Thermal insulating structure
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Solution Overview
Problem
Existing thermal insulating materials, particularly those with synthetic fibers and down feathers, fail to provide adequate thermal and lightweight properties, especially in textiles with baffles, and are compromised by moisture, leading to clumping and loss of insulation.
Innovation Solution
A thermal insulating structure comprising baffles with natural and synthetic down fibers and low-melt fibers, where the low-melt fibers are melted and bonded to the down fibers within the baffle, creating a 3D structure that enhances insulation and prevents clumping, while allowing for varied baffle designs and improved dry compression recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If down feathers are used for thermal insulation, then thermal properties and lightweight properties are improved, but moisture causes clumping and eliminates thermal properties
Solution Approach 1:
The patent copies the thermal insulation mechanism of down feathers by using synthetic fibers with similar loose, airy structure that trap air, achieving comparable thermal properties without the moisture sensitivity of natural down
Solution Approach 2:
The patent creates a composite material system combining synthetic base fibers with low-melt binder fibers, where the binder holds the loose fiber structure together while maintaining air-trapping capabilities for thermal insulation without moisture sensitivity
2Reliability
If synthetic fibers are used to mimic down feathers, then moisture resistance is improved, but thermal and lightweight properties are compromised
Solution Approach 1:
The patent optimizes fiber parameters including using ultra-fine synthetic fibers with specific diameter ranges and controlling fiber length, crimp, and distribution to achieve down-like thermal insulation properties while maintaining synthetic moisture resistance
Solution Approach 2:
The patent creates a porous, loose fiber structure within the baffle that traps air pockets, providing thermal insulation comparable to down while maintaining the moisture resistance of synthetic materials
3Stability of the object's composition
If low-melt binder fibers are used to secure down fibers, then structural stability is improved, but thermal and lightweight properties are reduced
Solution Approach 1:
The patent applies low-melt binder fibers selectively at specific locations within the baffle structure where structural support is needed, rather than uniformly throughout, preserving thermal insulation properties in the bulk fiber regions while providing localized stability
Solution Approach 2:
The patent utilizes the phase transition of low-melt binder fibers from solid to liquid during controlled heating, allowing the fibers to flow and bond the loose fiber structure together, then solidifies upon cooling to create a stable structure without adding significant weight or reducing thermal properties
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 superior thermal insulation per weight, improved dry compression recovery, and flexibility in baffle design, ensuring the structure remains effective even when wet and maintains loft, offering enhanced thermal performance and lightweight properties.
Implementation Method 1
the plurality of low-melt fibers have been melted to the plurality of at least one of the natural down fibers and the synthetic down fibers by heating inside the baffle
Implementation Method 2
the plurality of low-melt fibers have been melted to the plurality of at least one of the natural down fibers and the synthetic down fibers by heating inside the baffle
Implementation Method 3
The loose structure of down feathers traps air, which helps to insulate a wearer against heat loss
Data Source
AI summary
The present invention relates to a thermal insulating structure including at least one baffle, to an article of wear and a sleeping bag including such a thermal insulating structure, and to a method for manufacturing such a thermal insulating structure. In some embodiments, the baffle includes 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.