Patent Application
20110014406
1. Field of the Invention
The present invention pertains to the type of sheet material that is capable of serving as insulation or cushioning in an article of manufacture. More particularly, the present invention relates to light-weight constructions configured for rugged outdoor use, such as personal attire, ground covers, pillows, tenting, tarps, blankets, windscreens, watercraft, and containers for equipment or supplies, any of which may benefit from the incorporation of sheet material that exhibits insulating or cushioning properties.
2. Background
Activities in an outdoor environment frequently entail the use of specialized equipment that enables an individual to endure in the face of harsh conditions. To fend off extremes of cold or heat, to live comfortably on hard, rocky ground, and to deal with wind and precipitation, constructions such as personal attire, ground covers, pillows, tenting, tarps, blankets, windscreens, watercraft, and containers for equipment or supplies incorporate materials that exhibit insulating or cushioning properties.
Insulation and cushioning may take the form of pads of non-woven fibers enclosed for enhanced mechanical integrity in textile shells. Quilted ground coverings, quilted blankets, and quilted items of personal attire are examples. Alternatively, to introduce insulative or cushioning properties into a construction, loose synthetics, such as fleece or chopped polymer fibers, or natural materials, such as cotton fibers, animal fur, or bird down, are also enclosed in textile shells.
These approaches have drawbacks. Insulation and cushioning of the types described are relatively heavy and usually quite bulky. Such qualities contribute to transport challenges, to crowding in close quarters, and to dangerously awkward degrees of lost personal mobility.
It has been observed, however, that among the more light-weight of these approaches, it is actually the air in the loft of the material employed that supplies most of the desired insulating barrier to heat transfer. Air trapped among the unwoven constituent fibers in those materials may even contribute protective cushioning. The constituent fibers do not themselves so much insulate or cushion. Rather the constituent materials sustain therealong spaces that are filled with air. It is to enhance the air content of constructions employing such unwoven materials that the fluffing of those constructions is recommended prior to use. Whether by weight or by volume, few configurations of the constituents of unwoven materials are able to exceed the per unit effectiveness of common air as insulation or as cushion.
A material that is, by contrast, of unitary construction is cured open-cell foam. Bodies made of open-cell foam are enclosed within valved, air-impervious shells, thereby to function as air-filled cushioning.
In accord with teachings of the present invention, a sheet material having utility as insulation or cushioning in an article of manufacture includes a fluid-impervious first layer defining a first outer surface of the sheet material, a fluid-impervious second layer defining a second outer surface of the sheet material on the opposite side of the sheet material from the first outer surface, and a matrix of woven threads. The matrix has opposed first and second faces and is sandwiched between the first layer and the second layer with the first face of the matrix secured to the first layer and the second face of the matrix secured to the second layer. The matrix is capable of housing in open-cell fashion among the threads thereof a fluid isolated by the first layer and the second layer from the exterior of the sheet material. An example of such a matrix is a triple-layer weave of threads. The fluid typically is a gas, such as ambient air.
The first layer of the sheet material includes a fluid-impervious melt-adhesive sealing film carried on a side of a first fabric. The sealing film of the first layer is bonded to the first face of the matrix. The second layer of the sheet material includes a fluid-impervious melt-adhesive sealing film carried on a side of a second fabric. The sealing film of the second layer is bonded to the second face of the matrix.
According to another aspect of the present invention, an article exhibiting insulating or cushioning properties includes a multi-layered one-piece woven textile having opposed first and second faces and a continuous peripheral edge therebetween circumscribing the textile. A fluid-impervious laminate first sheet is secured to the first face of the textile, a fluid-impervious laminate second sheet is secured to the second face of the textile, and a continuous fluid-impervious seal between the first sheet and the second sheet circumscribes the peripheral edge of the textile. The first sheet defines a first outer surface of the article, while the second sheet defines a second outer surface of the article. The article is suitable for incorporation into a light-weight construction configured for rugged outdoor use and chosen from among the group of constructions including personal attire, ground covers, pillows, tenting, tarps, blankets, windscreens, watercraft, and containers for equipment or supplies.
The present invention also includes methods for manufacturing a light-weight construction configured for rugged outdoor use and exhibiting insulating or cushioning properties. One embodiment of such a method includes the steps of preparing a work piece of woven threads that has opposed first and second faces and a continuous peripheral circumscribing edge therebetween, encasing the work piece in an interior space within an air-tight enclosure, and effecting fluid access to the interior space.
The step of preparing includes the steps of weaving a one-piece triple-layer textile and of cutting the textile into a predetermined configuration suitable for use in the construction.
The step of encasing the work piece in an air-tight enclosure comprises the steps of securing an air-impervious first layer to the first face of the work piece with a circumscribing margin portion of the first layer extending beyond the peripheral edge of the work piece, securing an air-impervious second layer to the second face of the work piece with a circumscribing margin portion of the second layer extending beyond the peripheral edge of the work piece, and continuously sealing the margin portion of the first layer to the margin portion of the second layer. The step of securing the first layer involves applying an air-impervious melt-adhesive sealing film to a side of a first fabric to produce the first layer, and bonding the first layer to the first face of the work piece using the sealing film. Similarly, the step of securing the second layer involves applying an air-impervious melt-adhesive sealing film to a side of a second fabric to produce the second layer, and bonding the second layer to the second face of the work piece using the sealing film.
The step of effecting fluid access to the interior space comprises the steps of establishing a passageway communicating between the interior space and the exterior of the construction, and installing in the passageway a selectively operable valve capable of assuming an open condition wherein fluid communication is afforded between the exterior of the construction and the interior space and a closed condition wherein fluid in the interior space is isolated from the exterior of the construction.
In order that the manner in which the above-recited and other features and advantages of the present invention are obtained will be readily understood, a more particular description of the present invention briefly described above will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the present invention and are not therefore to be considered to be limiting of the scope thereof, the present invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
The presently preferred embodiments of the present invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. It will be readily understood that the components of the present invention, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the present invention, as represented in
Vest 14 includes a first front panel 15, a second front panel 16, and a back panel 18 that are stitched together at various variously peripheral edges thereof to produce a garment having a neck opening 20 and an armhole 22. A second armhole of vest 14 is not visible in
First front panel 15, like the other panels of vest 14, is constructed from a sheet material 40 that has utility as insulation or cushioning. Sheet material 40 includes a fluid-impervious first layer 42 that defines a first outer surface 44 of sheet material 40 and a fluid-impervious second layer 46 that defines a second outer surface 48 of sheet material 40 on the opposite side thereof from first outer surface 44.
When sheet material 40 is formed into first front panel 15 and assembled into vest 14, first layer 42 and first outer surface 44 of sheet material 40 are oriented outwardly from sportsperson 13, toward the outdoor environment in which sportsperson 13 would wear vest 14. For this reason, first layer 42 exhibits qualities that are of advantage in encountering outdoor environments. On the other hand, second layer 46 and second outer surface 48 of sheet material 40 are oriented inwardly, toward the torso of sportsperson 13, and second layer 46 exhibits qualities that are beneficial at that location. These particular qualities of first layer 42 and second layer 46 will be mentioned subsequently in the context of a discussion of the manufacture of first front panel 15.
Sandwiched between first layer 42 and second layer 46 is a matrix 50 of woven threads. A first face 52 of matrix 50 engages and is secured to first layer 42, while an opposed second face 54 of matrix 50 engages and is secured to second layer 46. Under normal circumstances, matrix 50 is a thin, relatively dense configuration of woven threads having a resting thickness TR measured perpendicular to the planar extent thereof between first face 52 and second face 54.
Due to the particular manner by which matrix 50 is fabricated and incorporated into sheet material 40, matrix 50 is capable of a controlled volumetric expansion in which the distance between first face 52 and second face 54 increases into an engorged thickness TE. This is suggested in
The engorgement of sheet material 40 is caused by a viscous fluid isolated between first layer 42 and second layer 46 from the exterior of sheet material 40 that is introduced among the woven threads of matrix 50. The fluid introduced percolates through the fibers of matrix 50, lending loft to matrix 50, much in the manner that air will fill cured open-cell foam. In the case of sheet material, such as sheet material 40 used in an article of outdoor clothing, it is most likely that the viscous fluid used to provide loft in matrix 50 will be a gas, such as ambient air. An example of a material that functions in the manner described above for matrix 50 is a one-piece, triple-layer textile. The manufacture of a textile of this type will be discussed in due course.
A continuous fluid-impervious seal 58 is formed between first layer 42 and second layer 46 circumscribing the peripheral edge 60 of matrix 50. This results in the creation within sheet material 40 of an interior space 62 that houses matrix 50 and that is isolated from the exterior of sheet material 40. Selectively controllable fluid communication is established between interior space 62 and the exterior of first front panel 15 by way of a fluid passageway 64 that extends longitudinally through the stem 66 of valve 32. Valve 32 controls the access through passageway 64 to interior space 62.
Valve 32 may assume an open condition in which fluid communication is afforded between the exterior of first front panel 15 and interior space 62, or valve 32 is capable of assuming a closed condition in which fluid in interior space 62 is completely isolated from the exterior of first front panel 15. If fluid is to be added to interior space 62, as for example to enhance the loft of matrix 50, or if fluid is to be extracted from interior space 62, as for example to permit vest 14 to be compressed for storage, valve 32 is manipulated into the open condition thereof. When the loft of matrix 50 is satisfactory and is to be maintained, valve 32 is manipulated into and left in the closed condition thereof.
In a construction, such as vest 14 that includes several distinct panels possessed of these properties, each panel is provided with its own respective valve, or the interior spaces in the individual panels are placed in fluid communication with each other by including in the construction internal fluid passageways that interconnect those interior spaces. Such passages traverse the locations, such as at first shoulder seam 24, at second shoulder seam 26, and at side seam 28, where the panels of vest 14 are attached to each other. Alternatively, an entire construction may be so designed as to include only a single panel that encloses a single, extensive interior space.
A better understanding of the nature and the manufacture of an article, such as first front panel 15 that incorporates a textile that functions in the manner of matrix 50, commences with an understanding of how a one-piece, triple-layer textile is actually produced.
By way of background, a woven fabric is made up of a field of parallel, generally coplanar warp threads that are traversed perpendicularly by weft threads that are generally parallel to each other. Each weft thread crosses each warp thread of the fabric, and visa versa.
During manufacturing, all of the warp threads for a future fabric are maintained under tension extending longitudinally through a loom. The warp threads form a foundation from which a fabric arises as a result of the weaving of successive weft threads across the loom and through the field of warp threads. Weft threads are advanced individually among the warp threads, passing over some and under others in a pattern that is particular to each individual weft thread. The weaving pattern of a given weft thread usually differs from the weaving pattern associated with the weft thread that immediately precedes it in the fabric.
Unwoven warp threads on a loom normally occupy a coplanar relationship that defines a base level in the loom. Weft threads passing across the field of unwoven warp thread do so in a weft plane that overlies warp threads that are at the base level. All unwoven warp threads do not, however, remain at the base level during the transit of a weft thread through the warp thread field. A typical loom includes a jacquard mechanism that extends across the width of the loom over the field of the unwoven warp threads. During each transit of a weft thread across the field of unwoven warp threads, the jacquard mechanism lifts individual warp threads out of the warp thread field into an elevated level in the loom that is above the weft plane. A weft thread thus passes over the warp threads at the base level and under warp threads at the elevated level. In this manner, the jacquard mechanism implements the weaving pattern for each particular weft thread.
Sequenced numerals along the top of each drawing in the series identify warp threads 1-12, or the locations of individual of warp threads 1-12 in the full warp thread field. In the lower portion of each drawing in the series, warp threads 1-12 appear in cross section in a loom 68. In each depiction of loom 68, the weft plane is occupied by a single, lettered weft thread, weft thread A in
The weaving patterns for all of weft threads A-F collectively are presented schematically at the top of each drawing in the series in the form of a jacquard pattern 70, a two-dimensional grid in which columns correspond to warp threads and rows correspond to weft threads. In jacquard pattern 70, a box occupied by the letter “X” indicates that the warp thread corresponding to the position of the box in the grid is to be in the elevated level, when the weft thread corresponding to the position of the box in the grid is in transit across the warp thread field. The particular weft thread pattern shown in loom 68 in each drawing in the series corresponds in the associated jacquard pattern 70 thereabove to the lettered row through which a braided horizontal bar is disposed. The progression of weaving from weft thread A through weft thread F is suggested by an weaving arrow W.
Thus, in
In
The weaving process continues by repeating the weaving cycle depicted collectively in
Warp threads 1-12 and two sets of weft threads A-F at the periphery of textile 72 correlate to the weaving steps illustrated in
Regions I and regions II are oriented at 45 degrees to the warp and weft of textile 72, but the elongated aspect of regions I and regions II are oriented at 90 degrees to each other. Regions I and regions II thus form a tessellating array that covers second face 54 of textile 72 and matrix 50.
In regions I, six adjacent warp threads are presented on second face 54 of textile 72, either warp threads 1-6 in some of regions I, or warp threads 7-12 in the others. Correspondingly, below the warp threads in regions I, adjacent weft threads A-F are presented on the face of textile 72 that is not visible in
In all of regions II, the six adjacent weft threads are presented on the second face 54 of textile 72 in the order of weft threads D-F followed by weft threads A-C. Correspondingly, below those weft threads, an equal number of adjacent warp threads are presented on the first face 52 of textile 72 that is not visible in
Under such conditions, regions I and regions II function like the quilting in a sheet material that is filled with loose fiber, batting, or a natural filler. Textile 72 is, however, lighter than such a quilted sheet material, as no fiber, batting, or filler is carried in the regions I and regions II to the sustain loft produced in textile 72 by the introduction of air into the interior space therein.
Between adjacent of regions I and regions II are transition corridors 74, areas of textile 72 in which groups of adjacent warp threads exchange faces of textile 72 with groups of adjacent weft threads. The fluid that provides loft in textile 72 percolates through transition corridors 74 more gradually than the fluid fills regions I and regions II. Thus, transition corridors 74 retard the rate of heat transfer among individual of regions I and regions II, enhancing the insulative capability of textile 72. Transition corridors 74 serve also as areas of textile 72 in which bending is facilitated, keeping textile 72 flexible, even when inflated to enhance loft.
In
The bonding of sealing film 80 to these elements of textile 72 is superficial in the sense that only the uppermost surfaces of those elements are attached thereby to second layer 46. Adjacent to the plane of section line 5-5 in
Additionally in
The bonding of sealing film 84 to these elements of textile 72 is superficial in the sense that only the lowermost surfaces of those elements are attached thereby to first layer 42. First layer 42 is not, for example, attached to weft thread D where weft thread D is above warp thread 1 or above warp thread 7. Neither is first layer 42 attached to, warp threads 2-6 or to warp threads 8-12 where these are above weft thread D.
With first layer 42 and second layer 46 of sheet material 40 secured in this superficial manner to the opposed faces of textile 72, the triple-layer woven nature of textile 72 permits a fluid introduced among threads of textile 72 to separate first layer 42 and the elements of textile 72 attached thereto from second layer 46 and the elements of textile 72 attached thereto. The resting thickness TR of matrix 50 and textile 72 shown in
Also fed toward bonding oven 94 are the pair of fluid-impervious layers that will eventually define the first outer surface 44 and the second outer surface 48 of sheet material 40 from which first front panel 15 of vest 14 will eventually be cut in chopping station 96. These, respectively, are first layer 42 and second layer 46.
To produce first layer 42, fluid-impervious melt-adhesive sealing film 84 is applied to one side of a fabric 86. This may be accomplished as shown in
To produce second layer 46, fluid-impervious melt-adhesive sealing film 80 is applied to one side of a fabric 82. This may be accomplished as shown in
Bonding oven 94 is maintained at an elevated temperature T94 that is calculated during the passage of work piece 90, first layer 42, and second layer 46 therethrough to sufficiently soften the material of film 80 and film 84 to enable each to become secured to a respective face of work piece 90. Bonding oven 94 includes a third compression station 102 that urges first layer 42 and second layer 46 against work piece 90 when film 80 and film 84 are in a softened state. Even once thusly secured to work piece 90, first layer 42 includes a circumscribing margin portion 104 that extends beyond peripheral edge 60 of work piece 90, while second layer 46 includes a similar circumscribing margin portion 106 that also extends beyond peripheral edge 60 of work piece 90. As work piece 90, first layer 42, and second layer 46 leave bonding oven 94, margin portion 104 of first layer 42 and margin portion 106 of second layer 46 are continuously sealed directly to each other at a fourth compression station 108. This seal circumscribes peripheral edge 60 of work piece 90, enclosing work piece 90 in an air-impervious casing.
Finally, at cutting station 96 each work piece 90 in the air-impervious casing formed thereabout of first layer 42 and second layer 46 is cut from the layered assemblage. This separates first front panel 15 of vest 14 from a sheet of waste 110 that contains only scraps of first layer 42 and second layer 46. Valve 32 is added to first front panel 15, providing a passageway between the space within front panel 15 and the exterior thereof, as well as a means for selectively closing that passageway. First front panel 15 is then secured to other similarly-structured panels to produce a construction, such as vest 14.
Method 120 begins at a commencement oval 122. By way of overview, method 120 includes three broad steps. First, as set forth in a subroutine enclosure 124, method 120 involves the step of preparing a work piece of woven threads that has opposed first and second faces and a continuous peripheral edge therebetween that circumscribes the work piece. Second, as indicated in a subroutine enclosure 126, method 120 continues with the step of encasing the work piece in an interior space within an air-tight enclosure. Then, as described in a subroutine enclosure 128, method 120 entails the step of effecting fluid access to that interior space. Method 120 concludes at a termination oval 129.
Each of these three broad steps of method 120 will be discussed in turn.
As indicated in an instruction rectangle 130, the preparation of the work piece of subroutine enclosure 124 requires first the weaving of a one-piece triple-layer textile. An example of such a weaving process was discussed above relative to
The encasement of the work piece of subroutine enclosure 126 in an air-tight enclosure, as required in subroutine enclosure 126, is a bit more complex. Two sub-subroutines are involved. First, as set forth in sub-subroutine enclosure 134, an air-impervious first layer is secured to the first face of the work piece. In so doing, a circumscribing margin portion of the first layer is left extending beyond the peripheral edge of the work piece. Then, as set forth in sub-subroutine enclosure 136, an air-impervious second layer is secured to the second face of the work piece. Here also, a circumscribing margin portion the second layer is left extending beyond the peripheral edge of the work piece. The margin portion of the first layer will thus oppose the margin portion of the second layer. Finally, as indicted in an instruction rectangle 138, the margin portion of the first layer is continuously sealed to the margin portion of the second layer. As a result, the work piece of subroutine enclosure 124 becomes housed in an interior space that is defined by the first layer, the second layer, and the continuous circumscribing seal therebetween.
The air-impervious first layer of sub-subroutine enclosure 134 is secured to the first face of the work piece by applying an air-impervious melt-adhesive sealing film to a side of a first fabric to produce the first layer and then by bonding the first layer to the first face of the work piece using the sealing film. These steps of method 120 are called for, respectively, in an instruction rectangle 140 and in an instruction rectangle 142. In
Similarly, the air-impervious second layer of sub-subroutine enclosure 136 is secured to the second face of the work piece by applying an air-impervious melt-adhesive sealing film to a side of a second fabric to produce the second layer and then by bonding the second layer to the second face of the work piece using the sealing film. These steps are called for, respectively, in
Lastly in method 120, as indicated in subroutine enclosure 128, fluid access is effected to the interior space in the air-tight enclosure produced in subroutine enclosure 126. To do so, a passageway is established communicating between the interior space and the exterior of the intended construction. This is indicated in an instruction rectangle 148. Then as indicated in an instruction rectangle 150, a selectively operable valve is installed in the passageway. The valve, like valve 32 in
The present invention may be embodied in other specific forms without departing from its structures, methods, or other essential characteristics as broadly described herein and claimed hereinafter. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.
