Woven Quilt Three-Layer Fabric Binding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional quilting methods result in broken stitches during washing, fiber protrusion causing discomfort, increased time, cost, power consumption, carbon footprint, and labor, leading to de-shaping of the product.
Innovation Solution
A woven textile fabric comprising three layers - a top layer, an intermediate layer of texturized polyester fibers, and a bottom layer, bonded through weaving with warp and weft fabrics to create a robust and secure binding element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional needle and thread quilting is used to join three layers, then the layers can be bonded together, but the stitches break during washing causing de-shaping
Solution Approach 1:
The patent replaces the conventional needle and thread mechanical stitching system with a weaving mechanism that interlaces warp and weft threads through the three layers. This creates a more robust mechanical bond that resists breaking during washing, as the woven structure distributes stress across multiple interlaced points rather than relying on individual stitches.
Solution Approach 2:
The invention creates a composite structure where three different layers (top layer, intermediate layer, and bottom layer) are bonded together through the weaving of warp and weft threads. This composite construction integrates the layers into a unified fabric that maintains structural integrity during washing, preventing the de-shaping issue associated with conventional stitching.
2Ease of manufacture
If conventional quilting with random fiber filler is used, then the quilt can be assembled, but individual fibers protrude through fabric pores causing discomfort
Solution Approach 1:
The patent utilizes the controlled porosity of the woven fabric structure to contain the intermediate layer material. The interlaced warp and weft threads create a matrix with controlled pore sizes that trap and secure the filler material, preventing individual fibers from protruding through the fabric surface while still allowing the structure to be manufactured efficiently.
Solution Approach 2:
The woven fabric structure acts as an intermediary between the top and bottom layers, containing and securing the intermediate layer material. This intermediary woven matrix prevents the filler material from migrating or protruding, while still allowing the three layers to be assembled into a functional quilt product.
3Stability of the object's composition
If conventional multi-step quilting process is used, then the quilt can be assembled with proper layering, but it increases time, labor, and power consumption
Solution Approach 1:
The patent merges multiple conventional quilting steps into a single weaving operation. Instead of separately assembling layers and then stitching them, the weaving process simultaneously bonds the three layers together as the warp and weft threads interlace through all layers during fabric formation. This eliminates multiple operations and significantly improves manufacturing efficiency.
Solution Approach 2:
The invention performs the layer bonding action preliminarily during the fabric formation stage itself, rather than as a subsequent separate quilting step. The warp and weft threads are interlaced through the three layers during the weaving process, pre-establishing the bonded structure before the product leaves the manufacturing line, thereby eliminating later quilting operations.
Data Source
AI summary
The present disclosure relates to a textile fabric comprising a casing of three layers, the three layers comprising a top layer, a bottom layer, and an intermediate layer that is arranged between the top layer and bottom layer, wherein the top layer, the intermediate layer, and the bottom layers are bonded together through weaving, and forming a casing including a binding element.