Heat-preserving compound fiber cloth and manufacturing process thereof

A heat-preserving compound fiber cloth includes a sheet of outer fabric, a sheet of inner fabric, and a sheet of heat insulating layer having a predetermined uniform thickness. The heat insulating layer includes at least a fiber layer which includes a plurality of fiber filaments bonded on a construction film having flexible ability and permeability, wherein the construction film firmly and integrally holds the fiber filaments of the fiber layer together in such a manner that the heat insulating layer is adapted for being stretched and retaining an original shape. The heat insulating layer is bonded between the outer fabric and the inner fabric to form the heat-preserving compound fiber cloth. Accordingly, the heat-preserving compound fiber cloth provides better heat insulation and flexibility while having a minimum thickness for making interior wears, such as vests, long johns, sweaters and underwears.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to FIGS. 4 and 5 of the drawings, a heat-preserving compound fiber cloth is illustrated. The compound fiber cloth is adapted for manufacturing underwears, blankets, sleeping bags, or the like, which has both the ventilating and heat insulating abilities. The compound fiber cloth comprises a sheet of outer fabric 10 , a sheet of inner fabric 20 , and a sheet of heat insulating layer 30 bonded between the outer fabric 10 and the inner fabric 20 . The sheet of heat insulating layer 30 has a predetermined uniform thickness and comprises at least a fiber layer 31 which comprises a plurality of fiber filaments 311 bonded on a construction film 32 having flexibility and permeability. The construction film 32 firmly and integrally holds the fiber filaments 311 together to form the fiber layer 31 , such a manner that the heat insulating layer 30 is adapted for being stretched and retaining an original shape so as to provide ventilating and heat insulating effects. Accordingly, the outer fabric 10 and the inner fabric 20 can be made of any material that fit for the products; however it is preferable to be made of flexible material. For example, when the product is the underwear, the outer fabric 10 and the inner fabric 20 should be made of stretchable and flexible fabric, such as cotton, that should be non-irritant, comfortable to wear. The inner fabric 20 should provide a soft surface in contact with human skin and is relatively close fitting to the wearer. When the product is a blanket or a sleeping bag, the outer fabric 10 should be durable and launderability because the outer fabric 10 is exposed to surroundings and protects the heat insulating layer 30 . So, the outer layer 10 should last for a long time and preferable made of polyester fabric. According to the preferred embodiment, the heat insulating layer 30 comprises two fiber layers 31 bonded on two side surfaces of the construction film 32 respectively. In other words, both side surfaces of the construction film 32 firmly hold and retain a predetermined thickness of the plurality of fiber filaments 311 thereon. However, the heat insulating layer 30 can be constructed by one single fiber layer 31 bonded on only one side surface of the construction film 32 or two construction films 32 bonded on one single fiber layer 31 at both side surfaces of the construction film 32 respectively, which depends on the usage of the product. It is worth to mention that we can increase the heat-preserving ability of the compound fiber cloth of the present invention simply by increasing the thickness of the fiber layer. Also, when the compound fiber cloth is used for constructing a blanket or sleeping bag as the product, more layers of the construction films 32 and the fiber layers 31 can be bonded together in sequence. In other words, it is possible to made the heat insulating layer 30 including two or more construction films 32 and three or more fiber layers 31 . For example, if there are two construction films 32 , a first fiber layer 31 can be attached to an outer side surface of the first construction film 32 , a second fiber layer can be attached to an outer side surface of the second construction film 32 , and a third fiber layer can be bonded between the two inner side surfaces of the first and second construction films 32 . Each fiber layer 31 is made of fluff fiber which can be an artificial fiber, a synthetic fiber, or a natural fiber, such as velvet, cotton, silk floss, or plastic cotton, wherein the fiber layer 31 provides an insulating effect that heat can be preserved by the fiber layer 31 . Preferably, each fiber layer 31 has a thickness approximately 0.4 to 1.8 mm. The construction film 32 , having stretchable and flexible ability, is made of a thin synthetic membrane such as ethylene-vinyl acetate copolymer, wherein the construction film 32 is adapted for providing a ventilating effect of the compound textile compound. Tiny pores may be formed on the construction film 32 for permeability. As shown in FIG. 3, a uniform density of fiber filaments 311 are attached on the two entire side surfaces of the construction film 32 . In other words, each section of the construction film 32 provides a predetermined density of the fiber layer 31 coated thereon. Since the construction film 32 has the stretchable and flexible ability, the heat insulating layer 30 is adapted for being stretched and retaining its original shape thereof. If both the outer fabric 10 and the inner fabric 20 for bonding the heat insulating layer 30 of the present invention therebetween are made of stretchable and flexible material, when a section of the heat insulating layer 30 is stretched, a corresponding section of the construction film 32 is enlarged but the density of the fiber layer 31 within the stretched section of the construction film 32 will remain the same, as shown in FIG. 6 . However, the density of the fiber layer 31 per the stretched section of the construction film 32 will be decreased in such a manner that air can pass through the stretched section of the construction film 32 from one side of the heat insulating layer 30 to the other side thereof. The construction film 32 is adapted for being stretched and condensed so as to function the ventilating and the insulating effects respectively. In normal condition, there is no stretching force applied on the compound fiber cloth, i.e. the heat insulating layer 30 is not being stretched, so that the fiber layer 31 is gathered together, as shown in FIG. 6 A, to prevent air from being exchanged or passing through from one side of compound fiber cloth to another side thereof. Therefore, the heat insulating layer 30 provides the insulating effect in the normal condition. The heat insulating layer 30 is bonded between the outer fabric 10 and the inner fabric 20 by pressurized, wherein adhesive is applied to the inner surfaces of both the outer fabric 10 and the inner fabric 20 and a predetermined pressure is applied to the outer fabric 10 and the inner fabric 20 between a pair of rolls such that the two fiber layers 31 of said heat insulating layer 30 are tightly adhered with the outer fabric 10 and the inner fabric 20 respectively. When a stretching force is applied on the compound fiber cloth, i.e. the heat insulating layer 30 is being stretched, the area of the construction film 32 is being enlarged so as to enable air penetrating therethrough for ventilation, as shown in FIG. 6 b. In other words, when the wearer has no exciting movement, which is in the normal condition, the compound fiber cloth provides the insulating effect to maintain the wearer's body temperature so as to keep himself or herself warm. However, when the wearer is excising, which will apply stretching force on the compound fiber cloth, the heat-insulating layer 30 is stretched out for providing ventilating effect for the compound fiber cloth such that the sweat on the wear's skin from perspiration can be vaporized by ventilation. Furthermore, the bigger movement the wearer has, the larger area of the construction film 32 being enlarged. So, the wearer will feel comfortable because heat can be dispersed to the atmosphere. It is worth to mention that the flexible construction film 32 will help the fiber layer 31 not to be distorted its shape while the heat insulating layer 30 is stretched which may cause permanently misshapen at the stretched section of the heat insulating layer 30 as described of the conventional compound fiber cloth in the background. Referring to FIG. 7, a manufacturing process of the heat-preserving compound fiber cloth is illustrated, which comprises the following steps. (a) Provide at least one construction film 32 . (b) Form a heat insulating layer 30 by attaching a plurality of fiber filaments 311 on at least one side surface of the construction film 32 which firmly and integrally holds the fiber filaments 311 in position so as to form at least a fiber layer 31 with a predetermined thickness on the side surface of the construction film 32 . (c) Provide a sheet of outer fabric 10 and a sheet of inner fabric 20 . (d) Bond the heat-insulating layer 30 between the outer fabric 10 and the inner fabric 20 . In the step (b), the fiber layer 31 is bonded on the construction film 32 by pressurized between a pair of rolls until the fiber filaments 311 are attached on the respective side surface of the construction film 32 so as to form the fiber layer 31 . Therefore, the fiber layer 31 is tightly coated on the construction film 32 to form the heat-insulating layer 30 with a predetermined thickness. In the step (d), the heat-insulating layer 30 is tightly adhered between the outer fabric 10 and the inner fabric 20 by pressurized between a pair of rolls. After the step (d), the steps of cutting the compound fiber cloth into a predetermined shape, checking the quality of the compound fiber cloth, and packaging can be preformed. In accordance with the preferred embodiment as disclosed above, the heat-preserving compound fiber cloth of the present invention is adapted for manufacturing a textile product that provides both ventilating and heat insulating effects. Due to the stretchable properties of the construction film 32 , the compound fiber cloth is adapted for being stretched without permanently distorting its shape. So, the compound fiber cloth can be long lasting over a period of continued use.