Stretchable Down Feather Sheet With Breathable Insulation
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Solution Overview
Problem
Existing down feather sheets lack multi-directional stretchability and breathability, leading to issues such as feather escape, tearing, and the formation of cold spots in garments, and are not suitable for applications requiring flexibility and secure attachment to various shapes and spaces.
Innovation Solution
A thermally insulating down feather sheet is created by mixing down feathers with an elastic binder and binding them with multi-directional stretchable elastomeric sheets, using a process that involves thermal treatment to trap the feathers and binder, ensuring the sheet can stretch and recover its original form without fracturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If down feathers are exposed on all sides of the sheet, then thermal insulation is improved, but down feathers detach from the faces of the sheet
Solution Approach 1:
The down feathers are nested within a three-dimensional matrix formed by rigid fibers and chemical binder agents. The rigid fibers create a cage-like structure that encapsulates the down feathers, preventing them from detaching while maintaining their exposed configuration for thermal insulation.
Solution Approach 2:
The invention uses a composite structure combining down feathers with rigid fibers (such as polyester) and chemical binder agents. This composite material integrates the insulating properties of down feathers with the structural integrity of rigid fibers, solving both insulation and detachment problems simultaneously.
2Object-generated harmful factors
If non-woven fabrics with glue binder are used to hold down feathers captive, then feather escape is prevented, but the material cannot be stretched
Solution Approach 1:
The invention replaces static glue binders with dynamic elastic filaments that can stretch and recover. These elastic filaments maintain the captive structure of down feathers while providing the necessary stretchability for the material to adapt to various shapes and movements in apparel applications.
Solution Approach 2:
The invention changes the physical parameters of the binding material from rigid glue to elastic filaments with specific elongation properties. This parameter change enables the material to transition from a fixed, non-stretchable state to a dynamic, stretchable state that maintains feather containment while providing versatility.
3Adaptability or versatility
If rigid down insulating sheets are stretched, then attachment to various shapes is achieved, but the sheets tear and form clumps
Solution Approach 1:
The invention uses flexible elastic filaments and stretchable elastomeric sheets as the binding and containment structure. These flexible components can deform and stretch without tearing, allowing the down feather sheet to attach to various shapes while maintaining structural integrity and preventing clump formation.
Solution Approach 2:
The elastic filaments act as intermediaries between the down feathers and the external forces applied during stretching. These filaments absorb and distribute the stress, preventing direct stress concentration on the down feather clusters that would cause tearing and clumping.
4Object-generated harmful factors
If down feathers are held captive between sheets with glue binder, then feather containment is improved, but breathability is reduced
Solution Approach 1:
The invention uses porous stretchable elastomeric sheets with open-cell structures that allow air and moisture vapor to pass through. These porous materials maintain effective feather containment while preserving breathability, allowing the insulation layer to regulate moisture and air flow for comfort in apparel applications.
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 resulting sheet is breathable, soft, lightweight, and prevents feather escape, offering improved thermal insulation and flexibility for diverse applications, including garments and vehicle enclosures, while maintaining insulation integrity during stretching and deformation.
Implementation Method 1
a binder exhibiting elastic properties mixed together with the down feathers in predetermined proportions to form a stretchable down feather core
Implementation Method 2
subjected to a thermal treatment to trap and bond the down feathers and the binder together and to the elastomeric sheet
Implementation Method 3
thermally insulating down feather sheet and particularly to one that has multi-directional stretchability
Data Source
AI summary
A thermally insulating stretchable down feather sheet and its method of manufacture is described. The core of the sheet is comprised of down feathers mixed with a binder which exhibits elastic properties. The core is sandwiched between a top and bottom stretchable elastomeric sheet having multi-directional stretchability. The core down feathers and the binder as well as the elastomeric sheet and bound together by heat treatment to provide a down feather insulating sheet which is stretchable in all directions without fractioning the sheet.