Functional Fabric with Porous Silica Insulation Coating

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Solution Overview

Problem

Existing insulation fabrics using heating fibers face limitations in functionality, such as requiring physical activity for moisture-absorption heating and exposure to strong light for photo-heating, and hollow fibers may lose their insulation structure during processing, leading to thickness control issues.

Innovation Solution

A functional fabric with an insulation flexible sheet formed by a base fabric layer and an insulation coating layer using a soft resin and silica particles, which includes a functional coating layer for additional features like UV blocking and water repellency, maintaining flexibility and durability after washing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If hollow fibers are used to achieve insulation effects, then insulation performance is improved, but the hollow shapes may be lost during processing and thickness control is limited

Engineering Contradiction:

Improveinsulation performanceVSAvoidthickness control

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The patent uses porous silica particles instead of hollow fibers to maintain insulation performance. The porous structure of silica particles preserves air pockets for thermal insulation while being more dimensionally stable during processing, allowing better thickness control in the final fabric product.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent creates a composite structure by combining silica particles with a resin matrix to form an insulation coating layer. This composite approach maintains the insulation properties of the porous silica while the resin provides structural integrity and dimensional stability during processing.

Inventive Principle:

Principle #40Composite materials

2Temperature

If heating fibers are used to provide heating function, then insulation effect is improved, but the fabric may not show functionality under certain conditions such as low physical activity or weak light

Engineering Contradiction:

Improveheating effectVSAvoidfunctionality under various conditions

Core Design Contradiction:

TemperatureVSAdaptability or versatility

Solution Approach 1:

The porous silica particles provide passive thermal insulation without requiring external energy input or specific environmental conditions. The insulation effect is inherent to the material structure and operates continuously regardless of physical activity level or light intensity, eliminating the conditional limitations of active heating fibers.

Inventive Principle:

Principle #25Self-service

3Temperature

If insulation coating layer is formed with silica particles, then insulation performance and strength are improved, but flexibility may be reduced

Engineering Contradiction:

Improveinsulation performanceVSAvoidflexibility

Core Design Contradiction:

TemperatureVSEase of operation

Solution Approach 1:

The patent optimizes the particle size of silica to maintain flexibility while providing insulation. By controlling the size and distribution parameters of the silica particles within the resin matrix, the coating layer achieves both insulation performance and fabric flexibility.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The insulation coating layer is applied as a thin film structure on the fabric surface. This thin film approach with embedded silica particles provides insulation while maintaining the flexibility and drape of the underlying fabric, avoiding the rigidity that would result from thick insulation layers.

Inventive Principle:

Principle #30Flexible shells and thin films

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 effective insulation performance with excellent strength and flexibility, maintaining functionality and durability even after washing, while allowing for control of thickness and additional functional properties.

Implementation Method 1

a porous insulating coating layer which has a porous structure and includes porous silica particles

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

fibers having a hollow structure forming an insulation air space

Methodology Applied

Scientific EffectAir space insulation: Thermal Insulation

Data Source

PatentUS11338560B2Functional fabric and manufacturing method therefor

Publication Date: 2022.05.24 SUKGYUNG AT

AI summary

Provided is a functional fabric including a base fabric layer; and an insulation flexible sheet attached to at least one surface of the base fabric layer. The insulation flexible sheet includes a first flexible base; and an insulation coating layer attached to at least one surface of the base. The insulation flexible sheet may additionally include a second flexible base on the insulation coating layer. Accordingly, the functional fabric may have effective insulation properties by using silica particles having pores in a small amount used, and may have excellent strength due to the strength of the silica particles. In addition, Manufacturing methods of an insulation flexible sheet and a functional fabric are provided.