Low-Density Yarn Insulation for Lightweight Winter Apparel
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current insulation materials for winter clothing and applications, such as synthetic fiber clusters and feather-down mixtures, are bulky, heavy, and lack compressibility and water resistance, necessitating a more effective low-density yarn product for temperature regulation and filling purposes.
Innovation Solution
A low-density yarn product is developed, comprising a combination of a straight base yarn and an overfed effect yarn that entangles to form a three-dimensional matrix, which can be chopped into discrete pieces for enhanced insulation properties, and a twisted yarn product with a core yarn, low-density yarn loops, and a binder yarn to create a lightweight, compressible, and insulating structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If synthetic fiber clusters or feather-down mixtures are used for insulation, then insulation coverage is provided, but the materials become bulky and heavy
Solution Approach 1:
The patent applies porous materials by creating a three-dimensional matrix structure from entangled yarn pieces that contains numerous air pockets. This porous structure provides thermal insulation while maintaining low density and weight, directly resolving the contradiction between insulation coverage and weight.
Solution Approach 2:
The patent changes the physical parameters of the insulation material by controlling yarn density, loop size, and matrix porosity. By optimizing these parameters, the material achieves superior insulation performance with significantly reduced weight compared to conventional synthetic fibers or feather-down mixtures.
2Temperature
If synthetic fiber clusters or feather-down mixtures are used for insulation, then insulation coverage is provided, but the materials are bulky
Solution Approach 1:
The three-dimensional matrix structure with controlled porosity provides maximum insulation coverage within minimum volume. The entangled yarn configuration creates efficient air trapping without excessive bulk, directly addressing the contradiction between insulation coverage and volume.
Solution Approach 2:
The patent creates a composite structure combining base yarn, effect yarn, and binder yarn in a specific three-dimensional arrangement. This composite configuration optimizes the insulation-to-volume ratio by integrating multiple functional elements into a compact yet highly effective insulation matrix.
3Quantity of substance
If conventional insulation materials are used, then filling is provided, but they do not compress well into storage bags
Solution Approach 1:
The patent applies dynamics by creating a flexible, adaptable three-dimensional matrix that can dynamically compress under pressure and rebound when released. The entangled yarn structure allows for reversible deformation, enabling excellent compressibility for storage while maintaining filling capacity during use.
Solution Approach 2:
The patent utilizes parameter changes in the yarn loop dimensions and matrix density to achieve variable compressibility. The structure can be compressed to high densities for storage then returns to its original loft for filling applications, directly resolving the contradiction between filling capacity and compressibility.
4Weight of stationary object
If natural down is used for insulation, then lightweight insulation is achieved, but it does not work in wet conditions and is expensive
Solution Approach 1:
The patent employs synthetic yarn materials that are inexpensive, durable, and maintain their insulating properties when wet. This replaces expensive natural down while providing superior reliability in wet conditions, directly addressing the contradiction between weight and water resistance.
Solution Approach 2:
The three-component yarn composite (base yarn, effect yarn, binder yarn) creates a hydrophobic structure that repels water while maintaining lightweight properties. The synthetic material composition ensures water resistance without sacrificing the lightweight advantage of natural down.
5Quantity of substance
If feather-down mixtures are used for filling, then cost reduction is achieved, but feathers escape through fabric enclosure
Solution Approach 1:
The patent uses entirely synthetic yarn materials that eliminate the feather escape problem while maintaining cost-effectiveness. The synthetic composition provides durability and containment without the quill penetration issues of natural feathers, directly resolving the contradiction between cost and feather escape prevention.
6Quantity of substance
If conventional insulation materials are used, then filling is provided, but they do not rebound well after compression
Solution Approach 1:
The patent applies dynamics by creating a resilient three-dimensional matrix with flexible yarn loops that can dynamically respond to compression forces. The structure rebounds efficiently after compression, maintaining filling capacity over time, directly resolving the contradiction between filling capacity and rebound ability.
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 low-density yarn products provide superior insulation by trapping air, maintaining loft after compression, and offering improved water resistance, making them suitable for various applications including winter clothing and furniture filling.
Implementation Method 1
superior insulation by trapping air
Data Source
AI summary
Disclosed are low-density yarn products, articles of manufacture that include such yarn products and methods of making such yarn products. The yarn products may be used for insulation, as for example in apparel or other articles, including building structures or any other application requiring temperature control. The yarn products may be a twisted yarn product that can include a core yarn and a low-density overfeed yarn of large loops protruding from the core and a binder yarn twisted around the core to hold the low-density overfeed yarn of large loops in place on the core yarn.