Thermal insulating structure
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Solution Overview
Problem
Existing thermal insulating materials, such as those using synthetic fibers and down feathers, fail to provide adequate thermal and lightweight properties, especially in textiles with baffles, and are prone to clumping and moisture issues.
Innovation Solution
A thermal insulating structure comprising a baffle box with natural and/or synthetic down fibers and low-melt fibers, where the low-melt fibers are melted onto the down fibers within the baffle box, creating a 3D structure that traps air molecules and provides improved insulation, flexibility, and dry compression recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If synthetic fibers and down feathers are used for thermal insulation in baffles, then thermal insulation is provided, but the material is prone to clumping and moisture absorption
Solution Approach 1:
The patent combines down feathers with hydrophobic coating materials to create a composite insulating material. The hydrophobic coating forms a protective layer on the down feathers, preventing moisture absorption while maintaining the thermal insulation properties of the down cluster structure.
2Weight of moving object
If down feathers are used for insulation, then lightweight and high thermal properties are achieved, but the material loses loft and thermal properties when wet
Solution Approach 1:
The patent applies a hydrophobic coating to the down feathers, changing the surface properties of the material. This parameter change makes the down feathers water-repellent, allowing them to maintain their loft and thermal properties even in damp conditions while retaining their lightweight characteristics.
3Ease of manufacture
If conventional synthetic fiber insulation is used in baffles, then manufacturing is simplified, but thermal and lightweight properties do not meet acceptance levels
Solution Approach 1:
The patent creates a composite material by coating down feathers with hydrophobic materials, combining the superior thermal insulation and lightweight properties of down with the moisture resistance and ease of manufacturing characteristics of synthetic materials. This allows conventional baffle manufacturing methods to be used while achieving superior thermal performance.
4Temperature
If down feathers are used for insulation, then high thermal properties are achieved, but the material absorbs and retains odors
Solution Approach 1:
The hydrophobic coating creates a barrier layer on the down feathers that prevents odor-causing substances from penetrating into the down cluster. This composite structure maintains the thermal insulation properties of down while eliminating its tendency to absorb and retain odors.
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 offers enhanced thermal insulation, flexibility, and reduced moisture absorption, allowing for customized baffle designs and faster manufacturing cycles while maintaining lightweight properties.
Implementation Method 1
the low-melt fibers have been melted to the natural and/or synthetic down fibers by heating inside the baffle box
Implementation Method 2
the low-melt fibers have been melted to the natural and/or synthetic down fibers by heating inside the baffle box
Implementation Method 3
The loose structure of down feathers traps air, which helps to insulate a wearer against heat loss
Data Source
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AI summary
The present invention relates to a thermal insulating structure comprising at least one baffle, an article of wear and a sleeping bag comprising such a thermal insulating structure and to a method for manufacturing such a thermal insulating structure. In one embodiment, the baffle comprises a plurality of natural and / or synthetic down fibers and a plurality of low-melt fibers, wherein the low-melt fibers have been melted to the natural and / or synthetic down fibers by heating inside the baffle.