Grooved Composite Wetsuit Inserts for Flexible Thermal Protection

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Solution Overview

Problem

Existing neoprene diving wetsuits face challenges in providing adequate thermal protection without compromising flexibility and ergonomics, and custom molds for composite suits make mass production difficult and expensive.

Innovation Solution

A grooved 'chocolate bar' shaped composite material with symmetric arrays of trapezoidal teeth and grooves is cast into standardized molds, allowing for flexible thermal insulation that adapts to body curvatures, reducing manufacturing complexity and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If thicker neoprene is used to provide thermal protection, then thermal insulation is improved, but flexibility and ergonomics deteriorate

Engineering Contradiction:

Improvethermal protectionVSAvoidflexibility

Core Design Contradiction:

TemperatureVSEase of operation

Solution Approach 1:

The wetsuit is divided into multiple segments with different thicknesses (e.g., 7mm chest, 6mm limbs) to provide thermal protection where needed while maintaining flexibility in areas requiring movement. This segmentation allows the suit to offer thermal insulation without uniformly compromising flexibility across the entire body.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the wetsuit have different neoprene thicknesses tailored to local thermal requirements and movement needs. High-movement areas use thinner material while high-thermal-loss areas use thicker material, optimizing both thermal protection and flexibility locally rather than uniformly.

Inventive Principle:

Principle #3Local quality

2Temperature

If thicker neoprene is used to provide thermal protection, then thermal insulation is improved, but device complexity increases due to ballast requirements

Engineering Contradiction:

Improvethermal protectionVSAvoidballast management

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The wetsuit incorporates buoyancy compensation features that counteract the positive buoyancy of thick neoprene, reducing the need for external ballast. This integration of counterbalancing elements within the suit structure itself simplifies the overall ballast management system and reduces diver workload.

Inventive Principle:

Principle #8Anti-weight (Counterweight)

3Temperature

If air bubbles are used to provide thermal insulation, then thermal protection is improved, but reliability deteriorates at depth due to bubble shrinkage

Engineering Contradiction:

Improvethermal insulationVSAvoidthermal protection at depth

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The neoprene is formulated as a composite material with specific bubble size distributions and wall thicknesses that maintain thermal insulation properties under pressure. The composite structure includes interconnected air cells with optimized geometry to resist compression and maintain insulative properties at depth.

Inventive Principle:

Principle #40Composite materials

4Temperature

If custom 3D-printed molds are used to create flexible composite suits, then thermal protection and flexibility are improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvethermal protectionVSAvoidmanufacturing complexity

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The design uses universal mold patterns that can accommodate various body sizes and shapes through adjustable positioning systems and modular composite panels. This allows a single mold design to serve multiple customer configurations, reducing the need for extensive custom mold fabrication while maintaining personalized fit and thermal performance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 grooved composite material provides superior thermal protection and flexibility compared to conventional suits, with improved ergonomics and manufacturability, allowing for mass production and customization to fit various divers.

Implementation Method 1

The composite was made of hollow glass microspheres embedded in thermally cured silicone

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

The composite effective density was ~500 kg/m3. The positive buoyancy meant the diver needed to compensate for it by increasing the carried load of ballast

Methodology Applied

Scientific EffectBuoyancy: Archimedes' Principle (Buoyancy)

Implementation Method 3

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 4

The microscopic air bubbles in the neoprene make it flexible and thermally resistive, as air is a good thermal insulator

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 5

Thicker neoprene is also more positively buoyant, which requires divers to add more ballast to compensate for it

Methodology Applied

Scientific EffectBuoyancy: Archimedes' Principle (Buoyancy)

Data Source

PatentUS12433352B2Thermally protective composite articles, and associated methods and wetsuits

Publication Date: 2025.10.07 THE GOVERNMENT OF THE UNITED STATES OF AMERICA AS REPRESENTED BY THE SECRETARY DEPARTMENT OF HEALTH & HUMAN SERVICES

AI summary

A flexible, thermally-insulating composite article includes: a base layer; a plurality of teeth extending from the base layer; and grooves extending between the teeth to enable the teeth to converge. The composite article may be in the form of a pad insertable into a pocket associated with a wetsuit.