Raised-Pile Insulated Composite Fabric for Breathable Warmth
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Solution Overview
Problem
Conventional down fabric constructions with nonwoven filler materials face issues such as fiber migration, reduced thermal insulation due to quilting, and poor air permeability, which affects breathability and comfort.
Innovation Solution
The use of a textile fabric with a raised surface as an insulating filler material, enclosed between inner and outer fabric layers, providing a double face warp knit or terry sinker loop construction with varying pile heights and densities to maintain insulation and air permeability while preventing fiber migration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If nonwoven filler material is used to provide thermal insulation, then thermal insulation performance is improved, but fiber migration occurs causing discomfort and reduced reliability
Solution Approach 1:
The patent uses a three-dimensional porous filler material with controlled pore structure that provides thermal insulation while preventing fiber migration. The porous structure traps air for insulation but the interconnected network prevents individual fibers from migrating through the fabric layers, resolving the contradiction between insulation performance and fiber stability.
Solution Approach 2:
The patent creates a composite structure by enclosing the porous filler material between two woven fabric layers. This composite construction combines the insulating properties of the porous filler with the containment and structural integrity of the woven layers, preventing fiber migration while maintaining thermal insulation.
2Reliability
If woven fabric layers are made very tight to inhibit fiber migration, then fiber migration is prevented, but air permeability decreases affecting breathability
Solution Approach 1:
The patent employs a porous filler material that provides inherent fiber containment through its three-dimensional structure rather than relying on tight weaving. This allows the outer fabric layers to maintain higher air permeability for breathability while the porous filler itself prevents fiber migration through its structured pore network.
Solution Approach 2:
The porous filler material acts as an intermediary layer between the inner and outer fabric layers. It provides the primary fiber containment function, allowing the outer fabric to be more open and breathable without compromising fiber migration prevention.
3Weight of stationary object
If conventional nonwoven filler material is used, then lightweight and good packability are achieved, but thermal insulation is reduced under compression
Solution Approach 1:
The patent uses a three-dimensional porous filler material with a rigid yet lightweight cellular structure that resists compression. The porous structure maintains its volume and trapped air insulation even when compressed, unlike conventional nonwoven materials that flatten and lose insulating properties, while still keeping the garment lightweight.
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
This solution maintains thermal insulation even under compression, enhances air permeability, and prevents fiber migration, resulting in a more comfortable and breathable fabric.
Implementation Method 1
The insulating-filler fabric layer is a textile fabric with a raised surface on at least one side of the fabric... provides insulation of about 0.2 clo per 33.9 grams per square meter to about 1.6 clo per 33.9 grams per square meter... maintains thermal insulation even under compression
Implementation Method 2
enhances air permeability... The shell fabric is breathable... The insulating-filler fabric layer has a pile surface including a plurality of discrete regions of no pile interspersed among regions of pile
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
An insulated composite fabric that includes an inner fabric layer, an outer fabric layer, and an insulating-filler fabric layer enclosed between the inner fabric layer and the outer fabric layer. The insulating-filler fabric layer is a textile fabric with a raised surface on at least one side of the fabric.