Breathable Composite With Moveable Baffles For Even Insulation

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Solution Overview

Problem

Articles of apparel with insulating materials often experience uneven thermal insulation due to the movement and uneven distribution of insulators within the material, leading to regions of varying thermal performance.

Innovation Solution

A composite fabric design featuring a first fabric layer with insulating structures that include a fabric shell defining a cavity containing insulating material, where these structures are either attached to the layer or retained by fabric strips, ensuring consistent insulation across the fabric.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If insulating material is used in articles of apparel, then thermal insulation is provided, but the insulator moves and becomes unevenly distributed leading to regions of varying thermal performance

Engineering Contradiction:

Improvethermal insulationVSAvoidevenness of insulator distribution

Core Design Contradiction:

TemperatureVSStability of the object's composition

Solution Approach 1:

The insulating material is divided into multiple discrete insulating structures (puffs or chambers) that are distributed throughout the fabric. Each structure contains a portion of the insulating material in a sealed cavity, preventing migration while maintaining overall insulation. This segmentation transforms the continuous insulating layer into discrete, stable units that cannot move independently.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each insulating structure is enclosed by a fabric shell that forms a sealed cavity. These flexible shells contain the insulating material within each structure, preventing it from moving to other areas. The shells maintain the structural integrity of the insulating material while allowing the overall fabric to remain flexible and breathable.

Inventive Principle:

Principle #30Flexible shells and thin films

2Temperature

If insulating material is used to provide thermal insulation, then warmth is maintained, but the material may restrict breathability

Engineering Contradiction:

Improvethermal insulationVSAvoidbreathability

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The fabric shells enclosing the insulating structures are designed to be breathable while maintaining thermal insulation. The shells allow moisture vapor to pass through while trapping heat, providing both insulation and breathability. The thin film structure creates microclimate zones that manage moisture and temperature simultaneously.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The insulating structures and fabric layers incorporate porous materials that allow moisture vapor transmission while trapping air for insulation. The porous structure enables breathability by allowing water molecules to pass through while maintaining thermal barriers through air pockets, resolving the contradiction between insulation and breathability.

Inventive Principle:

Principle #31Porous materials

3Temperature

If insulating material is distributed throughout the fabric, then thermal insulation is provided, but manufacturing complexity increases

Engineering Contradiction:

Improvethermal insulationVSAvoidmanufacturing complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The insulating material is pre-formed into discrete structures that can be independently manufactured and then assembled into the final fabric. This segmentation allows for simplified manufacturing processes where pre-made insulating units are attached to fabric layers, rather than attempting to distribute and seal continuous insulating material throughout the entire fabric structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple manufacturing steps are merged into integrated processes. The fabric shells are formed and the insulating material is enclosed within them in a single manufacturing operation, rather than separately producing shells and filling them. This merging of operations reduces overall manufacturing complexity while achieving the desired insulating structure.

Inventive Principle:

Principle #5Merging (Combining)

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 design provides a consistent and effective thermal insulation layer by preventing the migration of insulating materials and ensuring even distribution, enhancing the fabric's ability to maintain warmth and allow breathability.

Implementation Method 1

each of the plurality of insulating structures include a fabric shell defining a cavity and an insulating material located within the cavity

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS11279109B2Breathable composite with moveable baffles

Publication Date: 2022.03.22 NORTH FACE APPAREL CORP

AI summary

A composite fabric includes a first fabric layer and a plurality of insulating structures adjacent to the first fabric layer. Each of the plurality of insulating structures include a fabric shell defining a cavity and an insulating material located within the cavity. In further aspects a composite fabric includes a plurality of insulating structures separated by a plurality of spacers. Each of the plurality of spacers includes a fabric material and each of the plurality of insulating structures includes a fabric shell defining a cavity and an insulating material located within the cavity.