Three-dimensional down replacement
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Solution Overview
Problem
Conventional synthetic insulation materials do not perform as well as animal-derived insulation like down, and there is a need for a sustainable alternative that can replace animal-derived insulation while offering improved performance.
Innovation Solution
Three-dimensionally (3D) printed insulative baffles with lattice structures formed using additive manufacturing, capable of deformation under compression to constrict and then return, creating a cavity for air trapping and providing tunable rigidity, which can encapsulate synthetic fill in garments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional synthetic insulation materials are used, then sustainability is improved by replacing animal-derived materials, but insulation performance deteriorates compared to down
Solution Approach 1:
The patent employs a porous lattice structure with interconnected struts that define apertures, creating a three-dimensional network that traps air for insulation. This porous architecture mimics the effectiveness of down by capturing and holding air, achieving high insulation performance while using sustainable synthetic materials.
Solution Approach 2:
The invention transitions from conventional two-dimensional or simple three-dimensional synthetic insulation to a complex three-dimensional printed lattice structure. This dimensional complexity enables superior air trapping and insulation performance while maintaining sustainability through synthetic materials.
2Adaptability or versatility
If synthetic down replacement materials are used, then sustainability is improved, but insulation performance deteriorates relative to conventional down
Solution Approach 1:
The porous lattice structure with controlled apertures and interconnected struts creates extensive air-trapping capability, enabling the synthetic material to achieve insulation efficiency comparable to or exceeding conventional down while maintaining sustainability.
Solution Approach 2:
The patent combines synthetic base materials with a specifically designed three-dimensional lattice architecture, creating a composite structure that achieves down-like insulation performance through the synergistic combination of material and structural design.
3Reliability
If 3D printed lattice structures are used, then insulation performance is improved, but device complexity increases
Solution Approach 1:
The lattice structure is segmented into repeating units of interconnected struts and apertures that can be systematically arranged. This segmentation allows complex insulation performance to be achieved through modular, repeatable patterns rather than monolithic complex structures.
Solution Approach 2:
The three-dimensional lattice structure serves multiple functions simultaneously: it provides insulation through air trapping, maintains structural integrity, enables compression and recovery, and facilitates heat distribution. This multi-functionality reduces the need for additional separate components, managing overall system complexity.
4Ease of manufacture
If conventional synthetic insulation is used, then ease of manufacture is maintained, but insulation performance deteriorates
Solution Approach 1:
The patent utilizes parameters of additive manufacturing (such as strut thickness, aperture size, lattice density, and infill patterns) to optimize insulation performance. By adjusting these manufacturing parameters, high-performance insulation is achieved while leveraging the capabilities of modern 3D printing technology.
Solution Approach 2:
The invention replaces traditional mechanical insulation materials with a three-dimensionally printed lattice structure, substituting conventional manufacturing processes with additive manufacturing. This substitution enables complex geometries and optimized performance that were previously difficult to achieve with traditional methods.
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 3D printed structures offer enhanced insulation performance, potentially surpassing current synthetic insulation, with improved loft and efficiency, and are sustainable, replacing animal-derived materials.
Implementation Method 1
The first surface and the second surface may be capable of being deformed from a first state to a second state under a compression force to constrict a volume of the cavity. The first surface and the second surface may be capable of returning to the first state when the compression force is released.
Implementation Method 2
a first surface comprising by a plurality of first interconnected struts that define a plurality of first apertures through the first surface... The first surface and the second surface may define a cavity therebetween
Data Source
AI summary
Articles (100, 200, 300, 400) are described herein. An example article may comprise a first surface (404) comprising a first lattice. The example article may comprise a second surface (406) at least partially spaced from the first surface (404) and having at least one common terminal connection point with the first surface (404). The first surface (404) may comprise a second lattice. The first surface (404) and the second surface (406) may define a cavity (407) therebetween. The first surface (404) and the second surface (406) may be capable of being deformed from a first state to a second state under a compression force to constrict a volume of the cavity. The first surface (404) and the second surface (406) may be capable of returning to the first state when the compression force is released.