A four-layer, three-tube down direct-fill fabric

Abstract

This utility model discloses a four-layer, three-tube down-filled fabric. The fabric has four layers of high-density woven fabric and three layers of down-filling tubes within the same cross-section. The three down-filling tubes are staggered and connected by multiple connecting units located in the middle of the tubes. After being filled with down, it forms a three-layer insulating structure consisting of "fabric + down layer + fabric". Utilizing the advantages of multi-compartment and multi-layer design, the fabric can retain stagnant air to the maximum extent, minimizing heat loss and improving the down jacket's heat retention effect, providing longer-lasting warmth in low-temperature and cold environments.

Description

Technical Field

[0001] This utility model relates to the field of textiles, and in particular to a four-layer, three-tube down-filled fabric. Background Technology

[0002] Double-layer fleece-filled fabric is a functional material combining textile technology and filling technology, widely used in cold-weather clothing, outdoor equipment, and high-end home textiles. In recent years, with the increasing consumer demand for lightweight, high-warmth products, this technology has experienced rapid development. The industry has significantly improved warmth retention by improving fabric weaving processes (such as combining a high-density windproof outer layer with a breathable inner layer) and optimizing the fleece filling structure (such as zoned three-dimensional fleece filling). Simultaneously, environmental trends are driving the application of renewable fibers (such as recycled polyester fibers) and biodegradable coatings, giving the material a green attribute. The introduction of smart manufacturing technologies (such as automated fleece filling equipment) has also improved production precision and efficiency. Despite continuous technological upgrades, double-layer fleece-filled fabric still faces multiple challenges. Down leakage is a concern; traditional sewing processes easily lead to fleece seeping out from seams or fabric pores, affecting product lifespan and aesthetics. Environmental bottlenecks exist; the use of fluorinated compounds in waterproof coatings and the use of non-biodegradable synthetic fibers conflict with sustainable development goals. A performance balance is also problematic; improving windproofness may sacrifice breathability, leading to decreased wearing comfort. Cost pressures are another issue; high-end functional fabrics and environmentally friendly processes drive up production costs, limiting market penetration. The above-mentioned problems with down filling fabrics can be solved from the following aspects.

[0003] Through structural optimization, laser seamless bonding technology is used to replace traditional sewing, combined with high-count (e.g., 300T and above) anti-down leakage fabric, reducing the risk of down leakage. Material innovation involves developing fluorine-free, environmentally friendly waterproof coatings (e.g., based on siloxanes or waxes) and promoting polylactic acid fiber as a base fabric raw material. An intelligent down filling system achieves precise control of down filling density through airflow dynamics simulation, combined with 3D thermal imaging technology to optimize zoned warmth design. Composite functional design embeds phase change temperature-regulating fibers or graphene coatings into the double-layer structure, achieving dynamic temperature control and antibacterial dehumidification functions. With the deep integration of nanomaterials, IoT sensing technology, and textile processes, double-layer down-filled fabrics are evolving towards intelligence and zero carbonization. For example, an adaptive down filling structure integrating a micro temperature control sensor may become a technological breakthrough for next-generation products. Through collaborative innovation across the industry chain, this material is expected to achieve a higher-dimensional balance between performance, environmental friendliness, and economy. Utility Model Content

[0004] To address the aforementioned technical problems, the purpose of this invention is to design a four-layer, three-tube down-filled fabric. Within the same cross-section, the fabric comprises four layers of high-density woven fabric and three layers of down-filling tubes. These three tubes are staggered and connected by a connecting unit positioned in the middle of each tube. After being filled with down, it forms a three-layer insulating structure consisting of "fabric + down layer + fabric". Due to the use of an integrated design and ultra-fine denier raw materials, it not only avoids down leakage caused by needle hole deformation during sewing but also enhances the warmth and three-dimensionality of the finished product.

[0005] To achieve the aforementioned technical objectives and effects, this utility model provides the following technical solution: a four-layer, three-tube down-filled fabric, comprising a first filling tube, a second filling tube, and a third filling tube, the three filling tubes being vertically staggered within the same cross-section of the fabric. The four layers of fabric constituting the three filling tubes are all formed by the vertical interlacing of ultra-fine denier warp and weft yarns. The weft yarns are divided into six groups. The first group of weft yarns interlaces with the warp yarns to obtain the upper front half and lower front half of multiple first filling tubes. The second group of weft yarns interlaces with the warp yarns to obtain the lower front half of multiple second filling tubes and the lower rear half of multiple third filling tubes. The third group of warp yarns interlaces with the weft yarns to obtain the lower rear half of multiple second filling tubes and the lower front half of multiple third filling tubes. The fourth group of weft yarns interlaces with the warp yarns to obtain the upper front half of multiple second filling tubes and the upper rear half of multiple first filling tubes. The warp weave point (hereinafter referred to as "warp") indicates the interlacing point where the warp yarn is on top and the weft yarn is on the bottom. The weft weave point (hereinafter referred to as "weft") means that at the interlacing point, the weft yarn is on top and the warp yarn is on the bottom.

[0006] Furthermore, the upper layer of the first down tube and the upper layer of the second down tube are connected by multiple connecting structures located in the middle of the upper layer of the second down tube, and the first down tube is divided into multiple down-filling units; the lower layer of the second down tube and the upper layer of the third down tube are connected by multiple connecting units located in the middle, and the second down tube is divided into multiple down-filling units; the lower layer of the second down tube and the lower layer of the third down tube are connected by multiple connecting units located in the middle of the lower layer of the second down tube, and the second down tube is divided into multiple down-filling units.

[0007] Furthermore, among the 1st to 8th weft yarns, the warp and weft weft arrangement pattern of the 1st weft yarn is 1 weft 1 warp 1 weft 1 warp 3 weft 1 warp 1 weft 1 warp 1 weft 1 warp 1 warp; the warp and weft weft arrangement pattern of the 2nd weft yarn is 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp 1 weft 3 warp; the warp and weft weft arrangement pattern of the 3rd weft yarn is 1 weft 1 warp 1 weft 1 warp 3 weft 1 warp 1 weft 2 warp 1 weft; the warp and weft weft arrangement pattern of the 4th weft yarn is 1 weft 1 warp 1 weft 2 warp 2 weft 1 warp 1 weft 3 warp; the warp and weft weft arrangement pattern of the 5th weft yarn is 3 weft 1 warp 5 weft 1 warp 2 weft; the warp and weft weft arrangement pattern of the 6th weft yarn is 1 weft 5 warp 1 weft 5 warp; the warp and weft weft arrangement pattern of the 7th weft yarn is 1 weft 1 warp 5 weft 1 warp 4 weft; and the warp and weft weft arrangement pattern of the 8th weft yarn is 2 warp 1 weft 5 warp 1 weft 3 warp. The arrangement of the warp and weft stitches of the first to eighth weft yarns forms a complete down filling unit with 148 cycles, resulting in a tube width of 5cm.

[0008] Furthermore, among the 9th to 16th weft yarns, the warp and weft stitch arrangement of the 9th weft yarn is 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp 2 weft; the warp and weft stitch arrangement of the 10th weft yarn is 1 weft 1 warp 1 weft 3 warp 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp 1 warp; the warp and weft stitch arrangement of the 11th weft yarn is 1 weft 1 warp 1 weft 2 warp 2 weft 1 warp 1 weft 2 weft; and the warp and weft stitch arrangement of the 12th weft yarn is 1 weft 1 warp 1 weft 3 warp 1 weft 1 warp 1 weft 2 warp 1 The warp and weft weft arrangement of the 13th weft yarn is 2 warp 1 weft 5 warp 1 weft 3 warp; the warp and weft weft arrangement of the 14th weft yarn is 1 weft 1 warp 5 weft 1 warp 4 weft; the warp and weft weft arrangement of the 15th weft yarn is 1 weft 5 warp 1 weft 5 warp; and the warp and weft weft arrangement of the 16th weft yarn is 3 weft 1 warp 5 weft 1 warp 2 weft. The warp and weft weft arrangement of the 9th to 16th weft yarns forms a complete filling unit with 148 cycles, resulting in a tube width of 5cm.

[0009] Furthermore, the warp and weft stitch arrangement patterns of the 21st to 28th weft yarns and the 9th to 16th weft yarns are the same; the warp and weft stitch arrangement patterns of the 21st to 28th weft yarns form a complete filling unit with 148 cycles, resulting in a tube width of 5cm.

[0010] Furthermore, the warp and weft stitch arrangement patterns of the 29th to 36th weft yarns are the same as those of the 1st to 8th weft yarns. The warp and weft stitch arrangement patterns of the 29th to 36th weft yarns form a complete filling unit with 148 cycles, resulting in a tube width of 5cm.

[0011] Furthermore, the 17th to 20th weft yarns interweave with the warp yarns to form multiple connecting structures located in the middle of the upper fabric of the second down filling tube. The warp and weft ...

[0012] Furthermore, the 37th to 40th weft yarns interweave with the warp yarns to form multiple connecting structures located in the middle of the upper fabric of the second down filling tube. The warp and weft ...

[0013] Furthermore, the flattening width of the first filling tube, the second filling tube, and the third filling tube is all 10cm.

[0014] Furthermore, the overlap width between the first and second filling tubes is 5cm, and the overlap width between the second and third filling tubes is also 5cm.

[0015] Furthermore, the warp yarn is semi-dull polyester DTY with a linear density of 33.3 dtex / 48f.

[0016] Furthermore, the weft yarn is semi-dull polyester DTY with a linear density of 38.3 dtex / 144f.

[0017] Furthermore, the arrangement density of the warp yarns is 220-240 yarns / cm.

[0018] Furthermore, the weft yarn arrangement density is 195-205 yarns / cm.

[0019] Furthermore, the weight per square meter of the down-filled fabric is 168g / m². 2 .

[0020] The beneficial effects of this invention are as follows: Through a four-layer, three-tube structural design, utilizing the advantages of multi-compartment partitioning and multiple layers, the fabric can retain still air to the maximum extent, minimizing heat loss and improving the heat retention effect of the down jacket, providing longer-lasting warmth in low-temperature and cold environments. In particular, the down filling structure is more fluffy yet lightweight, making it comfortable to wear and superior to traditional heavy cotton or down jackets. Attached Figure Description

[0021] Figure 1 This is a structural schematic diagram of a four-layer, three-tube down direct-fill fabric according to the present invention.

[0022] Figure 2 This is a structural diagram of a four-layer, three-tube down-filled fabric according to the present invention.

[0023] Figure 1 In the middle: 1. First layer of fabric; 2. Second layer of fabric; 3. Third layer of fabric; 4. Fourth layer of fabric; 5. First down filling tube; 6. Second down filling tube; 7. Third down filling tube. Detailed Implementation

[0024] The present invention will now be described in detail with reference to the accompanying drawings, so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby making a clearer and more explicit definition of the scope of protection of the present invention.

[0025] like Figures 1 to 2 As shown, this utility model provides a four-layer, three-tube down-filled fabric, including a first down-filling tube 5, a second down-filling tube 6, and a third down-filling tube 7. The three down-filling tubes are connected by a connecting unit placed in the middle of each down-filling tube. The first down-filling tube 5, the second down-filling tube 6, and the third down-filling tube 7 are all formed by vertically interlacing warp and weft yarns. The width of the first down-filling tube 5 is 10cm, the width of the second down-filling tube 6 is 10cm, and the width of the overlap between the first down-filling tube 5 and the second down-filling tube 6 is 5cm. The width of the second down-filling tube 6 is 10cm, the width of the third down-filling tube 7 is 10cm, and the width of the overlap between the second down-filling tube 6 and the third down-filling tube 7 is 5cm.

[0026] Furthermore, the warp yarns are numbered 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, and 12, totaling 12 yarns; the weft yarns are divided into six groups, with the first group numbered 1, 2, 3, 4, 5, 6, 7, and 8; the second group numbered 9, 10, 11, 12, 13, 14, 15, and 16; the third group numbered 21, 22, 23, 24, 25, 26, 27, and 28; the fourth group numbered 29, 30, 31, 32, 33, 34, 35, and 36; the fifth group numbered 17, 18, 19, and 20; and the sixth group numbered 37, 38, 39, and 40.

[0027] Furthermore, in the first group of weft yarns, the warp and weft weft arrangement of the first weft yarn is 1 weft 1 warp 1 weft 1 warp 3 weft 1 warp 1 weft 1 warp 1 weft 1 warp 1 warp; the warp and weft weft arrangement of the second weft yarn is 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp 1 weft 3 warp; the warp and weft weft arrangement of the third weft yarn is 1 weft 1 warp 1 weft 1 warp 3 weft 1 warp 1 weft 2 warp 1 weft; the warp and weft weft arrangement of the fourth weft yarn is 1 weft 1 warp 1 weft 2 warp 2 weft 1 warp 1 weft 3 warp; the warp and weft weft arrangement of the fifth weft yarn is 3 weft 1 warp 5 weft 1 warp 2 weft; the warp and weft weft arrangement of the sixth weft yarn is 1 weft 5 warp 1 weft 5 warp; the warp and weft weft arrangement of the seventh weft yarn is 1 weft 1 warp 5 weft 1 warp 4 weft; and the warp and weft weft arrangement of the eighth weft yarn is 2 warp 1 weft 5 warp 1 weft 3 warp. The number of cycles required to form a filling tube is 148, resulting in a tube width of 5cm.

[0028] Furthermore, in the second group of weft yarns, the warp and weft stitch pattern of the 9th weft yarn is 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp 2 weft; the warp and weft stitch pattern of the 10th weft yarn is 1 weft 1 warp 1 weft 3 warp 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp 1 warp; the warp and weft stitch pattern of the 11th weft yarn is 1 weft 1 warp 1 weft 2 warp 2 weft 1 warp 1 weft 2 weft; the warp and weft stitch pattern of the 12th weft yarn is 1 weft 1 warp 1 weft 3 warp 1 weft 1 warp 1 weft 2 warp 1 weft; the warp and weft stitch pattern of the 13th weft yarn is 2 warp 1 weft 5 warp 1 weft 3 warp; the warp and weft stitch pattern of the 14th weft yarn is 1 weft 1 warp 5 weft 1 warp 4 weft; the warp and weft stitch pattern of the 15th weft yarn is 1 weft 5 warp 1 weft 5 warp; and the warp and weft stitch pattern of the 16th weft yarn is 3 weft 1 warp 5 weft 1 warp 2 weft. The number of cycles required to form a filling tube is 148, resulting in a tube width of 5cm.

[0029] Furthermore, the warp and weft stitches of the third weft yarn and the second weft yarn have the same arrangement pattern, forming a filling tube with 148 cycles and a tube width of 5cm.

[0030] Furthermore, the fourth group of weft yarns and the first group of weft yarns have the same warp and weft stitch arrangement, forming a filling tube with 148 cycles and a tube width of 5cm.

[0031] Furthermore, in the fifth group of warp yarns, the 17th to 20th weft yarns interweave with the warp yarns to form multiple connecting structures located in the middle of the upper fabric of the second down filling tube 6. The warp and weft ...

[0032] Furthermore, in the sixth group of warp yarns, the warp and weft weft arrangement pattern of the 37th weft yarn is 3 weft 1 warp 5 weft 1 warp 1 weft 1 warp, the warp and weft weft arrangement pattern of the 38th weft yarn is 1 weft 3 warp 1 weft 1 warp 1 weft 5 warp, the warp and weft weft arrangement pattern of the 39th weft yarn is 1 weft 1 warp 5 weft 1 warp 2 weft 1 warp 1 weft, and the warp and weft weft arrangement pattern of the 40th weft yarn is 2 weft 1 warp 2 weft 1 warp 2 weft 1 warp 3 weft.

[0033] Furthermore, the warp yarn is semi-dull polyester DTY with a linear density of 33.3 dtex / 48f.

[0034] Furthermore, the warp yarn is semi-dull polyester DTY with a linear density of 38.3 dtex / 144f.

[0035] Furthermore, the warp yarn arrangement density is 230 yarns / cm.

[0036] Furthermore, the weft yarn arrangement density is 200 yarns / cm.

[0037] Furthermore, the weight per square meter of the down-filled fabric is 168g / m². 2 .

[0038] In this embodiment, a four-layer high-density fabric structure is used to form three down-filling tubes. High-quality down or biomimetic down is filled into these tubes, creating a three-layer "fabric + down + fabric" insulation layer. This allows more air to be trapped inside the material, effectively blocking cold air penetration and locking in body heat. Theoretically, this provides three times the warmth compared to a single-layer fabric. The material is also lightweight, with an outer windproof and water-repellent finish, while the inner layer remains breathable, allowing moisture to escape quickly and maintaining a dry feel.

[0039] The above description is merely an embodiment of this utility model and does not limit the patent scope of this utility model. Any equivalent structural or procedural transformations made based on the description and drawings of this utility model, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this utility model.

Claims

1. A four-layer, three-pipe, down straight-charged fabric, characterized in that: The fabric includes a first filling tube, a second filling tube, and a third filling tube. These three filling tubes are vertically staggered within the same cross-section of the fabric. The four layers of fabric constituting the three filling tubes are all formed by vertically interlacing warp and weft yarns. The weft yarns are divided into six groups. The first group of weft yarns interlaced with warp yarns to form the upper front half and lower front half of multiple first filling tubes. The second group of weft yarns interlaced with warp yarns to form the lower front half of multiple second filling tubes and the lower rear half of multiple third filling tubes. The third group of warp yarns interlaced with weft yarns to form the lower rear half of multiple second filling tubes and the lower front half of multiple third filling tubes. The fourth group of weft yarns interlaced with warp yarns to form multiple second filling tubes. The upper half of the down tube and the lower half of the first down tube are connected by multiple connecting structures located in the middle of the upper second down tube, which divides the first down tube into multiple down units. The lower fabric of the second down tube and the upper fabric of the third down tube are connected by multiple connecting units located in the middle, which divides the second down tube into multiple down units. The lower fabric of the second down tube and the lower fabric of the third down tube are connected by multiple connecting units located in the middle of the lower fabric of the second down tube, which divides the second down tube into multiple down units.

2. The four-layer, three-tube down-filled fabric according to claim 1, characterized in that: Of the 1st to 8th weft yarns, the warp and weft stitch arrangement of the 1st weft yarn is 1 weft 1 warp 1 weft 1 warp 3 weft 1 warp 1 weft 1 warp 1 weft 1 warp; the warp and weft stitch arrangement of the 2nd weft yarn is 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp 1 weft 3 warp; the warp and weft stitch arrangement of the 3rd weft yarn is 1 weft 1 warp 1 weft 1 warp 3 weft 1 warp 1 weft 2 warp 1 weft; the warp and weft stitch arrangement of the 4th weft yarn is 1 weft 1 warp 1 weft 2 warp 2 weft 1 warp 1 weft 3 warp; and the 5th weft yarn... The warp and weft stitch arrangement of the first weft yarn is 3 weft, 1 warp, 5 weft, 1 warp, 2 weft; the warp and weft stitch arrangement of the sixth weft yarn is 1 weft, 5 warp, 1 weft, 5 warp; the warp and weft stitch arrangement of the seventh weft yarn is 1 weft, 1 warp, 5 weft, 1 warp, 4 weft; and the warp and weft stitch arrangement of the eighth weft yarn is 2 warp, 1 weft, 5 warp, 1 weft, 3 warp. The warp and weft stitch arrangement of the first to eighth weft yarns forms a complete filling unit with 148 cycles, resulting in a tube width of 5cm.

3. A four-layer, three-pipe, straight-charged down feather fabric according to claim 1, characterized in that: Of the 9th to 16th weft yarns, the warp and weft stitch arrangement of the 9th weft yarn is 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp 2 weft; the warp and weft stitch arrangement of the 10th weft yarn is 1 weft 1 warp 1 weft 3 warp 1 weft 1 warp 1 weft 1 warp 1 weft 1 warp; the warp and weft stitch arrangement of the 11th weft yarn is 1 weft 1 warp 1 weft 2 warp 2 weft 1 warp 1 weft 2 weft; and the warp and weft stitch arrangement of the 12th weft yarn is 1 weft 1 warp 1 weft 3 warp 1 weft 1 warp 1 weft 2 warp 1 weft. The warp and weft stitch arrangement of the 13th weft yarn is 2 warp, 1 weft, 5 warp, 1 weft, and 3 warp; the warp and weft stitch arrangement of the 14th weft yarn is 1 weft, 1 warp, 5 weft, 1 warp, and 4 weft; the warp and weft stitch arrangement of the 15th weft yarn is 1 weft, 5 warp, 1 weft, and 5 warp; and the warp and weft stitch arrangement of the 16th weft yarn is 3 weft, 1 warp, 5 weft, 1 warp, and 2 weft. The warp and weft stitch arrangement of the 9th to 16th weft yarns forms a complete filling unit with 148 cycles, resulting in a tube width of 5cm.

4. A four-layer, three-pipe, straight-charged down feather fabric according to claim 1, characterized in that: The warp and weft stitch arrangement patterns of the 21st to 28th weft yarns and the 9th to 16th weft yarns are the same. The warp and weft stitch arrangement patterns of the 21st to 28th weft yarns form a complete filling unit with a cycle count of 148 times, resulting in a tube width of 5cm.

5. A four-layer, three-pipe, straight-charged down feather fabric according to claim 1, characterized in that: The arrangement of warp and weft stitches of the 29th to 36th weft yarns is the same as that of the 1st to 8th weft yarns. The arrangement of warp and weft stitches of the 29th to 36th weft yarns forms a complete filling unit with 148 cycles and a tube width of 5cm.

6. A four-layer, three-pipe, straight-charged down feather fabric according to claim 1, characterized in that: The 17th to 20th weft yarns interweave with the warp yarns to form multiple connecting structures located in the middle of the upper layer of fabric of the second filling tube. The warp and weft ...

7. A four-layer, three-pipe, straight-charged down feather fabric according to claim 1, characterized in that: The 37th to 40th weft yarns interweave with the warp yarns to form multiple connecting structures located in the middle of the upper layer of fabric of the second filling tube. The warp and weft ...

8. The four-layer, three-tube down-filled fabric according to claim 1, characterized in that: The flattened width of the first filling tube, the second filling tube, and the third filling tube is 10cm; the overlap width between the first filling tube and the second filling tube is 5cm, and the overlap width between the second filling tube and the third filling tube is 5cm.

9. A four-layer, three-pipe, straight-charged down feather fabric according to claim 1, characterized in that: The warp yarn is polyester semi-lustrous DTY, the linear density is 33.3 dtex / 48 f, the arrangement density is 220-240 root / cm, and the weft yarn is polyester semi-lustrous DTY, the linear density is 38.3 dtex / 144 f, and the arrangement density is 195-205 root / cm.

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