Alternative to 3D down

Abstract

Articles are described herein. An exemplary article may include a first surface including a first lattice. An exemplary article may include a second surface at least partially spaced from the first surface and having at least one common terminal connection point with the first surface. The first surface may include a second lattice. The first surface and the second surface may define a cavity therebetween. The first surface and the second surface may be capable of deforming from a first state to a second state under a compressive force to contract the volume of the cavity. The first surface and the second surface may be capable of returning to the first state when the compressive force is released.

Description

[Background technology]

[0001] Clothing such as jackets and other items such as blankets may require insulation. Animal feathers (e.g., down) may be used as insulation. However, sustainable insulation materials that can replace animal-derived insulation are needed. Several synthetic down alternatives are known. However, synthetic down may not perform as well as traditional down. Therefore, improvements are needed. Summary of the Invention

[0002] Insulating baffles are described herein. An exemplary insulating baffle may include a first surface including a plurality of first interconnected struts defining a plurality of first openings therethrough. An exemplary insulating baffle may include a second surface at least partially spaced from the first surface and having at least one common terminal connection point with the first surface. The first surface may include a plurality of second interconnected struts defining a plurality of second openings therethrough. An exemplary insulating baffle may include one or more third struts disposed between the first and second surfaces and coupled to at least one of the first and second surfaces. The first and second surfaces may define a cavity therebetween. The one or more third struts may be disposed within or adjacent to the cavity. The first and second surfaces may be capable of deforming from a first state to a second state under a compressive force to contract the volume of the cavity. The first and second surfaces may be capable of returning to the first state when the compressive force is released.

[0003] Articles are described herein. An exemplary article may include a first surface including a first lattice. An exemplary article may include a second surface at least partially spaced from the first surface and having at least one common terminal connection point with the first surface. The first surface may include a second lattice. The first surface and the second surface may define a cavity therebetween. The first surface and the second surface may be capable of deforming from a first state to a second state under a compressive force to contract the volume of the cavity. The first surface and the second surface may be capable of returning to the first state when the compressive force is released. [Brief explanation of the drawings]

[0004] The following drawings illustrate generally, by way of example, but not by way of limitation, various examples discussed in this disclosure.

[0005] [Figure 1] FIG. 1 is a perspective view of an article including three baffles according to the present disclosure.

[0006] [Figure 2] 1. FIG. 2 shows an enlarged view of a portion of FIG.

[0007] [Figure 3] FIG. 1 illustrates a top perspective view of an exemplary insulating baffle according to the present disclosure.

[0008] [Figure 4] FIG. 1 is a side perspective view of a portion of an exemplary insulating baffle according to the present disclosure.

[0009] [Figure 5] FIG. 1 is a side perspective view of a portion of an exemplary insulating baffle according to the present disclosure.

[0010] [Figure 6] 1 illustrates an exemplary insulating baffle. DETAILED DESCRIPTION OF THE INVENTION

[0011] Described herein are three-dimensional (3D) printed structures that replace traditional insulation materials. While reference is made to down, such as goose feathers, it should be understood that other insulating materials (e.g., synthetics) traditionally used in apparel may also be substituted or supplemented.

[0012] Described herein are systems, methods, articles, and / or insulating baffles for creating a more sustainable solution than animal-derived products. Described herein are systems, methods, articles, and / or insulating baffles that may be superior to synthetic insulation currently on the market. Conventional synthetic insulation is limited to cut staple and continuous filament structures modified in various ways. The systems, methods, articles, and / or insulating baffles described herein may use different substrates and structures to achieve the purpose of trapping air (insulation). The 3D-printed structure may include an initial state. The 3D-printed structure may be compressed. During compression, the 3D-printed structure may include a state different from the initial state. The 3D-printed structure may return to its initial state after compression. The systems, methods, articles, and / or insulating baffles described herein may enable rapid and efficient lofting of the baffle structure that seals the synthetic fill into the garment.

[0013] As described herein, breathability may be tested using ASTM D737, hardness may be tested using ASTM D2240, and flexural properties (3-point bend) may be tested using ASTM D790. Various articles or sample sizes may be tested. Other parameters and criteria may be used.

[0014] Insulating baffles are described herein. An exemplary insulating baffle may include a first surface including a plurality of first interconnected struts defining a plurality of first openings through the first surface. The first surface may include a curved shape. The plurality of first interconnected struts may define a lattice structure. The first surface may be at least partially formed using additive manufacturing.

[0015] An exemplary insulating baffle may include a second surface at least partially spaced from the first surface and having at least one common terminal connection point with the first surface. The first surface may include a plurality of second interconnected struts defining a plurality of second openings therethrough. The second surface may include a curved shape. The plurality of second interconnected struts may define a lattice structure. The second surface may be at least partially formed using additive manufacturing.

[0016] An exemplary insulating baffle may include one or more third struts disposed between a first surface and a second surface and coupled to at least one of the first surface and the second surface. The first surface and the second surface may define a cavity therebetween. The one or more third struts may be disposed within or adjacent to the cavity. The first surface and the second surface may be capable of deforming from a first state to a second state under a compressive force to contract the volume of the cavity. The first surface and the second surface may be capable of returning to the first state when the compressive force is released.

[0017] The exemplary insulation baffle may include an overall semi-columnar shape. The plurality of third struts may define a lattice structure. The exemplary insulation baffle may include a first layer disposed to cover at least a portion of a first surface. The exemplary insulation baffle may include a second layer disposed to cover at least a portion of a second surface. The configuration of the first interconnected struts, the second interconnected struts, and the third struts may be adjustable to control the stiffness of the exemplary insulation baffle.

[0018] Articles are described herein. An exemplary article can include a first surface including a first grating. The first surface can include a curved shape. The first surface can be at least partially formed using additive manufacturing.

[0019] An exemplary article may include a second surface at least partially spaced from the first surface and having at least one common terminal connection point with the first surface. The first surface may include a second lattice. The second surface may include a curvilinear shape. The second surface may be at least partially formed using additive manufacturing.

[0020] The first and second surfaces may define a cavity therebetween. The first and second surfaces may be capable of deforming from a first state to a second state under a compressive force to contract a volume of the cavity. The first and second surfaces may be capable of returning to the first state when the compressive force is released.

[0021] The exemplary article may include a generally semi-cylindrical shape. The exemplary article may include a generally rectangular cross-section. Various shapes and sizes may be used. The exemplary article may include a first layer disposed over at least a portion of a first surface. The exemplary article may include a second layer disposed over at least a portion of a second surface. The configuration of the first lattice and the second lattice may be adjustable to control the stiffness of the exemplary article.

[0022] FIG. 1 illustrates an exemplary article 100. The article 100 may form part of an item such as a garment, a blanket, a back or body support, a backpack, or a bag. As shown, the article 100 includes three baffle structures or baffles 102. Any number of baffles 102 may be used. The baffles 102 may have various shapes and sizes. The baffles 102 may be formed using various processes, such as additive manufacturing. As shown, the baffles may include a lattice structure having a plurality of interconnecting struts. A material may be disposed around the baffles 102. The lattice structure may thus allow air to be trapped within the material of the baffles 102 to enhance thermal insulation. The lattice structure may be compressible and configured to return to an uncompressed form.

[0023] FIG. 2 shows an enlarged baffle 2020 of the insulating baffle structure 102 shown in FIG. 1. Various designs may be modeled and formed based on the model or other means. The baffle structure 202 may be configured to define several openings or lattice configurations to provide a desired insulation value and / or stiffness. The baffle structure 202 may be covered with one or more materials to facilitate insulation. The baffle structure 202 and covering materials may be configured for a specific purpose, such as a specific garment.

[0024] FIG. 3 shows an example of a baffle structure 302 fabricated using an additive manufacturing process. The baffle structure 302 may be similar to the baffle 102. Various designs may be modeled and formed based on the model or other means. The baffle structure 202 may be configured to define several openings or lattice configurations to provide a desired insulation value and / or stiffness. The baffle structure 302 may be covered with one or more materials to facilitate thermal insulation. The baffle structure 302 and covering materials may be configured for a specific purpose, such as a specific garment.

[0025] FIG. 4 illustrates a portion of an exemplary insulating baffle 402. The baffle 402 may include a first surface 404 and a second surface 406 at least partially spaced from the first surface 404. The first surface 404 and the second surface 406 may have at least one common endpoint therebetween. As an example, the first surface 404 may extend and join at least a portion of the second surface 406. As shown, the first surface 404 is a rectangular planar surface, and the second surface 406 is a semicircular curved surface. Other shapes and sizes may be used. The first surface 404 and the second surface 406 may define a cavity 407. The first surface 404 and the second surface 406 may be at least partially formed using additive manufacturing. The first surface 404 and the second surface 406 may include a plurality of interconnected struts 403 that define a plurality of openings 405 through the first surface 404 and the second surface 406. The plurality of interconnected struts 403 may include one or more lattice structures. One or more additional struts or lattice structures may be coupled to the first surface 404, the second surface 406, or both surfaces 404, 406. The configuration of the interconnected struts 403 may be adjustable to control the stiffness of the baffle 402. At least a portion of the first surface 404 or the second surface 406 may be covered by one or more layers. The layers may include fabric or other materials. Various material layers may be used. As an example, the material layers may differ from traditional downproof layers because the baffle structure provides insulation without traditional down.

[0026] FIG. 5 illustrates a portion of an exemplary insulating baffle 502. The baffle 502 may include a first surface 504 and a second surface 506 at least partially spaced from the first surface 504. The first surface 504 and the second surface 506 may have at least one common endpoint therebetween. As illustrated, the first surface 504 is a rectangular planar surface, and the second surface 506 is a semicircular planar surface. The first surface 504 and the second surface 506 may define a cavity 507. The first surface 504 and the second surface 506 may be at least partially formed using additive manufacturing. The first surface 504 and the second surface 506 may include a plurality of interconnected struts 503 that define a plurality of openings 505 through the first surface 504 and the second surface 506. The plurality of interconnected struts 503 may include one or more lattice structures. One or more additional struts or lattice structures may be coupled to the first surface 504, the second surface 506, or both surfaces 504, 506. The configuration of interconnected struts 503 may be adjustable to control the stiffness of the baffle 502. At least a portion of the first surface 504 or the second surface 506 may be covered by one or more layers. As an example, the material layer may differ from a traditional downproofing layer, as the baffle structure provides insulation without traditional down (or other insulating material). Various strut shapes, sizes, and patterns may be used, for example, as shown in FIG. 6.

Claims

1. A three-dimensional insulating baffle, a first surface including a plurality of interconnected struts defining a plurality of first openings through the first surface; a second surface at least partially spaced from the first surface, the second surface having at least one common terminating connection point with the first surface, the second surface including a plurality of interconnected struts defining a plurality of second openings through the second surface; one or more posts disposed between the first surface and the second surface and coupled to at least one of the first surface and the second surface; a fabric material disposed over at least a portion of the three-dimensional insulating baffle, whereby air trapped beneath the fabric material by the three-dimensional insulating baffle facilitates insulation. the first surface and the second surface define a cavity therebetween; the one or more posts disposed between the first surface and the second surface are disposed within or adjacent to the cavity; the first surface and the second surface are capable of deforming from a first state to a second state under a compressive force to contract a volume of the cavity, and the first surface and the second surface are capable of returning to the first state when the compressive force is released, and the first surface is a rectangular planar surface and the second surface is a semicircular curved surface, such that the three-dimensional insulating baffle comprises a semi-cylindrical shape; The three-dimensional insulating baffle covered with the fabric material is configured to form a part of a garment.

2. The three-dimensional insulating baffle of claim 1 , wherein the plurality of interconnected struts disposed on the first surface define a lattice structure.

3. The three-dimensional insulating baffle of claim 1 , wherein the plurality of interconnected struts disposed on the second surface define a lattice structure.

4. The three-dimensional insulating baffle of claim 1 , wherein the plurality of struts disposed between the first surface and the second surface define a lattice structure.

5. The three-dimensional insulating baffle of claim 1 , further comprising a first layer disposed over at least a portion of the first surface.

6. The three-dimensional insulating baffle of claim 1 , further comprising a second layer disposed over at least a portion of the second surface.

7. 10. The three-dimensional insulating baffle of claim 1, wherein the shapes of the interconnected struts disposed on the first surface, the interconnected struts disposed on the second surface, and the struts disposed between the first surface and the second surface are adjustable to control the stiffness of the three-dimensional insulating baffle.

8. A method of making the three-dimensional insulating baffle of any one of claims 1 to 7.

9. A three-dimensional insulating baffle, a first surface including a first grating; a second surface at least partially spaced from the first surface and having at least one common terminating connection point with the first surface, the first surface including a second grating; a fabric material disposed over at least a portion of the three-dimensional insulating baffle, whereby air trapped beneath the fabric material by the three-dimensional insulating baffle facilitates insulation; the first surface and the second surface define a cavity therebetween; the first surface and the second surface are capable of deforming from a first state to a second state under a compressive force to contract a volume of the cavity, and the first surface and the second surface are capable of returning to the first state when the compressive force is released, and the first surface is a rectangular planar surface and the second surface is a semicircular curved surface, such that the three-dimensional insulating baffle comprises a semi-cylindrical shape; The three-dimensional insulating baffle covered with the fabric material is configured to form a part of a garment.

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