Quilt, production method thereof and breathable anti-drilling down feather quilt

Abstract

The application provides a quilt shell, a production method thereof and a breathable anti-piercing down quilt. The production method of the quilt shell comprises the following steps: S1, pre-shrinking a breathable elastic supporting fabric; S2, performing plasma treatment on a film-coated fabric; S3, bonding the periphery of the pre-treated fabric with a strip-shaped anti-piercing down fabric through a first adhesive; S4, taking the pre-shrunk fabric as a vertical stand, and bonding the upper and lower sides of the pre-shrunk fabric with the bonded strips respectively; S5, taking the pre-shrunk fabric as a vertical stand, and bonding the central regions of the two pre-treated fabrics with the upper and lower sides of the pre-shrunk fabric respectively; the bonding manners in steps S4 and S5 are the same, and the bonding manner is hot-press bonding and / or ultrasonic bonding; the temperature of the hot-press bonding in step S4 is higher than that in step S5; the power of the ultrasonic bonding in step S4 is higher than that in step S5; and S6, constant temperature heat setting of the shell. The application can balance the breathability, anti-piercing down property and supporting property.

Description

Technical Field

[0001] This application relates to the field of textile technology, and in particular to comforter covers, their production methods, and breathable, down-proof, and warm comforters. Background Technology

[0002] As people's demands for sleep quality continue to increase, down comforters, as a type of warm bedding, are widely favored for their lightness, fluffiness, and excellent warmth retention.

[0003] To prevent down feathers from escaping from the shell, coated fabrics are commonly used in down comforter manufacturing. Coated fabrics offer advantages such as effective protection against bacteria and viruses, abrasion resistance, scratch resistance, tear resistance, extended lifespan, windproofing, warmth retention, and moisture repellency. Furthermore, using coated fabric instead of traditional down linings avoids the noise generated by friction during use due to the dense weave of the down lining, achieving a quieter operation.

[0004] However, to achieve good down-proof performance, down comforters made from existing coated fabrics typically have lower porosity than coated fabrics used in clothing, resulting in lower breathability and an inability to achieve optimal air permeability. Furthermore, the low-porosity coated structure makes the down comforter less prone to springing back after being compressed. Therefore, improving the breathability and supportive resilience of down comforters while maintaining down-proof performance has become a pressing technical challenge for the industry.

[0005] To improve breathability, a related technology discloses a bedding material with a sandwich mesh layer sandwiched between two outer fabric layers, utilizing the gaps in the three-dimensional fiber layer to quickly expel air. However, if this is directly applied to down products, the edges of the mesh are easily deformed under external force, causing the mesh to be exposed and creating channels for down leakage, thus failing to meet the requirements for preventing down leakage.

[0006] Another design incorporates a Z-shaped mesh fabric between the outer and lining fabrics. This mesh fabric includes a short side, a support side, and a long side, all arranged in a Z-shape. The short side is sewn onto the outer fabric, the long side onto the lining fabric, and the two ends of the support side are perpendicular to both the outer and lining fabrics. The short side is sewn onto the outer fabric via a first stitch, located at the junction of the short and support sides. The long side is sewn onto the lining fabric via a second stitch, also located at the junction of the long and support sides. However, in this design, the mesh fabric is sewn together with both the outer and lining fabrics. Due to the presence of needle holes, when subjected to pressure or washing, the high-pressure airflow inside can carry down feathers directly out through the needle holes, resulting in severe down leakage.

[0007] To achieve seamless down-proofing, a down-proof fabric has been disclosed, which employs a dotted composite of a thermoplastic polyurethane meltblown elastic nonwoven fabric layer and an elastic knitted base fabric layer. This solution utilizes the multi-layered stacked structure and high coefficient of friction of the meltblown nonwoven fabric to achieve viscous filtration and down-proofing. However, this fabric is a planar composite fabric, which cannot provide effective support when manufacturing textiles with high loft, such as down comforters. If used directly as a lining, the lining cavity is prone to lateral collapse under human pressure or turning over, completely blocking airflow channels and failing to balance support and breathability.

[0008] In summary, in related technologies, down products based on coated fabrics are prone to creating down leakage channels at the seams when using mesh fabrics; conventional flat down-proof fabrics cannot provide stable support, resulting in a mismatch between down prevention, breathability, and support. Summary of the Invention

[0009] This application provides a quilt cover, a method for producing the same, and a breathable, down-proof, and warm quilt to solve the aforementioned technical problems.

[0010] To achieve the above objectives, the technical solution of this application is as follows: This application provides a method for producing a shell, the method comprising the following steps: S1. Pre-shrink the breathable elastic support fabric to obtain a pre-shrink fabric; the breathable elastic support fabric includes an elastic support layer and a mesh layer composited with the elastic support layer. S2. Plasma treatment is performed on the coated fabric to obtain a pretreated fabric; S3. The four edges of the pretreated fabric are bonded to the strip-shaped downproof fabric with a first adhesive to form an edge binding strip; S4. Using the pre-shrink fabric as a longitudinal lining, the upper and lower sides of the pre-shrink fabric are respectively bonded to the binding strip to obtain a shell, with the mesh layer facing the inside of the shell; S5. Using the pre-shrinked fabric as a longitudinal lining, the central areas of the two pre-treated fabrics are respectively bonded to the upper and lower sides of the pre-shrinked fabric; the bonding methods in steps S4 and S5 are the same, namely hot-press bonding and / or ultrasonic bonding; the temperature of the hot-press bonding in step S4 is higher than the temperature of the hot-press bonding in step S5; the power of the ultrasonic bonding in step S4 is higher than the power of the ultrasonic bonding in step S5. S6. The shell is heat-set at a constant temperature to obtain the outer shell.

[0011] In one embodiment of this application, during the pre-shrinking process in step S1, the temperature is 110℃-120℃, preferably 115℃-120℃; the pre-shrinking time is 10s-15s, preferably 12s-15s.

[0012] In one embodiment of this application, step S1 satisfies at least one of the following requirements (1)-(5): (1) The elastic support layer includes elastic fibers and supporting fibers; (2) The thickness of the elastic support layer is 1.0mm-2.0mm, preferably 1.5mm-2.0mm; (3) The mesh size of the mesh layer is 40-80 mesh, preferably 60-80 mesh; (4) The thickness of the mesh layer is 0.8mm-1.5mm, preferably 1.0mm-1.5mm; (5) The elastic support layer and the mesh layer are hot-pressed together by applying a second adhesive in a dotted manner.

[0013] In one embodiment of this application, step S1 satisfies at least one of the following requirements (6)-(9): (6) The elastic fiber content in the elastic support layer is 60%-70% by mass, preferably 65%-70%; (7) The second adhesive includes polyester-based polyurethane hot melt adhesive; (8) During the hot-pressing composite process of the elastic support layer and the mesh layer, the diameter of the adhesive points is 0.3mm-0.6mm, preferably 0.4mm-0.6mm; the distance between adjacent adhesive points along the length direction of the shell is 2.2mm-3.0mm, preferably 2.4mm-3.0mm; the distance between adjacent adhesive points along the width direction of the shell is 1.8mm-2.5mm, preferably 2mm-2.5mm. (9) During the hot-pressing composite process of the elastic support layer and the mesh layer, the temperature is 80℃-90℃, preferably 85℃-90℃; the pressure is 0.2MPa-0.3MPa, preferably 0.25MPa-0.3MPa; and the hot-pressing composite time is 10s-15s, preferably 12s-15s.

[0014] In one embodiment of this application, during the plasma treatment process in step S2, the power is 300-400W, preferably 350-400W; the plasma treatment time is 2s-3s.

[0015] In one embodiment of this application, the coated fabric includes a fabric matrix and a film layer laminated together with the fabric matrix, wherein the fabric matrix includes cellulose fibers.

[0016] In one embodiment of this application, during the edge-wrapping composite process in step S3, the temperature is 105℃-110℃, preferably 108℃-110℃; the speed is 8m / min-9m / min, preferably 8.5m / min-9m / min; and the tension is 0.2MPa-0.3MPa, preferably 0.24MPa-0.3MPa.

[0017] In one embodiment of this application, in step S3, the strip-shaped downproof fabric includes at least one of cotton fiber, polyester fiber, and polyamide fiber.

[0018] In one embodiment of this application, step S5 satisfies at least one of the following requirements (10)-(14): (10) The temperature of hot pressing composite in step S4 is 145℃-150℃, preferably 148℃-150℃; the temperature of hot pressing composite in step S5 is 120℃-125℃, preferably 122℃-125℃. (11) The pressure of the hot-pressing composite is 0.35MPa-0.45MPa, preferably 0.38MPa-0.45MPa; the speed of the hot-pressing composite is 6m / min-7m / min, preferably 6.5m / min-7m / min; (12) The adhesive system used in the hot-pressing composite process includes a third adhesive and a compatibilizer; (13) The power of the ultrasonic composite in step S4 is 900W-1000W, preferably 940W-960W; the power of the ultrasonic composite in step S5 is 800W-900W, preferably 840W-860W.

[0019] (14) The frequency of the ultrasonic composite is 20kHz-25kHz, preferably 22kHz-25kHz.

[0020] In one embodiment of this application, during the constant temperature heat setting process in step S6, the temperature is 80℃-85℃, preferably 82℃-85℃; the constant temperature heat setting time is 15s-25s, preferably 20s-25s.

[0021] This application also provides a shell prepared according to the method described above.

[0022] This application also provides a breathable, down-proof, and warm quilt, which includes the quilt shell as described above.

[0023] The beneficial effects of this application are: In this application, the mesh of the breathable elastic support fabric imparts breathability to the duvet cover, while the elastic support layer provides excellent resilience. This not only allows the elastic support layer to provide effective longitudinal support, ensuring the cavity doesn't collapse, but also allows excess air inside the duvet to be evenly and quickly expelled through the mesh of the breathable elastic support fabric when the duvet is compressed. When the external force is removed, the elastic support layer rebounds rapidly, guiding external air to quickly replenish the duvet, achieving excellent breathability. Pre-shrinkage treatment eliminates residual internal stress accumulated in the mesh layer during weaving and winding, preventing the formation of pores in the composite area between the breathable elastic support fabric and the pre-treated fabric due to shrinkage and deformation, which could negatively impact the down-proof effect. Plasma treatment can create micro-etching on the coating surface, etching out rough micropores and increasing the specific surface area. During subsequent hot-pressing lamination, these micropores allow adhesives to penetrate and form a strong bond. Alternatively, during subsequent ultrasonic lamination, the rough interface can prevent the reflection of ultrasonic energy on smooth coating surfaces, promoting full melting and entanglement of the fabric, thereby improving adhesion and avoiding the delamination problem in the lamination area during use, as seen in existing technologies. Using pre-shrinkable fabric as a longitudinal backing, laminating the top and bottom sides of the pre-shrinkable fabric with the binding strips respectively can form a sealed structure, eliminating the need for traditional sewing needles and thread, achieving a needle-hole-free and seamless seal. During the lamination of strip-shaped downproof fabric with pre-shrinkable fabric, a needle-hole-free and seamless seal is formed through adhesives or ultrasonic lamination, reducing the probability of down and other filling materials escaping from the lamination area. The production process employs a "zonal gradient composite" technique. High-temperature or high-power lamination is used at the edges to achieve a good sealing effect and reduce the probability of edge delamination. Low-temperature or low-power lamination is used in the central area, ensuring the bonding strength of the upright fabric while avoiding adhesive overflow that could clog the mesh. This allows the surface laminate, the bottom laminate, and the longitudinal upright fabric to work together to form a circumferentially permeable air-guiding cavity, enabling air circulation. Constant-temperature heat setting eliminates localized internal stress caused by bending in the elastic support layer of the breathable elastic support fabric, resulting in a stable spatial shape for the air-guiding cavity. This ensures that the cavity structure remains firm, does not collapse, and does not crack after multiple machine washes and pats. In short, this application uses a breathable elastic support fabric as a longitudinal lining, and constructs a "three-in-one" combined structure at the connection between the longitudinal lining and the coated fabric, consisting of an edge binding formed by strip-shaped downproof fabric, an adhesive layer sealing structure, and a ventilation and air-permeable cavity. Combined with plasma treatment and zoned gradient composite technology, a needle-hole-free sealed connection is achieved without the need for traditional sewing needles and threads, thus taking into account the downproofness, breathability, and support of the duvet cover made of coated fabric. Attached Figure Description

[0024] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application. It is obvious that the drawings described below are merely some embodiments of this application, and those skilled in the art can obtain other drawings based on these drawings without any inventive effort.

[0025] In the attached diagram: Figure 1 This is a process flow diagram of the shell production method in this application; Figure 2 This is a schematic diagram of the shell structure in this application.

[0026] The attached figures are labeled as follows: Top layer fabric 1, vertical interlining 2, bottom layer fabric 3. Detailed Implementation

[0027] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0028] To improve breathability, a related technology discloses a bedding material with a mesh fabric sandwiched between two outer fabric layers, utilizing the gaps in the three-dimensional fiber layers to quickly expel air. However, if this is directly applied to down products, due to the lack of a pinhole-free sealing structure and a specialized down-proof edge design, the mesh edges are easily deformed under external force, resulting in exposed mesh holes and creating serious down leakage channels, thus failing to meet the requirements for preventing down leakage.

[0029] Another technical solution involves using a Z-shaped mesh fabric between the outer and lining fabrics. This mesh fabric includes a short side, a support side, and a long side, arranged in a Z-shape. The short side is sewn onto the outer fabric, the long side is sewn onto the lining fabric, and the two ends of the support side are perpendicular to the outer and lining fabrics, respectively. The short side is sewn onto the outer fabric via a first stitch, located at the junction of the short and support sides. The long side is sewn onto the lining fabric via a second stitch, also located at the junction of the long and support sides. However, in this solution, the mesh fabric is sewn together with both the outer and lining fabrics. Due to the presence of needle holes, when the down product is pressed or washed, the high-pressure airflow inside can carry down feathers directly through the needle holes, leading to severe down leakage and poking defects. Furthermore, this structure lacks edge sealing and flow guidance design, failing to achieve good down-proof performance while maintaining high breathability.

[0030] To achieve seamless down-proofing, a down-proof fabric has been disclosed, which employs a dotted composite of a thermoplastic polyurethane meltblown elastic nonwoven fabric layer and an elastic knitted base fabric layer. This solution utilizes the multi-layered stacked structure and high coefficient of friction of the meltblown nonwoven fabric to achieve viscous filtration and down-proofing. However, this fabric is a planar composite fabric, which cannot provide effective longitudinal support when manufacturing bedding with high loft, such as down comforters. If it is used directly as a lining, the lining cavity is prone to lateral collapse when subjected to pressure from the body or when turning over, resulting in complete blockage of air circulation channels, failing to balance support and breathability.

[0031] In summary, in related technologies, down products based on coated fabrics, when using mesh fabrics, are prone to developing down leakage channels at the seams due to the lack of a pinhole-free sealing structure and down-proof edge design. At the same time, heterogeneous materials have poor compatibility in conventional processing, and are prone to deformation, delamination and sealing failure. Furthermore, conventional flat down-proof fabrics cannot provide stable longitudinal support, resulting in an inability to simultaneously achieve down leakage prevention, breathability and support.

[0032] like Figure 1 As shown, based on the above-mentioned technical problems, one embodiment of this application provides a method for producing a shell, including the following steps: S1. Pre-shrink the breathable elastic support fabric to obtain the pre-shrink fabric; the breathable elastic support fabric includes an elastic support layer and a mesh layer compounded with the elastic support layer. S2. Plasma treatment is performed on the coated fabric to obtain a pretreated fabric; S3. The edges of the pre-treated fabric are bonded to the strip of downproof fabric with the first adhesive to form an edge binding strip; S4. Using the pre-shrink fabric as the longitudinal lining, the top and bottom sides of the pre-shrink fabric are respectively bonded with the binding strips (that is, the binding strips at the four edges of the two pre-treated fabrics are respectively bonded with the top and bottom sides of the pre-shrink fabric; in other words, the binding strips at the four edges of one pre-treated fabric are bonded with the top side of the pre-shrink fabric, and the binding strips at the four edges of the other pre-treated fabric are bonded with the bottom side of the pre-shrink fabric), to obtain the shell, with the mesh layer facing the inside of the shell. S5. Using the pre-shrinked fabric as a longitudinal lining, the central areas of the two pre-treated fabrics are respectively bonded to the upper and lower sides of the pre-shrinked fabric; the bonding methods in steps S4 and S5 are the same, namely hot-press bonding and / or ultrasonic bonding; the temperature of hot-press bonding in step S4 is higher than that in step S5; the power of ultrasonic bonding in step S4 is higher than that in step S5. S6. The shell is heat-set at a constant temperature to obtain the outer shell (e.g., Figure 2 As shown, 1 is the outer fabric, 2 is the longitudinal interlining, and 3 is the bottom fabric.

[0033] In this application, the mesh of the breathable elastic support fabric imparts breathability to the duvet cover, while the elastic support layer provides excellent resilience. This not only allows the elastic support layer to provide effective longitudinal support, ensuring the cavity doesn't collapse, but also allows excess air inside the duvet to be evenly and quickly expelled through the mesh of the breathable elastic support fabric when the duvet is compressed. When the external force is removed, the elastic support layer rebounds rapidly, guiding external air to quickly replenish the duvet, achieving excellent breathability. Pre-shrinkage treatment eliminates residual internal stress accumulated in the mesh layer during weaving and winding, preventing the formation of pores in the composite area between the breathable elastic support fabric and the pre-treated fabric due to shrinkage and deformation, which could negatively impact the down-proof effect. Plasma treatment can create micro-etching on the coating surface, etching out rough micropores and increasing the specific surface area. During subsequent hot-pressing lamination, these micropores allow adhesives to penetrate and form a strong bond. Alternatively, during subsequent ultrasonic lamination, the rough interface can prevent the reflection of ultrasonic energy on smooth coating surfaces, promoting full melting and entanglement of the fabric, thereby improving adhesion and avoiding the delamination problem in the lamination area during use, as seen in existing technologies. Using pre-shrinkable fabric as a longitudinal backing, laminating the top and bottom sides of the pre-shrinkable fabric with the binding strips respectively can form a sealed structure, eliminating the need for traditional sewing needles and thread, achieving a needle-hole-free and seamless seal. During the lamination of strip-shaped downproof fabric with pre-shrinkable fabric, a needle-hole-free and seamless seal is formed through adhesives or ultrasonic lamination, reducing the probability of down and other filling materials escaping from the lamination area. The production process employs a "zonal gradient composite" technique. High-temperature or high-power lamination is used at the edges to achieve a good sealing effect and reduce the probability of edge delamination. Low-temperature or low-power lamination is used in the central area, ensuring the bonding strength of the upright fabric while avoiding adhesive overflow that could clog the mesh. This allows the surface laminate, the bottom laminate, and the longitudinal upright fabric to work together to form a circumferentially permeable air-guiding cavity, enabling air circulation. Constant-temperature heat setting eliminates localized internal stress caused by bending in the elastic support layer of the breathable elastic support fabric, resulting in a stable spatial shape for the air-guiding cavity. This ensures that the cavity structure remains firm, does not collapse, and does not crack after multiple machine washes and pats. In short, this application uses a breathable elastic support fabric as a longitudinal lining, and constructs a "three-in-one" combined structure at the connection between the longitudinal lining and the coated fabric, consisting of an edge binding formed by strip-shaped downproof fabric, an adhesive layer sealing structure, and a ventilation and air-permeable cavity. Combined with plasma treatment and zoned gradient composite technology, a needle-hole-free sealed connection is achieved without the need for traditional sewing needles and threads, thus taking into account the downproofness, breathability, and support of the duvet cover made of coated fabric.

[0034] In this application, two coated fabrics serve as the outer and inner layers of the duvet cover, respectively. The pre-shrinked, breathable, elastic support fabric serves as the longitudinal support of the duvet cover, creating longitudinal support space.

[0035] In one embodiment of this application, during the pre-shrinking process in step S1, the temperature is 110℃-120℃, preferably 115℃-120℃; the pre-shrinking time is 10s-15s, preferably 12s-15s. The breathable elastic support fabric can also be a three-layer fabric. Specifically, the breathable elastic support fabric includes an elastic support layer and two mesh layers composited with the elastic support layer, forming a layered structure with the elastic support layer located in the middle layer and the two mesh layers located on either side of the middle layer. The elastic support layer includes elastic fibers and supporting fibers. The mass percentage of elastic fibers in the elastic support layer is 60%-70%, preferably 65%-70%. The elastic fibers include polyurethane fibers (i.e., spandex) and / or polyolefin elastic fibers. Support fibers can be, for example, polyester fibers. The thickness of the elastic support layer is 1.0mm-2.0mm, preferably 1.5mm-2.0mm. The mesh size of the mesh layer is 40 mesh-80 mesh, preferably 60 mesh-80 mesh. The mesh size of the grid layer is 40-80 mesh (corresponding to an aperture of 0.2mm-0.4mm), preferably 60-80 mesh (corresponding to an aperture of 0.2mm-0.3mm), with a mesh size of 250 per cm². 2 -990 pieces / cm 2 The preferred value is 560 pieces / cm. 2 - 990 pieces / cm 2The mesh shape is selected from rhombus, circle, or rectangle, preferably rhombus. The thickness of the mesh layer is 0.8mm-1.5mm, preferably 1.0mm-1.5mm; the mesh layer includes at least one of polyester fiber, polyamide fiber, cotton fiber, lyocell fiber, modal fiber, and adhesive fiber. The elastic support layer and the mesh layer are hot-pressed together using a second adhesive applied in a dot-matrix manner. During the hot-pressing process, the second adhesive is applied in a dot-matrix manner to form a linear structure and avoids covering the mesh openings of the mesh layer. The second adhesive includes a polyester-based polyurethane hot melt adhesive. During the hot-pressing process of the elastic support layer and the mesh layer, the diameter of the adhesive points is 0.3mm-0.6mm, preferably 0.5mm-0.6mm; the distance between adjacent adhesive points along the length of the cover (the length direction is from the head to the feet during use) is 2.2mm-3.0mm, preferably 2.4mm-3.0mm; the distance between adjacent adhesive points along the width of the cover is 1.8mm-2.5mm, preferably 2mm-2.5mm. During the hot-pressing process of the elastic support layer and the mesh layer, the temperature is 80℃-90℃, preferably 85℃-90℃; the pressure is 0.2MPa-0.3MPa, preferably 0.25MPa-0.3MPa; and the hot-pressing time is 10s-15s, preferably 12s-15s.

[0036] This application limits the mesh size of the grid layer to 40-80 mesh, corresponding to an aperture of 0.2mm-0.4mm, preferably 60-80 mesh, corresponding to an aperture of 0.2mm-0.3mm. This aperture is smaller than the diameter of the down cluster (usually greater than or equal to 1mm), achieving a stable down-proof effect through physical barrier; simultaneously, the sufficient number of mesh openings per unit area forms a continuous and interconnected airflow channel, ensuring good breathability and balancing down-proof effect with breathability.

[0037] In one embodiment of this application, during step S2, the power during plasma treatment is 300-400W, preferably 350-400W; the plasma treatment time is 2s-3s. The coated fabric includes a fabric substrate and a film layer bonded together with the fabric substrate. The fabric substrate includes cellulose fibers, such as cotton fibers, viscose fibers, modal fibers, lyocell fibers, etc.

[0038] In this application, during the edge-binding and lamination process, the edge of the laminated fabric is completely covered inside the strip-shaped downproof fabric, and the edge-binding strip, the laminated fabric, and the edge-binding strip form a three-layered structure arranged sequentially along the thickness direction. The "central area" refers to the area excluding the edge.

[0039] In this application, cellulose fibers can impart breathability to the coated fabric, further improving the breathability of the quilt body formed by the quilt cover.

[0040] In one embodiment of this application, in step S3, the strip-shaped downproof fabric includes polyester fiber, and the areal density of the strip-shaped downproof fabric is 80 g / m². 2 -100g / m 2 The preferred value is 88g / m 2 -95g / m 2 The width of the striped downproof fabric is 0.8cm-1.3cm, preferably 0.9cm-1.1cm. During the edge-binding and lamination process, the temperature is 105℃-110℃, preferably 108℃-110℃; the speed is 8m / min-9m / min, preferably 8.5m / min-9m / min; and the tension is 0.2MPa-0.3MPa, preferably 0.24MPa-0.3MPa. The first adhesive includes a polyester-based polyurethane hot melt adhesive. The striped downproof fabric includes at least one of cotton fiber, polyester fiber, and polyamide fiber.

[0041] In this application, the pre-shrinking temperature, the edge binding composite temperature, and the zoned gradient composite temperature form a progressively adapted temperature gradient. On the one hand, this avoids thermal shock deformation of the fabric due to sudden temperature changes; on the other hand, it achieves layer matching of adhesive layers in different processes, preventing secondary melting and failure of the previous adhesive layer during subsequent high-temperature processing, and ensuring stable bonding strength in each section. Based on this, combined with process and speed control, it ensures that the edge binding strip surface is flat and wrinkle-free, without curling edges, and completely covers the mesh end face openings of the composite area, preventing the end face openings from forming down-seeking channels and ensuring an anti-down-seeking effect.

[0042] In one embodiment of this application, in step S4, the duvet cover is divided into a head section, a middle section, and a tail section along its length (the length direction being the direction from head to toe when in use). The height of the longitudinal uprights in the head section is 8cm-10cm, and the height of the longitudinal uprights in the middle and tail sections is 6cm-8cm. The hot-pressing temperature in step S4 is 145℃-150℃, preferably 148℃-150℃; the hot-pressing temperature in step S5 is 120℃-125℃, preferably 122℃-125℃. The hot-pressing pressure is 0.35MPa-0.45MPa, preferably 0.38MPa-0.45MPa; the hot-pressing speed is 6m / min-7m / min, preferably 6.5m / min-7m / min. In other words, except for the hot-pressing temperature, the other parameters of the hot-pressing process are the same in steps S4 and S5. The adhesive system used in the hot-pressing bonding process includes a third adhesive and a compatibilizer. The third adhesive includes a polyester-based polyurethane hot melt adhesive, and the compatibilizer includes a glycidyl methacrylate-grafted polyolefin elastomer polyester compatibilizer (i.e., GMA epoxy-grafted POE polyester compatibilizer). The mass ratio of the compatibilizer to the third adhesive is 0.3:100-0.5:100, preferably 0.35:100-0.45:100. In step S4, the ultrasonic bonding power is 900W-1000W, preferably 940W-960W; in step S5, the ultrasonic bonding power is 800W-900W, preferably 840W-860W. The ultrasonic bonding frequency is 20kHz-25kHz, preferably 22kHz-25kHz. In other words, except for the ultrasonic bonding power, the other parameters of ultrasonic bonding are the same in steps S4 and S5. In step S5, the central areas of the two pre-treated fabrics are respectively bonded to the upper and lower sides of the pre-shrink fabric. In other words, the central area of ​​one pre-treated fabric is bonded to the upper side of the pre-shrink fabric, and the central area of ​​the other pre-treated fabric is bonded to the lower side of the pre-shrink fabric. Specifically, the cavity formed by the two pre-treated fabrics is divided into several independent filling units by several longitudinal uprights arranged alternately along the length and width of the duvet cover. The specifications of the filling units are (30cm-40cm) × (25cm-35cm). Preferably, the specifications of the filling units are (34cm-36cm) × (34cm-35cm). During the ultrasonic lamination process, high-frequency mechanical vibration of 20kHz-25kHz is applied to the lamination interface, causing high-frequency friction on the contact surface of the heterogeneous fabrics and instantaneously generating local heat, which promotes the melting and entanglement of polyester fibers and the coating surface. The compatibilizer at the interface melts synchronously with the local heating, playing a molecular bridging role between the coating layer and the backing fiber, improving the compatibility of heterogeneous materials and overcoming the problem of ultrasonic energy reflection on the smooth coating surface.In step S4, high-power ultrasonic bonding is used in the edge area to ensure full fusion and sealing at the joints, reducing the risk of delamination and down leakage. In step S5, low-power ultrasonic bonding is used in the central cavity area to ensure bonding strength while avoiding excessive melting and overflow of the adhesive layer and fibers, reducing the blockage of the mesh and making it easier to maintain the ventilation efficiency of the air-permeable cavity.

[0043] In this application, by adding a compatibilizer to the adhesive system, the interfacial tension between different fiber matrices and between the fiber matrix and the adhesive can be reduced, avoiding phase separation at the composite interface and negatively impacting structural stability. For hot-pressing composite processes, the compatibilizer promotes uniform wetting and spreading of the adhesive on the fabric surface, driving the adhesive layer and fiber matrix to form stable molecular entanglement and improving interfacial adhesion. For ultrasonic composite processes, high-frequency mechanical vibration of 20kHz-25kHz acts on the composite interface, causing high-frequency friction and instantaneous localized heat generation on the contact surfaces of the heterogeneous fabrics, prompting the polymer surface to melt. The compatibilizer at the interface melts synchronously with the localized heating, acting as a molecular bridge between the coating layer and the reinforcing fibers, improving the fusion compatibility of the heterogeneous materials, overcoming the reflection of ultrasonic energy by the smooth coating surface, promoting full diffusion and entanglement of interfacial molecules, and ultimately forming a strong fusion interface, effectively preventing delamination and cracking in the composite area during use and washing.

[0044] In one embodiment of this application, in step S6, during the constant temperature heat setting process, the temperature is 80℃-85℃, preferably 82℃-85℃; the constant temperature heat setting time is 15s-25s, preferably 20s-25s.

[0045] Another embodiment of this application also provides a shell prepared according to the method described above.

[0046] Another embodiment of this application provides a breathable, down-proof, and warm quilt, which includes the quilt shell as described above.

[0047] Furthermore, the term "and / or" in this application is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed in this application.

[0048] Example 1 according to Figure 1 The process shown is used to prepare the shell, and the specific steps are as follows: S1. Pre-shrinkage Adhesive was applied in a dotted pattern to the top surface of a 1.5mm thick elastic support fabric. The adhesive was a commercially available thermoplastic polyester-based polyurethane hot melt adhesive. The diameter of the adhesive dots was 0.5mm, the distance between adjacent adhesive dots along the length of the elastic support fabric was 2.5mm, and the distance between adjacent adhesive dots along the width of the elastic support fabric was 2mm. A 1mm thick mesh fabric (60 mesh size, corresponding to an aperture of 0.3mm, approximately 550 mesh openings / cm²) was then applied. 2 The mesh (with a diamond-shaped opening) is stacked on the elastic support fabric and hot-pressed for 12 seconds at a temperature of 85℃ and a pressure of 0.2MPa, thus combining the elastic support fabric and the mesh fabric. Then, using the exact same parameters, the bottom surface of the elastic support fabric is joined to another layer of mesh fabric (mesh size is 60 mesh, corresponding to an aperture of 0.3mm, with approximately 550 mesh openings per cm²). 2 The mesh is diamond-shaped and combined together to obtain a breathable, elastic, and supportive fabric. The breathable elastic support fabric is pre-shrinked at 115℃ for 15 seconds to obtain the pre-shrinked fabric. S2. Plasma treatment Commercially available cotton-based TPU-coated fabric (which consists of cotton fiber fabric and a TPU film bonded together with the cotton fiber fabric; TPU refers to thermoplastic polyurethane) was plasma-treated at 350W for 2.5s to obtain pretreated fabric. S3. Edge-sealing composite The edges of the pre-treated fabric are then joined with striped downproof fabric (this striped downproof fabric is a plain weave polyester fabric with a surface density of 90 g / m²). 2 (1cm wide) is edged and laminated with commercially available thermoplastic polyester polyurethane hot melt adhesive to form an edge strip. During the edge lamination process, the temperature is 108℃, the speed is 8.5m / min and the tension is 0.25MPa. S4. Edge Composite Using pre-shrink fabric as longitudinal vertical lining, the upper and lower sides of the pre-shrink fabric are heat-pressed together with the binding strip to obtain the shell; the height of the longitudinal vertical lining in the head area is 9cm, and the height of the longitudinal vertical lining in the tail area and the middle area is 7cm. S5. Central Area Composite Using pre-shrink fabric as longitudinal interlining, the central areas of two pre-treated fabrics are heat-pressed together with the upper and lower sides of the pre-shrink fabric respectively; the height of the longitudinal interlining in the head area is 9cm, and the height of the longitudinal interlining in the tail area and middle area is 7cm. The hot-pressing temperature in step S4 is 148℃, and the hot-pressing temperature in step S5 is 122℃. The hot-pressing pressure in both steps S4 and S5 is 0.4MPa, and the hot-pressing speed is 6.5m / min. The adhesive system used in the hot-pressing process is composed of commercially available thermoplastic polyester polyurethane hot melt adhesive and GMA epoxy grafted POE polyester compatibilizer in a mass ratio of 100:0.4. The cavity formed by the two pre-treated fabrics is divided into several filling units by several longitudinal uprights extending along the length and width of the duvet cover. The size of a single filling unit is 30cm×30cm. S6. Constant Temperature Heat Setting The shell was heat-set at 82℃ for 20 seconds to obtain a shell with dimensions of 220cm × 250cm (e.g. Figure 2 As shown, 1 is the outer fabric, 2 is the longitudinal interlining, and 3 is the bottom fabric. Both the outer and bottom fabrics are formed from pre-treated fabrics.

[0049] Example 2 according to Figure 1 The process shown is used to prepare the shell, and the specific steps are as follows: S1. Pre-shrinkage Adhesive was applied in a dotted pattern to the top surface of a 1mm thick elastic support fabric. The adhesive was a commercially available thermoplastic polyester-based polyurethane hot melt adhesive. The diameter of the adhesive dots was 0.3mm, the distance between adjacent adhesive dots along the length of the elastic support fabric was 2.2mm, and the distance between adjacent adhesive dots along the width of the elastic support fabric was 1.8mm. A 0.8mm thick mesh fabric (40 mesh size, corresponding to an aperture of 0.4mm, approximately 250 mesh openings / cm²) was then applied. 2 The mesh (with a diamond-shaped opening) is stacked on the elastic support fabric and hot-pressed for 10 seconds at a temperature of 80℃ and a pressure of 0.2MPa, thus combining the elastic support fabric and the mesh fabric together. Then, using the exact same parameters, the bottom surface of the elastic support fabric is joined to another layer of mesh fabric (mesh size is 40 mesh, corresponding to an aperture of 0.4mm, and the number of mesh holes per unit area is approximately 250 / cm²). 2 The mesh is diamond-shaped and combined together to obtain a breathable, elastic, and supportive fabric. The breathable elastic support fabric is pre-shrinked at 110℃ for 10 seconds to obtain the pre-shrinked fabric. S2. Plasma treatment Commercially available cotton-based TPU coated fabric (same as in Example 1) was plasma-treated at 300W for 2 seconds to obtain pretreated fabric; S3. Edge-sealing composite The edges of the pre-treated fabric are then joined with striped downproof fabric (this striped downproof fabric is a plain weave polyester fabric with a surface density of 80 g / m²). 2 (1cm wide) is edged and laminated with commercially available thermoplastic polyester polyurethane hot melt adhesive to form an edge strip. During the edge lamination process, the temperature is 105℃, the speed is 8m / min and the tension is 0.2Mpa. S4. Edge bonding: Using pre-shrink fabric as the longitudinal interlining, the upper and lower sides of the pre-shrink fabric are heat-pressed together with the edge binding strip to obtain the shell, with the mesh layer facing the inside of the shell; the height of the longitudinal interlining in the head area is 8cm, and the height of the longitudinal interlining in the tail area and the middle area is 6cm. S5. Central Area Composite Using pre-shrink fabric as longitudinal interlining, the central areas of two pre-treated fabrics are heat-pressed together with the upper and lower sides of the pre-shrink fabric respectively; the height of the longitudinal interlining in the head area is 8cm, and the height of the longitudinal interlining in the tail area and middle area is 6cm. The hot-pressing temperature in step S4 is 145℃, and the hot-pressing temperature in step S5 is 120℃. The hot-pressing pressure is 0.35MPa; the hot-pressing speed is 6m / min. The adhesive system used in the hot-pressing process consists of commercially available thermoplastic polyester-type polyurethane hot melt adhesive and GMA epoxy-grafted POE polyester compatibilizer in a mass ratio of 100:0.3.

[0050] The cavity formed by the two pre-treated fabrics is divided into several filling units by several longitudinal uprights extending along the length and width of the duvet cover. The size of the filling unit is 30cm×25cm. S6. Constant Temperature Heat Setting The shell was heat-set at 80℃ for 15 seconds to obtain a shell with dimensions of 220cm × 250cm (e.g. Figure 2 As shown, 1 is the outer fabric, 2 is the longitudinal interlining, and 3 is the bottom fabric. Both the outer and bottom fabrics are formed from pre-treated fabrics.

[0051] Example 3 according to Figure 1 The process shown is used to prepare the shell, and the specific steps are as follows: S1. Pre-shrinkage Adhesive was applied in a dotted pattern to the top surface of a 2.0mm thick elastic support fabric. The adhesive was a commercially available thermoplastic polyester-based polyurethane hot melt adhesive. The diameter of the adhesive dots was 0.6mm, the distance between adjacent adhesive dots along the length of the elastic support fabric was 3.0mm, and the distance between adjacent adhesive dots along the width of the elastic support fabric was 2.5mm. A 1.5mm thick mesh fabric (80 mesh size, corresponding to an aperture of 0.2mm, and approximately 990 mesh openings / cm²) was then applied.2 The mesh (with a diamond-shaped opening) is stacked on the elastic support fabric and hot-pressed for 15 seconds at a temperature of 90℃ and a pressure of 0.3MPa, thus combining the elastic support fabric and the mesh fabric together. Then, using the exact same parameters, the bottom surface of the elastic support fabric is joined to another layer of mesh fabric (mesh size is 80 mesh, corresponding to an aperture of 0.2mm, and the number of mesh holes per unit area is approximately 990 / cm²). 2 The mesh is diamond-shaped and combined together to obtain a breathable, elastic, and supportive fabric. The breathable elastic support fabric is pre-shrinked at 120℃ for 15 seconds to obtain the pre-shrinked fabric. S2. Plasma treatment Commercially available cotton-based coated fabric (same as in Example 1) was plasma-treated at 400W for 3 seconds to obtain pretreated fabric; S3. Edge-sealing composite The edges of the pre-treated fabric are then joined with striped downproof fabric (this striped downproof fabric is a plain weave polyester fabric with a surface density of 100g / m²). 2 (1cm wide) is edged and laminated with commercially available thermoplastic polyester polyurethane hot melt adhesive to form an edge strip. During the edge lamination process, the temperature is 110℃, the speed is 9m / min and the tension is 0.3MPa. S4. Edge bonding: Using pre-shrink fabric as longitudinal vertical lining, the upper and lower sides of the pre-shrink fabric are ultrasonically bonded to the edge strip to obtain the shell, with the mesh layer facing the inside of the shell; the height of the longitudinal vertical lining in the head area is 10cm, and the height of the longitudinal vertical lining in the tail area and middle area is 8cm. S5. Central area bonding: Using the pre-shrinked fabric as the longitudinal lining, the central areas of the two pre-treated fabrics are ultrasonically bonded to the upper and lower sides of the pre-shrinked fabric respectively; the height of the longitudinal lining in the head area is 10cm, and the height of the longitudinal lining in the tail area and the middle area is 8cm. In step S4, the power of ultrasonic superposition is 1000W; in step S5, the power of ultrasonic superposition is 900W; and the frequency of ultrasonic superposition is 25kHz. The cavity formed by the two pre-treated fabrics is divided into several filling units by several longitudinal uprights extending along the length and width of the duvet cover. The size of the filling unit is 35cm×35cm. S6. Constant Temperature Heat Setting: The shell is heat-set at 85℃ for 25 seconds to obtain a shell with dimensions of 220cm×250cm (e.g., Figure 2 As shown, 1 is the outer fabric, 2 is the longitudinal interlining, and 3 is the bottom fabric. Both the outer and bottom fabrics are formed from pre-treated fabrics.

[0052] Comparative Example 1 The difference between this comparative example and Example 1 is that no pre-shrinking treatment was performed.

[0053] Comparative Example 2 The difference between this comparative example and Example 1 is that the pre-shrinking temperature is 100°C.

[0054] Comparative Example 3 The difference between this comparative example and Example 1 is that the pre-shrinking temperature is 130°C.

[0055] Comparative Example 4 The difference between this comparative example and Example 1 is that the coated fabric was not subjected to plasma treatment.

[0056] Comparative Example 5 The difference between this comparative example and Example 1 is that: instead of edge binding, the upper and lower sides of the pre-shrinked fabric are directly heat-pressed or ultrasonically bonded to the pre-treated fabric.

[0057] Comparative Example 6 The difference between this comparative example and Example 1 is that the edge-wrapping temperature is 95°C.

[0058] Comparative Example 7 The difference between this comparative example and Example 1 is that the edge-wrapping temperature is 120°C.

[0059] Comparative Example 8 The difference between this comparative example and Example 1 is that the hot pressing temperature in step S4 and step S5 is the same, which is 145℃-150℃.

[0060] Comparative Example 9 The difference between this comparative example and Example 1 is that the hot pressing temperature in step S4 and step S5 is the same, which is 120℃-125℃.

[0061] Comparative Example 10 The difference between this comparative example and Example 1 is that constant temperature heat setting was not performed.

[0062] Comparative Example 11 The difference between this comparative example and Example 1 is that the adhesive system used in the hot-pressing process did not contain GMA epoxy-grafted POE polyester compatibilizer.

[0063] test The shells obtained in each embodiment and comparative example were processed into down comforters of the same specifications using the same process; The air permeability of each down comforter was tested according to Formula 1 in GB / T 5453-2022 Textiles - Determination of air permeability of fabrics. The test was repeated 10 times at different parts of the same sample, and the arithmetic mean was taken as the test result. The results are shown in Table 1. The support stability of the longitudinal uprights in the central area of ​​each down comforter was tested using the indentation and rebound method. A constant pressure was applied to simulate the stress state of human body pressing and turning over during sleep. After holding the pressure for a certain period of time, the pressure was unloaded, and the height recovery rate (i.e., support stability) of the longitudinal uprights was tested. The higher the recovery rate, the less likely the longitudinal uprights are to undergo plastic collapse after being compressed, and the better the spatial stability of the air vents under long-term use. The results are shown in Table 1. The number of down feathers that escaped from each down comforter was tested according to GB / T 12705.2-2009 Textiles - Test Method for Down-proof Fabrics - Part 2: Rotating Box Method. The results are shown in Table 1.

[0064] Table 1 Test Results

[0065] As shown in Table 1, compared with Comparative Example 11, the down comforter processed from the comforter shell prepared in Example 1 exhibits significantly improved support stability and a significantly reduced number of down fibers. This result demonstrates that by adding a compatibilizer to the adhesive system, this application can effectively improve the interfacial bonding force of heterogeneous materials, reduce the risk of delamination and edge opening, and thus enhance the long-term structural stability and down-proof reliability.

[0066] The above embodiments are merely illustrative of the principles and effects of this application and are not intended to limit this application. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this application. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this application should still be covered by the claims of this application.

Claims

1. A method for producing a shell, characterized in that, The production method includes the following steps: S1. Pre-shrink the breathable elastic support fabric to obtain a pre-shrink fabric; the breathable elastic support fabric includes an elastic support layer and a mesh layer composited with the elastic support layer. S2. Plasma treatment is performed on the coated fabric to obtain a pretreated fabric; S3. The four edges of the pretreated fabric are bonded to the strip-shaped downproof fabric with a first adhesive to form an edge binding strip; S4. Using the pre-shrink fabric as a longitudinal lining, the upper and lower sides of the pre-shrink fabric are respectively bonded to the binding strip to obtain a shell, with the mesh layer facing the inside of the shell; S5. Using the pre-shrinked fabric as a longitudinal lining, the central areas of the two pre-treated fabrics are respectively bonded to the upper and lower sides of the pre-shrinked fabric; the bonding methods in steps S4 and S5 are the same, namely hot-press bonding and / or ultrasonic bonding; the temperature of the hot-press bonding in step S4 is higher than the temperature of the hot-press bonding in step S5; the power of the ultrasonic bonding in step S4 is higher than the power of the ultrasonic bonding in step S5. S6. The shell is heat-set at a constant temperature to obtain the outer shell.

2. The method for producing the shell as described in claim 1, characterized in that, During the pre-shrinking process described in step S1, the temperature is 110℃-120℃, and the pre-shrinking time is 10s-15s.

3. The method for producing the shell as described in claim 1, characterized in that, Step S1 satisfies at least one of the following requirements (1)-(5): (1) The elastic support layer includes elastic fibers and supporting fibers; (2) The thickness of the elastic support layer is 1.0mm-2.0mm; (3) The mesh size of the mesh layer is 40-80 mesh; (4) The thickness of the mesh layer is 0.8mm-1.5mm; (5) The elastic support layer and the mesh layer are hot-pressed together by applying a second adhesive in a dotted manner.

4. The method for producing the shell as described in claim 3, characterized in that, Step S1 satisfies at least one of the following requirements (6)-(9): (6) The elastic fiber content in the elastic support layer is 60%-70% by mass; (7) The second adhesive includes polyester-based polyurethane hot melt adhesive; (8) During the hot-pressing composite process of the elastic support layer and the mesh layer, the diameter of the adhesive point is 0.3mm-0.6mm, the distance between adjacent adhesive points along the length direction of the shell is 2.2mm-3.0mm, and the distance between adjacent adhesive points along the width direction of the shell is 1.8mm-2.5mm. (9) During the hot-pressing composite process of the elastic support layer and the mesh layer, the temperature is 80℃-90℃, the pressure is 0.2MPa-0.3MPa, and the hot-pressing composite time is 10s-15s.

5. The method for producing the shell as described in claim 1 or 3, characterized in that, In step S2, the plasma treatment process uses a power of 300-400W and a treatment time of 2-3 seconds. And / or, in step S2, the coated fabric includes a fabric matrix and a film layer composited with the fabric matrix, wherein the fabric matrix includes cellulose fibers.

6. The method for producing the shell as described in claim 2, characterized in that, During the edge-wrapping process described in step S3, the temperature is 105℃-110℃, the speed is 8m / min-9m / min, and the tension is 0.2MPa-0.3MPa. And / or, in step S3, the strip-shaped downproof fabric includes at least one of cotton fiber, polyester fiber and polyamide fiber.

7. The method for producing the shell as described in claim 1, characterized in that, Step S5 satisfies at least one of the following requirements (10)-(14): (10) The temperature of hot pressing composite in step S4 is 145℃-150℃, and the temperature of hot pressing composite in step S5 is 120℃-125℃; (11) The pressure of the hot-pressing composite is 0.35MPa-0.45MPa, and the speed of the hot-pressing composite is 6m / min-7m / min; (12) The adhesive system used in the hot-pressing composite process includes a third adhesive and a compatibilizer; (13) The power of the ultrasonic composite in step S4 is 900W-1000W, and the power of the ultrasonic composite in step S5 is 800W-900W. (14) The frequency of the ultrasonic composite is 20kHz-25kHz.

8. The method for producing the shell as described in claim 1 or 7, characterized in that, During the constant temperature heat setting process described in step S6, the temperature is 80℃-85℃, and the constant temperature heat setting time is 15s-25s.

9. A shell prepared according to any one of claims 1-8.

10. A breathable, down-proof, and warm quilt, characterized in that, The breathable, down-proof, and warm quilt includes the quilt cover as described in claim 9.

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