A special three-dimensional flower-shaped structure, a manufacturing method and application thereof

Abstract

The application discloses a special three-dimensional flower-shaped structure and a manufacturing method and application thereof, and belongs to the technical field of textile and garment manufacturing. The structure comprises an outer fabric, an inner lining cloth, a loose cotton layer and at least one elastic band. The elastic band is sewn together with the fabric, the lining cloth and the loose cotton layer along a preset flower-shaped path in a stretched state, and the elastic band is retracted after sewing, so that the loose cotton layer forms a three-dimensional wrinkle flower shape. The manufacturing method comprises the following steps: flattening the fabric, the lining cloth, the loose cotton and the elastic band in sequence, prepositioning the elastic band between the fabric and the lining cloth according to a predetermined stretching ratio, clamping and fixing the elastic band by using a special clamp, sewing along the flower-shaped path by using an embroidery machine, and taking out the finished product after sewing. The application is one-time sewing forming, does not need secondary down filling, adopts the loose cotton to replace the down, has low cost, and has a three-dimensional flower shape which is full and stable in quality, and is suitable for three-dimensional decoration of garment cuffs, hems and other parts.

Description

Technical Field

[0001] This invention belongs to the field of textile and garment manufacturing technology, specifically relating to a special three-dimensional floral structure, its manufacturing method, and its application. Background Technology

[0002] In clothing design, to enhance the aesthetics and three-dimensionality of products, it is often necessary to create three-dimensional floral or stripe decorative structures on parts such as cuffs, hems, and bodies. Existing literature points out that the semi-three-dimensional decorative techniques in clothing design are mainly studied from the aspects of display effect and process materials. The common expression methods of semi-three-dimensional decoration in clothing are divided into those based on pleats and those based on partial three-dimensional decoration for case application research. Its application makes the flat surface of clothing present a semi-three-dimensional spatial sense in terms of vision and touch (Yang Lu. Application of semi-three-dimensional decorative techniques in clothing design [J]. Progress in Textile Technology, 2024, (11): 46-50.). With the continuous development and innovation of knitting technology and processes, knitted garments with three-dimensional effects have more vivid textures and richer shapes than ordinary fabrics. However, in order to achieve a three-dimensional voluminous effect similar to down stripes, the traditional process usually uses the sewing machine stitching method, which tightens the lower layer of fabric and loosens the upper layer of fabric, and fills the formed channel with down. Specifically, the process requires laying out the fabric, the inner lining, and the down in sequence, and then filling the strip-shaped areas with down through a needle-hole filling method to create a three-dimensional, raised appearance.

[0003] The aforementioned traditional down filling processes have also been the focus of numerous patent documents in actual production. For example, Chinese patent CN210309425U discloses a seamless three-dimensional patterned down direct-fill fabric and its products, which forms a three-dimensional pattern through foaming printing to prevent down from leaking through the sewing needle holes. Chinese patent application CN121242307A discloses a three-dimensional layered down filling structure, which sets the layered layer between the outer fabric layer and the inner fabric layer to solve the technical problems of cold bridging and down leakage caused by the seams penetrating the fabric in traditional quilted structures. Chinese patent application CN121242316A discloses a vertical channel down filling process that prevents down shedding, which connects horizontally distributed three-dimensional strips between the inner and outer garment pieces to form an independent three-dimensional space for the down filling layer, and binds the down material with quilting to achieve a uniform distribution of the down material. Although the solutions involved in the above patents have improved the down filling process from different perspectives, they all use down as the filling material and still require two separate processes: channel forming and down filling. The process chain is relatively long, and there are still potential risks of uneven distribution and decreased warmth retention of down during use and washing.

[0004] However, the aforementioned traditional processes and existing improvements still have many shortcomings in actual production. First, the down-filling process is cumbersome, requiring specialized equipment and multiple operations, resulting in low production efficiency. Second, the distribution of down within the sliver is difficult to achieve evenly, easily leading to localized accumulation or gaps, resulting in unstable three-dimensional patterns. Third, down easily escapes through needle holes or seams, a problem known as "down leakage." Although some solutions attempt to mitigate this through structural improvements, it is difficult to completely eliminate, severely impacting product quality and user experience. Furthermore, the three-dimensional patterns produced by this process are prone to deformation and collapse after multiple washes, significantly reducing their three-dimensionality. Finally, this process requires highly skilled operators, and both material (down) and labor costs are high, hindering mass production and widespread adoption.

[0005] Therefore, there is an urgent need for a new type of three-dimensional floral structure and its manufacturing method that can simplify operation, reduce costs, and improve the three-dimensionality and quality stability of the floral shape. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides a special three-dimensional floral structure, its manufacturing method, and its application. By using elastic band stretching and shrinking combined with loose cotton for one-time sewing, it achieves the effects of simplified process, reduced cost, full and three-dimensional floral shape, and stable quality.

[0007] This invention is achieved through the following technical solution:

[0008] A special three-dimensional floral structure includes: an outer fabric, an inner lining, a cotton wadding layer, and at least one elastic band; along the outward-inward direction of the finished product, the lining is located between the outer fabric and the cotton wadding layer, and the cotton wadding layer is located between the lining and the elastic band; the elastic band, when stretched, is sewn together with the outer fabric, the lining, and the cotton wadding layer along a preset floral path, and after sewing, the elastic band retracts, causing the cotton wadding layer to form a three-dimensional pleated floral shape.

[0009] Preferably, the elastic band is stretched to a ratio of 1:1.4 before sewing.

[0010] Preferably, the fabric, lining, cotton layer, and elastic band are sewn together in one go using a special embroidery machine.

[0011] Preferably, the thread used for sewing is 108D mercerized thread.

[0012] The method for creating the aforementioned special three-dimensional flower structure includes the following steps:

[0013] Step 1) Lay out the fabric, lining, cotton batting, and elastic band in sequence, and place the elastic band between the fabric and lining according to the predetermined stretch ratio;

[0014] Step 2) Use special clamps to evenly clamp and fix the multiple layers of material;

[0015] Step 3) Use an embroidery machine to sew along the set flower pattern path. During the sewing process, the elastic band will naturally shrink back, causing the loose cotton to form even three-dimensional pleats.

[0016] Step 4) After sewing, take out the finished product.

[0017] Preferably, the predetermined stretching ratio in step 1) is 1:1.4; the loose cotton replaces traditional down as filling material.

[0018] Preferably, the special clamp in step 2) is used to evenly clamp the multiple layers of material before sewing to ensure that the material is flat and fixed.

[0019] Preferably, the embroidery machine in step 3) is a special embroidery machine; the sewing uses 108D mercerized thread.

[0020] The above-mentioned special three-dimensional floral structure is applied in garment manufacturing. The structure is used on the cuffs, hem, collar or body of the garment where three-dimensional decoration is required, so as to form a uniform and full three-dimensional floral effect.

[0021] A garment comprising the aforementioned special three-dimensional floral structure.

[0022] The beneficial effects of this invention are as follows:

[0023] (1) This invention achieves one-step processing of three-dimensional floral patterns by stacking and sewing the fabric, lining, cotton, and elastic band together in one go, without the need for separate lining or filling operations. The entire process is simple to operate, greatly reduces the number of steps and manual intervention, significantly improves production efficiency, and is suitable for mass industrial production.

[0024] (2) This invention uses pine cotton instead of traditional down as filling material. Pine cotton is widely available and has a stable price, resulting in lower material costs compared to down. At the same time, since there is no need for complex down filling equipment and multiple filling operations, equipment investment and labor costs are further reduced, and the overall production cost is effectively controlled.

[0025] (3) This invention utilizes the natural shrinkage of the elastic band during the sewing process to uniformly compress the cotton and form regular three-dimensional pleats. This structure results in a full flower shape, clear outline, strong three-dimensionality, and high consistency. At the same time, since the cotton itself is not easy to leak out and the sewing process does not require needle punching, it effectively avoids problems such as uneven distribution of traditional fillings, deformation after washing, and leakage of cotton, ensuring stable and reliable product quality.

[0026] (4) The three-dimensional floral structure obtained by the present invention can flexibly adjust the floral path according to design requirements, and is suitable for various textile and garment products, especially for parts such as cuffs, hems, collars, and bodies that require both aesthetic appeal and three-dimensional decorative effect. This structure can also be used in other textile fields such as home textiles and decorative items, and has good promotional value.

[0027] (5) This invention can be realized with just a conventional special embroidery machine and simple clamping tools. It does not require large-scale modification of the existing production line, has low technical requirements for operators, and is easy to promote and implement. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the special three-dimensional flower shape of the present invention;

[0029] Figure 1 In Chinese: 1. Outer fabric; 2. Lining fabric; 3. Cotton layer; 4. Elastic band; 5. Sewing thread;

[0030] Figure 2 This is a diagram of the semi-finished cuff after the material has been fixed and before sewing.

[0031] Figure 3 This is a finished image of the cuff after the invention has been sewn;

[0032] Figure 4 This is a partial enlarged view of the finished cuff of the present invention;

[0033] Figure 5 This is a rendering showing the effect of applying the present invention to the cuff area of ​​a down jacket;

[0034] Figure 6 This is a rendering of the invention applied to a complete garment. Detailed Implementation

[0035] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0036] In the description of this invention, terms such as "upper," "lower," "inner," and "outer" that indicate orientation or positional relationship are used only based on the orientation shown in the accompanying drawings for the purpose of describing this invention, and are not intended to indicate or imply that the device referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0037] Example 1

[0038] This embodiment provides a special three-dimensional floral structure and its manufacturing method. This structure can be applied to the cuffs, hems, and other parts of down jackets and seasonal clothing products to meet the styling needs of clothing in different seasons.

[0039] 1. Material preparation

[0040] Outer fabric: 15D polyester satin calendered fabric, 1.46 m wide, 61 g / m² weight. 2 ;

[0041] Inner lining fabric: 20D polyester soft lining, width 1.43 m, weight 31 g / m² 2 ;

[0042] Filler: Loose cotton (three-dimensional hollow crimped cotton), weight 80 g / m² 2 ;

[0043] Elastic material: a flat elastic band with a width of 8 cm and a stretch ratio of 1.4 times;

[0044] Sewing thread: 108D mercerized thread, color matching the fabric.

[0045] like Figure 1 The diagram shows the structure of the multi-layer material in this embodiment. From top to bottom, the material consists of an outer fabric 1, an inner lining fabric 2, and a loose cotton layer 3. The bottom is an elastic band 4. When stretched, the elastic band 4 is sewn together with the fabric 1, the lining fabric 2, and the loose cotton layer 3 along a preset pattern path using sewing thread 5. After sewing, the elastic band 4 shrinks back, causing the loose cotton layer 3 to form a three-dimensional pleated pattern.

[0046] 2. Equipment and tools

[0047] Special embroidery machine: YUEMEI SHP-M series high-speed embroidery machine, which has the function of program-controlled flower path;

[0048] Special clips: Spring clips, used to evenly clamp multiple layers of material and prevent shifting during sewing.

[0049] 3. Production steps

[0050] (1) Laying out the outer fabric: Lay the outer fabric face down on the workbench, and then lay the inner fabric and the cotton layer on it in sequence. Then place the elastic bands according to the preset pattern path. Before sewing, stretch the elastic bands at a ratio of 1:1.4, that is, stretch the original 10 cm elastic bands to 14 cm and place them between the outer fabric and the inner fabric.

[0051] (2) Fixing: Use special clamps to evenly clamp the multi-layer material along the edge of the workbench to ensure that each layer of material is free of wrinkles and shifts, and that the elastic band remains stretched.

[0052] like Figure 2 The image shows the semi-finished state of the cuff after the fabric has been fixed and before sewing. The wavy floral pattern can be seen, and the layers of material from top to bottom are: outer fabric, lining fabric, cotton padding, and elastic band.

[0053] (3) Sewing: Start the special embroidery machine and sew according to the pre-designed flower pattern path. In this embodiment, a continuous wavy curve is used, with the following specific parameters: wave crest spacing 1.5 cm, wave height 0.6 cm, and double thread spacing 0.3 cm. 108D mercerized thread is used during the sewing process, with a stitch length of 13 stitches within 3 cm (i.e., a stitch length of approximately 2.3 mm), and a sewing speed of 260 stitches / min. During the sewing process, the elastic band gradually returns to its natural length, and its shrinkage force evenly squeezes the loose cotton to both sides of the seam, thereby forming a full three-dimensional pleated flower pattern on both sides of the seam.

[0054] (4) Removal: After sewing, loosen the special clips and remove the finished product. No further filling or finishing is required. Figure 3 The image shows the finished cuff after sewing. The resulting three-dimensional floral structure has a clear outline and a strong three-dimensional effect. (See image for details.) Figure 4 The image shown is a magnified partial photograph of the finished cuff, which shows that no loose cotton has poked out around the seam, proving that the structure of this invention has a good cotton-proof effect.

[0055] 4. Effect Verification

[0056] (1) Production efficiency

[0057] Sewing time for the floral pattern on a single cuff: approximately 10 minutes per piece, a 67% improvement compared to the traditional down filling process (approximately 30 minutes per piece);

[0058] (2) Cost comparison

[0059] Material cost per cuff: The amount of loose cotton used is about 5.5 cm (based on the spread length) per piece, costing about 0.15 yuan; the amount of traditional down used is about 2 g per piece, costing about 1.2 yuan, reducing material costs by 88%.

[0060] 5. Performance Testing

[0061] To verify whether the three-dimensional pleated / quilted structure made with loose cotton and elastic bands can maintain its initial fullness and three-dimensional pattern after multiple washes / dry cleanings, without issues such as sagging, deformation, or loss of pleats, the following tests were conducted:

[0062] (1) Retention rate of three-dimensional pleated pattern (washing durability test)

[0063] Following the washing procedure of GB / T 8629 standard, after 10, 20, and 30 water washing cycles respectively, the change in flower thickness was measured. The effect of flower retention was comprehensively evaluated from the following three dimensions (Table 1), and the test results are shown in Table 2.

[0064] Table 1. Criteria for Judging Flower Pattern

[0065]

[0066] Table 2 Results of the floral pattern rebound water wash test

[0067]

[0068] As shown in Table 2, this embodiment still maintains 86% after 30 washes, reaching a qualified or above level.

[0069] (2) Flower-shaped rebound tensile test

[0070] A constant pressure (5 N) was applied to the three-dimensional flower-shaped area for 10 s, 15 s, and 20 s, respectively. After release, the rebound time and the thickness after recovery were measured. The results are shown in Table 3 below.

[0071] Table 3 Results of the rebound tensile test for floral patterns

[0072]

[0073] As shown in Table 3, the structure of the present invention can fully rebound under short-term pressure and can still maintain more than 95% of its three-dimensionality under long-term pressure.

[0074] (3) Thread strength test

[0075] Friction tests were conducted using a tribometer under standard loads and reciprocating cycles in both dry and wet conditions. The results are shown in Table 4 below.

[0076] Table 4. Results of line durability test

[0077]

[0078] As shown in Table 4, the present invention uses 108D mercerized thread and optimized stitch length and sewing speed, which has excellent thread durability and meets the requirements of daily wear and washing of clothing.

[0079] like Figure 5 The image shown is an illustration of the cuff of a down jacket using the structure of this embodiment. The wavy, three-dimensional pleats are full and clearly defined. Figure 6 The image shown is a rendering of the finished garment. The three-dimensional floral pattern on the cuffs is coordinated and unified with the overall garment design, making it beautiful and elegant.

[0080] The test results above show that the present invention achieves the beneficial effects of simplified process, reduced cost, full and three-dimensional floral pattern and stable quality, and is suitable for three-dimensional decorative parts of various garments.

[0081] The embodiments described above are only some, not all, of the embodiments of the present invention. The detailed description of the embodiments of the present invention is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments. The scope of protection of the present invention is determined by the scope claimed in the claims. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

Claims

1. A special three-dimensional flower-shaped structure, characterized in that, include: Outer fabric, inner lining, cotton padding, and at least one elastic band; Along the finished product from the outside to the inside, the inner fabric is located between the outer fabric and the loose cotton layer, and the loose cotton layer is located between the inner fabric and the elastic band; the elastic band is sewn together with the outer fabric, inner fabric and loose cotton layer along a preset pattern path when stretched, and the elastic band shrinks back after sewing, so that the loose cotton layer forms a three-dimensional pleated pattern.

2. The structure of a special three-dimensional flower shape according to claim 1, characterized in that, The elastic band is stretched to a ratio of 1:1.4 before sewing.

3. The structure of a special three-dimensional flower shape according to claim 1 or 2, characterized in that, The fabric, lining, cotton layer, and elastic band are sewn together in one go using a special embroidery machine.

4. The structure of a special three-dimensional flower shape according to claim 1, characterized in that, The thread used for sewing is 108D mercerized thread.

5. A method for manufacturing a special three-dimensional flower structure as described in any one of claims 1-4, characterized in that, Includes the following steps: Step 1) Lay out the fabric, lining, cotton batting, and elastic band in sequence, and place the elastic band between the fabric and lining according to the predetermined stretch ratio; Step 2) Use special clamps to evenly clamp and fix the multiple layers of material; Step 3) Use an embroidery machine to sew along the set flower pattern path. During the sewing process, the elastic band will naturally shrink back, causing the loose cotton to form even three-dimensional pleats. Step 4) After sewing, take out the finished product.

6. The manufacturing method according to claim 5, characterized in that, Step 1) The predetermined stretching ratio is 1:1.4; the loose cotton replaces traditional down as filling material.

7. The manufacturing method according to claim 5, characterized in that, Step 2) The special clamp is used to evenly clamp multiple layers of material before sewing to ensure that the material is flat and fixed.

8. The manufacturing method according to claim 5, characterized in that, Step 3) The embroidery machine is a special embroidery machine; the sewing uses 108D mercerized thread.

9. The application of the special three-dimensional floral structure as described in any one of claims 1-4 in garment manufacturing, characterized in that, The structure is used on the cuffs, hem, collar, or other parts of the garment that require three-dimensional decoration, to create a uniform and full three-dimensional floral effect.

10. A garment, characterized in that, The structure includes the special three-dimensional flower shape as described in any one of claims 1-4.

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