Stretchable Down Feather Insulation Sheet Using Thermoplastic Binder
Find Innovative SolutionsGenerate Solutions
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 stretchable elastomeric sheets, allowing for multi-directional stretching and breathability, while preventing feather escape through a combination of elastic glue and polymer filaments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If down feathers are retained in a homogeneous form by a chemical binder agent or rigid fibers, then the down feathers are held captive in the sheet, but the sheet loses stretchability and becomes rigid
Solution Approach 1:
The patent changes the physical-chemical parameters of the binder by using thermoplastic polymers that transition from solid to molten state with temperature changes. During manufacturing, the binder is in molten state to allow feather embedding, then cooled to solidify and retain feathers. This parameter change enables both feather retention and subsequent stretchability when heated above the melting point.
Solution Approach 2:
The invention creates a composite material system combining down feathers with thermoplastic polymer binders (such as polyethylene, polypropylene, or polyester). This composite structure provides both the binding function to hold feathers and the thermal-responsive mechanical properties enabling stretchability when the polymer is heated above its melting point.
2Adaptability or versatility
If rigid down insulating sheets are stretched, then they can be attached to various shapes, but the sheets tear to form clumps of insulation that gather and become visible
Solution Approach 1:
The patent applies thermal parameter changes to transform the mechanical properties of the down feather sheet. When heated above the melting point of the thermoplastic binder, the sheet becomes pliable and stretchable, allowing attachment to various shapes without tearing. The binder re-solidifies upon cooling, maintaining insulation integrity.
Solution Approach 2:
The invention introduces dynamic mechanical properties to the down feather sheet through the thermoplastic binder. The sheet transitions from a rigid state at room temperature to a flexible, stretchable state when heated, enabling adaptive attachment to different geometries while maintaining structural integrity through the reversible phase transition.
3Reliability
If down feathers are exposed on all sides of the sheet, then the sheet provides superior insulation, but extra care is necessary to prevent down feathers from detaching
Solution Approach 1:
The patent utilizes temperature parameter changes to control the binding state of the thermoplastic polymer. During manufacturing, the binder is heated to molten state for easy feather incorporation, then cooled to solidify and firmly attach feathers to the sheet surface, preventing detachment while maintaining insulation performance.
4Stability of the object's composition
If non-woven fabrics with glue binder are used to hold down feathers captive, then feather escape is prevented, but the material does not provide stretching capability for installation in restricted spaces
Solution Approach 1:
The invention replaces permanent glue binders with thermoplastic polymer binders that undergo reversible phase transitions. The binder maintains feather containment through solid-state binding at room temperature but enables stretching when heated above the melting point, providing both containment and installation flexibility.
Solution Approach 2:
The patent introduces dynamic mechanical behavior to the down feather sheet through thermoplastic binders. The material transitions from a rigid, containment-focused state to a flexible, stretchable state through thermal activation, enabling installation in restricted spaces while maintaining feather containment after cooling.
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 solution provides a soft, lightweight, and breathable down feather sheet that maintains insulation integrity during stretching, preventing feather escape and ensuring uniform thermal insulation across various applications, including garments and vehicle enclosures.
Implementation Method 1
a binder exhibiting elastic properties and mixed together with the down feathers in predetermined proportions to form a stretchable down feather core
Implementation Method 2
conveyed to a thermal chamber to be subjected to a thermal treatment to trap and bond the down feathers and the binder together and to the elastomeric sheet
Data Source
Figure 1A~4
Figure 2~3
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.