Engineered Thermal Fabric With Body-Mapped Insulation and Fewer Seams
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Solution Overview
Problem
Existing thermal fabric articles require multiple layers to achieve varying levels of insulation, which add bulk, impair mobility, and are costly due to numerous seams, while also being uncomfortable and prone to seam failure.
Innovation Solution
A single-layer engineered thermal fabric with discrete regions of contrasting insulative capacity is created by designing a pattern of loop yarns and incorporating smart yarns or fibers, such as phase change materials or ceramic-embedded fibers, to provide tailored insulation without the need for multiple layers, reducing seams and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple layers of fabric are used to achieve varying levels of insulation, then thermal insulation performance is improved, but device complexity and number of seams increase
Solution Approach 1:
The fabric is segmented into multiple functional layers at the fiber level rather than requiring multiple separate fabric layers. Each fiber contains multiple polymer phases with different thermal properties, allowing varying insulation levels within a single fabric layer through localized fiber composition changes
Solution Approach 2:
The invention uses composite fibers containing multiple polymer phases (e.g., thermoplastic and thermosetting polymers) with different thermal conductivities. These composite fibers are arranged in patterns to create regions of contrasting insulative capacity, eliminating the need for multiple separate fabric layers while achieving the desired thermal gradient
2Temperature
If multiple layers of fabric are used to provide tailored insulation, then thermal performance is improved, but weight and bulk increase
Solution Approach 1:
The fabric provides locally differentiated thermal insulation by varying the composition and structure of fibers in specific regions. High-insulation regions contain fibers with higher proportions of thermoplastic polymer phases, while low-insulation regions use fibers with more thermosetting polymer phases, achieving tailored insulation without adding overall weight or bulk
3Temperature
If numerous seams are used to join multiple fabric layers, then thermal insulation is improved, but manufacturing cost increases
Solution Approach 1:
The invention merges multiple insulation functions into a single fabric layer by incorporating multi-phase composite fibers with varying thermal properties throughout the fabric structure. This eliminates the need to join multiple separate fabric layers with seams, significantly reducing manufacturing complexity and cost while maintaining the thermal insulation performance
4Temperature
If numerous seams are used to join fabric layers, then thermal insulation is improved, but reliability decreases due to seam failure
Solution Approach 1:
The invention eliminates seams by providing tailored insulation through a single continuous fabric layer containing composite fibers with different thermal properties. Without seams to join multiple layers, the risk of seam failure and discomfort is completely eliminated while maintaining the desired thermal insulation performance through fiber-level material differentiation
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 allows for effective insulation and comfort by tailoring thermal performance to specific body regions, reducing bulk, improving mobility, and minimizing seam-related issues, while enabling intricate patterns for customized warmth and breathability.
Implementation Method 1
forming loop yarn to a first pile height, the one or more first discrete regions corresponding to one or more regions of the user's body having first insulative requirements, and in one or more other discrete regions of said fabric element, forming loop yarn to a second pile height different from and relatively greater than the first pile height
Implementation Method 2
incorporating a smart yarn and/or smart fiber into the web... The smart yarn and/or smart fiber comprises a phase change material
Implementation Method 3
The smart yarn and/or smart fiber comprises a ceramic or a synthetic material embedded with ceramic particles, e.g. zirconium carbide
Data Source
AI summary
Methods are described for forming unitary fabric elements for use in engineered thermal fabric articles, including, but not limited to, thermal fabric garments, thermal fabric home textiles, and thermal fabric upholstery covers, and for forming these engineered thermal fabric articles, having predetermined discrete regions of contrasting insulative capacity positioned about the thermal fabric article in correlation to insulative requirements of a user's body.