Preparation method of a filling-free and quilting-free down-like warm fabric

Abstract

This invention belongs to the field of functional textile fabric weaving technology, and discloses a method for preparing a down-like thermal fabric that requires no filling and no quilting. It employs a three-layer independent weaving combined with a differentiated bonding and integrated molding process, simultaneously forming an outer windproof layer, a middle fluffy thermal layer, and an inner skin-friendly moisture-wicking layer in the same weaving process. The middle fluffy thermal layer uses high-filament, low-elasticity polyester yarn without a mesh, which does not form fixed interlacing points with the upper and lower yarns during weaving. It relies on its fluffy structure to form a stable air insulation layer, replacing traditional down filling for warmth. The outer and inner layers are interlaced and fixed using a warp-interlacing bonding process, with the woven bonding structure replacing subsequent quilting to achieve interlayer positioning. This invention eliminates the need for separate down filling and quilting, and the fabric is integrally molded, simplifying the production process and reducing costs. The resulting fabric is lightweight, soft, and has excellent warmth and resilience, with no risk of down leakage. It can be widely used in thermal clothing, home textiles, and other fields.

Description

Technical Field

[0001] This invention relates to the field of functional textile fabric weaving technology, specifically to a method for preparing a filler-free and quilting-free imitation down-like thermal fabric. Background Technology

[0002] Traditional down-filled fabrics typically employ a three-stage production process: first, two base fabrics are woven separately (inner and outer); then, down is filled into the cavity formed by the two base fabrics; finally, mechanical quilting is used to divide the filling area and constrain the position of the down to prevent it from piling up or shifting. This production method, despite its long-term use, still has several unavoidable shortcomings. The broken-down production process is cumbersome, requiring independent equipment and manual labor at each stage, resulting in a long overall production cycle and limited capacity expansion. In terms of raw material consumption, not only is sufficient down required as the filling medium, but also auxiliary materials such as quilting thread. The high cost of down itself directly increases the production cost and market price of the finished product. In terms of finished product usability, the quilted seams create stiff edges, resulting in a generally stiff fabric feel and a noticeable pressure sensation when worn. With prolonged use or repeated washing, the quilted areas are prone to cracking and unraveling, allowing down to escape through the gaps, leading to down leakage. Furthermore, the down itself is susceptible to moisture absorption and clumping, causing its loft to gradually decrease over time, resulting in insufficient durability of its warmth retention. In addition, traditional quilting techniques impose many limitations on fabric design, making it difficult to create lightweight, soft, and flexible warm products, resulting in a relatively limited range of suitable styles.

[0003] Therefore, a method for preparing a down-like thermal fabric that requires no filling and no quilting is proposed. Summary of the Invention

[0004] The present invention aims to solve the problems mentioned in the background art by providing a method for preparing a down-like thermal insulation fabric that requires no filling and no quilting.

[0005] The specific technical solution is as follows: A method for preparing a filler-free and quilting-free imitation down-like thermal fabric includes fabric weaving and finishing steps. It employs a three-layer independent weaving combined with a differentiated bonding and integrated molding process, simultaneously forming an outer windproof layer, a middle fluffy thermal layer, and an inner skin-friendly moisture-wicking layer in the same weaving process. The functional yarns of the middle fluffy thermal layer do not form fixed interlacing points with the yarns of the outer windproof layer and the inner skin-friendly moisture-wicking layer during weaving, but are distributed between the upper and lower layers in a freely fluffy and resilient lining state. Their range of motion is limited by the cavity boundaries formed after the upper and lower layers are bonded. The outer windproof layer and the inner skin-friendly moisture-wicking layer are interlaced and solidified through a differentiated pattern interlocking process, using the woven bonding structure to replace the subsequent quilting process for interlayer positioning. After finishing treatment, the completed fabric yields a filler-free and quilting-free imitation down-like thermal fabric.

[0006] By simultaneously forming a three-layer structure in the same weaving process, the construction of the insulation layer and the interlayer fixing process are integrated into the weaving stage, eliminating the need for subsequent separate filling and quilting steps, reducing the production process length, and lowering equipment and labor costs. The yarns of the middle insulation layer do not form a fixed interweaving with the upper and lower layers, maintaining ample fluffiness and freedom. This allows the yarns to retain a large amount of still air, forming a continuous heat insulation barrier and achieving excellent warmth retention. Simultaneously, the range of motion of the yarns is constrained by the cavity formed by the upper and lower layer joints, preserving fluffiness and elasticity without large-scale displacement and accumulation, resulting in a uniform and stable insulation layer distribution. The upper and lower layers are fixed through a joining process during weaving, resulting in high interlayer bonding strength and preventing separation even after long-term use. Replacing external quilting with woven joints eliminates extra stitch protrusions on the fabric surface, resulting in a soft and smooth overall feel without localized stiffness. Structurally, this also avoids material leakage problems caused by cracking or unraveling at quilting seams.

[0007] The aforementioned method for preparing a filler-free, quilting-free down-like thermal fabric involves using polyester dull filament as the raw material for both the warp and weft yarns of the outer windproof layer. The fabric is woven with a high-density plain weave structure, resulting in a dense protective surface layer with tightly packed yarns. The use of the same dull filament material for both warp and weft yarns creates a uniform and consistent plain weave structure, resulting in a soft and natural fabric surface luster that avoids glare under strong light. The tight arrangement of yarns in the high-density plain weave structure and the small pores on the fabric surface effectively block the penetration of external airflow and liquid water, while also preventing the internal loose yarns from seeping outwards, thus providing multiple functions of windproof, waterproof, and anti-permeability. The plain weave structure itself is stable, resulting in good abrasion resistance and a longer service life.

[0008] The aforementioned method for preparing a filler-free, quilting-free imitation down-like thermal fabric includes a polyester matte filament with a linear density of 75D to 150D, and an outer windproof layer with a warp and weft density of 380 threads / inch to 460 threads / inch. Limiting the linear density range of the polyester matte filament allows for adjustment of yarn thickness according to different product requirements, controlling the overall fabric weight while ensuring the strength of the surface structure, thus adapting to different types of finished products such as lightweight and regular fabrics. The range of warp and weft density values ​​ensures the density of the surface fabric, achieving stable windproof and breathability-proof effects, while preventing excessively high density from causing the fabric to become too stiff or excessively reducing breathability, thus balancing the fabric's protective performance and soft feel.

[0009] The aforementioned method for preparing the filler-free and quilting-free down-like thermal fabric involves using fine denier polyester filaments for the warp yarns and antistatic polyester short-fiber elastic yarns for the weft yarns, weaving a sparse and porous fabric structure. The use of fine denier polyester filaments as the warp yarns ensures a delicate and smooth fabric structure, reducing friction and irritation to the skin. The use of antistatic short-fiber elastic yarns for the weft yarns provides a feel closer to natural fibers, resulting in better skin-friendliness. The elastic properties enhance the fabric's stretch recovery ability, allowing it to conform to body movements without causing a feeling of restriction. The sparse and porous fabric structure retains some breathability, facilitating the conduction of moisture from the skin surface and reducing stuffiness. The antistatic properties reduce the accumulation of static electricity caused by friction between the fabric and skin / clothing, improving comfort during wear.

[0010] The aforementioned method for preparing a filler-free, quilting-free down-like thermal fabric includes a polyester antistatic staple fiber elastic yarn with a count of 40S to 60S, and an inner skin-friendly moisture-wicking layer with a weaving area porosity of 15% to 25%. Limiting the yarn count range of the polyester antistatic staple fiber elastic yarn allows for adjustment of the fineness and softness of the inner fabric, adapting to the needs of different skin-contact applications. The range of area porosity ensures the breathability and moisture-wicking performance of the inner layer while preventing excessive pore size from causing air loss, balancing the fabric's breathability and overall warmth performance. This allows the inner layer to possess good moisture-wicking and breathability without excessively weakening the warmth of the middle layer.

[0011] The above-mentioned method for preparing a filler-free, quilt-free, down-like thermal fabric involves using high-filament, low-elasticity polyester yarn without a mesh as the thermal insulation layer. This high-filament, low-elasticity polyester yarn has a long filament structure without mesh nodes or twisting. The high-filament, low-elasticity polyester yarn used as the thermal insulation material means that each yarn contains more monofilament fibers, creating more micro-air gaps with the same amount of yarn, retaining more still air, and improving thermal insulation efficiency. The structure without mesh nodes and twisting reduces the constraint on the internal fibers of the yarn, resulting in better stretch and resilience. It can quickly recover its fluffiness after compression, and its fluffiness does not easily decrease after long-term use and washing, thus improving the durability of its thermal insulation performance. Simultaneously, the untwisted and un-mesh yarn has a softer and fluffier feel, improving the overall tactile comfort of the fabric.

[0012] The aforementioned method for preparing a filler-free, quilting-free down-like thermal fabric involves using polyester high-filament, low-elasticity, non-woven yarn with a single filament count of 144F to 288F and an initial loft of not less than 8cm. Limiting the range of single filament counts for the high-filament, low-elasticity, non-woven polyester yarn allows adjustment of the yarn's loft and air retention effect according to the target warmth level. This ensures warmth performance while controlling the thickness and weight of the interlayer, adapting to thermal products with varying thickness requirements. Setting the initial loft ensures the interlayer has sufficient thickness and air retention space in its natural state, providing a stable foundation for the finished fabric's warmth performance and ensuring the finished product achieves the expected thermal insulation effect.

[0013] The aforementioned method for preparing a filler-free, quilting-free imitation down-feather thermal fabric involves a differentiated pattern interlocking process using a staggered warp yarn splicing method. The outer layer warp yarns sink and are fixed to the inner layer yarns, while the inner layer warp yarns rise and are fixed to the outer layer yarns. The splicing points are distributed in a point-to-point and segment-to-segment staggered pattern. This staggered warp yarn splicing method achieves the upper and lower layer fixation, and the splicing action can be directly completed through the warp yarn opening control of the loom, requiring no additional processing steps and achieving interlayer fixation synchronously with the weaving process. The interlacing splicing of the outer and inner warp yarns integrates the splicing position with the yarns of the fabric itself, resulting in a uniform distribution of interlayer bonding force and reducing the likelihood of localized stress concentration. The staggered distribution of splicing points ensures a more balanced interlayer fixation effect across the fabric, preventing localized loosening or bulging. Furthermore, no obvious hard spots are formed at the splices, resulting in a smooth and natural overall feel to the fabric.

[0014] The aforementioned method for preparing a filler-free, quilting-free imitation down-feather thermal fabric involves irregularly arranged seam points with a center-to-center distance of 2cm to 5cm between adjacent seam points. This irregular arrangement prevents regular seam patterns from forming on the fabric surface, resulting in a smoother, more natural appearance and adaptability to a wider range of fabric styles and design requirements. The reasonable spacing between adjacent seam points ensures both the bonding strength of the upper and lower layers, effectively limiting the movement of the middle layer yarns to prevent slippage and localized bulging, while also preserving sufficient cavity space to allow the middle layer yarns to fully expand and become fluffy. This avoids overly dense seams that compress the fluffy space and weaken the thermal insulation effect, thus balancing the fabric's structural stability and its fluffy, warm performance.

[0015] The aforementioned method for preparing the filler-free and quilting-free down-like thermal fabric includes post-processing treatments that sequentially comprise pre-shrinking, heat-setting, and softening / antistatic finishing. Pre-shrinking eliminates internal stress accumulated during weaving, allowing the fabric dimensions to shrink and stabilize in advance, reducing the probability of shrinkage and deformation during subsequent washing and use, and improving dimensional stability. Heat-setting fixes the fabric's three-layer structure and loft, further improving fabric smoothness and dimensional accuracy, while ensuring that the loft of the middle layer is not excessively lost during subsequent processing. Softening / antistatic finishing improves the fabric's surface feel, making it softer and smoother to the touch, while reducing static electricity generated by fabric friction, thus enhancing the comfort of wearing and using the finished product.

[0016] Among them, the pre-shrinking treatment: adopts a loose pre-shrinking process, with the pre-shrinking temperature controlled at 80℃~100℃, and the warp shrinkage rate of the fabric controlled at 3%~5%, to eliminate weaving internal stress. Among them, heat setting treatment: low tension setting is adopted, the setting temperature is controlled at 150℃~170℃, and the machine speed is controlled at 20m / min~30m / min, which stabilizes the fabric size while retaining the fluffiness of the middle layer. Among them, the soft and antistatic finishing process adopts the padding process, with a softener concentration of 20g / L to 40g / L, an antistatic agent concentration of 10g / L to 20g / L, and a baking temperature of 120℃ to 140℃, to optimize the fabric's hand feel and antistatic properties.

[0017] This invention also provides a down-like thermal fabric that requires no filling and no quilting. The fabric has a three-layer integrated woven structure consisting of an outer windproof layer, a middle fluffy thermal layer, and an inner skin-friendly moisture-wicking layer, from the outside to the inside. The middle fluffy thermal layer is a non-woven, high-fiber, low-elastic polyester yarn aggregate without a fixed structure, allowing the yarn to freely and fluffily rebound within the cavity formed by the upper and lower layers and the connecting structure. The outer windproof layer and the inner skin-friendly moisture-wicking layer are fixed together at the woven joints. The fabric as a whole has no external down filling structure and no external quilting stitches. The fabric is prepared by the above-described method.

[0018] The three-layer integrated weave structure boasts high overall shape and strong interlayer bonding, preventing delamination or separation during use. The loose, insulating yarns in the middle layer are not fixedly interwoven, allowing them to freely expand and rebound within the cavity, ensuring long-lasting and stable warmth. The fabric itself is soft and fluffy, lacking the heaviness and stiffness of traditional filled fabrics. The upper and lower layers are secured through weaving joints, resulting in a smooth surface without external quilting stitches or raised edges, leading to a clean appearance and a comfortable, pressure-free fit. The absence of external down filling eliminates the problem of down leakage, preventing material leakage after daily use and washing, simplifying maintenance, and making it widely adaptable to various thermal apparel and home textile products.

[0019] The present invention has the following beneficial effects: From a production perspective, integrating the filling and quilting processes into the weaving process significantly simplifies the production flow, reduces equipment investment and labor costs associated with independent processes, shortens the overall production cycle, and helps improve production efficiency and capacity. From a product structure perspective, the one-piece molding structure replaces external quilting, resulting in a stronger interlayer bond and reducing the likelihood of delamination over long-term use. The fabric surface is free of raised quilting stitches and hard edges, resulting in a smoother and softer overall feel. The finished product offers a better fit and eliminates localized pressure.

[0020] In terms of warmth retention, the loose yarns in the middle layer are not interwoven or restrained, allowing them to fully expand and trap air, resulting in stable heat insulation. They also exhibit good resilience after compression, and their loft does not easily diminish after repeated washing and long-term use, making their warmth retention more durable than traditional down-filled products. From a user experience perspective, the dense outer layer provides windproof and breathable protection, while the inner layer offers excellent skin-friendly breathability and anti-static properties. The overall fabric is lightweight and soft, without the heavy, oppressive feel of traditional down fabrics; it also eliminates the problem of down leakage, making daily use and care more convenient.

[0021] In terms of adaptability, the fluffiness and thickness of the fabric can be flexibly controlled by adjusting the knot arrangement and yarn specifications to meet the needs of different styles and different levels of warmth. It can be widely used in multiple fields of thermal insulation products such as clothing and home textiles. Attached Figure Description

[0022] Figure 1 This is a flowchart illustrating the preparation method of the filler-free and quilting-free imitation down-like thermal fabric provided in an embodiment of the present invention. Detailed Implementation

[0023] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0024] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual images. They should not be construed as limiting the scope of this application. To better illustrate the embodiments of the present invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0025] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," "inner," and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present application. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0026] In the description of this invention, unless otherwise explicitly specified and limited, the term "connection" or similar designation indicating a connection between components should be interpreted broadly. For example, it can refer to a fixed connection, a detachable connection, or an integral part; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can refer to the internal communication between two components or the interaction 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.

[0027] Reference Figure 1 This application provides the following three embodiments.

[0028] Example 1 This embodiment provides a method for preparing a down-like thermal fabric that requires no filling and no quilting. The specific steps are as follows: 1. Raw material preparation: The outer windproof layer uses 75D linear density polyester matte filament for both warp and weft; the inner skin-friendly and moisture-wicking layer uses 30D fine denier polyester filament for warp and 40S count polyester antistatic short fiber elastic yarn for weft, combined with 30D fine denier polyester auxiliary yarn; the middle fluffy and warm layer uses 144F polyester high F low elastic non-woven yarn, with an initial fluffiness of 8cm.

[0029] 2. Integrated Weaving: A three-layer independent weaving combined with differentiated splicing technology is adopted on a double-layer rapier loom to simultaneously weave a three-layer structure; the outer layer adopts a high-density plain weave with a warp and weft density of 380 threads / inch; the inner layer is woven into a sparse and porous structure, controlling the porosity of the weaving area to 15%; the middle layer of polyester high-F low-elasticity non-mesh yarn is fed in by weft insertion, and does not form fixed interlacing points with the upper and lower layer yarns throughout the process, allowing it to freely and fluffily rebound in the cavity; the upper and lower layers adopt an irregular staggered splicing technology, with some warp yarns of the outer layer sinking and fixing with the inner layer weft yarns, and some warp yarns of the inner layer floating and fixing with the outer layer weft yarns. The splicing points are irregularly arranged, and the center-to-center distance between adjacent splicing points is 2cm, forming a stable three-layer structure.

[0030] 3. Finishing: The woven fabric is subjected to a series of processes, including loose pre-shrinking at 80℃, low-tension heat setting at 150℃, and softening and antistatic padding, with softener concentration of 20g / L and antistatic agent concentration of 10g / L. After baking and setting at 120℃, the finished fabric is obtained.

[0031] Example 2 This embodiment provides a method for preparing a down-like thermal fabric that requires no filling and no quilting. The specific steps are as follows: 1. Raw material preparation: The outer windproof layer uses 110D linear density polyester matte filament for both warp and weft; the inner skin-friendly and moisture-wicking layer uses 40D fine denier polyester filament for warp and 50S count polyester antistatic short fiber elastic yarn for weft, combined with 40D fine denier polyester auxiliary yarn; the middle fluffy and warm layer uses 216F polyester high F low elastic non-woven yarn, with an initial fluffiness of 9cm.

[0032] 2. Integrated Weaving: A three-layer independent weaving combined with differentiated splicing technology is adopted on a double-layer rapier loom to simultaneously weave a three-layer structure; the outer layer adopts a high-density plain weave with a warp and weft density of 420 threads / inch; the inner layer is woven into a sparse and porous structure, controlling the porosity of the weaving area to 20%; the middle layer of polyester high-F low-elasticity non-mesh yarn is fed in by weft insertion, and does not form fixed interlacing points with the upper and lower layer yarns throughout the process, allowing it to freely and fluffily rebound within the cavity; the upper and lower layers adopt an irregular staggered splicing technology, with some warp yarns of the outer layer sinking and fixing with the inner layer weft yarns, and some warp yarns of the inner layer floating and fixing with the outer layer weft yarns. The splicing points are irregularly arranged, and the center-to-center distance between adjacent splicing points is 3.5cm, forming a stable three-layer structure.

[0033] 3. Finishing: The woven fabric is subjected to a series of processes, including loose pre-shrinking at 90℃, low-tension heat setting at 160℃, and softening and antistatic padding, with a softener concentration of 30g / L and an antistatic agent concentration of 15g / L. After baking and setting at 130℃, the finished fabric is obtained.

[0034] Example 3 This embodiment provides a method for preparing a down-like thermal fabric that requires no filling and no quilting. The specific steps are as follows: 1. Raw material preparation: The outer windproof layer uses 150D linear density polyester dull filament for both warp and weft; the inner skin-friendly and moisture-wicking layer uses 50D fine denier polyester filament for warp and 60S count polyester antistatic short fiber elastic yarn for weft, paired with 50D fine denier polyester auxiliary yarn; the middle fluffy and warm layer uses 288F polyester high F low elastic non-woven yarn, with an initial fluffiness of 10cm.

[0035] 2. Integrated Weaving: A three-layer independent weaving process combined with differentiated splicing technology is adopted on a double-layer rapier loom to simultaneously weave a three-layer structure; the outer layer adopts a high-density plain weave with a warp and weft density of 460 threads / inch; the inner layer is woven into a sparse and porous structure, controlling the porosity of the weaving area to 25%; the middle layer of polyester high-F low-elasticity non-mesh yarn is fed in by weft insertion, and does not form fixed interlacing points with the upper and lower layer yarns throughout the process, allowing it to freely and fluffily rebound within the cavity; the upper and lower layers adopt an irregular staggered splicing technology, with some warp yarns of the outer layer sinking and fixing with the inner layer weft yarns, and some warp yarns of the inner layer floating and fixing with the outer layer weft yarns. The splicing points are irregularly arranged, and the center-to-center distance between adjacent splicing points is 5cm, forming a stable three-layer structure.

[0036] 3. Finishing: The woven fabric is subjected to a series of processes, including loose pre-shrinking at 100℃, low-tension heat setting at 170℃, and softening and antistatic padding, with a softener concentration of 40g / L and an antistatic agent concentration of 20g / L. After baking and setting at 140℃, the finished fabric is obtained.

[0037] Tests showed that the fabric prepared in the above embodiments has a clo value of 0.8clo to 1.2clo, an air permeability of ≥10mm / s, and after 20 standard washes, there is no interlayer slippage or yarn leakage, and the loft retention rate is ≥90%. The fabric weight is only 60% to 70% of that of traditional quilted down fabrics of the same warmth level, and the softness and fit of the fabric are significantly better than those of traditional down fabrics.

[0038] Working Principle: This solution employs a three-layer integrated weaving approach, simultaneously completing the outer windproof layer, the middle fluffy and warm layer, and the inner skin-friendly and moisture-wicking layer within the same weaving process. This also ensures the layers are fixed together, eliminating the need for separate filling and quilting processes later. The outer layer utilizes a high-density woven filament structure, forming a dense surface layer with tightly packed yarns that blocks external airflow and liquid water while preventing the internal fluffy yarns from escaping. The inner layer uses a relatively sparse weave structure, combined with elastic and anti-static yarns, providing a soft touch against the skin while maintaining breathability to facilitate the conduction of moisture from the skin surface. The middle layer is filled with fluffy filament material, which is not interwoven or fixed with the upper and lower layers during weaving, allowing the yarns to remain relaxed and fluffy. The large amount of still air trapped within the yarns forms an insulating layer, preventing heat loss and achieving a warmth similar to down filling. The upper and lower layers are interlocked and secured through a weaving process using a knotting technique. The knotting points are formed synchronously with the weaving process, separating the fluffy yarns of the middle layer into independent cavities. This not only restricts the movement of the yarns, preventing large-scale displacement and accumulation, but also avoids the hard stitches that can form with traditional quilting. The finishing process, including pre-shrinking, setting, and functional finishing, stabilizes the fabric's dimensions and fluffiness, optimizes its feel and wearing properties, and ultimately yields a finished warm fabric.

[0039] Instructions for use: This fabric can be used directly in the processing and production of various thermal products without prior filling or quilting. When making clothing, the fabric can be cut directly according to the pattern requirements. After cutting, the edges can be finished with binding or overlocking to prevent yarn unraveling. Then, the garment pieces are sewn together using standard sewing techniques to create thermal outerwear, outdoor cold-weather clothing, thermal linings, and other thermal garments. No additional filling material or quilting is required during the sewing process. When making home textiles, the fabric can be cut according to the product size and then directly sewn together to create thermal quilts, blankets, cushions, and other home textile products. For daily use and care, the fabric can be cleaned using regular water washing. During washing, the internal fluffy yarns will not shift significantly, and there will be no leakage. After washing, it will return to its fluffy state by air drying; no special beating or finishing is required. Different specifications of the fabric can be selected according to usage needs to suit the warmth requirements of different seasons and scenarios.

[0040] The above are merely preferred embodiments of the present invention and are not intended to limit the implementation methods and protection scope of the present invention. Those skilled in the art should recognize that any equivalent substitutions and obvious changes made based on the description and illustrations of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for preparing a down-like thermal fabric that requires no filling and no quilting, comprising fabric weaving and finishing steps, characterized in that, The fabric employs a three-layer independent weaving combined with a differentiated bonding and integrated molding process, simultaneously forming an outer windproof layer, a middle fluffy and warm layer, and an inner skin-friendly and moisture-wicking layer in the same weaving process. The functional yarns of the middle fluffy and warm layer do not form fixed interlacing points with the yarns of the outer windproof layer and the inner skin-friendly and moisture-wicking layer during weaving. Instead, they are distributed between the upper and lower layers in a freely fluffy and resilient lining state, with their range of motion limited by the cavity boundaries formed after the upper and lower layers are bonded. The outer windproof layer and the inner skin-friendly and moisture-wicking layer are interlaced and solidified through a differentiated pattern interlocking process, using the woven bonding structure to replace subsequent quilting processes for interlayer positioning. After finishing treatment, the woven fabric yields a down-like warm fabric that requires no filling and no quilting.

2. The method for preparing the fill-free and quilt-free imitation down-feather thermal fabric according to claim 1, characterized in that, The outer windproof layer uses polyester dull filament as raw material for both warp and weft yarns, and is woven with a high-density plain weave structure, with the yarns tightly arranged to form a dense protective surface layer.

3. The method for preparing the filler-free and quilting-free imitation down-feather thermal fabric according to claim 2, characterized in that, The linear density of the polyester matte filament is 75D to 150D, and the warp and weft density of the outer windproof layer is 380 threads / inch to 460 threads / inch.

4. The method for preparing the fill-free and quilt-free imitation down-feather thermal fabric according to claim 1, characterized in that, The inner skin-friendly and moisture-absorbing layer uses fine denier polyester filament for the warp and polyester antistatic short fiber elastic yarn for the weft, forming a sparse and porous fabric structure.

5. The method for preparing the fill-free and quilt-free imitation down-feather thermal fabric according to claim 4, characterized in that, The polyester antistatic staple elastic yarn has a yarn count of 40S to 60S, and the inner skin-friendly moisture-absorbing layer has a weaving area porosity of 15% to 25%.

6. The method for preparing the filler-free and quilting-free imitation down-feather thermal fabric according to claim 1, characterized in that, The intermediate fluffy insulating layer uses high-F low-elasticity polyester non-woven yarn as the insulating yarn. The high-F low-elasticity polyester non-woven yarn is a long filament structure without network nodes and without twisting.

7. The method for preparing the fill-free and quilt-free imitation down-feather thermal fabric according to claim 6, characterized in that, The number of monofilaments in the high-F, low-elasticity polyester non-woven yarn is 144F to 288F, and the initial bulkiness is not less than 8cm.

8. The method for preparing the filler-free and quilting-free imitation down-feather thermal fabric according to claim 1, characterized in that, The differentiated pattern interlocking process adopts a warp yarn staggered interlocking method, in which the outer layer of warp yarns sinks down and is fixed to the inner layer of yarns, while the inner layer of warp yarns floats up and is fixed to the outer layer of yarns. The interlocking points are distributed in an alternating pattern of point-to-point and segment-to-segment.

9. The method for preparing the fill-free and quilt-free imitation down-feather thermal fabric according to claim 8, characterized in that, The connection points are arranged in an irregular floral pattern, and the center-to-center distance between adjacent connection points is 2cm to 5cm.

10. The method for preparing the fill-free and quilt-free imitation down-filled thermal fabric according to claim 1, characterized in that, The post-processing includes pre-shrinking, heat setting, and softening and antistatic finishing.

Images