Resin-Coated Down-Proof Fabric for Low Air Permeability
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Solution Overview
Problem
Existing methods for creating lightweight down-proof woven fabrics face challenges in maintaining low air permeability and tear tenacity while preventing the deterioration of fabric hand and weight, especially in thin woven fabrics used for down jackets.
Innovation Solution
A down-proof woven fabric is developed using synthetic fibers with a yarn fineness of 33 decitex or less, coated with a resin on one surface in an amount of 0.1 g/m2 to 5 g/m2, employing a plain weave or modified plain weave, and treated with water repellency and calendering to control resin penetration and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the weave density is enhanced to achieve low air permeability, then the air permeability is reduced, but the tear tenacity declines and the yarn breaking frequency increases
Solution Approach 1:
The patent applies local quality by selectively coating only specific areas of the fabric surface with resin. The coating is applied at a surface cover rate of 30-80%, meaning not the entire surface is coated. This localized coating approach reduces the overall resin content in the fabric, thereby maintaining tear tenacity while still achieving the desired air permeability control in the coated regions.
Solution Approach 2:
The patent employs partial action by using a surface cover rate between 30-80% rather than 100% coating. This partial coating is sufficient to achieve the required air permeability reduction without the excessive resin application that would cause yarn binding and tear tenacity decline. The optimized coating amount balances air permeability control with fabric strength preservation.
2Object-affected harmful factors
If the weave density is enhanced to achieve low air permeability, then the air permeability is reduced, but the yarn breaking frequency increases and productivity decreases
Solution Approach 1:
By coating only 30-80% of the fabric surface rather than the entire surface, the resin content is reduced, which lessens the binding force between yarns. This allows the fabric to be woven at higher speeds with fewer yarn breaks, thereby improving productivity while still achieving adequate air permeability control in the coated regions.
3Object-affected harmful factors
If a continuously microporous film is coated or laminated to achieve low air permeability, then the air permeability is reduced, but the fabric hand hardens and the weight increases
Solution Approach 1:
The patent uses localized coating at 30-80% surface cover rate instead of continuous film coating. This reduces the total resin content and film weight on the fabric, thereby controlling air permeability in the coated areas without significantly increasing the overall fabric weight and while preserving fabric hand in the uncoated areas.
Solution Approach 2:
By applying resin coating at a controlled surface cover rate of 30-80% rather than forming a continuous film, the patent achieves sufficient air permeability reduction without the excessive weight gain and hand hardening that would result from complete surface coverage with a continuous microporous film.
4Object-affected harmful factors
If a continuously microporous film is coated or laminated to achieve low air permeability, then the air permeability is reduced, but the fabric hand hardens
Solution Approach 1:
The patent preserves fabric hand by coating only 30-80% of the surface. The uncoated portions maintain the original fabric softness and drape, while the coated portions provide air permeability control. This localized approach prevents the overall hand hardening that would occur with continuous film coating.
Solution Approach 2:
By using partial coating at 30-80% surface cover rate instead of continuous film formation, the patent achieves adequate air permeability control without the excessive hand hardening effect that results from complete surface coverage with a microporous film.
5Object-affected harmful factors
If the fabric is partially coated with resin at a surface cover rate of 50-90% to maintain low air permeability, then the air permeability is controlled, but the tear tenacity declines
Solution Approach 1:
The patent optimizes the surface cover rate to 30-80%, which is lower than the conventional 50-90% range. This reduced coating coverage decreases the total resin content binding the yarns, thereby minimizing the decline in tear tenacity while still achieving effective air permeability control in the coated regions through localized resin deposition.
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 balance of low air permeability, high tear tenacity, and lightweight properties, maintaining fabric hand and preventing seam slippage and air permeability deterioration after washing, suitable for use in garments like down jackets and bedclothes.
Implementation Method 1
the capability of smoothly undergoing the process is very low since yarn breaking frequently occurs and that the productivity remains low since the weaving speed is low, especially when a high-density thin woven fabric is produced by using yarns with a small fineness as required for recent down jackets
Implementation Method 2
methods of enhancing the weave density of the fabric and calendering the fabric, to compress the fibers, for lessening the inter-thread clearance
Implementation Method 3
the force of binding yarns together increases, causing the tear tenacity to decline
Data Source
AI summary
A down-proof woven fabric includes a cloth composed of synthetic fibers with a yarn fineness of 33 decitex or less and having a weight per unit area of 50 g/m2 or less and a cover factor of 1,400 to 1,800, wherein the cloth is coated at least on one surface thereof with a resin by an amount of 0.1 g/m2 to 5 g/m2 as a solid component.