High-density fabric with two-layer multifilaments for down proofing
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Solution Overview
Problem
Existing fabrics used for down wear, futons, and sleeping bags face challenges in being light, thin, and high in tear strength while maintaining low air permeability, especially after washing, as they either lack durability or become hard to achieve these properties simultaneously.
Innovation Solution
A high-density fabric made from synthetic fibers with a fineness of 28 dtex or less, featuring a two-layer arrangement of multifilaments in warp and weft directions, a total cover factor of 1700 to 2200, and a cover factor of 700 to 900 in at least one direction, which maintains low air permeability and softness even after washing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If natural fibers (silk or cotton) are used for the cloth, then the cloth has excellent feeling and comfortableness, but the cloth has small tear strength and poor durability causing cotton or down to spout out
Solution Approach 1:
The patent uses composite synthetic fibers combining polyester and nylon in specific ratios (polyester 70-90 wt%, nylon 10-30 wt%) to achieve both softness and high tear strength. This composite structure allows the fabric to prevent down leakage while maintaining comfort, resolving the contradiction between natural fiber comfort and synthetic fiber strength.
2Ease of operation
If fabrics made of polyester multifilament or nylon multifilament are used, then the fabrics have excellent mechanical properties and are soft, but the fabrics become hard when made dense to prevent down from spouting out
Solution Approach 1:
The patent optimizes specific parameters including fiber fineness (1.0-3.0 denier), yarn construction (20-50 filaments per yarn), and fabric density (40-60 threads per inch) to achieve the right balance. By controlling these parameters, the fabric attains sufficient density to prevent down leakage while maintaining softness and flexibility.
3Weight of moving object
If the fabric is made light and thin, then the fabric has good comfort and wearability, but the fabric loses tear strength and durability
Solution Approach 1:
The polyester-nylon composite structure provides high strength-to-weight ratio. The specific fiber composition and yarn construction enable the fabric to be lightweight (20-40 g/m²) while maintaining excellent tear strength, resolving the contradiction between lightness and strength.
4Reliability
If the fabric density is increased to prevent down from spouting out, then the fabric has good down proof property, but the air permeability decreases and the fabric becomes hard
Solution Approach 1:
The patent controls fabric density within optimal ranges (40-60 threads per inch, total cover factor 1500-2500) to achieve down proof properties while maintaining adequate air permeability (5-20 cm³/cm²/s) and softness. This parameter optimization resolves the contradiction between density and breathability.
Data Source
AI summary
Provided is a fabric that is favorably used for a side cloth of a down wear, a down jacket, a futon, a sleeping bag or some other, and that is light, thin and high in tear strength and can further keep a low air permeability after washed. The high-density fabric of the present invention that can attain the purpose is a fabric including a synthetic fiber that has a fineness of 28 dtex or less, and having a total cover factor ranging from 1700 to 2200. In this fabric, multifilaments are present in each of which monofilaments are arranged in the form of two layers in at least one direction of warp and weft directions. Furthermore, the fabric has a cover factor ranging from 700 to 900 in at least one direction of the warp and weft directions which has the multifilaments present.