Three-Layer Insulation Fabric With Laser-Sealed Bundle Channels
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Solution Overview
Problem
Existing thermal insulation materials for garments, such as those described in U.S. Pat. No. 2,607,104 and GB 1,390,609, lack a third intermediate fabric layer to enhance air-seal properties and are economically inefficient due to labor-intensive stitching and separate insulation filling processes, while U.S. Pat. No. 3,805,720 and WO 2014/190319 A1 suggest additional insulation layers but do not provide practical methods for integration.
Innovation Solution
A 3-fabric layer thermal insulation material with a corrugated middle layer, where continuous fiber slivers float in bundle channels between fabric layers, and laser welding is used to attach the layers without needle holes, allowing for direct integration of insulation during the manufacturing process, enhancing insulation efficiency and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional quilting methods with stitching are used to attach insulation layers, then the insulation material can be secured between fabric layers, but needle holes create cold bridges that reduce insulation efficiency
Solution Approach 1:
The patent replaces the mechanical stitching system with a laser welding system. Instead of using needles and threads that create holes through the fabric layers, laser welding uses electromagnetic energy to melt and fuse the thermoplastic fabric layers together at the seams, sealing the insulation channels without creating penetrating holes that would allow cold air penetration.
Solution Approach 2:
The laser welding process utilizes phase transitions of the thermoplastic fabric material. The laser energy heats the fabric layers to their melting point, causing them to transition from solid to molten state, then upon cooling they fuse together, creating a sealed bond that maintains the insulation channel integrity without needle holes.
2Reliability
If a third intermediate fabric layer is added to enhance air-seal properties, then insulation efficiency improves, but manufacturing complexity and production costs increase
Solution Approach 1:
The patent combines multiple functions into the intermediate fabric layer. This layer not only provides additional air-sealing capability but also serves as a structural component that maintains channel geometry and as a bonding surface for laser welding to the outer fabric layers, thereby reducing overall manufacturing complexity despite the additional layer.
Solution Approach 2:
The intermediate fabric layer is made from thermoplastic material that can be laser-welded to the outer fabric layers. This creates a composite structure where all three layers are bonded together through laser welding, forming an integrated assembly that seals the insulation channels effectively while maintaining manufacturability.
3Stability of the object's composition
If insulation material is attached to fabric layers using stitching, then insulation is secured in place, but the stitching process creates needle holes that compromise thermal insulation
Solution Approach 1:
The patent replaces the mechanical stitching system with a laser welding system. Instead of using needles and threads that create holes through the fabric layers, laser welding uses electromagnetic energy to melt and fuse the thermoplastic fabric layers together at the seams, sealing the insulation channels without creating penetrating holes that would allow cold air penetration.
4Quantity of substance
If separate insulation filling process is used after weaving and shrinking, then insulation can be added to corrugated channels, but production time and manufacturing costs increase
Solution Approach 1:
The patent performs the insulation filling action during the laser welding process itself. The laser welding head is equipped with a mechanism that feeds insulation material into the corrugated channels as the welding progresses, so the insulation is placed beforehand rather than in a separate subsequent operation, thereby reducing total production time.
Solution Approach 2:
The patent combines multiple functions into the intermediate fabric layer. This layer not only provides additional air-sealing capability but also serves as a structural component that maintains channel geometry and as a bonding surface for laser welding to the outer fabric layers, thereby reducing overall manufacturing complexity despite the additional layer.
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 3-fabric layer design with laser-welded seams provides superior insulation by preventing air leakage and cold bridges, increasing production efficiency and reducing costs compared to traditional quilting methods.
Implementation Method 1
laser welding is used to attach the layers without needle holes
Implementation Method 2
Insulation is not attached to fabric but is floating in bundle channels merely by friction between insulation and fabric walls
Data Source
AI summary
This invention describes a 3-layer insulation material comprising a first fabric layer, a second fabric layer and a third fluted intermediate fabric layer between the first and the second fabric layers, the fluted intermediate fabric layer being attached alternately to the first and the second fabric layer with longitudinal seams forming longitudinal channels for the insulation material having individual insulation material bundle inside each longitudinal channel. Also disclosed are a method and an arrangement for producing the same.