Pile-Zone Textile Needlepunching for Seamless Weather Resistance
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Solution Overview
Problem
Traditional garments with insulation and pile zones formed using panel-type, cut-and-sew construction suffer from structural weaknesses, aesthetic issues, and discomfort due to seams, and lack weather-resistant properties in pile zones.
Innovation Solution
A textile construction where insulation and pile zones seamlessly extend from each other, comprising a first and second woven layer with a nonwoven layer in between, entangled through needlepunching, providing weather-resistant and insulating properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If panel-type cut-and-sew construction is used to form insulation and pile zones, then the garment can be manufactured using traditional methods, but the seams introduce structural weakness and aesthetic issues
Solution Approach 1:
The patent merges the insulation zone and pile zone into a single seamless textile structure, eliminating the need for seams between these zones. The insulating layer and pile面层 are integrated through knitting or weaving processes, creating a unified garment structure that maintains structural integrity while providing both insulation and pile functions in different regions.
Solution Approach 2:
The textile is segmented into different functional zones (insulation zone and pile zone) at the fiber/yarn level rather than at the panel level. This allows different properties to be distributed throughout the textile structure without requiring physical seams, as each zone is formed by specific yarn arrangements or knitting patterns within the continuous fabric.
2Ease of manufacture
If panel-type cut-and-sew construction is used to form insulation and pile zones, then the garment can be manufactured using traditional methods, but the seams cause chaffing or discomfort for wearers
Solution Approach 1:
By combining the insulation and pile zones into a seamless textile structure, the patent eliminates seam lines that would otherwise contact the wearer's skin. The continuous fabric construction ensures that no rough seam edges or stitching protrusions are present to cause chaffing or discomfort.
Solution Approach 2:
The textile incorporates local quality variations through different yarn selections, knitting patterns, or weaving structures in specific zones. The pile zone uses softer, more flexible yarns and structures that are particularly comfortable against the skin, while the insulating zone uses different constructions optimized for thermal performance, all within a seamless structure.
3Shape
If traditional pile zone textiles are used, then the fleece-like texture is achieved, but weather-resistant properties are lacking
Solution Approach 1:
The patent uses composite material construction where the textile combines different fiber types, yarn structures, and layer configurations to achieve both fleece-like texture and weather resistance. The pile面层 provides soft texture while the underlying insulating layer and outer shell (in jacket embodiments) provide weather protection, creating a multi-functional composite structure.
Solution Approach 2:
Different zones of the textile have different local properties: the pile zone provides fleece-like texture for comfort, while other zones (such as the outer shell in jackets or specific reinforced areas) provide weather-resistant properties. This local differentiation allows the garment to have both soft texture where needed and weather protection where required.
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 solution achieves a seamless, aesthetically pleasing, and weather-resistant textile with improved insulation and comfort by integrating tightly woven layers and a nonwoven layer, enhancing wind and rain resistance while maintaining a fleece-like texture.
Implementation Method 1
entangled through needlepunching
Implementation Method 2
insulation zone and a pile zone that seamlessly extend from the insulation zone
Implementation Method 3
enhancing wind and rain resistance while maintaining a fleece-like texture
Data Source
Figure 1~3
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AI summary
Aspects herein are directed to a method of forming a textile (100). The method includes positioning a woven layer (114) and a nonwoven layer (310) to form a layered construction, and executing a needlepunching process (520) on the layered construction one or more times to at least partially form a pile zone (112) and to entangle fibers/filaments (116) from the nonwoven layer (310) with fibers/filaments/yarns of the woven layer (114).