3-fabric layer insulation material and a method and an arrangement for producing the same
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Solution Overview
Problem
Existing thermal insulation materials for garments, such as those described in U.S. Pat. No. 2,607,104 and GB 1,390,609, are inefficient due to the lack of a third intermediate fabric layer, which affects air-seal integrity and insulation performance, and traditional quilting methods are labor-intensive and costly.
Innovation Solution
A 3-fabric layer thermal insulation material with a corrugated middle layer, where a multiplicity of sliver insulation is guided individually to fabric lengthwise running corrugated bundle channels, using laser welding to attach the fabric layers without needle holes, thereby enhancing insulation efficiency and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional quilting methods are used to attach insulation material to fabric layers, then the insulation material can be secured, but the production process becomes labor-intensive and costly with needle holes creating cold bridges
Solution Approach 1:
The patent replaces the mechanical needle-punching system with a thermal bonding system. The knit fabric layer is thermally bonded to the insulating fiber layer through heat and pressure, eliminating the need for needles and needle holes. This substitution resolves the contradiction by providing both cost-effective automated production and maintained air-seal integrity through thermal bonding instead of mechanical penetration.
Solution Approach 2:
The patent changes the bonding parameters from mechanical (needle penetration) to thermal (heat and pressure application). By controlling temperature, pressure, and time parameters during the bonding process, the fabric layers are fused together without creating holes, thereby maintaining air-seal integrity while enabling efficient automated production.
2Reliability
If a three-layer fabric structure with corrugated intermediate layer is used, then air-seal integrity and insulation performance are improved, but the manufacturing complexity increases
Solution Approach 1:
The patent merges the formation of the corrugated structure and the bonding of layers into a single integrated knitting and bonding process. The knit fabric is knitted with integrated corrugations, and the insulating fibers are incorporated during the same process, then thermally bonded in one step. This merging reduces manufacturing complexity despite the advanced three-layer structure with corrugated intermediate layer.
Solution Approach 2:
The intermediate knit fabric layer serves multiple functions simultaneously: it provides the corrugated structure for air trapping, acts as the bonding medium between outer fabric layers and insulating fibers, and maintains air-seal integrity. This multi-functionality reduces the need for separate components and simplifies the overall manufacturing process.
3Strength
If insulation material is attached to fabric layers using stitches, then the insulation is secured, but cold bridges are created at needle hole locations
Solution Approach 1:
The patent replaces the mechanical stitching system with a thermal bonding system. Instead of using needles that create holes and potential cold bridges, the insulation material is attached through thermal bonding where heat and pressure fuse the knit fabric layer with the insulating fibers, maintaining continuous air seals and eliminating cold bridge formation while providing sufficient attachment strength.
4Reliability
If two layers of insulation material are quilted separately and then assembled, then insulation performance is enhanced, but production cost and complexity increase significantly
Solution Approach 1:
The patent merges the bonding of multiple insulation layers into a single integrated thermal bonding process. All insulating fiber layers are positioned between fabric layers and bonded simultaneously in one operation, rather than quilting separate insulation layers individually and then assembling them. This merging maintains enhanced insulation performance while dramatically improving production efficiency and reducing costs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides superior insulating abilities by trapping warm air and preventing cold air infiltration, while simplifying the manufacturing process and reducing costs through increased production efficiency compared to traditional quilting methods.
Implementation Method 1
said fabric layers are joined together in longitudinal direction by multiplicity of lengthwise welded seams produced by laser beams
Implementation Method 2
Insulation is not attached to fabric but is floating in bundle channels merely by friction between insulation and fabric walls
Data Source
AI summary
This invention describes a 3-layer insulation material (10) comprising a first fabric layer (12), a second fabric layer (14) and a third fluted intermediate fabric layer (16) between the first and the second fabric layers (12, 14), the fluted intermediate fabric layer (16) being attached alternately to the first and the second fabric layer (12, 14) with longitudinal seams (18a-18n) forming longitudinal channels (20a-20n) for the insulation material (22) having individual insulation material (22) bundle in-side each longitudinal channel (20a-20n). Also disclosed are a method and an arrangement for producing the same.