Textile Layered Construction With Laser-Welded Joints Against Down Loss
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Solution Overview
Problem
Existing textile constructions for insulation garments suffer from down loss and moisture penetration through traditional quilting seams, compromising thermal insulation and durability.
Innovation Solution
A textile layered construction with laser-welded joints forming chambers filled with insulating material, using an absorber component integrated between or within the layers to create seamless connections that prevent down loss and moisture ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional quilting seams are used to connect layers, then the construction is simple to manufacture, but down loss and moisture penetration occur through the seams
Solution Approach 1:
The patent replaces traditional mechanical sewing connections with laser-welded joints that fuse the outer and inner layers. This substitution eliminates needle puncture holes that cause down loss and moisture penetration, while the laser welding process integrates seamlessly with automated production lines, maintaining manufacturing efficiency despite the advanced joining technique
Solution Approach 2:
The patent utilizes phase transition of thermoplastic materials during laser welding. The laser beam heats the thermoplastic outer layer and absorber component, causing them to melt and fuse together, then cools to form a strong sealed joint. This phase change enables creation of hermetic seals that prevent down and moisture leakage while maintaining material integrity
2Reliability
If laser welding is used to create sealed chambers, then thermal insulation and durability are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent introduces an absorber component as an intermediary element between the outer layer and inner layer. This absorber, made of laser-absorbing material, facilitates the laser welding process by absorbing the laser energy and transferring it to the thermoplastic outer layer, enabling reliable welding without requiring complex laser systems. The absorber acts as a mediator that simplifies the overall welding system while ensuring durable sealed joints
Solution Approach 2:
The patent employs composite material structure combining thermoplastic outer layer, absorber component, and inner layer. This composite construction allows each material to be optimized for its specific function: the thermoplastic provides structural integrity and sealability, the absorber enables efficient laser energy absorption, and the inner layer provides insulation. The synergistic combination of materials simplifies the manufacturing system while achieving high durability
3Temperature
If chambers are filled with insulating material, then thermal insulation is enhanced, but the construction complexity increases
Solution Approach 1:
The patent divides the insulation space into multiple separate chambers formed by laser-welded joints between outer and inner layers. Each chamber can be independently filled with insulating material, allowing for optimized insulation distribution and easier manufacturing. The segmented structure maintains simplicity by using repetitive modular units rather than complex continuous insulation systems
Solution Approach 2:
The patent implements a nested structure where the absorber component is positioned between the outer layer and inner layer, with insulating material filling the chamber formed by these nested layers. This nested arrangement consolidates multiple functional elements (outer layer, absorber, insulator, inner layer) into a compact integrated unit, reducing overall construction complexity while maximizing thermal insulation performance
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 insulation and durability by preventing down loss and moisture penetration, allowing for customizable insulation distribution and improved design flexibility.
Implementation Method 1
an absorbent component within the textile layered construction, whereby the line-shaped connections between the outer layer, the inner layer and the absorber are designed as a laser welded joint
Implementation Method 2
the line-shaped connections between the outer layer, the inner layer and the absorber are designed as a laser welded joint
Implementation Method 3
chambers fillable with insulating material are formed between the welded joints
Implementation Method 4
chambers fillable with insulating material
Data Source
AI summary
A textile layered construction has a textile outer layer, a textile inner layer and an absorbing component, whereby line-shaped connections between the outer layer and the inner layer are designed as a laser welded joint, forming chambers fillable with insulating material between the welded joints. At least one line-shaped welded joint connection includes an interruption separating the line-shaped welded joint connection into two line-shaped welded joint connection parts.