Multi-layered Composite Material for Breathable Thermal Insulation
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Solution Overview
Problem
Current technical clothing and footwear materials that are impermeable for various climatic conditions lack breathability, leading to humidity accumulation and reduced comfort, while breathable materials often compromise thermal insulation.
Innovation Solution
A multi-layered composite material comprising an impermeable layer and an open-cell polyurethane foam insulating layer, with the insulating layer positioned inside to facilitate vapor transfer and maintain thermal insulation, utilizing a water-based polyurethane foam with specific density and hydrophilic properties to optimize breathability and prevent humidity stagnation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If impermeable materials (neoprene, expanded PTFE, elastomeric foams) are used to prevent water penetration and provide thermal insulation, then water impermeability and thermal insulation are improved, but breathability deteriorates leading to humidity accumulation
Solution Approach 1:
The material is divided into multiple functional layers: an outer impermeable layer for water protection, an intermediate breathable membrane for vapor transmission, and an inner insulating layer for thermal insulation. Each layer performs its specific function without compromising the others, resolving the contradiction between impermeability and breathability.
Solution Approach 2:
The invention uses a composite structure combining different materials with complementary properties: hydrophobic expanded PTFE for water impermeability, hydrophilic elastomeric foam for breathability and vapor transport, and aerogel or vacuum insulation for thermal insulation. The composite nature allows simultaneous achievement of impermeability and breathability.
2Temperature
If impermeable materials are used to provide thermal insulation, then thermal insulation is improved, but breathability deteriorates causing vapor accumulation and discomfort
Solution Approach 1:
Thermal insulation and breathability functions are separated into different layers. The insulating layer (aerogel or vacuum) provides thermal protection while the breathable membrane layer handles vapor transmission. This segmentation allows both functions to perform optimally without interfering with each other.
Solution Approach 2:
The composite combines materials with different primary functions: aerogel or vacuum for superior thermal insulation, and hydrophilic elastomeric foam or breathable membrane for vapor permeability. The combination achieves both thermal protection and breathability simultaneously.
3Ease of operation
If breathable materials are used to allow vapor discharge, then breathability is improved, but thermal insulation deteriorates
Solution Approach 1:
The breathable function is assigned to a specific membrane layer while a separate insulating layer provides thermal protection. This functional segmentation allows the breathable layer to perform vapor transport without compromising overall thermal insulation, as the insulation is provided by the dedicated insulating layer.
Solution Approach 2:
The composite structure pairs breathable materials (breathable membrane, hydrophilic foam) with high-performance insulating materials (aerogel, vacuum). The breathable layer enables vapor discharge while the insulating layer maintains thermal performance, resolving the trade-off between breathability and insulation.
4Reliability
If multi-layered composite materials are constructed to achieve both impermeability and breathability, then functional performance is improved, but device complexity increases
Solution Approach 1:
Multiple functions (water impermeability, breathability, thermal insulation) are merged into a single integrated composite material structure. The layers are bonded together to form one cohesive material that performs all functions simultaneously, reducing the need for separate components and simplifying the overall system.
Solution Approach 2:
The invention creates a unified composite material where different functional layers are combined into one integrated structure. This composite approach achieves multiple functions in a single material system rather than requiring separate components, balancing performance improvement with manageable complexity.
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 material achieves excellent breathability and thermal insulation, preventing humidity accumulation and maintaining user comfort while allowing efficient vapor transpiration, even when coupled with other layers, thus addressing the limitations of existing impermeable and breathable materials.
Implementation Method 1
said impermeable layer and said insulating layer are breathable in order to allow the passage of water vapour through them
Implementation Method 2
said insulating layer is produced from open-cell polyurethane foam having a density between 200 and 500 kg/m3
Implementation Method 3
an impermeable layer which is capable of preventing the penetration of water
Implementation Method 4
an insulating layer which is associated with said impermeable layer in order to thermally insulate the multi-layered material
Data Source
Figure 1~2
AI summary
A multi-layered composite material (100) comprises an impermeable layer (1) which is capable of preventing the penetration of water, an insulating layer (2) which is associated with said impermeable layer (1) in order to thermally insulate the multi-layered material (100), wherein said impermeable layer (1) and the insulating layer (2) are breathable in order to allow the passage of water vapour through them and the discharge of water vapour from the multi-layered composite material (100) and wherein the insulating layer (2) is produced from open-cell polyurethane foam having a density between 200 and 500 kg/m3, preferably approximately of 300 kg/m3.