Partitioned filling and three-dimensional forming method for down jackets
By using a zoned down filling and three-dimensional molding method, the problem of low down filling efficiency in down jackets has been solved, achieving efficient zoned down filling and three-dimensional molding, thus improving the warmth and comfort of down jackets.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- HANGZHOU LUFEIYA CLOTHING CO LTD
- Filing Date
- 2026-05-26
- Publication Date
- 2026-07-03
AI Technical Summary
The current technology for filling down jackets is inefficient, making it difficult to achieve zoned filling and three-dimensional molding, which affects production efficiency and results.
By employing a zoned filling and three-dimensional molding method, the down jacket fabric is divided into zones. Using a down filling mechanism and a sewing mechanism, the appropriate amount of down is filled into each zone, and a stable, fluffy structure is formed through three-dimensional sewing. Combined with high-precision weighing and testing equipment, it is ensured that the filling amount and loft meet the design standards.
This improved the processing efficiency of down jackets, ensuring that the amount of down and the loft in each area met design requirements, thus enhancing the warmth and comfort of the down jackets.
Smart Images
Figure CN122320291A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of down filling technology, and more particularly to a method for partitioned down filling and three-dimensional molding of down jackets. Background Technology
[0002] Down is a natural insulating material, mainly derived from the down feathers of geese and ducks. Due to its excellent loft, lightness, and breathability, down has become one of the most popular filling materials in winter clothing. It can effectively trap air to form an insulating layer and keep the body warm. In order to improve the warmth and comfort of down jackets, designers have gradually introduced the concept of zoned filling. This method divides the down jacket into multiple zones, and each zone is filled with down according to different warmth requirements to ensure the best warmth effect in different parts. The chest and shoulders usually need more down, while the sleeves and hem can have relatively less down filling.
[0003] In Chinese patent CN121242307A, down filling is basically done by directly inserting down into the down jacket fabric, and the quality of the down jacket is measured in real time to determine the amount of down inserted. When too much down is inserted, the down is pulled out by a down grabbing mechanism. When the down is too small, more down is added. This method greatly affects production efficiency. Therefore, this invention proposes a method of partitioned down filling and three-dimensional molding for down jackets to solve the problems existing in the prior art. Summary of the Invention
[0004] To address the aforementioned problems, the present invention aims to propose a method for partitioned filling and three-dimensional molding of down jackets. This method partitions the down jacket fabric into sections, with each specific section corresponding to a certain amount of down based on its size. In actual operation, a down filling machine can be used to fill the specific section with down in one go, and a down filling mechanism can be used to fill the corresponding section with down.
[0005] To achieve the objectives of this invention, the invention is implemented through the following technical solution: a method for partitioned down filling and three-dimensional molding of down jackets, comprising the following steps; Step 1: Divide the down jacket fabric into sections, and sort and group the down to be filled according to the sections, with the groups corresponding to the sections; Step 2: First, sew the bottom sections of the down jacket fabric together, leaving a down filling inlet. Then, use the down filling mechanism to fill the sewn area with down corresponding to the section. Finally, use the sewing mechanism to sew the down filling inlet closed. Step 3: Following the method in Step 2 above, fill and completely sew the down jacket fabric into each section in order from dark to light. Then, divide the large area of the filled down jacket fabric into sections and use a sewing machine to sew the top and bottom sections together. Step 4: During the sewing process, three-dimensional sewing is used to create a stable, fluffy structure in each section of down through multi-dimensional stitching. Step 5: Perform overall down filling calibration and loft test on the completed 3D sewn down jacket semi-finished product. Use high-precision weighing equipment to verify the actual down filling of each independent section to ensure that the deviation from the design standard is controlled within ±3%, thereby completing the 3D molding.
[0006] A further improvement is that, in step one, the zoning process includes dividing the down jacket fabric into large zoning areas and small zoning areas.
[0007] A further improvement is made in the following steps: In step one, the down is sorted and grouped by an airflow sorting device to classify the down by loft, and the down with a loft difference of less than 5% is grouped into the same group. Each group of down is also tested by a metal detector to ensure that no metal impurities with a diameter greater than 0.5mm are mixed in.
[0008] A further improvement is made in step two, where the down filling mechanism uses a spiral airflow delivery pipe with an adjustable down filling nozzle at the end of the pipe. The nozzle diameter is 8mm, depending on the volume of different zones, to ensure that the down is filled evenly and to prevent the down from scattering and being lost due to excessive airflow during the filling process.
[0009] Further improvements are made in the following steps: In step three, when the large area is further divided, dynamic zoning is planned according to the three-dimensional cutting curvature of the down jacket style. In the shoulder area, the original large shoulder area is subdivided into 3-4 fan-shaped small areas according to the natural protrusion angle of the human shoulder blade. The fit error between the edge seam of each small area and the curve of the human shoulder does not exceed 2mm.
[0010] A further improvement is made in step four by using diagonal cross stitches in frequently used areas such as the shoulders and elbows.
[0011] A further improvement is made in step five, where a loft tester is used to measure the loft height of the down in each section, with the loft of each section being 700FP under standard pressure.
[0012] A further improvement is made in the partitioning process in step one, where the down filling the partitions is grouped by weight, with the weight values corresponding to the area size of the partitions.
[0013] A further improvement is made in step two: a CCD vision inspection system is used to scan and identify defects in the sutures in real time, with a defect identification accuracy of 0.02mm. The beneficial effects of this invention are as follows: This invention divides the down jacket fabric into sections, with each specific section corresponding to a certain amount of down based on its size. In actual operation, a down filling machine can be used to fill the down belonging to this specific section at once, and a down filling mechanism can be used to fill the down in the corresponding section. After the area is sewn, the down filling inlet is sewn closed by a sewing mechanism. The down filling mechanism only needs to fill all the down in the corresponding section into that section, without having to weigh the entire down fabric repeatedly, thus greatly improving the processing efficiency of down jacket filling. Attached Figure Description
[0014] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0015] Figure 1 This is a flowchart of the steps of the present invention. Detailed Implementation
[0016] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0017] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms installation, connection, and linking should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.
[0018] In document CN121242307A, a layered structure is set between the outer fabric layer and the lining layer, and the stitching of the outer fabric layer is sealed by the layered structure, thereby forming multiple interconnected fabric down cavities with equal spacing. This allows the down to be evenly and fluffily distributed in the down cavities, avoiding the cold bridge effect and down leakage caused by the stitching directly penetrating the fabric. While achieving basic warmth, it significantly improves the overall heat insulation performance and durability of the down jacket. The layered structure consists of layered fabric and overlapping quilting. Adjacent overlapping quilting lines are stitched together to form multiple layered cavities, so that the down can obtain three-dimensional support when filling the cavities, reducing the deformation of the cavities caused by external pressure. The geometric stability of this triangular stacked cavity enhances the stability of the chamber structure and the loft of the down, thus maintaining good warmth during wear and exercise. However, the down is pulled out of the down jacket by the down grabbing mechanism, and when the down is small, more down is added, which greatly affects the production efficiency. The partitioned down filling technology in this application allows the down filling process to be completed quickly and accurately. Combined with the three-dimensional molding process, the production cycle can be shortened.
[0019] Example 1 according to Figure 1 As shown, this embodiment provides a method for partitioned down filling and three-dimensional molding of down jackets, including the following steps; Step 1: Divide the down jacket fabric into sections, and then group the down to be filled according to the sections, with each group corresponding to one of the sections. Step 2: First, sew the bottom sections of the down jacket fabric together, leaving a down filling inlet. Then, use the down filling mechanism to fill the sewn area with down corresponding to the section. Finally, use the sewing mechanism to sew the down filling inlet closed. Step 3: Following the method in Step 2 above, fill and completely sew the down jacket fabric into each section in order from dark to light. Then, divide the large area of the filled down jacket fabric into sections and use a sewing machine to sew the top and bottom sections together. Step 4: During the sewing process, three-dimensional sewing is used to create a stable, fluffy structure in each section of down through multi-dimensional stitching. Step 5: Perform overall down filling calibration and loft test on the completed 3D sewn down jacket semi-finished product. Use high-precision weighing equipment to verify the actual down filling of each independent section to ensure that the deviation from the design standard is controlled within ±3%, thereby completing the 3D molding.
[0020] In step one, the zoning process includes dividing the down jacket fabric into large zoning areas and small zoning areas, with the zoning boundary line width being 3-5mm.
[0021] In step one, the down is sorted and grouped by airflow sorting equipment to classify the down by loft. Down with a loft difference of less than 5% is grouped into the same group, and each group of down must be tested by a metal detector to ensure that no metal impurities with a diameter greater than 0.5mm are mixed in. In view of the different warmth requirements of different zones, the proportion of down after grouping is adjusted. 8%-12% of antibacterial down is added to the neck zone, while 15%-20% of water-repellent down is mixed into the inner cuff zone to improve the functionality of specific areas.
[0022] In step two, the down filling mechanism adopts a spiral airflow delivery pipe with an adjustable filling nozzle at the end of the pipe. The nozzle diameter is within 8mm depending on the volume of different zones to ensure that the down is filled evenly and to avoid down loss due to excessive airflow during filling. Before filling, the filling nozzle needs to be static-eliminating treated by blowing it with an ion air gun for 10-15 seconds to prevent down from being attracted to the inner wall of the pipe due to static electricity and affecting the accuracy of the filling amount. During the filling process, the down filling height in the zone is monitored in real time by an infrared sensor. When the preset filling amount of 90% is reached, the filling mechanism automatically switches to low-speed filling mode until the quantitative filling of down in that zone is completed.
[0023] In step three, during the re-division of the large area, dynamic zoning is planned according to the three-dimensional cutting curvature of the down jacket style. In the shoulder area, the original large shoulder area is subdivided into 3-4 fan-shaped small areas according to the natural protrusion angle of the human shoulder blade. The fit error between the edge seam of each small area and the curve of the human shoulder does not exceed 2mm. The sewing process adopts a combination of double-line overlocking and single-needle blind stitching. The double-line overlocking is used with a stitch length of 0.8mm to fix the outline of the zoning. Then, a single-needle blind stitch is made along the inner edge of the zoning with a fine thread of the same color as the fabric, 0.5cm from the edge of the zoning. This makes the seam hidden in the fabric texture, ensuring the stability of the zoning structure and improving the aesthetics of the finished product.
[0024] In step four, diagonal cross stitches are used in frequently moving areas such as the shoulders and elbows to enhance the structural stability and stretchability of the zones; while parallel and equidistant stitches are used in core warming areas such as the back and abdomen to ensure that the down is evenly distributed and does not easily pile up. During the three-dimensional sewing process, a 0.5-1cm loft allowance is reserved so that the filled down can naturally expand to form an ergonomic three-dimensional silhouette, which not only ensures the warmth of the down jacket, but also improves the fit and comfort of wearing it.
[0025] In step five, a fill power tester is used to measure the fill power of the down in each section. Under standard pressure, the fill power of each section is 700FP; the allowable error is no more than ±50FP. For sections where the fill power and fill power do not meet the standards, precise down filling is performed through a dedicated down filling channel or a small amount of down removal is performed using a negative pressure device to ensure that the warmth performance of each section meets the design requirements.
[0026] In step one, the down filling in each zone is grouped by weight, with the weight corresponding to the area of the zone. The weight of the down filling in the chest area is set to 120-150g, the weight in the back area to 110-140g, the weight in the shoulder area to 80-100g, the weight at the cuff of the sleeve area to 40-50g, the weight at the upper arm to 60-70g, and the weight at the hem area to 50-60g. The weight of the down in each zone is precisely weighed, with the error controlled within ±2g.
[0027] In step two, after the suturing is completed, the suture stitches are scanned in real time using a CCD vision inspection system to identify defects such as skipped stitches, loose threads, or broken threads. The defect identification accuracy is 0.02mm.
[0028] Example 2 The down jacket fabric to be filled is divided into sections, including large and small sections. Smaller sections allow for fuller down filling and are less prone to down shifting. The down to be filled is then grouped according to these sections, with each group corresponding to a section. Grouping is done by weight, with the weight corresponding to the area of the section. The calculation method is to multiply the total area of down to be filled by the area of the section. The bottom sections of the down jacket fabric are sewn together, leaving down filling inlets. The down filling mechanism is then used to fill the corresponding sections... The down filling area is filled into the sewn area, and then the down filling inlet is sewn shut by the sewing mechanism. The down filling mechanism only needs to fill all the down of the corresponding area into the area, without repeatedly weighing, filling and taking out the entire down fabric. The down filling mechanism can be a down filling machine or a down grabbing machine. When using a down grabbing machine, the reserved down filling inlet should be easy for the down grabbing claw to insert down. The down jacket fabric is filled and completely sewn into each section in a way from dark to light. The large area of the filled down jacket fabric is then divided into sections, and the sewing mechanism is used to sew the top and bottom sections together.
[0029] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.
Claims
1. A method for partitioned down filling and three-dimensional molding of down jackets, characterized in that, Includes the following steps; Step 1: Divide the down jacket fabric into sections, and sort and group the down to be filled according to the sections, with the groups corresponding to the sections; Step 2: First, sew the bottom sections of the down jacket fabric together, leaving a down filling inlet. Then, use the down filling mechanism to fill the sewn area with down corresponding to the section. Finally, use the sewing mechanism to sew the down filling inlet closed. Step 3: Following the method in Step 2 above, fill and completely sew the down jacket fabric into each section in order from dark to light. Then, divide the large area of the filled down jacket fabric into sections and use a sewing machine to sew the top and bottom sections together. Step 4: During the sewing process, three-dimensional sewing is used to create a stable, fluffy structure in each section of down through multi-dimensional stitching. Step 5: Perform overall down filling calibration and loft test on the semi-finished down jacket after 3D sewing. Use high-precision weighing equipment to verify the actual down filling of each independent section to complete the 3D molding.
2. The method for partitioned down filling and three-dimensional molding of down jackets according to claim 1, characterized in that: In step one, the zoning process includes dividing the down jacket fabric into large zoning areas and small zoning areas.
3. The method for partitioned down filling and three-dimensional molding of down jackets according to claim 1, characterized in that: In step one, the down is sorted and grouped by an airflow sorting device to classify the down by loft. Down with a loft difference of less than 5% is grouped into the same group, and each group of down is tested by a metal detector to ensure that no metal impurities with a diameter greater than 0.5mm are mixed in.
4. The method for partitioned down filling and three-dimensional molding of down jackets according to claim 1, characterized in that: In step two, the down filling mechanism adopts a spiral airflow conveying pipe. The end of the pipe is equipped with an adjustable down filling nozzle. The diameter of the down filling nozzle is 8mm, depending on the volume of different zones, to ensure that the down is filled evenly and to avoid down scattering and loss due to excessive airflow during the filling process.
5. The method for partitioned down filling and three-dimensional molding of down jackets according to claim 1, characterized in that: In step three, when the large area is further divided, dynamic zoning is planned according to the three-dimensional cutting curvature of the down jacket style. In the shoulder area, the original shoulder area is subdivided into 3-4 fan-shaped small areas according to the natural protrusion angle of the human shoulder blade. The fit error between the edge seam of each small area and the curve of the human shoulder does not exceed 2mm.
6. The method for partitioned down filling and three-dimensional molding of down jackets according to claim 1, characterized in that: In step four, diagonal cross stitches are used in the frequently moving areas of the shoulder and elbow.
7. The method for partitioned down filling and three-dimensional molding of down jackets according to claim 1, characterized in that: In step five, a loft tester is used to measure the loft height of the down in each section. Under standard pressure, the loft of each section is 700FP.
8. The method for partitioned down filling and three-dimensional molding of down jackets according to claim 1, characterized in that: In step one, the down filling the partition is grouped by weight, with the weight value corresponding to the area size of the partition.
9. The method for partitioned down filling and three-dimensional molding of down jackets according to claim 1, characterized in that: In step two, a CCD vision inspection system is used to scan and identify defects in the sutures in real time, with a defect identification accuracy of 0.02 mm.