Method for filling a filliable portion of a garment to be padded, padded garment and plant for filling a fillable portion of a garment to be padded
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Solution Overview
Problem
Current methods for manufacturing padded garments face challenges with goose feathers, including fabric damage, reduced thermal insulation after washing, and animal welfare concerns, while alternative fillings like wool and cashmere have limitations such as reduced washing resistance and unsuitable natural forms.
Innovation Solution
A method involving carding and air flow processing of cashmere fibers to create fluffy, soft, and bulkier staple fibers suitable for filling padded garments, which are then inserted into fillable portions using a carding machine and beating station to maintain thermal insulation and softness, and a filling plant that includes a carding station, beating station, and push injection means for efficient filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If goose feathers are used for filling padded garments, then thermal insulation and lightness are improved, but the quill damages and pierces the fabric, reducing reliability
Solution Approach 1:
The patent extracts and removes the harmful quill portion from the feather structure, using only the soft down fibers for filling. This is achieved through mechanical processing that separates the quill from the down, eliminating the fabric-piercing element while retaining the insulating properties
Solution Approach 2:
The patent replaces durable but harmful goose feathers with a more affordable, processed alternative - purified down fibers that can be replenished or replaced without damaging the garment structure, as the harmful quill component has been removed
2Temperature
If goose feathers are used for filling padded garments, then initial thermal insulation is improved, but repeated washings bunch the feathers and reduce insulating power
Solution Approach 1:
The patent replaces the mechanical interlocking structure of whole feathers with individually processed down fibers that move independently. This substitution prevents the bunching effect during washing, as the loose fibers can redistribute freely rather than being constrained by rigid quill structures
Solution Approach 2:
The patent changes the physical state and distribution parameters of the filling material by processing feathers into separated down fibers. This transformation alters how the material responds to washing - from a structured, bunch-prone configuration to a flexible, redistributable fiber mass that maintains insulation
3Object-affected harmful factors
If wool is used as filling material, then animal welfare is improved, but repeated washings remove lanolin and reduce softness and insulating power
Solution Approach 1:
The patent extracts the harmful collection practice from the supply chain by using by-product down fibers from feather processing rather than collecting wool from living animals. This eliminates the animal welfare issue while using a material that doesn't rely on lanolin for its properties
Solution Approach 2:
The patent uses down fibers that are by-products of the feather industry, transforming a waste material into a valuable filling. This alternative to wool doesn't require the same animal husbandry practices and provides a filling that maintains properties through washing
4Temperature
If cashmere is used as filling material, then softness and insulating power are improved, but it is provided in compressed bales with impurities that require extensive processing
Solution Approach 1:
The patent merges the carding and cleaning processes into a single integrated treatment step for the down fibers. By combining these operations, the patent simplifies the overall processing required to prepare cashmere or down for filling, reducing the number of separate equipment and process stages needed
Solution Approach 2:
The patent develops a universal processing method that can handle both cashmere and down fibers through the same carding and cleaning system. This multi-functional approach allows the same equipment to process different types of natural fibers, reducing overall device complexity
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 method allows for padded garments with enhanced thermal insulation, softness, and lightness that withstand repeated washings without fabric damage, using 100% cashmere fibers, and eliminates animal welfare concerns associated with feather collection, while maintaining the garments' properties and comfort.
Implementation Method 1
The carding machine (27) is adapted to receive an incoming cashmere fibre mass (10) and to open said cashmere fibre mass to provide exiting staple cashmere fibre (17)
Implementation Method 2
The beating station (19) is adapted to be crossed by said staple cashmere fibre (17), comprising means for providing an air flow (45) to cross the staple cashmere fibre (17) to remove residual impurities and dust (41) from the staple cashmere fibre (17)
Implementation Method 3
The plant (2) comprises a filling station (22) for introducing the staple cashmere fibre (17) into the fillable portion (24), and push injection means (29) for introducing the staple cashmere fibre (17) into the fillable portion (24)
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
A method for filling (1) a fillable portion (24) of a garment to be padded in order to obtain a padded garment (25), e.g. a garment or blanket, comprises the steps of providing (11) a cashmere fibre mass (10) to be fed towards a carding station (15); mechanically opening and blending (16) the cashmere fibre mass (10) in said carding station (15) by means of a carding machine (27) to obtain a staple cashmere fibre (17); feeding (18) said staple cashmere fibre (17) exiting from said carding station (15) towards a beating station (19); subjecting said staple cashmere fibre (17) to a cleaning step (20) in said beating station (19), by means of a cleaning air flow adapted to cross and inflate the staple cashmere fibre (17) to remove residual impurities and dusts (41) from the staple cashmere fibre (17); feeding (21) the staple cashmere fibre (17) exiting from said beating station (19) towards an injecting station (22); injecting (23) the staple cashmere fibre (17) into said fillable portion (24) to obtain said padded garment (25) in said injecting station (22), by means of push means (29) for introducing the staple cashmere fibre (17) into said fillable portion (24).