A 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 US 2,607,104 and GB 1,390,609, lack a third intermediate fabric layer to enhance air-seal properties and are economically inefficient due to the need for separate insulation filling processes and costly manufacturing methods like quilting or adhesive bonding, which often result in cold bridges and labor-intensive production.
Innovation Solution
A 3-fabric layer thermal insulation material with a corrugated middle layer, where continuous fiber slivers float in bundle channels between fabric layers, and laser welding is used to attach the layers without needle holes, allowing for direct integration of insulation during the manufacturing process and reducing production costs and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional quilting or adhesive bonding methods are used to attach insulation layers, then the insulation material can be secured between fabric layers, but the production becomes labor-intensive and expensive with cold bridges formed at stitching points
Solution Approach 1:
The patent removes the intermediate fabric layer entirely, extracting the problematic stitching/bonding step from the manufacturing process. The insulation material is directly enclosed between the outer fabric layers without requiring attachment to an intermediate layer, eliminating cold bridges and labor-intensive quilting operations while maintaining insulation continuity.
Solution Approach 2:
The patent merges the insulation material placement and fabric layer assembly into a single integrated structure. The insulation is directly positioned between the outer fabric layers without requiring separate attachment operations, combining what were previously separate steps (layer attachment and insulation placement) into one streamlined process.
2Reliability
If a third intermediate fabric layer is added to enhance air-seal properties, then insulation performance improves, but manufacturing cost and complexity increase
Solution Approach 1:
The patent extracts the intermediate fabric layer from the three-layer structure, reducing complexity while maintaining air-seal properties through the direct enclosure of insulation material between the outer fabric layers. The simplified two-layer structure with directly enclosed insulation achieves comparable or superior air-sealing without the complexity of attaching a third layer.
3Quantity of substance
If separate insulation filling processes are used after weaving, then insulation can be added to corrugated channels, but production time and manufacturing cost increase
Solution Approach 1:
The patent applies preliminary action by positioning the insulation material between the fabric layers during the fabric assembly process itself, rather than adding it separately after the channels are formed. This integration of insulation placement into the primary manufacturing process eliminates subsequent filling operations and accelerates production.
Solution Approach 2:
The patent merges the insulation material addition with the fabric layer assembly process. Instead of treating insulation filling as a separate post-weaving operation, the insulation is incorporated during the initial layer assembly, combining multiple manufacturing steps into one efficient process.
4Strength
If stitching is used to attach fabric layers, then the layers can be securely connected, but needle holes create cold bridges that reduce insulation effectiveness
Solution Approach 1:
The patent extracts the stitching operation entirely from the manufacturing process by eliminating the intermediate layer that would require attachment. The outer fabric layers are connected through the enclosed insulation material without needle holes penetrating the insulation barrier, maintaining both structural integrity and thermal performance.
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
This solution provides superior insulation by trapping warm air and preventing cold air infiltration, while being more economical and efficient than traditional methods, with laser welding offering faster production and improved seam quality compared to stitching or adhesive bonding.
Implementation Method 1
laser welding is used to attach the layers without needle holes
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
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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.