Method of fabricating a thermally insulating stretchable down feather sheet and the product therefrom
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Solution Overview
Problem
Existing down feather sheets lack multi-directional stretchability and tend to release down clusters during use or washing, leading to reduced insulation quality and aesthetic issues, especially in applications requiring flexibility and movement.
Innovation Solution
A thermally insulating stretchable down sheet is fabricated by mixing down feathers with elastic binding filaments and glue, then bonding them between multi-directional stretchable elastomeric sheets using a thermal treatment to create a breathable, soft, and lightweight material that prevents down cluster escape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If down feathers are retained in a homogeneous form by chemical binder agent or rigid fibers, then the down feathers are exposed on all sides of the sheet providing uniform insulation distribution, but the down feathers can detach from the faces of the sheet and extra care is necessary to prevent detachment
Solution Approach 1:
The patent combines down feathers with a combination of chemical binder agent and rigid fibers to create a composite structure. The rigid fibers (such as polyester or nylon) provide structural support and mechanical strength to hold down feathers in place, while the chemical binder agent adheres the down feathers to the substrate. This composite approach allows the down feathers to be exposed on all sides for uniform insulation while preventing detachment through the combined mechanical and adhesive holding mechanisms.
2Reliability
If down feathers are held captive between sheets of non-woven fabrics adhered by glue binder, then some escapement of down feathers is prevented, but the material does not provide stretching capability for installation or use in restricted spaces
Solution Approach 1:
The patent modifies the physical and chemical parameters of the binder system by using a multi-component binder composition including rigid fibers, flexible polymers, and chemical adhesives. The rigid fibers provide structural integrity for containment, while the flexible polymer components (such as elastomers or thermoplastic polymers with elastic properties) enable the material to stretch and deform. This parameter modification allows the material to maintain down feather containment while gaining stretching capability for installation in restricted spaces and use with flexible or rigid shaped objects.
3Ease of operation
If rigid down insulating sheets are stretched in areas requiring movement such as underarm or knee areas, then the sheets can be installed, but they tear to form clumps of insulation that gather in specific areas and become visible forming cold spots
Solution Approach 1:
The patent introduces dynamic properties to the down feather sheet by incorporating flexible polymer components and elastomeric materials that allow the structure to deform and recover. The binder system includes materials with elastic memory that enable the sheet to stretch in movement areas (underarm, knee) without permanent deformation or tearing. When stretched, the flexible components redistribute the down feathers uniformly rather than forming clumps, maintaining insulation homogeneity even in high-movement zones. The material can dynamically adapt to body movements while preventing visible clumping and cold spot formation.
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 stretchable, breathable, and durable down feather sheet that maintains insulation quality and aesthetic appearance, suitable for various applications including garments and vehicle enclosures, while allowing for secure attachment to flexible and rigid objects in restricted spaces.
Implementation Method 1
conveyed to a thermal chamber to be subjected to a thermal treatment to bond the down feathers and the binder together
Implementation Method 2
a binder comprised of a mixture of binding strands and glue particles exhibiting binding and elastic properties
Data Source
AI summary
A method of fabricating a thermally insulating stretchable down feather sheet is described. The core of the sheet is comprised of down mixed with a binder mixture which exhibits elastic properties. The binder mixture consists of heat fusible stretchable glue particles and heat fusible elastomeric binding strands in dry form. The core is sandwiched between a bottom and a top stretchable elastomeric sheet having multi-directional stretchability. The core of down and the binder as well as the elastomeric sheet are bound together by heat treatment to provide a down insulating sheet which is stretchable in all directions without fractioning the sheet and which is capable of recovering substantially its original relaxed form after stretching or deformation.