Long-Fiber Wad Stuffed Article for Wash-Resistant Bulkiness
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Solution Overview
Problem
Existing stuffed articles, such as down comforters and jackets, face issues with bulkiness retention and wash resistance due to concentration of filling materials during washing, leading to inferior durability and cleanliness challenges.
Innovation Solution
A stuffed article using a long-fiber wad formed by integrating an effect yarn with a core yarn, where the effect yarn is opened to form loop-like fibers and arranged in parallel, then sewn into the ticking to provide bulkiness and improved wash resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If natural plumage is used for filling, then bulkiness and warmth are improved, but supply limitation and cleanliness control issues occur
Solution Approach 1:
The patent replaces scarce natural plumage with synthetic fibers that can be mass-produced. The polyester or polypropylene fibers are designed to mimic the bulkiness of natural down while being available in unlimited quantities, eliminating supply constraints and price volatility associated with natural plumage harvesting.
Solution Approach 2:
The invention uses composite fiber structures combining different synthetic materials to replicate the properties of natural plumage. The core yarn and effect yarn combination creates a composite structure that provides both bulkiness and durability, while remaining fully synthetic and mass-producible.
2Volume of moving object
If natural plumage is used for filling, then bulkiness is improved, but wash resistance deteriorates due to concentration during washing
Solution Approach 1:
The filling material is divided into multiple independent long-fiber wads, each containing core yarn and effect yarn components. This segmentation prevents concentration during washing as the individual wads maintain their structural integrity and distribute evenly throughout the garment, unlike natural plumage that clumps together.
Solution Approach 2:
The patent changes the physical parameters of the filling material by using synthetic fibers with controlled length, diameter, and elasticity. The long-fiber structure with specific dimensional parameters ensures that the wads resist compression and maintain bulkiness through repeated washing cycles, overcoming the wash resistance problems of natural plumage.
3Ease of manufacture
If simple air entanglement is used to fuse fibers, then manufacturing ease is improved, but sufficient bulkiness cannot be achieved
Solution Approach 1:
The invention employs a composite yarn structure with core yarn providing structural support and effect yarn creating the bulkiness through its configuration. This composite approach allows the material to achieve sufficient bulkiness while maintaining ease of manufacture, as the bulk is generated by the yarn structure itself rather than complex processing.
Solution Approach 2:
The bulkiness is built into the yarn structure during manufacturing through the arrangement of core yarn and effect yarn. This preliminary creation of bulk at the yarn level eliminates the need for complex post-processing to achieve volume, maintaining manufacturing simplicity while ensuring sufficient bulkiness.
4Volume of moving object
If fiber crimping is used to develop bulkiness, then bulkiness is improved, but wash resistance deteriorates due to stuffing concentration
Solution Approach 1:
The filling is segmented into multiple long-fiber wads that are independently structured with core and effect yarns. This segmentation prevents the stuffing from concentrating during washing, as each wad maintains its structural integrity and distributes evenly, unlike crimped fibers that tend to clump together during the washing process.
Data Source
AI summary
This stuffed article (1) of the present invention is made of ticking (2a, 2b) filled with a stuffing. The stuffing is a long-fiber wad (8) formed by integrating an effect yarn with a core yarn. The effect yarn is opened to form loop-like fibers. A plurality of strings of the long-fiber wad (8) are arranged in parallel in at least one direction, and sewn to the ticking so as to be integrated with the ticking. The long-fiber wad in the stuffed article is fixed to the ticking, and the effect yarn is integrated with the core yarn. Therefore, the present invention can provide a stuffed article where the displacement of the long-fiber wad is limited even after repeated washing, the wad is less concentrated, and the bulkiness is high.