A weaving method of light and thin warm polyester fabric

Abstract

The present application relates to the technical field of polyester fabric weaving, and discloses a weaving method of light and thin warm-keeping polyester fabric, which comprises configuration of surface layer warp yarn, inner layer warp yarn, edge jointing yarn, surface layer weft yarn, inner layer weft yarn and arch support weft yarn; surface layer tissue and inner layer tissue are woven according to preset warm-keeping units, and first edge jointing bands and second edge jointing bands are formed on both sides of the warm-keeping units; the arch support weft yarn is introduced between the two edge jointing bands, so that a floating section with an actual weft feeding length greater than the plane distance between the two edge jointing bands is formed; limiting warp yarn or limiting short jointing tissue is arranged in the middle of the floating section, and the edge jointing bands of adjacent warm-keeping units are arranged in a staggered manner; the gray fabric is subjected to low-tension heat setting, so that the edge jointing bands are shrunk and closed, and the arch support weft yarn is bent to form a micro-arch support, thereby forming a plurality of non-penetrating micro air cavities between the surface layer tissue and the inner layer tissue. The method can improve the interlayer air locking stability and continuous warm-keeping performance of the light and thin polyester fabric.

Description

Technical Field

[0001] This invention relates to the technical field of polyester fabric weaving, specifically a method for weaving a lightweight and warm polyester fabric. Background Technology

[0002] Polyester fabrics are characterized by high strength, dimensional stability, ease of care, and moderate cost, making them widely used in clothing fabrics, outdoor lining fabrics, and lightweight autumn / winter fabrics. With the application of fine denier polyester filaments, hollow polyester filaments, and hollow high-elastic composite polyester filaments in apparel fabrics, lightweight polyester fabrics are gradually developing towards softness, elasticity, and warmth. To improve warmth, existing polyester fabrics typically employ hollow polyester fibers, multi-layer weaving, air-layer structures, napping finishing, or functional finishing processes to create air-retaining spaces within or on the surface of the fabric, thereby reducing heat loss.

[0003] Existing lightweight and warm polyester fabrics, after reducing weight and thickness, have a smaller interlayer space between the outer and inner layers. The air layer is easily compressed during wearing, washing, rubbing, or repeated bending. If the warmth space is maintained by adding a middle layer, lengthening the connecting yarns, or increasing the fabric thickness, it can easily lead to excessive fabric fluffiness, a stiffer hand feel, and increased heaviness, making it difficult to meet the demand for lightweight wear.

[0004] Meanwhile, existing air layer structures are mostly continuous interlayer spaces or regular joint structures, which easily form airflow channels extending along the fabric plane between adjacent areas. When the fabric is compressed, the collapse of local air layers will further disrupt the interlayer air-locking state, causing the warmth retention effect to decrease during wearing and washing, affecting the continuous warmth retention performance of lightweight polyester fabrics. Summary of the Invention

[0005] The purpose of this invention is to provide a weaving method for lightweight and warm polyester fabrics, in order to solve the problem that the air space between layers of existing lightweight and warm polyester fabrics is prone to collapse due to compression during wearing and washing and rubbing after reducing weight and thickness, resulting in a decrease in air-locking stability and continuous warmth retention.

[0006] To achieve the above-mentioned objectives, the present invention employs the following technical solution: a method for weaving a lightweight and warm polyester fabric, comprising the following steps:

[0007] S1. Configure surface warp yarns, inner warp yarns, edge sealing yarns, surface weft yarns, inner weft yarns, and arching weft yarns. The surface warp yarns and surface weft yarns are woven into a surface structure, the inner warp yarns and inner weft yarns are woven into an inner structure, and the edge sealing yarns are woven into an edge sealing tape connecting the surface structure and the inner structure. The dry heat shrinkage rate of the arching weft yarns is lower than that of the edge sealing yarns.

[0008] S2. Weave in sections according to the preset insulation unit, so that the surface and inner layers are set opposite to each other, and form a first edge sealing strip and a second edge sealing strip on both sides of each insulation unit. The first edge sealing strip and the second edge sealing strip are both composed of continuous surface and inner joint points, which are used to define the closing boundaries on both sides of the insulation unit.

[0009] S3. An arched weft yarn is introduced between the first and second sealing edge joining tapes to form a floating section. The actual weft feed length of the floating section is greater than the planar distance between the first and second sealing edge joining tapes, and the floating section does not continuously participate in the interweaving of the surface and inner layers.

[0010] S4. A limiting warp or limiting short joint structure is set in the middle area of ​​the floating section so that the limiting warp or limiting short joint structure presses or wraps around the floating section, and the surface structure and the inner structure are not completely joined in the middle area.

[0011] S5. The sealing strips of adjacent insulation units are staggered along the warp or weft direction to form a non-straight-through broken flow path between adjacent insulation units.

[0012] S6. The woven fabric is subjected to low-tension heat setting, which causes the first and second edge sealing tapes to shrink and drive the closing boundaries on both sides of the insulation unit to gather inward. Under the action of the remaining length of the floating section, the arching weft yarn bends between the surface and inner layers to form micro-arch support, thereby forming multiple non-through micro air cavities.

[0013] Preferably, both the surface warp and weft yarns are made of fine denier polyester filaments, and the surface weave is a plain weave, a modified plain weave, or a fine twill weave, with the warp and weft density of the surface weave being higher than that of the inner weave.

[0014] Preferably, both the inner warp and weft yarns are made of polyester low-elasticity yarn or polyester filament with irregular cross-section, and the inner layer structure is a twill weave or a modified satin weave, so that the inner layer structure forms a skin-friendly and fluffy surface.

[0015] Preferably, the edge-sealing yarn is made of heat-shrinkable polyester filament, and the arching weft yarn is made of hollow low-elastic polyester filament, hollow high-elastic composite polyester filament, or crimp-recovery polyester multifilament, and the dry heat shrinkage rate of the edge-sealing yarn is 3% to 12% higher than that of the arching weft yarn.

[0016] Preferably, the actual weft feed length of the arched weft yarn between the first and second edge-sealing tapes is 1.05 to 1.35 times the planar distance between the first and second edge-sealing tapes.

[0017] Preferably, each insulation unit is defined by 4 to 10 warp yarns along the warp direction and by 4 to 12 weft yarns along the weft direction, with the first and second edge sealing tapes located on both sides of the insulation unit along the weft direction, respectively.

[0018] Preferably, the sealing strips in adjacent rows of insulation units are staggered along the latitudinal direction, with a stagger distance of 1 / 4 to 1 / 2 of the width of a single insulation unit, so that the boundaries of adjacent non-through micro air cavities are not in the same straight line direction.

[0019] Preferably, the limiting warp yarn or limiting short joint structure is located in the middle 1 / 3 area of ​​the floating section in the length direction, and forms a single-point pressing structure or wrapping structure with the arching weft yarn, so that the floating section forms a recoverable semi-arch section on both sides of the limiting position.

[0020] Preferably, the low-tension heat setting temperature is 160°C to 190°C. During heat setting, the fabric is in a relaxed or low-tension state along both the warp and weft directions, so that the first and second edge-sealing tapes deform before the arching weft yarns.

[0021] Preferably, the non-through micro air cavities are arranged in an array along the warp and weft directions of the fabric, and adjacent non-through micro air cavities are separated by staggered edge-sealing tapes, so that a segmented air-locking structure is formed inside the fabric.

[0022] Compared with existing technologies, the weaving method of a lightweight and warm polyester fabric using the above-mentioned technical solution has the following beneficial effects:

[0023] I. This application achieves the effect of the sealing weft yarn shrinking first and then pulling the closing edges of the insulation unit inward during low-tension heat setting by setting a first sealing weft yarn, a second sealing weft yarn, and arching weft yarn between the surface and inner layers, and making the dry heat shrinkage rate of the sealing weft yarn higher than that of the arching weft yarn. Because the arching weft yarn has a floating length greater than the planar distance between the two sealing weft yarns, it forms a micro-arch support under the constraint of the closing edges, thereby forming multiple non-penetrating micro-air cavities between the surface and inner layers without significantly increasing the overall fabric thickness, thus providing the fabric with a stable interlayer air-locking space.

[0024] II. This application achieves the effect of limiting the lateral movement of the arched weft yarn and preserving the interlayer space by setting a limiting warp yarn or limiting short-joint structure in the middle area of ​​the floating section of the arched weft yarn. This limiting warp yarn or limiting short-joint structure only presses or wraps around the arched weft yarn without completely connecting the surface and inner layers. The floating section forms semi-arched sections on both sides of the limiting position, which can maintain good recovery after wearing compression or washing and rubbing, reducing the problems of pressure adhesion and air cavity collapse in ordinary double-layer air-layer fabrics.

[0025] Third, this application achieves the effect of creating a zigzag flow obstruction path between adjacent non-through micro air cavities by staggering the edge sealing tapes of adjacent insulation units along the warp or weft direction. This structure makes it difficult for air inside the fabric to form a straight through-flow channel along the fabric plane. Combined with the tightly windproof surface of the outer layer and the skin-friendly, fluffy surface of the inner layer, this allows the lightweight polyester fabric to maintain softness and low weight while possessing relatively stable warmth retention and good durability. Attached Figure Description

[0026] Figure 1 This is a flowchart of the method in an embodiment. Detailed Implementation

[0027] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0028] like Figure 1 As shown, this embodiment provides a method for weaving a lightweight and warm polyester fabric. Figure 1 This is a flowchart of the weaving method in this embodiment. The lightweight, warm polyester fabric produced by this weaving method includes a surface layer, an inner layer, and multiple non-penetrating micro-air cavities located between the surface layer and the inner layer. These non-penetrating micro-air cavities do not form straight, continuous airflow channels along the fabric's planar direction. The weaving method includes the following steps:

[0029] S1. Configure surface warp yarns, inner warp yarns, edge sealing yarns, surface weft yarns, inner weft yarns, and arching weft yarns. The surface warp yarns and surface weft yarns are woven into a surface structure, the inner warp yarns and inner weft yarns are woven into an inner structure, and the edge sealing yarns are woven into an edge sealing tape connecting the surface structure and the inner structure. The dry heat shrinkage rate of the arching weft yarns is lower than that of the edge sealing yarns.

[0030] In this embodiment, the hollow high-elastic composite polyester filament has a hollow structure and crimp recovery properties. When used as an arching weft yarn, the floating section located between the surface and inner layers can maintain a micro-arched support state after heat setting.

[0031] In this embodiment, the outer warp yarn is made of 40D / 24F polyester FDY, and the outer weft yarn is made of 40D / 24F polyester FDY; the inner warp yarn is made of 75D / 72F polyester DTY, and the inner weft yarn is made of 75D / 72F polyester DTY; the edge-sealing and knotting yarn is made of 50D heat-shrinkable polyester filament; the arching weft yarn is made of 75D hollow high-elastic composite polyester filament; in other embodiments, the arching weft yarn is made of 75D hollow low-elastic polyester yarn or 75D crimp-recovery polyester multifilament. The dry heat shrinkage rate of the edge-sealing and knotting yarn and the arching weft yarn was measured under the same dry heat conditions of 180°C for 30 seconds. The dry heat shrinkage rate of the edge-sealing and knotting yarn was 12%, and the dry heat shrinkage rate of the arching weft yarn was 5%.

[0032] In this embodiment, the weaving equipment is a multi-arm loom capable of separately controlling the surface weave, inner weave, edge-sealing weft, and limiting structure. The surface warp, inner warp, edge-sealing weft, and limiting warp are threaded into their respective heald frames. The surface weft, inner weft, and arching weft are introduced through different weft insertion channels. The surface and inner warp are mounted on the warp beams, and the edge-sealing weft and limiting warp are threaded onto the healds according to the arrangement of the insulation units. The weft insertion tension of the arching weft is lower than that of the surface and inner weft.

[0033] In this embodiment, the surface and inner layers are formed using a layered weaving method. Except for the positions of the edge sealing tape and the limiting structure, the surface weft yarns interweave with the surface warp yarns, and the inner weft yarns interweave with the inner warp yarns. The edge sealing yarns participate in the interweaving of the surface and inner layers at the corresponding positions of the first and second edge sealing tapes, and at other positions, they enter the corresponding layer according to the weave cycle of the insulation unit. The limiting warp yarns participate in the limiting structure at the middle position of the arched weft yarn floating section, and at other positions, they move with the layer they belong to.

[0034] S2. The insulation unit is woven in sections, with the surface and inner layers arranged opposite each other. A first edge sealing strip and a second edge sealing strip are formed on both sides of each insulation unit. Both the first and second edge sealing strips are composed of continuous surface and inner bonding points, which are used to define the closing boundaries on both sides of the insulation unit.

[0035] In this embodiment, each insulation unit is defined by 6 warp yarns along the warp direction and 8 weft yarns along the weft direction. The first and second edge-sealing tapes extend along the warp direction and are spaced apart along the weft direction. The edge-sealing yarns interweave with the surface and inner layers at the first and second edge-sealing tapes, respectively, so that the surface and inner layers form continuous sealing boundaries on both sides of the insulation unit.

[0036] In this embodiment, both the first and second edge-sealing bonding tapes are composed of continuously arranged front and back bonding points along the warp direction. Each front and back bonding point is formed by the edge-sealing yarn interlacing sequentially with the outer weft yarn and the inner weft yarn, and adjacent front and back bonding points within the same edge-sealing tape maintain a continuous weave cycle. The first and second edge-sealing tapes serve as the weft-side boundaries of the insulation unit, respectively, and an interlayer area is reserved between the two edge-sealing tapes for arranging the arched weft yarn floating section.

[0037] In this embodiment, the insulation units are arranged in a continuous warp direction and a repetitive weft direction. Adjacent insulation units share or are adjacent to each other with edge sealing strips, the width of which is one to two rows of joint points. When using two rows of joint points, the two rows of joint points are staggered along the warp direction.

[0038] S3. An arched weft yarn is introduced between the first and second edge-sealing bonding tapes to form a floating section. The actual weft feed length of the floating section is greater than the planar distance between the first and second edge-sealing bonding tapes, and the floating section does not continuously participate in the interweaving of the surface and inner layers.

[0039] In this embodiment, the planar distance between the first and second edge-sealing bonding tapes is denoted as L. The weft feeding amount of the arched weft yarn is controlled by the weft feeding mechanism, so that the actual weft feeding length of the arched weft yarn between the first and second edge-sealing bonding tapes is 1.15L. The arched weft yarn spans between the surface and inner layers of the weave and forms a floating section.

[0040] In this embodiment, the planar distance L between the first and second edge-sealing bonding tapes is determined by the distance between the center lines of the two edge-sealing bonding tapes. The actual weft feed length of the arched weft yarn is controlled by both the weft feed length setting and the weft feed tension. After the greige fabric comes off the machine, the corresponding insulation unit is selected, and the floating section of the arched weft yarn is straightened and measured along its extension direction. The measured length of the floating section is taken as the actual weft feed length.

[0041] In this embodiment, the arched weft yarn is woven into the edge-sealing tape at the first edge-sealing tape and again at the second edge-sealing tape. The portion located between the two edge-sealing tapes forms a floating section. The floating section is located between the surface layer and the inner layer and does not continuously interweave with the surface warp yarns or the inner warp yarns.

[0042] S4. A limiting warp or limiting short joint structure is provided in the middle region of the floating section, so that the limiting warp or limiting short joint structure presses or wraps around the floating section, and the surface structure and the inner structure are not completely joined in the middle region.

[0043] In this embodiment, the limiting warp yarn is threaded within the limiting heald frame assembly. When forming a single-point pressing structure, the limiting warp yarn passes over the arched weft yarn in the middle of the floating section of the arched weft yarn, and returns to the original weave cycle after this weave point. The limiting warp yarn contacts and engages with the arched weft yarn at this position, and does not continuously connect the surface weave and the inner weave.

[0044] In another embodiment, the limiting warp yarn is replaced with a limiting short-joint structure, which forms a holding structure for the arching weft yarn in the middle of the floating section, and the limiting short-joint structure does not continuously join the surface structure and the inner structure into a solid joint area.

[0045] In this embodiment, the limiting warp yarn is threaded within the limiting heald frame assembly. When forming a single-point pressing structure, the limiting warp yarn rises above the arched weft yarn in the middle of the floating section of the arched weft yarn, and returns to the original weave layer after passing the arched weft yarn. The limiting warp yarn contacts and engages with the arched weft yarn at this position, and the limiting warp yarn discontinuously connects the surface weave and the inner weave.

[0046] In this embodiment, the limiting short-joint structure is formed by adjacent outer and inner warp yarns alternating at short distances in the middle of the floating section. The joint length of the limiting short-joint structure is less than the joint length of the first and second edge sealing joints, and the limiting short-joint structure is only located in the middle of the arched weft floating section and does not extend continuously along the boundary of the insulation unit.

[0047] S5. The sealing strips of adjacent insulation units are staggered along the warp or weft direction to form a non-straight-through broken flow path between adjacent insulation units.

[0048] In this embodiment, the first and second sealing strips in two adjacent rows of insulation units are staggered along the latitudinal direction, with a stagger distance of 1 / 3 of the width of a single insulation unit. The boundaries of adjacent non-through micro air cavities are not in the same straight line direction, forming a broken flow obstruction path between adjacent insulation units.

[0049] In this embodiment, adjacent rows of insulation units are staggered along the latitudinal direction. Using the first edge-sealing strip of the preceding row of insulation units as a reference, the first edge-sealing strip of the following row of insulation units is offset 1 / 3 of the width of a single insulation unit along the latitudinal direction. The second edge-sealing strip of the following row of insulation units is offset synchronously with the first edge-sealing strip, ensuring that the two edge-sealing strips of the following row of insulation units maintain the same spacing.

[0050] In this embodiment, the staggered edge-sealing tapes form segmented boundaries within the fabric plane. The boundaries of adjacent rows of non-through micro air cavities do not overlap, and the edge-sealing areas are spaced apart in both the warp and weft directions of the fabric.

[0051] S6. The woven fabric is subjected to low-tension heat setting, which causes the first and second edge sealing tapes to shrink and drive the closing boundaries on both sides of the insulation unit to gather inward. Under the action of the remaining length of the floating section, the arching weft yarn bends between the surface and inner layers to form micro-arch support, thereby forming multiple non-through micro air cavities.

[0052] In this embodiment, after the fabric is woven, it undergoes low-tension heat setting at a temperature of 175°C for 45 seconds. During heat setting, the warp tension is lower than the conventional setting tension of a polyester double-layer fabric of the same specification, and the weft is only spread out and flattened without strong stretching. During the heat setting process, the first and second edge-sealing tapes shrink, the edges of the insulation units on both sides converge inward, and the arching weft yarns bend between the outer and inner layers to form micro-arch supports. After heat setting and cooling, multiple insulation units form non-through micro-air cavities distributed in an array along the warp and weft directions of the fabric.

[0053] In this embodiment, the fabric is kept in a naturally shrunken state before entering the heat setting equipment. During heat setting, the warp elongation of the fabric is controlled within 0.5%, and the weft spread is controlled to be 0% to 2% of the natural width of the fabric. After heat setting, the fabric is cooled and shaped under low tension.

[0054] In this embodiment, after heat setting, a sample fabric is cut along the weft direction of the fabric and the cross-section of the insulation unit is observed. An interlayer region is formed between the first and second edge-sealing tapes. The arching weft yarn is located within this interlayer region and is in a bent state. The limiting warp yarn is located in the middle of the floating section of the arching weft yarn. The first and second semi-arched sections are located on both sides of the limiting position, respectively. Adjacent non-through micro air cavities are arranged at intervals along the warp and weft directions of the fabric.

[0055] Furthermore, both the surface warp and weft yarns are made of fine denier polyester filament, and the surface structure is a plain weave, a modified plain weave, or a fine twill weave, with the warp and weft density of the surface structure being higher than that of the inner structure.

[0056] In this embodiment, the surface layer is a plain weave, and both the surface warp and weft yarns are made of 40D / 24F polyester FDY. The warp and weft densities of the surface layer are higher than those of the inner layer, forming a tight outer surface layer on the outside of the fabric.

[0057] Furthermore, both the inner warp and weft yarns are made of polyester low-elasticity yarn or polyester filament with irregular cross-section, and the inner layer structure is made of twill weave or modified satin weave, so that the inner layer structure forms a skin-friendly and fluffy surface.

[0058] In this embodiment, the inner layer weave employs a 2 / 2 twill weave variation, and both the inner layer warp and weft yarns are made of 75D / 72F polyester DTY. The weave density of the inner layer is lower than that of the outer layer weave.

[0059] Furthermore, the edge-sealing yarn is made of heat-shrinkable polyester filament, and the arching weft yarn is made of hollow polyester low-elasticity yarn, hollow high-elasticity composite polyester filament, or crimp-recovery polyester multifilament. The dry heat shrinkage rate of the edge-sealing yarn is 3% to 12% higher than that of the arching weft yarn.

[0060] In the example, the dry heat shrinkage rate of the sealing and knotting yarn is 12%, and the dry heat shrinkage rate of the arching weft yarn is 5%, with a difference of 7% between the two.

[0061] Furthermore, the actual weft feed length of the arched weft yarn between the first and second edge-sealing tapes is 1.05 to 1.35 times the planar distance between the first and second edge-sealing tapes.

[0062] In this embodiment, the actual weft feed length of the arched weft yarn is 1.15 times the planar distance between the first and second edge-sealing tapes. The actual weft feed length is set by the weft feed mechanism and confirmed by measuring the corresponding floating section after the fabric comes off the machine.

[0063] Furthermore, each insulation unit is defined by 4 to 10 warp yarns along the warp direction and by 4 to 12 weft yarns along the weft direction, with the first and second edge sealing tapes located on both sides of the insulation unit along the weft direction, respectively.

[0064] In this embodiment, each insulation unit is defined by 6 warp yarns along the warp direction and by 8 weft yarns along the weft direction. The first edge sealing tape and the second edge sealing tape are respectively provided on both sides of the insulation unit along the weft direction.

[0065] Furthermore, the sealing strips in adjacent rows of insulation units are staggered along the latitudinal direction, with a stagger distance of 1 / 4 to 1 / 2 of the width of a single insulation unit, so that the boundaries of adjacent non-through micro air cavities are not in the same straight line direction.

[0066] In this embodiment, the sealing strips in two adjacent rows of insulation units are staggered along the latitudinal direction, and the stagger distance is 1 / 3 of the width of a single insulation unit.

[0067] Furthermore, the limiting warp yarn or limiting short joint structure is located in the middle 1 / 3 area of ​​the floating section in the length direction, and forms a single-point pressing structure or wrapping structure with the arching weft yarn, so that the floating section forms a recoverable semi-arch section on both sides of the limiting position.

[0068] In this embodiment, the limiting warp is located in the middle 1 / 3 area of ​​the floating section in the length direction. The limiting warp and the arching weft form a single-point pressing structure, so that the floating section forms a first semi-arched section and a second semi-arched section on both sides of the limiting position.

[0069] Furthermore, the low-tension heat setting temperature is 160°C to 190°C. During heat setting, the fabric is in a relaxed or low-tension state along both the warp and weft directions, causing the first and second edge-sealing tapes to undergo end-sealing deformation before the arching weft yarns.

[0070] In this embodiment, the low-tension heat setting temperature is 175°C, and the heat setting time is 45 seconds. During heat setting, the warp stretching tension is lower than the conventional setting tension of polyester double-layer fabric of the same specification, and the weft only spreads flat without strong stretching.

[0071] Furthermore, the non-penetrating micro air cavities are arranged in an array along the warp and weft directions of the fabric, and adjacent non-penetrating micro air cavities are separated by staggered edge-sealing tapes, so that a segmented air-locking structure is formed inside the fabric.

[0072] In this embodiment, the non-through micro air cavities are defined by a first sealing strip, a second sealing strip, a surface layer, an inner layer, and arching weft yarns. Multiple non-through micro air cavities are arranged in an array along the warp and weft directions of the fabric, and adjacent non-through micro air cavities are separated by staggered sealing strips to form a segmented air-locking structure.

[0073] In this embodiment, after the fabric is heat-set with low tension, the first and second edge-sealing tapes form an inwardly tapered boundary. The arched weft yarns are located between the surface and inner layers and form a micro-arch support. The limiting warp yarns or limiting short knots are located in the middle of the floating section of the arched weft yarns. Adjacent insulation units are separated by staggered edge-sealing tapes. Multiple non-through micro air cavities are arranged along the warp and weft directions of the fabric.

[0074] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A method for weaving a lightweight, warm polyester fabric, characterized in that, Includes the following steps: S1. Configure surface warp yarns, inner warp yarns, edge sealing yarns, surface weft yarns, inner weft yarns, and arching weft yarns. The surface warp yarns and surface weft yarns are woven into a surface structure, the inner warp yarns and inner weft yarns are woven into an inner structure, and the edge sealing yarns are woven into an edge sealing tape connecting the surface structure and the inner structure. The dry heat shrinkage rate of the arching weft yarns is lower than that of the edge sealing yarns. S2. Weave in sections according to the preset insulation unit, so that the surface and inner layers are set opposite to each other, and form a first edge sealing strip and a second edge sealing strip on both sides of each insulation unit. The first edge sealing strip and the second edge sealing strip are both composed of continuous surface and inner joint points, which are used to define the closing boundaries on both sides of the insulation unit. S3. An arched weft yarn is introduced between the first and second sealing edge joining tapes to form a floating section. The actual weft feed length of the floating section is greater than the planar distance between the first and second sealing edge joining tapes, and the floating section does not continuously participate in the interweaving of the surface and inner layers. S4. A limiting warp or limiting short joint structure is set in the middle area of ​​the floating section so that the limiting warp or limiting short joint structure presses or wraps around the floating section, and the surface structure and the inner structure are not completely joined in the middle area. S5. The sealing strips of adjacent insulation units are staggered along the warp or weft direction to form a non-straight-through broken flow path between adjacent insulation units. S6. The woven fabric is subjected to low-tension heat setting, which causes the first and second edge sealing tapes to shrink and drive the closing boundaries on both sides of the insulation unit to gather inward. Under the action of the remaining length of the floating section, the arching weft yarn bends between the surface and inner layers to form micro-arch support, thereby forming multiple non-through micro air cavities.

2. The method for weaving a lightweight, warm polyester fabric according to claim 1, characterized in that, Both the surface warp and weft yarns are made of fine denier polyester filaments. The surface weave is a plain weave, a modified plain weave, or a fine twill weave, and the warp and weft density of the surface weave is higher than that of the inner weave.

3. The method for weaving a lightweight, warm polyester fabric according to claim 1, characterized in that, Both the inner warp and weft yarns are made of polyester low-elasticity yarn or polyester filament with irregular cross-section. The inner layer structure is a twill weave or a modified satin weave, so that the inner layer structure forms a skin-friendly and fluffy surface.

4. The method for weaving a lightweight, warm polyester fabric according to claim 1, characterized in that, The edge-sealing and knotting yarn is made of heat-shrinkable polyester filament, and the arching weft yarn is made of hollow polyester low-elasticity yarn, hollow high-elasticity composite polyester filament, or crimp-recovery polyester multifilament. The dry heat shrinkage rate of the edge-sealing and knotting yarn is 3% to 12% higher than that of the arching weft yarn.

5. The method for weaving a lightweight, warm polyester fabric according to claim 1, characterized in that, The actual weft feed length of the arched weft yarn between the first and second edge-sealing tapes is 1.05 to 1.35 times the planar distance between the first and second edge-sealing tapes.

6. The method for weaving a lightweight, warm polyester fabric according to claim 1, characterized in that, Each insulation unit is defined by 4 to 10 warp yarns along the warp direction and by 4 to 12 weft yarns along the weft direction. The first and second edge sealing tapes are located on both sides of the insulation unit along the weft direction, respectively.

7. The method for weaving a lightweight, warm polyester fabric according to claim 1, characterized in that, The sealing strips in adjacent rows of insulation units are staggered along the latitudinal direction, with a stagger distance of 1 / 4 to 1 / 2 of the width of a single insulation unit, so that the boundaries of adjacent non-through micro air cavities are not in the same straight line direction.

8. The method for weaving a lightweight, warm polyester fabric according to claim 1, characterized in that, The limiting warp yarn or limiting short joint structure is located in the middle 1 / 3 area of ​​the floating section length direction, and forms a single-point pressing structure or wrapping structure with the arching weft yarn, so that the floating section forms a recoverable semi-arch section on both sides of the limiting position.

9. The method for weaving a lightweight, warm polyester fabric according to claim 1, characterized in that, The low-tension heat setting temperature is 160°C to 190°C. During heat setting, the fabric is in a relaxed or low-tension state along both the warp and weft directions, so that the first and second edge-sealing tapes deform before the arching weft yarns.

10. The method for weaving a lightweight, warm polyester fabric according to claim 1, characterized in that, The non-through micro air cavities are arranged in an array along the warp and weft directions of the fabric, and adjacent non-through micro air cavities are separated by staggered edge-sealing tapes, forming a segmented air-locking structure inside the fabric.

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