Stretch Woven Fabric Structure for Downproof Low Air Permeability
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Solution Overview
Problem
Existing woven fabrics face challenges in achieving both downproofness and stretchability, as these properties are conflicting, and there is a need for fabrics that also excel in smoothness and surface appearance.
Innovation Solution
A low-breathability woven fabric is developed using stretch fibers, such as polyurethane or conjugate fibers, with specific cover factors and densities, and without waterproof coatings or laminations, to achieve high downproofness, stretchability, smoothness, and surface appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If woven fabric structure is used to achieve downproofness, then down leakage is reduced, but stretchability deteriorates
Solution Approach 1:
The patent uses composite yarns combining different fiber types (e.g., polyester and polyurethane) to create woven fabric that simultaneously achieves downproofness and stretchability. The composite structure allows the fabric to maintain tight weave for down barrier while incorporating elastic components for stretch.
Solution Approach 2:
The patent optimizes specific parameters including yarn count (using finer yarns to increase weaving density without compromising strength), weave density (increasing picks and ends per inch), and fabric weight to achieve the balance between downproofness and stretchability. Cover factor is specifically controlled within defined ranges to ensure both properties.
2Reliability
If weaving density is increased to improve downproofness, then down leakage is reduced, but surface appearance and smoothness deteriorate
Solution Approach 1:
The patent applies different yarn characteristics in warp and weft directions, using yarns with specific crimp rates and torque values in different orientations. This allows localized optimization where high density provides downproofness while controlled yarn properties maintain surface smoothness and appearance in visible areas.
Solution Approach 2:
The patent carefully controls yarn parameters including crimp rate (5-20%), torque (10-50 gf·cm), and yarn count (10-30 tex) to achieve optimal balance. By adjusting these parameters, the fabric achieves high weaving density for downproofness while maintaining surface smoothness through controlled yarn flexibility and lay.
Data Source
AI summary
The invention addresses the problem of providing a low-breathability woven fabric and a textile product that are excellent not only in downproofness but also in stretchability. As a means for resolution, a low-breathability woven fabric having a breathability of 1.0 cc/sec/cm2 or less is configured to include a stretch fiber.