulders, necks, and feet) for temperature and air permeability, making it difficult to adapt to the physiological characteristics of the human body, and limiting the overall comfort. SUMMARY

[0004] In view of the deficiencies of the prior art, the present application provides an integrally woven and formed zoned breathable quilt and a manufacturing method thereof, which solves the problems in the background art.

[0005] To achieve the above purpose, the present application is realized by the following technical scheme: an integrally woven and formed zoned breathable quilt, comprising a three-layer woven fabric composed of an upper fabric layer, a lower fabric layer and a connecting layer; the connecting layer is provided by a connecting warp yarn penetrating through the upper and lower fabric layers, and the three-layer woven fabric is divided into a warm-keeping zone and a breathable zone. Among them, the connecting warp yarn in the warm-keeping zone is connected with high density to form a closed chamber, and the closed chamber is filled with a heat preservation material; the connecting warp yarn in the breathable zone is connected intermittently to form a through-hole organization, and the through-hole organization is a hollow channel directly formed during weaving.

[0006] Preferably, the through-hole organization is an eight-shaped through-hole or a honeycomb organization, the pore size of the through-hole organization is 1-10mm, and the porosity is 20%-80%.

[0007] Preferably, the connecting warp yarn is a hot melt yarn, the connecting warp yarn is bonded to the upper and lower fabric layers after hot melt treatment, and the melting point of the hot melt yarn is 110℃.

[0008] Preferably, the area ratio of the warm-keeping zone to the air-permeable zone is 6:4 to 8:2, and the air-permeable zone is concentratedly distributed in the shoulder-neck and foot-projection areas of the body.

[0009] Preferably, the lower fabric layer is woven with conductive silver wires, and the proportion of the conductive silver wires in the lower fabric layer is 0.5%, for realizing the antibacterial and antistatic functions.

[0010] Preferably, the upper fabric layer is made of air-permeable yarns, and the air-permeable yarns are 40S combed cotton; and the lower fabric layer is made of skin-friendly yarns, and the skin-friendly yarns are Tencel / Modal blended yarns.

[0011] Preferably, the thermal insulation material is phase change microcapsule PCM, and the particle size of the phase change microcapsule PCM is 10 mu m.

[0012] A manufacturing method of an integrally woven and formed zoned air-permeable quilt comprises the following steps: S1: an electronic jacquard loom is used to program and control one-time weaving to form the three-layer woven fabric, wherein the warm-keeping zone is formed by binding stitches, and the air-permeable zone is formed by through-hole stitches; S2: the three-layer woven fabric after weaving is subjected to hot melting treatment to solidify the binding warp yarns and realize stable adhesion of the upper and lower fabric layers; S3: the thermal insulation material is injected into the closed cavity through the filling opening reserved in the warm-keeping zone, and the filling is completed; S4: the three-layer woven fabric after filling is subjected to hydrophilic finishing and is immersed and padded with moisture absorption and sweat release additives.

[0013] Preferably, in step S1, the binding stitches of the warm-keeping zone are 1:1 binding stitches, and every 2 weft yarns are bound once; the binding warp yarns of the air-permeable zone are 4:1 intermittent binding, and eight-character through-holes are simultaneously woven to form, and the weft float length of the eight-character through-holes is 5 yarns.

[0014] Preferably, in step S2, the hot melting treatment is performed at 150 DEG C for 3 minutes; and the electronic jacquard loom is a jet electronic multi-arm loom, and the reed width is 230 cm.

[0015] The application provides an integrally woven and formed zoned air-permeable quilt and a manufacturing method, and has the following beneficial effects: 1. The function adaptability is significantly improved: the innovative structural design of the three-layer weaving and zoned binding makes the quilt have excellent warm-keeping and air-permeable performances; the warm-keeping zone can effectively lock heat to meet the demand of the human body for warmth; the air-permeable zone can realize efficient air permeation to avoid stuffiness, and the distribution of the air-permeable zone and the warm-keeping zone can accurately match the demand of different parts of the human body such as the shoulder-neck and the feet, thereby completely solving the problem that the traditional quilt cannot simultaneously have warm-keeping and air permeation and cannot be zoned and controlled, and greatly improving the use comfort.

[0016] 2. Process simplification and cost optimization: The use of the integrated weaving process can complete the weaving of the three-layer structure and functional partitioning at one time, directly saving the complex processes such as fabric compounding, quilting, and mesh fabric splicing in traditional processes; this innovation not only reduces the cutting loss in the production process, reduces the equipment modification cost and labor cost, but also effectively improves the production efficiency, and is more suitable for the popular application scenarios of existing shuttle looms without the need for large-scale replacement of production equipment.

[0017] 3. Enhanced structural stability and durability: The connecting warp yarns pass through the upper and lower layers of fabric to form a connecting layer, replacing the traditional quilting thread, which fundamentally avoids the problem of filler displacement caused by the quilting structure; at the same time, the connecting warp yarns are made of hot melt yarns, which can be firmly bonded with the upper and lower layers of fabric after hot melt treatment, solving the industry pain point of easy peeling of the shuttle layered structure, significantly improving the structural stability of the quilt, and prolonging the service life of the product.

[0018] 4. Additional performance and optimized user experience: The lower layer of fabric is woven with conductive silver wire to achieve antibacterial and antistatic functions simultaneously, reducing bacterial growth and static interference during use, and improving the health and comfort of use; the breathable area uses a directly formed perforated organization during weaving, which has more stable breathability than traditional mesh fabric spliced later, and avoids the problems of easy wear and tear at the splicing site and the decay of breathability over time, ensuring long-term use experience. BRIEF DESCRIPTION OF DRAWINGS

[0019] Figure 1 is a three-layer shuttle weaving structure of the present application; Figure 2 is a manufacturing method flowchart of the one-piece woven and formed partitioned breathable quilt of the present application. DETAILED DESCRIPTION

[0020] The technical solutions in the embodiments of the present application will be described in detail below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative labor are within the scope of protection of the present application.

[0021] As Figure 1As shown, the present application provides a technical solution: an integrated woven shaped partition breathable quilt, the core structure of which is a three-layer woven fabric, which is composed of an upper fabric layer, a lower fabric layer and a connecting layer. The connecting layer is formed by vertical through bonding warp yarns through the upper and lower fabric layers, and the three-layer structure is formed into a stable whole through the connecting action of the bonding warp yarns. Based on the differentiated needs of different parts of the human body for temperature and air permeability during sleep, the three-layer woven fabric is divided into two functional areas, namely the warm-keeping area and the air-permeable area, and the two areas are functionally divided by different bonding processes of the bonding warp yarns.

[0022] Specifically, the design core of the warm-keeping area is to achieve efficient temperature locking, so a high-density bonding process is adopted, and the bonding warp yarns are bonded to the upper and lower fabric layers in a dense manner in this area, thereby forming multiple independent closed chambers inside the three-layer woven fabric. These closed chambers provide stable accommodation space for the heat preservation material, and further enhance the warm-keeping effect through the heat storage characteristics of the heat preservation material. In contrast, the air-permeable area aims to achieve air circulation as the core target, and the bonding warp yarns in this area adopt an intermittent bonding method, i.e. bonding to the upper and lower fabric layers at specific intervals, and the un-bonded area naturally forms a mesh organization. This mesh organization is not formed by post-processing, but is a hollow channel directly integrated during the weaving process, which can achieve efficient air circulation.

[0023] To optimize the air permeability, the mesh organization in this embodiment selects an eight-shaped mesh or a honeycomb organization, both of which have excellent air permeability stability. The pore size of the mesh organization is controlled within the range of 1-10mm, and the porosity is 20%-80%, which can be accurately adjusted according to the air permeability requirements of the actual use scene. The bonding warp yarns used in the connecting layer specifically adopt hot melt wire, and the melting point of the hot melt wire is 110℃. After the weaving of the three-layer woven fabric is completed, the hot melt wire is melted and solidified through hot melting treatment, thereby stably bonding the upper and lower fabric layers and avoiding the delamination problem that is prone to occur in traditional connection methods.

[0024] From the distribution of the functional areas, the area ratio of the warm-keeping area to the air-permeable area is set to 6:4 to 8:2, which can ensure the overall warm-keeping effect and meet the air permeability requirements of the key parts. The air-permeable area is concentrated in the shoulder and neck and foot projection area of the quilt, because the human body is prone to air leakage due to movement in the shoulder and neck area during sleep, and the skin metabolism in this area is vigorous, requiring good air permeability. The foot is a part of the human body that is sensitive to temperature regulation, and appropriate air permeability can prevent the foot from sweating due to heat and improve sleep comfort.

[0025] In the selection of the material of the fabric layer, the upper fabric layer is preferably made of yarn with excellent air permeability, and in this embodiment, 40S combed cotton is specifically selected. The yarn not only has good air permeability, but also has good moisture absorption performance, can quickly absorb moisture in the air, and maintain the surface of the body dry; the lower fabric layer directly contacts the human skin, so a skin-friendly yarn is used, specifically a Tencel / Modal blended yarn, which has the smooth luster of Tencel and the soft and skin-friendly properties of Modal, and can improve the comfort when contacting the skin. At the same time, in order to give the quilt additional health functions, conductive silver wire is woven into the lower fabric layer, and the proportion of the conductive silver wire in the lower fabric layer is 0.5%. Through the characteristics of the conductive silver wire, the functions of antibiosis and antistatic are realized, which can not only inhibit the breeding of bacteria on the surface of the body, but also avoid the interference of static electricity on the human body in a dry environment.

[0026] The thermal insulation material filled in the closed chamber of the warm-keeping area is selected as phase change microcapsule PCM. The material has the characteristics of phase change energy storage, can absorb or release heat when the temperature changes, thereby maintaining the internal temperature of the body stable and improving the comfort of warmth. The particle size is controlled to be 10 pm, which can ensure that the phase change microcapsule PCM is uniformly filled in the closed chamber, avoiding the problems of accumulation or uneven distribution.

[0027] As shown in Figure 2 , the manufacturing method of the integrated woven and formed partitioned air-permeable quilt is also disclosed, which specifically includes the following steps: The woven and formed step (S1) is to use an electronic jacquard loom, specifically a jet electronic multi-arm loom. The reed width of the loom is 230 cm, which can meet the size requirements of conventional quilts. The warp and weft interweaving mode of the loom is controlled by programming, and the three-layer woven fabric is formed at one time. In the programming process, 1:1 linking stitches are set for the warm-keeping area, i.e. 1 linking stitch is performed every 2 weft yarns, to ensure the formation of a closed chamber; and 4:1 intermittent linking of the linking warp yarns is set for the air-permeable area, and an eight-character through hole is simultaneously woven, the weft float length of the eight-character through hole is 5 yarns, to ensure the stability and air permeability of the through hole.

[0028] The hot melting fixing step (S2) is to perform hot melting treatment on the three-layer woven fabric, and the treatment condition is set to be baked at 150 DEG C for 3 minutes. This condition can ensure that the hot melting wire with a melting point of 110 DEG C is completely melted, and then solidified after cooling, thereby realizing the stable adhesion of the upper and lower fabric layers and improving the overall stability of the three-layer structure.

[0029] The thermal insulation material filling step (S3) is to reserve a filling port at a specific position of the warm-keeping area, inject phase change microcapsule PCM with a particle size of 10 pm into the closed chamber through the filling port, and seal the filling port after filling to ensure that the thermal insulation material does not leak or shift.

[0030] Hydrophilic finishing step (S4): hydrophilic finishing is performed on the three-layer woven fabric after filling and sealing. The specific process is to dip and pad moisture absorption and sweat release aids to improve the moisture absorption and sweat release performance of the quilt and further maintain the dry and comfortable sleep environment.

[0031] The structure, preparation process and performance of the "integrally woven and formed partitioned breathable quilt" of the present application are described in combination with specific examples and comparative examples. All performance tests are performed in accordance with industry standards.

[0032] Example 1, basic parameter group; Raw material configuration: Assembly Specific specifications Upper fabric layer 40S combed cotton yarn (warp density 120 ends / inch, weft density 90 ends / inch) Lower fabric layer 40S Tencel / Modal blended yarn (blending ratio 6:4), woven with 0.5% conductive silver wire (diameter 0.05mm) Binding warp yarn 75D polyester hot melt yarn (melting point 110°C, proportion 15%) Thermal insulation material Phase change microcapsule PCM (particle size 10μm, phase change temperature 28-32°C) Moisture absorption and sweat release aid Polyether modified silicone oil type aid (solid content 30%) Weaving process: Equipment: air jet electronic multi-arm loom (rake width 230 cm, speed 300 rpm); Functional partition control: warm-keeping area (area ratio 70%): 1:1 linking stitch is used for linking warp yarns (linking once every 2 weft yarns), forming a closed chamber; breathable area (area ratio 30%, distributed in shoulder and neck + feet): 4:1 intermittent linking of linking warp yarns, and eight-character through holes are woven synchronously (weft float length 5 yarns, hole diameter 5 mm, porosity 50%).

[0033] Post-finishing step: hot melting treatment: 150℃ baking for 3 minutes, hot melting wire completely solidifies and bonds the upper and lower layers; S3 PCM filling: inject PCM through the reserved filling port (diameter 8 mm) in the warm-keeping area, filling amount 200g / m²; hydrophilic finishing: dip and pad moisture absorption and sweat release aids (pick-up rate 80%), 120℃ drying for 2 minutes. Example 2:

[0034] The difference from example 1 is only that the area ratio of the breathable area is adjusted to 35% (warm-keeping area 65%), the hole diameter of the breathable area is expanded to 8mm (porosity 60%), and the rest of the raw materials and process parameters are completely consistent.

[0035] Example 3, adjusting PCM particle size and hot melting wire ratio; The difference from example 1 is: Thermal insulation material: the particle size of phase change microcapsule PCM is adjusted to 8μm (filling amount 180g / m²); Linking warp yarn: 75D polyester hot melting wire ratio is increased to 18% (melting point still 110℃); The rest of the raw materials and process parameters are completely consistent.

[0036] Comparative example design, variable control group; In order to verify the effect of the core innovation point of the present application, 4 groups of comparative examples are set, each of which lacks one or more key technical features: Comparative example Difference from example 1 Comparative example 1 No functional area (all warm area, no breathable area and hole structure), the rest of the parameters are the same Comparative example 2 Binding warp yarn with ordinary polyester yarn (not hot melt yarn), no hot melt treatment step, the rest of the parameters are the same Comparative example 3 No conductive silver wire in the lower fabric layer, the rest of the parameters are the same Comparative example 4 Use traditional process: upper and lower layers are ordinary shuttle fabric, middle layer is filled with chemical cotton, realize breathable through quilting and sewing mesh fabric Performance testing method: Thermal resistance value (warmth): refer to ISO11092 "Determination of thermal resistance and evaporation resistance of a fabric", test the thermal resistance value of the warm area (unit: clo); air permeability (air permeability): refer to GB / T5453-1997 "Determination of air permeability of textile fabrics", test the air permeability of the air permeable area (unit: mm / s, 100Pa pressure); antibacterial rate: refer to GB / T20944.3-2008 "Evaluation of antibacterial properties of textiles Part 3: oscillation method", test the antibacterial rate against Staphylococcus aureus (unit: %); Structural stability: simulate domestic washing (5 times, water temperature 30℃, rotation speed 800rpm), test the delamination rate of the fabric after washing (unit: %, delamination area / total area).

[0037] Performance test results and analysis: Detection data summary table: Group Thermal resistance value (clo) of warm area Breathability (mm / s) of breathable area Antibacterial rate against Staphylococcus aureus (%) Layering rate after 5 times of washing (%) Example 1 0.82 4520 96.5 0 Example 2 0.79 5130 96.2 0 Example 3 0.85 4480 96.8 0 Comparative example 1 0.83 1850 96.4 0 Comparative example 2 0.81 4490 96.3 28.5 Comparative example 3 0.82 4510 68.2 0 Comparative example 4 0.75 1620 65.8 15.3 Result analysis: (1) The necessity of functional partition (Example 1 compared with Counterexample 1): Counterexample 1 has no air permeable area, with an air permeability of only 1850mm / s, which is much lower than the 4520mm / s of Example 1, proving that "partitioning and linking and perforated organization" is the core of improving air permeability. The thermal resistance values of the two are close, indicating that the design of the air permeable area does not affect the overall warmth.

[0038] (2) The structural stability of hot melt wire (Example 1 compared with Counterexample 2): Counterexample 2 uses ordinary linking yarn without hot melt treatment, with a delamination rate of 28.5% after washing, while Example 1 has a delamination rate of 0, verifying that "heating and solidification adhesion" of hot melt wire can completely solve the problem of woven delamination and improve the structural durability.

[0039] (3) The antibacterial effect of conductive silver wire (Example 1 compared with Counterexample 3): Counterexample 3 does not add conductive silver wire, with an antibacterial rate of only 68.2%, while Example 1 has an antibacterial rate of 96.5% due to the addition of 0.5% conductive silver wire, meeting the antibacterial standard for household textiles (≥90%), proving that the antibacterial and antistatic functions are effective.

[0040] (4) The invention compared with traditional process (Example 1 compared with Counterexample 4): Counterexample 4 (traditional quilting and spliced mesh fabric) has a low thermal resistance value (0.75 clo), poor air permeability (1620mm / s), high delamination rate (15.3%), and no antibacterial properties, highlighting the comprehensive advantages of the invention in warmth, air permeability, stability, and health in four dimensions.

[0041] Examples 1-3 all achieve the excellent performance of "warm-keeping area thermal resistance value ≥ 0.79 clo, air-permeable area air permeability ≥ 4480 mm / s, antibacterial rate ≥ 96.2%, and delamination rate 0" by reasonably regulating the air-permeable area ratio, PCM particle size, hot melt yarn proportion and other parameters; the comparative examples prove that the "three-layer woven partition structure, hot melt yarn interlining, and modified conductive silver wire" of the present application are key technical points that are distinguished from traditional technologies.

[0042] Although embodiments of the present application have been shown and described, it is to be understood that various modifications, substitutions, replacements and changes can be made to these embodiments without departing from the principles and spirit of the present application, and the scope of the present application is defined by the appended claims and their equivalents.

Claims

1. A one-piece woven, partitioned, breathable quilt, characterized in that, The fabric comprises a three-layer woven fabric consisting of an upper fabric layer, a lower fabric layer, and a connecting layer. The connecting layer is formed by joining warp yarns that run through the upper and lower fabric layers. The three-layer woven fabric is divided into a heat-insulating zone and a breathable zone. In the heat-insulating zone, the joining warp yarns are joined at a high density to form a closed chamber, which is filled with heat-insulating material. In the breathable zone, the joining warp yarns are joined intermittently to form a perforated structure, which is a hollow channel formed directly during weaving.

2. The one-piece woven, partitioned, breathable quilt according to claim 1, characterized in that, The perforated structure is a figure-eight shaped perforation or a honeycomb structure, with a pore diameter of 1-10 mm and a porosity of 20%-80%.

3. The one-piece woven, partitioned, breathable quilt according to claim 2, characterized in that, The bonding warp yarn is a hot melt yarn, which is bonded to the upper and lower fabric layers after being heat-melted. The melting point of the hot melt yarn is 110°C.

4. The one-piece woven, partitioned, breathable quilt according to claim 3, characterized in that, The area ratio of the warm zone to the breathable zone is 6:4 to 8:2, and the breathable zone is concentrated in the shoulder, neck and foot projection areas of the quilt.

5. The one-piece woven, partitioned, breathable quilt according to claim 4, characterized in that, Conductive silver wires are woven into the lower fabric layer, and the proportion of conductive silver wires in the lower fabric layer is 0.5%, which is used to achieve antibacterial and antistatic functions.

6. The one-piece woven, partitioned, breathable quilt according to claim 5, characterized in that, The upper fabric layer is made of breathable yarn, which is 40S combed cotton; the lower fabric layer is made of skin-friendly yarn, which is a Tencel / Modal blended yarn.

7. The one-piece woven, partitioned, breathable quilt according to claim 6, characterized in that, The thermal insulation material is phase change microcapsule PCM, and the particle size of the phase change microcapsule PCM is 10 μm.

8. The manufacturing method of a one-piece woven, partitioned breathable quilt according to claim 7, characterized in that, Includes the following steps: S1: The three-layer woven fabric is formed in one go by using an electronic jacquard shuttle loom and programming control. The programmable control forms a joint structure in the heat-insulating zone and a perforated structure in the breathable zone. S2: The three-layer woven fabric is heat-melted after weaving to solidify the spliced ​​warp yarns and achieve a stable bond between the upper and lower fabric layers. S3: Insulation material is injected into the sealed cavity through the filling port reserved in the insulation area to complete the filling; S4: The three-layer woven fabric after filling is hydrophilic treated and impregnated with moisture-wicking agent.

9. The integrated woven, partitioned, breathable quilt and its manufacturing method according to claim 8, characterized in that, In step S1, the splicing structure of the insulation zone is a 1:1 splicing structure, with every 2 weft yarns spliced ​​once; the splicing warp yarns of the breathable zone are spliced ​​in a 4:1 discontinuous splicing, and are woven synchronously to form a figure-eight perforation, with the weft float of the figure-eight perforation being 5 yarns.

10. The integrated woven, partitioned, breathable quilt and its manufacturing method according to claim 9, characterized in that, In step S2, the hot melt treatment conditions are baking at 150°C for 3 minutes; the electronic jacquard loom is an air-jet electronic multi-arm loom with a reed width of 230cm.

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