Three-dimensional down replacement

Abstract

To provide a three-dimensional (3D) printed structure as a replacement for a conventional heat insulating material.SOLUTION: An exemplary article of a three-dimensional printed structure as a replacement for a conventional heat insulating material may comprise a first surface comprising a first lattice. The article may include a second surface at least partially spaced from the first surface and having at least one terminal connection point common 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 are capable of being deformed from a first state to a second state under a compression force to reduce a volume of the cavity. The first surface and the second surface may return to the first state when the compression force is released.SELECTED DRAWING: Figure 1

Description

Background Art

[0001] Clothes such as jackets and other items such as blankets may require heat insulation materials. Animal feathers (e.g., down) can be used as heat insulation materials. However, a sustainable heat insulation material that can replace animal-derived heat insulation materials is needed. Some synthetic down alternatives are known. However, synthetic down may not function as well as conventional down. Therefore, improvement is needed.

Summary of the Invention

[0002] A heat insulation baffle is described herein. An exemplary heat insulation baffle may include a first surface including a plurality of first interconnected struts defining a plurality of first openings through the first surface. An exemplary heat insulation 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 through the second surface. An exemplary heat insulation baffle may include one or more third struts disposed between the first surface and the 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. One or more third struts may be disposed within or adjacent to the cavity. The first surface and the second surface may be deformed 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 able to return to the first state when the compressive force is released.

[0003] Articles are described herein. An exemplary article may include a first surface comprising a first grid. An exemplary article may include a second surface at least partially spaced apart from the first surface and having at least one common terminal connection point with the first surface. The first surface may include a second grid. The first and second surfaces may define a cavity between them. The first and second surfaces may deform from a first state to a second state under compressive force, thereby reducing the volume of the cavity. The first and second surfaces may return to the first state when the compressive force is released. [Brief explanation of the drawing]

[0004] The following drawings, in general, illustrate various examples discussed in this disclosure, not as limitations. In the drawings,

[0005] [Figure 1] This is a perspective view of the article including the three baffles as disclosed herein.

[0006] [Figure 2] A magnified view of a portion of Figure 1 is shown.

[0007] [Figure 3] An exemplary top perspective view of an insulating baffle as described herein is shown.

[0008] [Figure 4] This is a partial side perspective view of an exemplary thermal insulation baffle as described in this disclosure.

[0009] [Figure 5] This is a partial side perspective view of an exemplary thermal insulation baffle as described in this disclosure.

[0010] [Figure 6] An example of an insulating baffle is shown. [Modes for carrying out the invention]

[0011] This specification describes three-dimensional (3D) printed structures as an alternative to conventional insulation materials. While down, such as goose feathers, is mentioned, it should be understood that other insulation materials conventionally used in apparel (e.g., synthetics) can also be used as alternatives or complements.

[0012] Described herein are systems, methods, articles, and / or insulating baffles for producing more sustainable solutions than animal-derived products. Described herein are systems, methods, articles, and / or insulating baffles that may be superior to synthetic insulating materials currently on the market. Conventional synthetic insulating materials are 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 different structures to achieve the purpose of trapping air (insulation). 3D printed structures may include an initial state. 3D printed structures may be compressible. During compression, 3D printed structures may include a state different from the initial state. 3D printed structures may return to the initial state after compression. The systems, methods, articles, and / or insulating baffles described herein may enable rapid and efficient lofting of baffle structures that seal synthetic fill in clothing.

[0013] As described herein, air permeability can be tested using ASTM D737, hardness can be tested using ASTM D2240, and bending properties (three-point bend) can be tested using ASTM D790. Various articles or sample sizes can be tested. Other parameters and criteria can be used.

[0014] An insulating baffle is described herein. An exemplary insulating baffle may include a first surface comprising 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 formed at least partially using additive manufacturing.

[0015] An exemplary thermal insulation baffle may include a second surface that is at least partially spaced apart from a first surface and has at least one common terminal connection point with the first surface. The first surface may include a plurality of second interconnected struts that define a plurality of second openings through the second surface. 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 supports positioned between a first surface and a second surface and coupled to at least one of the first and second surfaces. The first and second surfaces may define a cavity between them. One or more third supports may be positioned within or adjacent to the cavity. The first and second surfaces may deform from a first state to a second state under compressive force, thereby reducing the volume of the cavity. The first and second surfaces may return to the first state when the compressive force is released.

[0017] An exemplary thermal insulation baffle may include a semi-columnar shape as a whole. Multiple third supports may define a lattice structure. An exemplary thermal insulation baffle may include a first layer positioned to cover at least a portion of the first surface. An exemplary thermal insulation baffle may include a second layer positioned to cover at least a portion of the second surface. The configuration of the first interconnected supports, the second interconnected supports, and the third supports may be adjustable to control the rigidity of the exemplary thermal insulation baffle.

[0018] Articles are described herein. Exemplary articles may include a first surface comprising a first grid. The first surface may include a curved shape. The first surface may be at least partially formed using additive manufacturing.

[0019] An exemplary article may include a second surface that is at least partially spaced apart from a first surface and has at least one common terminal connection point with the first surface. The first surface may include a second grid. The second surface may include a curved shape. The second surface may be at least partially formed using additive manufacturing.

[0020] A first surface and a second surface may define a cavity between them. The first and second surfaces may deform from a first state to a second state under compressive force, thereby reducing the volume of the cavity. The first and second surfaces may return to the first state when the compressive force is released.

[0021] The exemplary article may have a semi-columnar shape as a whole. The exemplary article may have a rectangular cross-section as a whole. Various shapes and sizes may be used. The exemplary article may include a first layer disposed to cover at least a portion of the first surface. The exemplary article may include a second layer disposed to cover at least a portion of the second surface. The configuration of the first and second grids may be adjustable to control the rigidity of the exemplary article.

[0022] Figure 1 shows an exemplary article 100. Article 100 may form part of an item such as clothing, a blanket, a back or body support, a backpack or a bag. As shown, article 100 includes three baffle structures or baffles 102. Any number of baffles 102 may be used. Baffles 102 may have various shapes and sizes. Baffles 102 may be formed using various processes such as additive manufacturing. As shown, the baffles may include a lattice structure having multiple interconnected supports. Material may be placed around the baffles 102. Thus, the lattice structure may allow air to be trapped in the baffles 102 within the material to enhance thermal insulation. The lattice structure may be compressible and may be configured to return to an incompressible form.

[0023] Figure 2 shows the enlarged baffle 2020 of the heat insulation baffle structure 102 shown in Figure 1. It can be formed based on various designs modeled, on a model or other means. The baffle structure 202 can be configured to define several openings or lattice configurations to provide the desired insulation value and / or rigidity. The baffle structure 202 can be covered with one or more materials to facilitate heat insulation. The baffle structure 202 and the cover material can be configured for a specific purpose such as a specific piece of clothing.

[0024] Figure 3 shows an example of a baffle structure 302 manufactured using an additive manufacturing process. The baffle structure 302 can be similar to the baffle 102. It can be formed based on various designs modeled, on a model or other means. The baffle structure 202 can be configured to define several openings or lattice configurations to provide the desired insulation value and / or rigidity. The baffle structure 302 can be covered with one or more materials to facilitate heat insulation. The baffle structure 302 and the cover material can be configured for a specific purpose such as a specific piece of clothing.

[0025] FIG. 4 shows a part of an exemplary heat insulation baffle 402. The baffle 402 may include a first surface 404 and a second surface 406 that is at least partially spaced apart from the first surface 404. The first surface 404 and the second surface 406 may have at least one common end point therebetween. As an example, the first surface 404 may extend and join at least a part of the second surface 406. As shown in the figure, the first surface 404 is a rectangular plane, and the second surface 406 is a semi-circular 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 passing 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 rigidity of the baffle 402. At least a part of the first surface 404 or the second surface 406 may be covered by one or more layers. The layer may include cloth or other materials. Various material layers may be used. As an example, since the baffle structure provides heat insulation without conventional down, the material layer may be different from a conventional down-proof layer.

[0026] Figure 5 shows a portion of an exemplary thermal insulation baffle 502. The baffle 502 may include a first surface 504 and a second surface 506 at least partially spaced apart from the first surface 504. The first surface 504 and the second surface 506 may have at least one common endpoint between them. As shown, the first surface 504 is a rectangular plane and the second surface 506 is a semicircular plane. 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 passing through the first surface 504 and the second surface 506. The plurality of interconnected struts 503 may include one or more grid 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 the interconnected struts 503 may be adjustable to control the rigidity 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. For example, the material layer may differ from a conventional downproof layer, as the baffle structure provides insulation without conventional down (other insulating material). Various strut shapes, sizes, and patterns may be used, for example, as shown in Figure 6.

Claims

[Claim 1] An insulating baffle, A first surface including a plurality of first interconnected supports that define a plurality of first openings passing through the first surface, A second surface that is at least partially spaced apart from the first surface and has at least one common terminal connection point with the first surface, and includes a plurality of second interconnected posts that define a plurality of second openings passing through the second surface, The structure comprises one or more third pillars positioned between the first surface and the second surface and coupled to at least one of the first surface and the second surface, The first surface and the second surface define a cavity between them, The one or more third support columns are arranged within or adjacent to the cavity, The aforementioned insulating baffle is configured to trap air within the cavity and provide increased thermal insulation when covered with the material. The first surface and the second surface can deform from a first state to a second state under compressive force, thereby reducing the volume of the cavity, and the first surface and the second surface can return to the first state when the compressive force is released. The aforementioned insulating baffle is an insulating baffle covered with a layer of material.

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