A multi-layered laminated channel cloth and a preparation process thereof

Abstract

The application discloses a kind of multilayer adhesion channel cloth and its preparation process, it is related to cloth technical field, including the establishment of containing shape, adhesion, sealing and the partition lamination layout of steam zone;Preparation of fabric and film and form window and flow boundary;In channel shape area layout releasable shape core belt;Segmented hot-pressing and limit channel compaction;Remove core belt and pulse open cavity;After differential pressure, thermal response and appearance detection, repair or reject.The application is by partition lamination layout, different melting adhesive film, flow limiting adhesive film, releasable shape core belt and partition pressing roller cooperation, so that the reliable adhesion of compartment, channel is not easy to collapse or stick, improve the filling channel penetration rate and filling uniformity;At the same time, through the misaligned steam zone, steam and anti-drilling down are considered, and combined with differential pressure, thermal response and appearance detection, improve the stability and reliability of channel cloth product.

Description

Technical Field

[0001] This invention relates to the field of fabric technology, and in particular to a multi-layer laminated channel fabric and its preparation process. Background Technology

[0002] Multi-layered channel fabrics are commonly used in down jackets, thermal clothing, sleeping bags, and other filled textile products. Their function is to create compartmentalized channels between fabric layers, allowing down, fiber fillers, or other insulating materials to enter. Existing channel fabrics typically employ methods such as sewn compartmentation, adhesive film lamination, heat-pressing, or tubular fabric lamination to form the channel structure. Sewing methods are prone to pinholes, leading to issues like down leakage, air leakage, and reduced waterproofing. While heat-pressing with a full-surface adhesive film reduces stitching, the adhesive can easily flow into the channel area during heat pressing, causing narrowing of the channels, localized adhesion, or even blockage, affecting the smoothness of subsequent down filling.

[0003] Furthermore, existing multi-layer bonded channel fabrics are typically processed with uniform channel spacing and heat-pressing parameters, making it difficult to simultaneously address the bending, loft, and breathability requirements of different parts of the garment. For example, using wider and stiffer channel structures in active areas such as the armpits, shoulders, and elbows can easily lead to creases, bulges, and a feeling of foreign objects when wearing the garment; conversely, narrower channels in insulation areas such as the chest and back can affect filling capacity and loft. Additionally, current post-bonding channel inspections rely heavily on manual observation or simple ventilation checks, making it difficult to promptly distinguish between different defects such as channel blockage, poor interlayer bonding, and surface indentations. This results in insufficient consistency of finished products and inadequate stability in subsequent garment processing. Therefore, we propose a multi-layer bonded channel fabric and its manufacturing process. Summary of the Invention

[0004] The purpose of this invention is to provide a multilayer laminated channel fabric and its preparation process to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a process for preparing multilayer laminated channel fabric, comprising:

[0006] Step 1: Based on the filling direction, compartment width, bending position, and ventilation requirements of the channel fabric, establish a partitioned lamination pattern. The partitioned lamination pattern includes the channel shape-preserving area, compartment bonding area, edge sealing area, and staggered ventilation area.

[0007] Step 2: Prepare the outer fabric, inner fabric, first thermally activated adhesive film, second thermally activated adhesive film and flow-limiting adhesive film respectively, and form corresponding adhesive film windows and flow-limiting boundaries on the first thermally activated adhesive film and the second thermally activated adhesive film according to the partitioned lamination pattern.

[0008] Step 3: Arrange a releasable conformal core strip between the outer and inner fabric layers, ensuring that the releasable conformal core strip is located within the conformal zone of the channel, and align the compartment bonding area with the flow-limiting adhesive film.

[0009] Step 4: Perform segmented hot pressing on the stacked multi-layer materials. First, pre-fix the compartment bonding area, then reinforce the edge sealing area, and during the hot pressing process, the releasable conformal core tape restricts the conformal area from being compacted.

[0010] Step 5: After the bonding layer has cooled and set, release or remove the releasable conformal core tape, and introduce a pulsed airflow into the conformal channel area to form a continuous down filling channel in the conformal channel area;

[0011] Step 6: Perform differential pressure testing, thermal response testing, and appearance flatness testing on the continuous down filling channel. Based on the test results, perform secondary cavitation or removal on the local non-through areas to obtain multi-layered bonded channel fabric.

[0012] Preferably, in step 1, the partitioned lamination pattern is graded according to the bending area of ​​the channel fabric in the garment. The shape-preserving area of ​​the channel located under the armpit, shoulder, or elbow is set as a narrow-spacing flexible channel, while the shape-preserving area of ​​the channel located on the chest, back, or both sides of the placket is set as a wide-spacing fluffy channel, so that the channels in different positions have different pressure recovery space after being fitted.

[0013] Preferably, in step 2, the first and second thermally activated adhesive films have different melting temperatures. The adhesive film near the compartment bonding area softens and bonds first, while the adhesive film near the channel conformal area softens and bonds later, thus forming a bonding sequence of positioning followed by sealing in the same hot pressing process.

[0014] Preferably, the flow-limiting adhesive film is disposed on both sides of the bonding area of ​​the compartment, and the melt flow distance of the flow-limiting adhesive film is less than that of the first thermally activated adhesive film and the second thermally activated adhesive film, so as to prevent the adhesive material from entering the channel conformal area during hot pressing.

[0015] Preferably, in step 3, the releasable conformal core tape is one of heat-resistant release core tape, water-soluble core tape, or low-adhesion core tape. The thickness of the releasable conformal core tape is greater than the target minimum height of the continuous down filling channel after lamination, so as to reserve channel rebound margin during the hot pressing lamination stage. Micro-convex positioning edges are provided on both sides of the releasable conformal core tape. A non-lamination gap is maintained between the micro-convex positioning edges and the flow-limiting adhesive film, so that a transition buffer zone is formed between the compartment lamination line and the inner cavity of the channel during hot pressing.

[0016] Preferably, the segmented hot pressing bonding in step 4 is completed using partitioned pressure rollers. The partitioned pressure rollers include a high-pressure roller surface corresponding to the bonding area of ​​the compartment and an avoidance roller surface corresponding to the conformal area of ​​the channel. The high-pressure roller surface is used to improve the bonding strength of the compartment, and the avoidance roller surface is used to reduce the compaction effect on the conformal area of ​​the channel.

[0017] Preferably, in step 5, the pulsed airflow is input along the length of the continuous down filling channel, and the exhaust status is detected at the end of the channel; when the exhaust status is lower than the preset ventilation standard, a reverse pulse opening is performed on the corresponding channel to separate the locally adhered inner wall.

[0018] Preferably, in step 6, differential pressure detection is used to determine whether the continuous down filling channel is unobstructed, thermal response detection is used to determine whether there is false bonding in the compartment bonding area, and appearance flatness detection is used to determine whether there are indentations, glue spots, or wrinkles on the outer fabric. When the differential pressure is abnormal and the thermal response is normal, it is determined that the channel is partially blocked and enters the secondary cavity. When the thermal response is abnormal, it is determined that the bonding is ineffective and is rejected.

[0019] Preferably, the misaligned breathable zone is formed by the misalignment of the film openings of the first thermally activated adhesive film and the film openings of the second thermally activated adhesive film, so that a non-straight-through breathable path is formed between the outer fabric and the inner fabric, and down or fiber debris is prevented from escaping along straight pores.

[0020] A multilayer laminated channel fabric is prepared using any one of the multilayer laminated channel fabric preparation processes described above.

[0021] The technical effects and advantages of this invention are as follows:

[0022] This invention pre-plans the channel conformal area, compartment bonding area, edge sealing area, and staggered vapor permeability area through a partitioned laminated pattern. Combined with heat-activated adhesive films at different melting temperatures, flow-limiting adhesive films, releasable conformal core belts, partitioned pressure rollers, and pulsed cavity opening technology, it ensures reliable bonding of the compartment areas and prevents the channel areas from being compacted or stuck during hot pressing. This improves the continuity and uniformity of the continuous down filling channel. Simultaneously, the graded arrangement of narrow-spacing flexible channels and wide-spacing fluffy channels balances the softness of moving parts and the insulation and fluffiness of the main body of the garment. The staggered vapor permeability area forms a non-straight-through vapor permeability path, reducing the risk of down leakage while maintaining ventilation comfort. The combination of differential pressure detection, thermal response detection, and appearance flatness detection can distinguish between channel blockage, bonding failure, and surface defects, improving the production stability, finished product qualification rate, and long-term reliability of the multi-layer laminated channel fabric. Attached Figure Description

[0023] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention, but do not constitute a limitation thereof. In the drawings:

[0024] Figure 1 This is a schematic diagram of the process flow of the present invention. Detailed Implementation

[0025] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] This invention provides, for example Figure 1 The process for preparing a multilayer laminated channel fabric shown includes:

[0027] Step 1: Based on the filling direction, compartment width, bending position, and ventilation requirements of the channel fabric, establish a partitioned lamination pattern. The partitioned lamination pattern includes the channel shape-preserving area, compartment bonding area, edge sealing area, and staggered ventilation area.

[0028] During implementation, the filling direction, compartment width, bending positions, and ventilation requirements are first determined based on the subsequent use of the channel fabric. For example, channels located in the main body area of ​​the garment can be set as wider, more voluminous channels, while channels in easily bendable areas such as the armpits, shoulders, and elbows can be set as narrower, more flexible channels. For areas requiring moisture wicking and ventilation, staggered ventilation zones are reserved. Subsequently, the above parameters are converted into a partitioned lamination pattern, which includes at least a channel shape-preserving zone, a compartment bonding zone, an edge sealing zone, and a staggered ventilation zone. The channel shape-preserving zone is used to form the subsequent filling channels, the compartment bonding zone is used to separate adjacent channels, the edge sealing zone is used to improve the fabric boundary strength, and the staggered ventilation zone is used to form a non-straight-through ventilation path. Through this step, the overall planning of the channels, compartments, edge sealing, and ventilation structure can be completed before lamination, avoiding inconsistent channel widths, compartment misalignment, or ventilation zone failure caused by relying solely on experience for positioning in subsequent processing. This design gives the functional areas of the multi-layer bonding channel fabric clear boundaries, which helps to improve bonding accuracy and batch processing consistency.

[0029] Step 2: Prepare the outer fabric, inner fabric, first thermally activated adhesive film, second thermally activated adhesive film and current-limiting adhesive film respectively, and form corresponding adhesive film windows and current-limiting boundaries on the first thermally activated adhesive film and the second thermally activated adhesive film according to the partitioned lamination pattern.

[0030] During implementation, an outer layer fabric, an inner layer fabric, a first heat-activated adhesive film, a second heat-activated adhesive film, and a flow-limiting adhesive film are selected respectively. The outer layer fabric can be nylon fabric, polyester fabric, or a composite windproof fabric, while the inner layer fabric can be a lightweight down-proof fabric, a breathable fabric, or a knitted base fabric. The first and second heat-activated adhesive films are used to achieve interlayer bonding between the outer and inner layers, while the flow-limiting adhesive film is placed in the compartment bonding area or its adjacent position to restrict the flow of adhesive material into the channel conformal area under heat and pressure.

[0031] According to the zoning and lamination layout, the first and second thermally activated adhesive films are windowed to align with the conformal zones and staggered vapor permeability zones of the channels; simultaneously, flow-limiting boundaries are formed on both sides of the compartment bonding area. The adhesive film windows can be formed by die-cutting, laser cutting, punching, or hot-blade cutting, while the flow-limiting boundaries can be achieved using narrow strip-shaped flow-limiting adhesive films, low-flow adhesive films, or pre-formed adhesive strips.

[0032] This step prevents the entire adhesive film from covering the channel area during hot pressing, reducing the problem of the channel being stuck, narrowed, or blocked by the adhesive. At the same time, the flow-limiting adhesive film can suppress the overflow of hot melt adhesive, making the compartment bonding line clearer and more stable, thereby improving the throughput of the continuous filling channel and the appearance quality of the finished product.

[0033] Step 3: Lay a releasable conformal core tape between the outer and inner fabric layers, ensuring that the releasable conformal core tape is located within the conformal zone of the channel, and align the compartment bonding area with the flow-limiting adhesive film.

[0034] During implementation, the outer fabric, the first heat-activated adhesive film, the flow-limiting adhesive film, the releasable conformal core tape, the second heat-activated adhesive film, and the inner fabric are stacked in a predetermined order. The releasable conformal core tape is positioned within the conformal zone of the channel, its width matching the target down-filling channel width, and its thickness greater than or equal to the minimum required inner cavity height of the channel after bonding. The releasable conformal core tape can be made of heat-resistant release material, water-soluble material, low-adhesion flexible material, or a flat tape material with a release layer on its surface.

[0035] During the installation process, ensure that the releasable conformal core strip accurately aligns with the conformal zone of the channel, and that the compartment bonding area is aligned with the flow-limiting adhesive film. To improve positioning stability, slight raised edges can be provided on both sides of the core strip, or positioning marks can be placed in the lamination diagram to prevent the core strip from shifting before entering the hot pressing process.

[0036] This step creates a temporary support within the channel's shape-preserving zone before hot pressing, preventing the channel area from being completely compacted during subsequent heating and pressing. Compared to directly bonding and then attempting to blow open the channel, this method allows for pre-reserving internal space for the channel, reducing the risk of inner wall adhesion and improving the smoothness of the filling process.

[0037] Step 4: Perform segmented hot pressing on the stacked multi-layer materials. First, pre-fix the compartment bonding area, then reinforce the edge sealing area, and during the hot pressing process, the releasable conformal core tape restricts the conformal area from being compacted.

[0038] During implementation, the multi-layered materials are hot-pressed in sections. Specifically, flatbed hot pressing, continuous roller hot pressing, or zoned roller hot pressing can be used. First, the compartment bonding area is pre-fixed to create an initial separation between adjacent channels; then, the edge sealing area is reinforced to ensure sufficient tensile strength and crack resistance at the channel fabric boundaries. During hot pressing, a release conformal core strip is located within the channel conformal zone, capable of withstanding some pressure and preventing direct adhesion between upper and lower adhesive films, thus limiting the compaction of the channel conformal zone.

[0039] The hot-pressing parameters can be adjusted according to the fabric and adhesive film type. For example, the compartment bonding area can be set to higher pressure and medium temperature, the channel conformal area to low pressure or avoidance pressure, and the edge sealing area to a longer holding time. By controlling the temperature, pressure, and holding time in segments, different bonding states can be achieved for different functional areas.

[0040] This step achieves the processing effect of "reliable bonding of compartments, firm sealing of edges, and maintenance of cavities in the channel area," avoiding channel collapse or adhesive blockage caused by traditional full-surface hot pressing. Segmented hot pressing can also reduce indentations, adhesive spots, and localized wrinkles on the outer fabric surface, improving the smoothness of the multi-layer bonded channel fabric.

[0041] Step 5: After the bonding layer has cooled and set, release or remove the releasable conformal core tape and introduce pulsed airflow into the conformal channel area to form a continuous down filling channel.

[0042] During implementation, after hot pressing, the bonding layer enters the cooling and setting stage. Once the adhesive film has cured and formed a stable bond, the releasable conformal core tape is released or removed. If the releasable conformal core tape is a heat-resistant release tape, it can be removed by pulling; if it is a water-soluble core tape, it can be removed by wet treatment or washing; if it is a low-adhesion core tape, it can be separated from the inner wall of the channel by mechanical traction.

[0043] After the core strip is released or removed, a pulsed airflow is introduced into the conformal zone of the channel. The pulsed airflow is intermittently introduced along the length of the channel, causing the slightly fitted or closely spaced inner walls to be opened by the airflow, and forming a continuous filling channel in the conformal zone of the channel. The pressure of the pulsed airflow should not be too high to avoid damaging the compartment fitting area; multiple short pulses can be used to gradually open the cavity.

[0044] This step further restores the internal shape of the channel, eliminates minor adhesions or flattening, and makes the down filling channel more continuous and smooth. Compared with simply relying on the core strip to maintain shape, pulsed airflow can reshape the channel after bonding, improve the subsequent down filling efficiency, and reduce problems such as localized down blockage, down breakage, or uneven filling during down filling.

[0045] Step 6: Perform differential pressure testing, thermal response testing, and appearance flatness testing on the continuous down filling channel. Based on the test results, perform secondary cavitation or removal on the local non-through areas to obtain multi-layered bonded channel fabric.

[0046] During implementation, the formed continuous down filling channels are inspected. Differential pressure detection can be performed by inputting a detection airflow into one end of the channel and detecting the air pressure, flow rate, or exhaust status at the other end to determine whether the channel is unobstructed; thermal response detection can be performed by local heating or infrared detection to determine whether there is loose bonding, delamination, or uneven bonding in the compartment bonding area; appearance flatness detection can be performed by manual observation, visual inspection, or surface height detection to determine whether there are indentations, glue spots, wrinkles, or channel misalignment in the outer fabric.

[0047] When the differential pressure detection is abnormal but the thermal response detection is normal, it can be determined that the channel is not fully connected or slightly blocked. In this case, a secondary pulse opening can be performed on the corresponding area. When the thermal response detection is abnormal, it indicates that there may be a loose bond or sealing failure in the compartment bonding area. The area should be marked as unqualified and removed. When the appearance flatness detection is abnormal, it can be repaired, downgraded or removed according to the degree of abnormality.

[0048] This step allows for a comprehensive assessment of the channel's continuity, bonding reliability, and appearance quality before finished product output, avoiding missed inspections due to reliance on manual touch or visual inspection alone. This testing method simultaneously incorporates three key indicators—"whether the channel can be filled with down, whether the partitions are secure, and whether the surface is smooth"—into quality control, improving the finished product stability of multi-layer bonded channel fabric and its adaptability to subsequent garment processing.

[0049] In step 1, the zoning and lamination pattern is graded according to the bending areas of the channel fabric in the garment. Channel shaping areas located under the armpits, shoulders, or elbows are designed as narrow-spacing flexible channels, while channel shaping areas located on the chest, back, or sides of the placket are designed as wide-spacing, fluffy channels. This ensures that channels in different locations have different compressive recovery space after lamination. During implementation, the corresponding application areas of the channel fabric can be determined first based on the garment pattern or 3D template, and high-frequency bending areas such as the armpits, shoulders, and elbows, as well as relatively flat areas such as the chest, back, and sides of the placket, can be marked. For high-frequency bending areas, the channel shaping areas are designed as narrow-spacing flexible channels, resulting in smaller individual channel widths and shorter bending radii, making it less prone to hard creases or bulges due to human movement after lamination. For relatively flat areas, the channel shaping areas are designed as wide-spacing, fluffy channels to increase filling capacity and insulation thickness. As a result, different areas can obtain different pressure-resistant recovery spaces, which not only ensures that the active parts are soft and fit well, but also ensures that the main body is fluffy and warm, reducing channel collapse, filling displacement and the feeling of foreign objects when wearing.

[0050] In step 2, the first and second thermally activated adhesive films have different melting temperatures. The film closer to the compartment bonding area softens and bonds first, while the film closer to the channel conformal area softens and bonds later. This creates a "positioning first, sealing later" bonding sequence in the same hot-pressing process. In implementation, first and second thermally activated adhesive films with different melting temperatures can be used, with the lower melting point film corresponding to the compartment bonding area and the higher melting point film corresponding to the channel conformal area or its adjacent area. Initially, the lower melting point film softens first, allowing the compartment bonding area to complete preliminary positioning and preventing the fabric layer and core strip from shifting under subsequent pressure. As the temperature continues to rise or the holding time extends, the higher melting point film bonds later, completing boundary sealing and interlayer reinforcement. This sequence allows for a "positioning first, sealing later" bonding process in a single hot-pressing operation, reducing the problem of adhesive material prematurely flowing into the channel conformal area and causing adhesion and blockage, thus improving the compartment positioning accuracy and channel connectivity stability.

[0051] The flow-limiting adhesive film is positioned on both sides of the compartment bonding area. The melt flow distance of the flow-limiting adhesive film is shorter than that of the first and second thermally activated adhesive films. It prevents the adhesive from entering the channel conformal zone during hot pressing. In practice, the flow-limiting adhesive film can be continuously or intermittently arranged along both sides of the compartment bonding area, positioned between the compartment bonding line and the channel conformal zone. The flow-limiting adhesive film can be a low-flow-rate hot melt adhesive film or a high-viscosity adhesive strip, whose melt diffusion distance after heating is shorter than that of the first and second thermally activated adhesive films. During hot pressing, the flow-limiting adhesive film first forms a blocking band at the edge of the compartment, restricting the overflow of other adhesive film melts into the channel conformal zone. This maintains a clear boundary within the channel cavity, preventing the channel from being stuck, narrowed, or blocked by the adhesive, thus improving the compartment bonding strength and the continuity and stability of the continuous filling channel.

[0052] In step 3, the releasable conformal core tape is one of a heat-resistant release core tape, a water-soluble core tape, or a low-adhesion core tape. The thickness of the releasable conformal core tape is greater than the target minimum height of the continuous down-filling channel after lamination, so as to reserve channel springback margin during the hot-pressing lamination stage. Micro-convex positioning edges are provided on both sides of the releasable conformal core tape. A non-lamination gap is maintained between the micro-convex positioning edges and the flow-limiting adhesive film, forming a transition buffer zone between the compartment lamination line and the channel cavity during hot pressing. In implementation, the heat-resistant release core tape, water-soluble core tape, or low-adhesion core tape can be selected according to the subsequent removal method, and its thickness should be slightly greater than the target minimum height of the continuous down-filling channel, so that springback space is still reserved for the channel after hot pressing. The micro-convex positioning edges on both sides of the core tape are used to limit the lateral displacement of the core tape during assembly and to maintain a non-lamination gap with the flow-limiting adhesive film. During hot pressing, the non-bonding gap forms a transition buffer zone between the compartment bonding line and the inner cavity of the channel, which can reduce the pressure of the hard edge of the bonding line on the channel, reduce channel collapse, edge adhesion and adhesive intrusion, and improve the stability of channel forming and the smoothness of subsequent filling.

[0053] In step 4, segmented hot pressing is performed using partitioned rollers. These partitioned rollers include a high-pressure roller surface corresponding to the compartment bonding area and a clearance roller surface corresponding to the channel conformal area. The high-pressure roller surface enhances the compartment bonding strength, while the clearance roller surface reduces the compaction effect on the channel conformal area. During implementation, partitioned rollers with different radial heights or surface hardness can be used to continuously hot press multi-layer materials. In the partitioned rollers, the high-pressure roller surface corresponds to the compartment bonding area and applies high pressure to the compartment bonding line, allowing the adhesive film to fully melt and penetrate the fabric fiber gaps, forming a stable barrier. The clearance roller surface corresponds to the channel conformal area, and its surface can be set as a recessed area or a low-pressure elastic area to reduce the compaction effect on the releasable conformal core and the channel conformal area. This structure allows for strong adhesion in the compartment area and weak compression in the channel area during the same hot pressing process, preventing channel collapse or inner wall adhesion caused by overall pressure, thus improving the tensile strength of the compartments and the forming reliability of the continuous filling channel.

[0054] In step 5, the pulsed airflow is input along the length of the continuous filling channel, and the exhaust status is detected at the end of the channel. When the exhaust status is lower than the preset ventilation standard, a reverse pulse opening is performed on the corresponding channel to separate the locally adhered inner walls. During implementation, after the releasable conformal core strip is removed and cooled and shaped, the pulsed airflow is input from one end of the continuous filling channel, allowing the airflow to intermittently advance along the channel length. The exhaust volume, exhaust pressure, or exhaust continuity is detected at the end of the channel. If the detected value is lower than the preset ventilation standard, it indicates that there is local adhesion, flattening, or incomplete opening in the channel. In this case, a reverse pulsed airflow is input from the end of the channel to reverse the opening of the blocked area. By combining forward detection with reverse opening, adhesion and local blockage of the channel inner walls can be reduced, improving channel throughput and subsequent filling uniformity.

[0055] In step 6, differential pressure detection is used to determine whether the continuous down filling channel is unobstructed, thermal response detection is used to determine whether there is any loose bonding in the compartment bonding area, and appearance flatness detection is used to determine whether there are indentations, glue spots, or wrinkles on the outer fabric. When the differential pressure is abnormal and the thermal response is normal, it is determined that the channel is partially blocked and a secondary cavity opening is performed. When the thermal response is abnormal, it is determined that the bonding has failed and the product is rejected. In practice, a detection airflow can be input at one end of the continuous down filling channel, and the channel unobstructed can be determined by the pressure difference or flow rate change at both ends. At the same time, the compartment bonding area is locally heated or infrared detected to determine whether there is any loose bonding, delamination, or uneven bonding. Indentations, glue spots, and wrinkles are then identified by visual or surface height detection. When the differential pressure is abnormal and the thermal response is normal, it indicates that the compartment bonding is reliable but the channel is partially blocked, and a secondary cavity opening can be performed. When the thermal response is abnormal, the bonding has failed and the product is rejected. This can improve the accuracy of finished product inspection and reduce down clogging, down leakage, and appearance defects.

[0056] The staggered breathable zone is formed by the misalignment of the openings in the first and second heat-activated adhesive films. This creates a non-direct breathable path between the outer and inner fabric layers, preventing down or fiber debris from escaping along straight pores. In practice, openings can be formed on both the first and second heat-activated adhesive films, with the openings staggered in the thickness direction rather than completely overlapping. After heat pressing, the staggered openings create a bent, non-direct breathable path between the outer and inner fabric layers, allowing moisture to gradually escape along the interlayer gaps, while down, short fibers, or fine fibers cannot escape directly along straight pores. This structure maintains a certain level of breathability while reducing the risk of down leakage, avoiding the loss of insulation filling caused by traditional direct openings, and improving the wearing comfort and long-term stability of multi-layered bonded channel fabrics.

[0057] A multilayer laminated channel fabric is prepared using any of the above-mentioned multilayer laminated channel fabric preparation processes.

[0058] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A process for preparing multi-layer laminated channel fabric, characterized in that, include: Step 1: Based on the filling direction, compartment width, bending position, and ventilation requirements of the channel fabric, establish a partitioned lamination pattern. The partitioned lamination pattern includes the channel shape-preserving area, compartment bonding area, edge sealing area, and staggered ventilation area. Step 2: Prepare the outer fabric, inner fabric, first thermally activated adhesive film, second thermally activated adhesive film and flow-limiting adhesive film respectively, and form corresponding adhesive film windows and flow-limiting boundaries on the first thermally activated adhesive film and the second thermally activated adhesive film according to the partitioned lamination pattern. Step 3: Arrange a releasable conformal core strip between the outer and inner fabric layers, ensuring that the releasable conformal core strip is located within the conformal zone of the channel, and align the compartment bonding area with the flow-limiting adhesive film. Step 4: Perform segmented hot pressing on the stacked multi-layer materials. First, pre-fix the compartment bonding area, then reinforce the edge sealing area, and during the hot pressing process, the releasable conformal core tape restricts the conformal area from being compacted. Step 5: After the bonding layer has cooled and set, release or remove the releasable conformal core tape, and introduce a pulsed airflow into the conformal channel area to form a continuous down filling channel in the conformal channel area; Step 6: Perform differential pressure testing, thermal response testing, and appearance flatness testing on the continuous down filling channel. Based on the test results, perform secondary cavitation or removal on the local non-through areas to obtain multi-layered bonded channel fabric.

2. The process for preparing a multi-layer laminated channel fabric according to claim 1, characterized in that, In step 1, the partitioned lamination pattern is graded according to the bending area of ​​the channel fabric in the garment. The shape-preserving area of ​​the channel located under the armpit, shoulder or elbow is set as a narrow-spacing flexible channel, and the shape-preserving area of ​​the channel located on the front chest, back or both sides of the placket is set as a wide-spacing fluffy channel, so that the channels in different positions have different pressure recovery space after being fitted.

3. The process for preparing a multi-layer laminated channel fabric according to claim 1, characterized in that, In step 2, the first and second thermally activated adhesive films have different melting temperatures. The adhesive film near the compartment bonding area softens and bonds first, while the adhesive film near the channel conformal area softens and bonds later, thus forming a bonding sequence of positioning followed by sealing in the same hot pressing process.

4. The process for preparing a multi-layer laminated channel fabric according to claim 1, characterized in that, The flow-limiting adhesive film is disposed on both sides of the bonding area of ​​the compartment. The melt flow distance of the flow-limiting adhesive film is less than that of the first thermally activated adhesive film and the second thermally activated adhesive film, which is used to prevent the adhesive material from entering the channel conformal area during hot pressing.

5. The process for preparing a multi-layer laminated channel fabric according to claim 1, characterized in that, In step 3, the releasable conformal core tape is one of heat-resistant release core tape, water-soluble core tape, or low-adhesion core tape. The thickness of the releasable conformal core tape is greater than the target minimum height of the continuous filling channel after lamination, so as to reserve channel rebound margin during the hot pressing stage. Micro-convex positioning edges are provided on both sides of the releasable conformal core tape. A non-lamination gap is maintained between the micro-convex positioning edges and the flow-limiting adhesive film, so that a transition buffer zone is formed between the compartment lamination line and the inner cavity of the channel during hot pressing.

6. The process for preparing a multi-layer laminated channel fabric according to claim 1, characterized in that, In step 4, the segmented hot pressing and bonding is completed using partitioned pressure rollers. The partitioned pressure rollers include high-pressure roller surfaces corresponding to the compartment bonding areas and clearance roller surfaces corresponding to the channel conformal areas. The high-pressure roller surfaces are used to improve the compartment bonding strength, and the clearance roller surfaces are used to reduce the compaction effect on the channel conformal areas.

7. The process for preparing a multi-layer laminated channel fabric according to claim 1, characterized in that, In step 5, the pulsed airflow is input along the length of the continuous down filling channel, and the exhaust status is detected at the end of the channel. When the exhaust status is lower than the preset ventilation standard, the corresponding channel is opened by a reverse pulse to separate the locally adhered inner walls.

8. The process for preparing a multi-layer laminated channel fabric according to claim 1, characterized in that, In step 6, differential pressure detection is used to determine whether the continuous down filling channel is unobstructed, thermal response detection is used to determine whether there is false bonding in the compartment bonding area, and appearance flatness detection is used to determine whether there are indentations, glue spots, or wrinkles on the outer fabric. When the differential pressure is abnormal and the thermal response is normal, it is determined that the channel is partially blocked and enters the secondary cavity. When the thermal response is abnormal, it is determined that the bonding is ineffective and is rejected.

9. The process for preparing a multi-layer laminated channel fabric according to claim 1, characterized in that, The misaligned ventilation zone is formed by the misalignment of the film openings of the first heat-activated adhesive film and the second heat-activated adhesive film, so that a non-straight-through ventilation path is formed between the outer and inner fabrics, and down or fiber debris is prevented from escaping along straight pores.

10. A multi-layer laminated channel fabric, characterized in that, It is prepared using the multilayer bonding channel fabric preparation process described in any one of claims 1 to 9.

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