Woven fabric
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Solution Overview
Problem
Existing woven fabrics fail to effectively prevent down leakage from seams due to low air permeability and strength issues, particularly when using flat single yarns or fused multifilaments, which lead to durability and texture problems.
Innovation Solution
A woven fabric with single yarns having convex and concave portions in a cross-section, characterized by specific air permeability, fineness, cover factor, and structural features such as fitting ratio, laminating rate, and modification degree, which enhances the restoring force and resistance to needle penetration, preventing down leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multifilament with increased cover factor is used and subjected to calendering to achieve low air permeability, then down leakage prevention is improved, but basis weight increases and light weight cannot be achieved
Solution Approach 1:
The invention changes the cross-sectional shape parameter of the single yarn from conventional round or flat shapes to a specific shape with convex and concave portions. This geometric parameter change enables the yarn to achieve both low air permeability (for down leakage prevention) and reduced basis weight (lightweight), resolving the contradiction between reliability and weight.
2Weight of moving object
If the cover factor is reduced to achieve lighter weight, then basis weight decreases, but single yarns move due to rubbing and low air permeability cannot be maintained
Solution Approach 1:
The invention modifies the cross-sectional shape parameter of single yarns to include convex and concave portions. This geometric change increases the friction and interlocking between adjacent yarns, preventing yarn movement during rubbing while maintaining low air permeability. This allows reduced cover factor (lighter weight) without sacrificing air permeability control.
3Reliability
If flat single yarn is used to create mutually engaging structure, then down leakage prevention is improved, but yarn strength decreases and cutting resistance is poor
Solution Approach 1:
The invention changes the cross-sectional shape parameter from flat to a specific configuration with convex and concave portions. This geometric modification maintains the mutual engagement capability for down leakage prevention while significantly improving yarn strength and resistance to cutting by sewing machine needles, as the convex portions provide structural reinforcement.
4Stability of the object's composition
If fused multifilament is used to prevent yarn movement, then single yarn stability is improved, but fabric texture becomes hard and unsuitable for clothing
Solution Approach 1:
The invention changes the cross-sectional shape parameter of single yarns to include convex and concave portions, which provide mechanical interlocking and stability without requiring fusion. This achieves single yarn stability while maintaining fabric softness and comfort, making it suitable for clothing applications.
Data Source
AI summary
Provided is a down-proof woven fabric which is highly effective to prevent leakage of down from a seam of a product, even having a low cover factor, the woven fabric containing a single yarn having a convex portion and a concave portion in a cross section, in which an air permeability is 0.1 cm3/cm2·s or more and 2.0 cm3/cm2·s or less; a total fineness is 5 dtex or more and 80 dtex or less; a total cover factor of a warp and a weft is 1500 or more and 2200 or less; a hole is formed in the woven fabric with a sewing machine needle having a cross-sectional diameter (thickness of a main body of the sewing machine needle) of 1.00 mm, and in an area having a radius of 1.5 mm about the hole, a total number of warps and wefts that are displaced by 0.08 mm or more with the sewing machine needle is 3 or less at 15 minutes after the sewing machine needle is pulled out from the woven fabric; and the following characteristics:(i) a fitting ratio of single yarns is 10% or more and 80% or less(ii) a laminating rate of the single yarn is 0.4 or more and 3.0 or less(iii) a number of convex portions of the single yarn is 2 or more and 12 or less(iv) the single yarn has a modification degree of 1.2 or more and 3.0 or less(v) a concave portion of the single yarn has a depth of 0.6 μm or more and 8 μm or lessCF=CFT+CFW where CF represents the total cover factor of the warp and the weft; CFT represents a cover factor of the warp; and CFW represents the cover factor of the weft.