Multi-Zone Thermal Apparel With Low-Moisture Outer Layers

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Solution Overview

Problem

Existing thermoregulatory apparel does not effectively address the need for varying thermal regulation across different body areas, leading to suboptimal performance in managing body temperature during physical activity.

Innovation Solution

Articles of clothing with multiple thermal zones, comprising a first thermal zone with a low moisture regain outer layer and a knitted inner liner, and a second thermal zone with a knitted fabric layer, designed to provide differential thermal comfort and moisture management through engineered compression and ventilation zones.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If existing thermoregulatory apparel uses uniform thermal regulation panels throughout, then manufacturing is simplified, but thermal comfort and performance are suboptimal due to inability to address varying thermal needs across different body areas

Engineering Contradiction:

Improvethermal regulation adaptabilityVSAvoidapparel structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The apparel is divided into multiple thermal zones (first thermal zone with outer layer and second thermal zone without outer layer) that can be strategically positioned on different body areas. This segmentation allows each zone to provide appropriate thermal regulation for its specific location, addressing the varying thermal needs of different body regions while maintaining a relatively simple overall structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different thermal zones are assigned to different body areas based on their specific thermal requirements. The first thermal zone with outer layer is placed on areas needing higher thermal comfort, while the second thermal zone is placed on areas with different thermal needs. This local quality approach optimizes thermal regulation performance for each specific body region.

Inventive Principle:

Principle #3Local quality

2Reliability

If thermoregulatory apparel uses multiple layers and zones for optimized thermal comfort, then thermal regulation performance is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvethermal regulation effectivenessVSAvoidapparel manufacturing ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The apparel structure is segmented into modular thermal zones that can be independently manufactured and then assembled. The outer layer with heat retention panels is manufactured separately and attached to specific zones, allowing for standardized production processes while achieving complex thermal regulation functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The apparel combines different material layers (outer layer with heat retention panels, inner layers) to create composite structures that provide enhanced thermal regulation. These composite materials and layered structures are integrated into specific thermal zones, achieving reliable thermal performance while allowing for efficient manufacturing through modular assembly.

Inventive Principle:

Principle #40Composite materials

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

Enhances thermal regulation by providing higher thermal comfort and moisture control in exposed areas, improving performance and comfort during physical activity by optimizing temperature and moisture management across different body regions.

Implementation Method 1

The outer fabric layer is an outer composite fabric layer that comprises a knitted face layer, a knitted back layer, and at least one middle layer having a low moisture regain fused between the knitted face layer and the knitted back layer

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

The knitted face layer of the outer composite fabric layer comprises a durable water repellency (DWR) additive finishing

Methodology Applied

Scientific EffectHydrophobe: Hydrophobe

Implementation Method 3

thermoregulatory apparel includes panels which enhance the skin's ability to dissipate or retain heat as necessary to maintain a constant body temperature

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 4

Heat dissipation panels increase the skin's ability to evaporate perspiration by wicking moisture (i.e., perspiration) away from the skin

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20250325058A1Article of apparel having multiple thermal regulatory zones

Publication Date: 2025.10.23 LULULEMON ATHLETICA CANADA INC

AI summary

Examples of an article of apparel with two or more thermal zones are described. The article of apparel comprises at least one first thermal zone and at least one second thermal zone. The at least one first thermal zone comprises an outer fabric layer having a low moisture regain and a knitted inner liner positioned underneath and separated from the outer fabric layer so that the knitted inner liner is facing a wearer when worn. The at least one second thermal zone comprises a knitted fabric layer with an inner side facing the wearer being brushed. The at least one first thermal zone is positioned in a part of the article of apparel significantly exposed to the elements and configured to provide higher thermal comfort to the wearer than the at least one second thermal zone.