Filled Cloth 3D Structure for Uniform Seam-Side Insulation
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Solution Overview
Problem
Existing filling-material filled clothes face challenges in maintaining uniform loft and thermal insulation due to narrower spaces near the seam, leading to reduced insulation effectiveness and increased manufacturing complexity.
Innovation Solution
A filling-material filled cloth product with a pair of fabrics where one fabric is larger than the other, featuring tucks or darts to create three-dimensional filling-material accommodation spaces, ensuring uniform thickness and improved thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional sewing method is used to define bag-shaped space between front fabric and lining fabric, then manufacturing process is simple, but filling material thickness becomes non-uniform and thermal insulation decreases near the periphery
Solution Approach 1:
The invention transitions from a conventional flat 2D fabric arrangement to a 3D structured configuration by forming the first fabric into a three-dimensional shape with folded portions that extend in the thickness direction. This dimensional change creates additional space that allows filling material to be uniformly distributed throughout, including near the periphery, thereby resolving the thickness uniformity issue without complicating the manufacturing process
Solution Approach 2:
The first fabric is segmented into multiple portions through folding, creating distinct regions (first folded portion, second folded portion, third folded portion) that serve different functions. This segmentation allows each region to contribute to maintaining uniform filling material thickness in specific areas, particularly near the periphery, while keeping the overall manufacturing approach simple
2Reliability
If three-dimensionally shaped warming cells are attached at intervals to generate air channels, then thermal insulation level is high, but manufacturing steps increase
Solution Approach 1:
The invention merges the thermal insulation function with the fabric structure itself by forming the first fabric into a three-dimensional shape that inherently creates air channels and maintains uniform filling material distribution. This eliminates the need for separate attached warming cells, achieving high thermal insulation while reducing manufacturing steps
Solution Approach 2:
The first fabric serves multiple functions simultaneously: it provides the outer shell structure, creates air channels through its folded configuration, and maintains uniform filling material thickness. This self-service approach eliminates the need for additional warming cell components and their associated attachment steps
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The product achieves high thermal insulation with a simple manufacturing method, reducing filling material usage, enhancing fit, and providing economic benefits while maintaining uniform loft and heat retention.
Implementation Method 1
a thermally insulating filling material accommodated within the bag-shaped filling-material accommodation space
Data Source
AI summary
A filling-material filled cloth product includes: a pair of fabrics layered together and sewn peripherally at a filling-material partition stitch defining therein a bag-shaped filling-material accommodation space; and a thermally insulating filling material accommodated within the bag-shaped filling-material accommodation space, wherein one fabric of the pair of fabrics is cut so as to be larger than the other fabric of the pair of fabrics so that the one fabric having a surplus portion such as a tuck or dart in proximity to the filling-material partition stitch made as a result of largely cutting is pushed up away from the filling material so as to stand up in a three-dimensional manner from the other fabric, and thereby, the filling-material accommodation space is three-dimensionally shaped so as to accommodate the filling material having a substantially uniform thickness in proximity to the filling-material partition stitch.