Insulation assembly

Abstract

The invention relates to an insulation assembly comprising a planar sheet having a first surface and a second surface, and a plurality of openings extending through the planar sheet from the first surface to the second surface, and one or more bundles comprising a plurality of elongate fibres, wherein each bundle is threaded through two or more of the plurality of openings. Also provided as part of the invention is a method of manufacturing the insulation assembly and an insulation panel comprising the insulation assembly.

Description

[0001] Insulation Assembly

[0002] The present invention relates to an insulation assembly and in particular, but not exclusively, to an insulation assembly for clothing and sleeping bags. The invention also relates to a method of manufacturing such an insulation assembly; and an insulation panel comprising such an assembly.

[0003] Mountaineers, climbers and other outdoor activity enthusiasts often value products that are low in weight and small in packed size. These properties confer ease of movement and reduced fatigue when compared to heavier and larger equivalent products.

[0004] Mountaineers and climbers also frequently encounter cold temperatures. The adiabatic lapse rate on earth of one degree Celsius per one hundred metres means that even moderately high peaks are often accompanied by cold temperatures. Additionally, climbs may be more safely undertaken in cold conditions when the risk of rockfall is reduced. Additionally, some types of climbs are only undertaken in the winter months or in colder conditions. As such, for mountaineers and climbers, protection from the cold is paramount and in such outdoor environments, insulated clothing and sleeping bags are the most practical preventative measures against cold.

[0005] Most commonly available insulated outdoor clothing and insulated sleeping bags can be subdivided into two main categories: those insulated with down feathers; and those insulated with synthetic materials.

[0006] Down feathers possess superior compressibility to many other forms of insulation and have exceptional loftiness which contributes to their very high warmth to weight ratio. Down feathers must be contained within fabrics to keep them captive. Numerous construction methods to keep down captive are well-known to those skilled in the art. Some of these methods, such as box wall constructions, are relatively heavy and difficult to produce. Other constructions, such as stitch through, offer uneven warmth. In addition, down insulation is highly effective when dry, however its performance is significantly reduced if it gets wet, thus making it of limited use in certain weather conditions and climates. Synthetic insulation is available in both loose and sheet forms. Loose synthetic insulation is sometimes referred to as ‘down-like’ insulation because it has high loft and high compressibility and is comfortable to wear. However, like down it must be baffled to keep it captive. Sheet synthetic insulation is widely known and can offer better performance in wet weather than down insulation. However, sheet synthetic’s loftiness and subsequent warmth is often inferior to an equivalent down product, meaning that greater weight must be carried for an equivalent warmth to be achieved. Synthetic insulation is also less compressible than a down insulated product of equivalent thermal resistance.

[0007] The decreased effectiveness of down in wet conditions and the limitations inferred by keeping the down captive, and the comparatively low insulation values and compressibility of synthetic insulations means that there is a need for an improved insulation for use by mountaineers, climbers and outdoor enthusiasts.

[0008] The aim of the invention is to provide an insulation assembly that possesses comparable or higher warmth to weight ratio when compared to existing insulations, particularly existing synthetic insulations.

[0009] According to a first aspect of the invention, there is provided an insulation assembly comprising: a planar sheet having a first surface and a second surface, and a plurality of openings extending through the planar sheet from the first surface to the second surface, and one or more bundles comprising a plurality of elongate fibres, wherein each bundle is threaded through two or more of the plurality of openings.

[0010] According to a second aspect of the invention, there is provided a method of manufacturing an insulation assembly according to the first aspect, the method comprising: providing a planar sheet having a first surface and a second surface, and a plurality of openings extending from the first surface to the second surface, and providing one or more bundles comprising a plurality of elongate fibres, threading each bundle through two or more of the plurality of openings. According to a third aspect of the invention, there is provided an insulation panel comprising the insulation assembly of the invention enclosed within a fabric casing.

[0011] The insulation assembly may have a loft to weight ratio (thickness / areal density) of 7 cm m2kg"1or more, such as for example 7 cm m2kg"1or more, 8 cm m2kg"1or more, 9 cm m2kg"1or more, 10 cm m2kg"1or more, 15 cm m2kg"1or more.

[0012] The insulation assembly may have a density of 0.014 g cm"3or more, such as for example 0.014 g cm"3or more, 0.015 g cm"3or more, 0.016 g cm"3or more, 0.0175 g cm"3or more, 0.020 g cm"3or more, 0.025 g cm"3or more.

[0013] The warmth to weight ratio (RCT / weight) of the insulation assembly may be 2 m2K Kg"1W"1or more, such as for example 3 m2K Kg"1W-1or more, 4 m2K Kg"1W-1or more, 5 m2K Kg"1W-1or more, 6 m2K Kg"1W-1or more, 6.5 m2K Kg"1W-1or more, 7 m2K Kg"1W-1or more.

[0014] The thermal resistance per areal density (RCT / areal density) of the insulation assembly may be 0.2 m4K W"1kg"1or more, such as 0.5 m4K W"1kg"1or more, 0.6 m4K W"1kg-1or more, 0.7 m4K W"1kg"1or more.

[0015] The planar sheet may comprise a synthetic material, such as for example polyamide, polyester, polyurethane or a combination thereof.

[0016] The planar sheet may comprise a woven textile, a nonwoven textile, or a film.

[0017] The planar sheet may weigh 150 g / m2or less, 125 g / m2or less, 100 g / m2or less, 90 g / m2or less, 80 g / m2or less, 70 g / m2or less, 60 g / m2or less, 50 g / m2or less, 40 g / m2or less, 30 g / m2or less, 25 g / m2or less, 20 g / m2or less, 15 g / m2or less, 10 g / m2or less, such as for example 150 g / m2, 125 g / m2, 100 g / m2, 90 g / m2, 80 g / m2, 70 g / m2, 60 g / m2, 50 g / m2, 40 g / m2, 30 g / m2, 25 g / m2, 20 g / m2, 15 g / m2, 12g / m2, 10 g / m2, 8 g / m2.

[0018] The planar sheet may weigh 1 g / m2or more, such as for example 1 g / m2or more, 2 g / m2or more, 3 g / m2or more, 4 g / m2or more, 5 g / m2or more, 10 g / m2or more, 15 g / m2or more, 20 g / m2or more, 25 g / m2or more. The planar sheet may be coated to provide additional beneficial properties, such as to increase or decrease hydrophobicity, affect surface tension, or could be metallised to change radiative properties.

[0019] The planar sheet may comprise a nonwoven polyester scrim. The nonwoven polyester scrim may have an aluminium coating. The nonwoven polyester scrim may be a spunbond-meltblown-spunbond nonwoven.

[0020] The planar sheet may comprise a thermoplastic polyurethane (TPU) film. The film may have a Shore hardness of 80 to 90, for example 85. The film may have a tensile strength of 400 -1000kg / cm2, for example 500-900kg / cm2or 600-800kg / cm2. The film may have a melting point of 150°C-165°C, for example 155°C -160°C, for example 157°C.

[0021] The openings may be sized and / or shaped such that the bundles can be threaded therethrough with relative ease.

[0022] The openings may be sized and / or shaped such that the bundles stay in place.

[0023] The openings may be sized and / or shaped such that the bundles, or fibres within the bundles, can loft.

[0024] The openings may be spaced such that the bundles can be threaded with relative speed.

[0025] The openings may be spaced such that optimal tension is placed on the fibres.

[0026] The openings may be spaced such that evenly spread insulation is possible over the extent of the area to be threaded.

[0027] The openings may be spaced such that the distribution of insulation may be varied over the extent of the area to be threaded. The openings may be slits. The slits may have a length of from 1.5-6cm, for example 2-5cm or 2.5-4.5cm, or for example 2.5cm or 3.5cm. The slits may be spaced apart by a distance of 2-7cm, or 3-7cm or 3-6cm, for example 3cm or 4cm or 5cm or 6cm.

[0028] The openings may be circular or near-circular. The openings may have a diameter of l-6cm, for example 1.5-2.5cm or 2cm. The openings may be spaced apart by a distance of 2-7cm, or 3-7cm or 3-6cm, for example 3cm or 4cm or 5cm or 6cm.

[0029] Each elongate fibre may have a diameter of 1 or more micrometres, such as for example 2 or more, 3 or more, 4 or more, 5 or more, 10 or more, 15 or more, 20 or more, 30 or more micrometres. Each elongate fibre may have a diameter of 1, 2, 3, 4, 5, 10, 15, 20, 30 micrometres.

[0030] Each elongate fibre may have a diameter of 100 micrometres or less, such as for example 99 or less, 98 or less, 97 or less, 96 or less, 95 or less, 90 or less, 70 or less, 60 or less, 50 or less, 40 micrometres or less. Each elongate fibre may have a diameter of 100, 99, 98, 97, 96, 95, 90, 70, 60, 50, 40 micrometres.

[0031] Each elongate fibre may have a weight of 1 denier or more, such as for example 2 denier or more, 3 denier or more, 5 denier or more, 10 denier or more, 15 denier or more, 20 denier or more, 25 denier or more, 30 denier or more, 35 denier or more.

[0032] Each elongate fibre may have a weight of 100 denier or less, such as for example 90 denier or less, 80 denier or less, 70 denier or less, 60 denier or less, 50 denier or less, 40 denier or less.

[0033] Each elongate fibre may have a weight of 1, 2, 3, 5, 10, 15, 20, 24, 30, 38, 40, 50, 60, 70, 80, 90, 100 denier.

[0034] The elongate fibres may be natural or synthetic.

[0035] The elongate fibres may comprise a synthetic material, for example nylon, polyester or polypropylene. The elongate fibres may comprise a natural material, such as for example wool, silk or hair.

[0036] Each bundle may comprise a mixture or blend of synthetic and natural fibres.

[0037] The elongate fibres may each have a length of 5mm or more, such as for example 10mm or more, 20mm or more, 30mm or more, 50mm or more, 60mm or more, 70mm or more, 80mm or more, 90 mm or more, 100mm or more, 150mm or more, 300mm or more.

[0038] Each bundle may comprise 2 or more elongate fibres, such as for example 10 or more, 15 or more, 25 or more, 50 or more, 100 or more, 500 or more, 700 or more, 850 or more, 900 or more elongate fibres.

[0039] Each bundle may comprise 2000 elongate fibres or fewer, such as for example 1900 or fewer, 1750 or fewer, 1500 or fewer, 1250 or fewer, 1000 or fewer, 500 or fewer, 200 or fewer, 100 or fewer, 50 or fewer elongate fibres.

[0040] Each bundle may comprise 2, 10, 15, 20, 25, 30, 40, 50, 75, 100, 250, 500, 700, 850, 900 elongate fibres.

[0041] Each bundle may comprise elongate fibres each having a length that is less than or equal to the length of the bundle. For example, each of the elongate fibres may be substantially the same length as the bundle. Alternatively, each of the elongate fibres may have a length that is shorter than the length of the bundle.

[0042] In one embodiment, the elongate fibres comprise synthetic materials and have a length that is substantially the same as the length of the bundle.

[0043] In another embodiment, the elongate fibres comprise natural materials and have a length that is shorter than the length of the bundle.

[0044] Each bundle of individual elongate fibres may be threaded through the plurality of openings in the planar sheet, for example such that the fibres are proximate the first surface and, upon threading through an opening, are proximate the second surface. The fibres may then be threaded through another opening to become proximate the first surface. This process is repeated.

[0045] Each bundle is ideally not welded, sewn or otherwise secured to the planar sheet but is held in place by virtue of interstitial friction.

[0046] Each bundle may be threaded through the two or more openings in any suitable manner. For example, each bundle may be threaded through the two or more openings in a running stitch arrangement.

[0047] Each bundle may run through consecutive openings, skip openings, be threaded in a repeating pattern, be threaded in a non-repeating pattern, or be threaded in any other manner.

[0048] Each bundle may be pulled or pushed through the planar sheet in any manner.

[0049] For example, each bundle may be threaded through the planar sheet starting from the end of the bundle, or from the middle, or elsewhere along the length of the bundle. Threading a bundle starting from the middle or elsewhere along the length of the bundle may enable ‘doubling’ of the thickness of the bundle.

[0050] Each bundle may be pre-cut to a specific length to run across the width or length of a planar sheet, or across multiple lengths or widths of a planar sheet.

[0051] Alternatively, the assembly may comprise one bundle laced through the planar sheet in a continuous length.

[0052] The length of each bundle may be substantially the same as or greater than the width or length of the planar sheet to be threaded.

[0053] The length of each bundle may be substantially the same as the width or length of the planar sheet to be threaded.

[0054] The length of each bundle may be greater than the width or length of planar sheet to be threaded. The length of each bundle may exceed the width or length of planar sheet to be threaded by 5% or more, such as for example 10% or more, 20% or more, 50% or more, 100% or more, 150% or more, 200% or more. The length of each bundle may exceed the width or length of planar sheet to be threaded by 300% or less, such as for example 275% or less, 250% or less, 225% or less.

[0055] When threaded between openings a bundle may stand away from the planar sheet and form a loop that stands proud from the surface of the planar sheet. Optionally, further bundle(s) may run through these loops, orthogonally or at any angle to the loops.

[0056] The insulation assembly may be enclosed within a fabric casing.

[0057] A plurality of insulation assemblies may be enclosed within the fabric casing.

[0058] Other elements may also be present inside this casing, including other insulated materials, other textiles, or other elements used in the construction of insulated garments, sleeping bags, or sleeping mats.

[0059] The casing may comprise a plurality of layers of fabric.

[0060] The plurality of layers may have substantially the same length and / or width as the insulation assembly. The layers may be substantially co-extensive with each other and with the planar sheet of the insulation assembly.

[0061] The plurality of layers may have a length and / or width that differs from the insulation assembly. For example, the layers may be larger in area than the insulation assembly, such that more than one insulation assembly may be arranged within one casing.

[0062] The casing may comprise synthetic or natural fabric. The fabric may be coated with or contain membranes comprising a polymer such as polyurethane (PU), thermoplastic polyurethane (TPU), expanded polytetrafluoroethylene (ePTFE), or polyester (PES).

[0063] The plurality of layers, and optionally the insulation assembly, may be joined at their edges by any suitable means, such as for example sewing, lamination, welding, or bonding. As an example an insulation assembly may be provided with a first layer of fabric adjacent to the first surface of the planar sheet and a second layer of fabric adjacent to the second surface of the planar sheet forming a casing for the insulation assembly. The first and second layers may be coextensive with each other and the insulation assembly. The first and second layers and optionally the insulation assembly may be joined at their edges, for example by sewing.

[0064] Reducing movement, or increasing stability, of the synthetic insulated filling without inhibiting its ability to loft leads to an increase in thermal resistance and reduced heat loss due to convection, conduction and radiation. These improved thermal properties also enable reduction in mass of insulation required. This in turn allows the total mass and packed / compressed size of the clothing / equipment in which the insulation is to be carried to be reduced.

[0065] The insulation assembly of the present invention can be used in the manufacture of insulated products for outdoor enthusiasts such as in clothing for example jackets, gloves and trousers, and in sleeping equipment such as sleeping bags, blankets and sleeping mats.

[0066] There now follows description of embodiments of the invention described by way of example only with reference to the accompanying Figures, in which:

[0067] Figure 1 shows a planar sheet and an insulation assembly according to the invention.

[0068] Figure 2 shows a planar sheet and an alternative insulation assembly according to the invention.

[0069] Figure 3 shows a planar sheet and a further alternative insulation assembly according to the invention.

[0070] Figure 4a shows the ‘doubling’ of a bundle according to an embodiment of the invention. Figure 4b shows a planar sheet and an insulation assembly according to the invention using the ‘doubled’ bundles of Fig. 4a.

[0071] Examples

[0072] Example 1 - normal Airflake construction (Fig. 1)

[0073] The planar sheet comprises a nonwoven polyester scrim with an aluminium coating, more specifically the 12g m-2XReflex scrim product from HeiQ® (Switzerland).

[0074] The bundles used are the Airflake product of 1.7g per linear metre supplied by Toyota Tsusho Corp. Each bundle is made up of 15 fibres, each fibre has a weight of 38 denier and is composed of 12 filaments.

[0075] The planar sheet 100 is perforated with openings or “slits” 101 of with a length 102 of 2.5 cm. The slits are arranged in rows with 4 cm spacings 103 between slits, orthogonal to the plane of the slits. The spacing between rows is substantially zero, and the slits of one row are offset from the slits of the adjacent row.

[0076] Each bundle 200 is cut so that the length exceeds by ten percent the width of the planar sheet 100.

[0077] A bundle 200 is then threaded from the end of the bundle, starting at a first slit 101 in a row extending across the width of the planar sheet, back and forth through the slits in the row of individual slits in a repeating pattern until a last slit in the row is reached.

[0078] This process is repeated using another bundle for each row of slits, until each slit in the planar sheet is threaded with bundles of fibres.

[0079] Example 2 - alternating Airflake construction (Fig. 2)

[0080] The planar sheet comprises a nonwoven polyester scrim with an aluminium coating, more specifically the 12g m-2XReflex scrim product from HeiQ® (Switzerland).

[0081] The bundles used are the Airflake product of 1.7g per linear metre supplied by Toyota Tsusho Corp. Each bundle is made up of 15 fibres, each fibre has a weight of 38 denier and is composed of 12 filaments. The planar sheet 100 is perforated with openings or “slits” 101 of near-zero width and a length 102 of 2.5 cm. The slits are arranged in rows with 4 cm spacings 103 between slits, orthogonal to the plane of the slits. The spacing between rows is substantially zero, and the slits of one row are offset from the slits of the adjacent row.

[0082] A bundle 200 is cut so that the length exceeds by ten percent the width of the planar sheet 100. The bundle 200 is then threaded from the end of the bundle, starting at a first slit 101 in a row extending across the width of the planar sheet 100, back and forth through the slits in the row of individual slits in a repeating pattern until a last slit in the row is reached.

[0083] The next bundle 201 is cut so that the length is substantially the same as the width of the planar sheet 100. This bundle 201 is threaded only through a first and last slit of the adjacent row of slits in the planar sheet 100. In this way the bundle does not alternate surface of the planar sheet along the width of the planar sheet like the first bundle, but instead is mostly visible only on one surface.

[0084] The aforementioned process is repeated, with an alternating pattern of threaded bundle 200 followed by non-threaded bundle 201, until the planar sheet 100 is covered.

[0085] Example 3 - alternating Airflake construction 2 (Fig. 3)

[0086] The planar sheet comprises a nonwoven polyester scrim with an aluminium coating, more specifically the 12g m-2XReflex scrim product from HeiQ® (Switzerland).

[0087] The bundles used are the Airflake product of 1.7g per linear metre supplied by Toyota Tsusho Corp. Each bundle is made up of 15 fibres, each fibre has a weight of 38 denier and is composed of 12 filaments.

[0088] The planar sheet 100 is perforated with openings or “slits” 101 of near-zero width and a length 102 of 2.5cm. The slits are arranged in rows with 4 cm spacings 103 between slits, orthogonal to the plane of the slits. The spacing between rows is substantially zero, and the slits of one row are offset from the slits of the adjacent row. A bundle 200 is cut so that the length exceeds by ten percent the width of the planar sheet 100. The bundle 200 is then threaded from the end of the bundle, starting at a first slit in a row extending across the width of the planar sheet 100, back and forth through the slits in the row of individual slits in a repeating pattern until a last slit in the row is reached.

[0089] The next bundle 200 is inserted into a second row of slits which is not adjacent to the previous bundle. As such, a row of unthreaded slits remains.

[0090] The aforementioned process is repeated, with an alternating pattern of threaded slits followed by non-threaded slits, until the planar sheet 100 is covered.

[0091] Example 4 - double strand Airflake construction (Fig. 4a and 4b)

[0092] The planar sheet comprises a nonwoven polyester scrim with an aluminium coating, more specifically the 12g m-2XReflex scrim product from HeiQ® (Switzerland).

[0093] The bundles used are the Airflake product of 1.7g per linear metre supplied by Toyota Tsusho Corp. Each bundle is made up of 15 fibres, each fibre has a weight of 38 denier and is composed of 12 filaments.

[0094] The planar sheet 100 is perforated with openings or “slits” 101 of near-zero width and a length 102 of 2.5 cm. The slits are arranged in rows with 4 cm spacings 103 between slits, orthogonal to the plane of the slits. There spacing between rows is substantially zero, and the slits of one row are offset from the slits of the adjacent row.

[0095] Each bundle 200 is cut so that the length exceeds the width of the planar sheet by 220%. A bundle is then folded in half lengthways and the folded bundle is threaded (direction of threading 300) from the folded point in a “doubled” manner (see Fig. 4a) starting at a first slit in a row extending across the width of the planar sheet 100, back and forth through the slits in the row of individual slits in a repeating pattern until a last slit in the row is reached.

[0096] This process is repeated using another bundle for each row of slits until each slit in the planar sheet is threaded with bundle (see Fig. 4b). Example 5 - wool construction

[0097] The planar sheet comprises a nonwoven polyester scrim, more specifically a 20g m-2spunbond-meltblown-spunbond nonwoven.

[0098] The bundles used are a wool sliver from HDWool Ltd. (UK) with a fibre diameter of 31-33 micrometres and staple length (“upper-half-mean” length) of 70-80 mm. The wool sliver weighs 25 grams per linear metre.

[0099] The planar sheet is perforated in a manner known by those skilled in the art with slits of near-zero width but 3.5 cm length, with 6cm cut spacings orthogonal to the plane of the slits. The spacing between rows is substantially zero, and the slits of one row are offset from the slits of the adjacent row.

[0100] A bundle is cut so that the length exceeds by ten percent the width of the planar sheet. A bundle is then threaded from the end of the bundle, starting at a first slit in a row extending across the width of the planar sheet, back and forth through the slits in a row of individual slits in a repeating pattern until a last slit in the row is reached.

[0101] This process is repeated until each slit in the planar sheet is threaded with bundle.

[0102] Example 6 - Airflake threaded through TPU

[0103] The planar sheet is a thermoplastic polyurethane (TPU) film, more specifically thermoplastic polyurethane with a Shore hardness of 85, tensile strength of 600-800 kg / cm2, and a melting point of 157 °C.

[0104] The bundle is the 30 bundle Airflake product of 3.4g per linear metre supplied by Toyota Tsusho Corp.

[0105] The planar sheet is perforated with near-circular openings of 2.0 cm diameter, with 6cm cut spacings orthogonal to the plane of the slits. There spacing between rows is substantially zero, and the openings of one row are offset from the openings of the adjacent row.

[0106] Each bundle is cut so that the length exceeds by fifteen percent the width of the planar sheet. A bundle is then threaded, starting at a first opening in a row extending across the width of the planar sheet, through individual openings in a repeating pattern until a last opening in the row is reached.

[0107] This process is repeated until each opening in the planar sheet is threaded with bundle.

[0108] Laboratory test results

[0109] In testing based on ISO 11092, five different insulation assemblies according to the invention, each held inside the same casing materials (downproof fabric FY1197DWR3 sourced from supplier Toyota Tsusho Corp: 100% polyamide, 10 denier, 26g m-2.), were tested alongside the benchmark branded insulation of PrimaLoft Gold (PrimaLoft Inc., USA). All samples were of identical size.

[0110] The warmth to weight ratio (RCT / weight) was greatest in the ‘Standard Airflake’ assembly (sample 3, below - described in Example 1 above). From the results it can be seen that all of the samples outperformed PrimaLoft Gold 60gsm in warmth to weight ratio. Samples 2 and 3 of the invention outperformed PrimaLoft Gold lOOgsm in warmth to weight ratio, and sample 1 was similar to PrimaLoft Gold lOOgsm in warmth to weight ratio.

[0111] The RCT / RET (i.e. a measure of how warm the sample is for its level of evaporative resistance) was highest in sample 2. Sample 1 was comparable to PrimaLoft Gold 60gsm in RCT / RET and sample 3 was comparable to PrimaLoft lOOgsm in RCT / RET.

[0112] The sample insulation assemblies all possessed a reflective HeiQ scrim and as such were measured with the reflective surface facing up and facing down.

[0113] Advantages associated with assemblies of the present invention may be as follows.

[0114] Greater loft vs equivalent weight synthetic insulations The present invention has a greater thickness than PrimaLoft Gold and other analogous synthetic insulations. Depending on the iteration, thickness may be 1 10%, 150%, 200%, 250% or 300% of the loft of equivalent weight synthetic wadding insulations. This greater loft is also associated with greater softness and therefore greater compressibility.

[0115] High thermal resistance to weight (‘warmth to weight’) ratio As demonstrated in the above Laboratory test results.

[0116] High design flexibility Down feathers must be sewn into baffles for them to be contained. This means that designs usually contain stitch lines which may increase moisture ingress and reduce windproofness. The sizes and shapes of baffles are limited by down’s tendency to migrate, and as such it is difficult to produce a wide range of aesthetics. In addition, down can protrude or migrate through open fabrics, and so fabric choice is self- limiting. The present invention can be treated as if it were a sheet of synthetic insulation, offering greater design flexibility and with none of the quilting restrictions that can be present in some synthetic insulations. Fibre migration is reduced versus that of many down insulations.

[0117] Ease of washing and good wash durability

[0118] Laundering a down product can be a daunting task and one that many users are reluctant to undertake. Indeed, dry cleaning services do not generally undertake washing of down garments, and specialist cleaners exist to service this market. As such, a product such as the present invention that can be washed and dried at home in a domestic washing machine, without specialist knowledge, is advantageous. In our tests examples of the present invention have undergone ten wash cycles in a domestic washing machine without noticeable adverse effect, and samples have been field tested for six months without noticeable adverse change.

[0119] Improved performance in wet conditions vs down insulation

[0120] Down insulation is initially hydrophobic but can absorb water readily once its outer surface has been penetrated. When this happens the insulation loses thickness, clumps together, increases in weight, its insulating properties decrease, and it takes a long time to dry. The present invention absorbs significantly less water than down insulation.

[0121] Reduced material costs vs down insulation

[0122] The cost per kilogram of high quality duck and goose down is much higher than products such as Airflake. 700 fill power 90 / 10 duck down, a high quality filling material commonly used in the outdoor industry is more expensive than Airflake on a cost per weight basis; 800 fill power 90 / 10 goose down which is again commonly used in the outdoor industry and which represents very high quality insulation is more expensive still:

Claims

CLAIMS1. An insulation assembly comprising: a planar sheet having a first surface and a second surface, and a plurality of openings extending through the planar sheet from the first surface to the second surface, and one or more bundles comprising a plurality of elongate fibres, wherein each bundle is threaded through two or more of the plurality of openings.

2. The insulation assembly of claim 1 having a loft to weight ratio of 7 cm m2 kg1or more.

3. The insulation assembly of claim 1 or claim 2 having a density of 0.014 g cm'3or more.

4. The insulation assembly of any one of claims 1 to 3 having a warmth to weight ratio of 5 m2K Kg1W1or more.

5. The insulation assembly of any one of the preceding claims having thermal resistance per areal density of 0.2 m4K W1kg1or more.

6. The insulation assembly of any one of the preceding claims, wherein one of the following applies:(i) the planar sheet comprises a synthetic material, such as for example polyamide, polyester, polyurethane or a combination thereof;(ii) the planar sheet comprises a natural material, such as for example silk, wool or hair.

7. The insulation assembly of any one of the preceding claims, wherein the planar sheet comprises a woven textile, a nonwoven textile, or a film.

8. The insulation assembly of claim 7, wherein the planar sheet comprises a nonwoven polyester scrim, wherein optionally one or more of the following applies:(i) the nonwoven polyester scrim has an aluminium coating;(ii) the nonwoven polyester scrim is a spunbond-meltblown-spunbond nonwoven.

9. The insulation assembly of any one of the preceding claims, wherein one or more of the following applies:(i) the planar sheet weighs from 1 g / m2to 150 g / m2; and(ii) the planar sheet is coated to provide additional beneficial properties, such as to increase or decrease hydrophobicity, affect surface tension, or metallised to change radiative properties.

10. The insulation assembly of any one of the preceding claims, wherein the planar sheet comprises a thermoplastic polyurethane (TPU) film, and wherein optionally one or more of the following applies:(i) the film has a Shore hardness of 80 to 90;(ii) the film has a tensile strength of 400 -1000kg / cm2;(iii) the film has a melting point of 150°C-165°C.

11. The insulation assembly of any one of the preceding claims, wherein the openings are slits, and wherein optionally one or more of the following applies:(i) the slits have a length of from 1.5-6cm;(ii) the slits are spaced apart by a distance of 2-7cm.

12. The insulation assembly of any one of claims 1 to 10, wherein the openings are circular or near-circular, and wherein optionally one or more of the following apply:(i) the openings have a diameter of l-6cm;(ii) the openings are spaced apart by a distance of 2-7cm.

13. The insulation assembly of any one of the preceding claims, wherein one or more of the following applies:(i) the elongate fibres are natural, for example nylon, polyester or polypropylene;(ii) the elongate fibres are synthetic, for example wool, silk or hair;(iii) each bundle comprises a mixture or blend of natural and synthetic fibres;(iv) each elongate fibre has a diameter of from 1 micrometre to 100 micrometres;(v) each elongate fibre has a weight of from 1 denier to 100 denier.

14. The insulation assembly of any one of the preceding claims, wherein the elongate fibres have a length of 5mm or more.

15. The insulation assembly of any one of the preceding claims, wherein each bundle comprises from 2 to 2000 elongate fibres.

16. The insulation assembly of any one of the preceding claims, wherein each bundle comprises elongate fibres each having a length that is less than or equal to the length of the bundle, and wherein optionally one of the following apples:(i) the elongate fibres comprise synthetic materials and have a length that is substantially the same as the length of the bundle;(ii) the elongate fibres comprise natural materials and have a length that is shorter than the length of the bundle.

17. The insulation assembly of any one of the preceding claims, wherein each bundle of individual elongate fibres is threaded through the plurality of openings in the planar sheet such that the fibres are proximate the first surface and, upon threading through an opening, are proximate the second surface.

18. The insulation assembly of any one of the preceding claims, wherein each bundle is threaded through the planar sheet starting from the end of the bundle; or each bundle is threaded through the planar sheet starting from the middle, or elsewhere along the length of the bundle.

19. The insulation assembly of any one of the preceding claims, wherein one of the following applies:(i) each bundle is pre-cut to a specific length to run across the width or length of a planar sheet, or across multiple lengths or widths of a planar sheet; or(ii) the assembly comprises one bundle laced through the planar sheet in a continuous length.

20. The insulation assembly of any one of the preceding claims, wherein the length of each bundle is substantially the same as the width or length of the planar sheet to be threaded.

21. The insulation assembly of any one of claims 1 to 19, wherein the length of each bundle is greater than the width or length of the planar sheet to be threaded, whereinoptionally the length of each bundle exceeds the width or length of planar sheet to be threaded by between 5% and 300%.

22. A method of manufacturing an insulation assembly according to claim 1, the method comprising: providing a planar sheet having a first surface and a second surface, and a plurality of openings extending from the first surface to the second surface, and providing one or more bundles comprising a plurality of elongate fibres, threading each bundle through two or more of the plurality of openings.

23. An insulation panel comprising the insulation assembly of claim 1 enclosed within a fabric casing.

24. The insulation panel of claim 23, wherein the fabric casing comprises a plurality of layers of fabric, and wherein optionally one of the following applies:(i) the plurality of layers have substantially the same length and / or width as the insulation assembly, wherein optionally the layers are substantially co-extensive with each other and with the planar sheet of the insulation assembly;(ii) the plurality of layers have a length and / or width that differs from the insulation assembly, wherein optionally the layers are larger in area than the insulation assembly, such that more than one insulation assembly may be arranged within one casing.

25. The insulation panel of claim 23 or claim 24, wherein one or more of the following applies:(i) a plurality of insulation assemblies are enclosed within the fabric casing;(ii) other elements are also present inside this casing, including other insulated materials, other textiles, or other elements used in the construction of insulated garments, sleeping bags, or sleeping mats;(iii) the casing comprises synthetic or natural fabric, wherein optionally the fabric is coated with or contains membranes comprising a polymer such as polyurethane (PU), thermoplastic polyurethane (TPU), expanded polytetrafluoroethylene (ePTFE), or polyester (PES);(iv) the plurality of layers, and optionally the insulation assembly, are joined at their edges by any suitable means, such as for example sewing, lamination, welding, or bonding.

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