GB2604211A - Casing for insulation material and method of manufacture - Google Patents

Casing for insulation material and method of manufacture Download PDF

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Publication number
GB2604211A
GB2604211A GB2116332.4A GB202116332A GB2604211A GB 2604211 A GB2604211 A GB 2604211A GB 202116332 A GB202116332 A GB 202116332A GB 2604211 A GB2604211 A GB 2604211A
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GB
United Kingdom
Prior art keywords
layer
joints
casing
combination
insulation
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
GB2116332.4A
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GB202116332D0 (en
Inventor
Dunn Hamish
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Mountain Equipment Ltd
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Mountain Equipment Ltd
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Filing date
Publication date
Application filed by Mountain Equipment Ltd filed Critical Mountain Equipment Ltd
Publication of GB202116332D0 publication Critical patent/GB202116332D0/en
Publication of GB2604211A publication Critical patent/GB2604211A/en
Pending legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/05—Interconnection of layers the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
    • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
    • A41D31/06—Thermally protective, e.g. insulating
    • A41D31/065—Thermally protective, e.g. insulating using layered materials
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
    • A41D31/02—Layered materials
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
    • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
    • A41D31/06—Thermally protective, e.g. insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/08—Interconnection of layers by mechanical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/16—Structural features of fibres, filaments or yarns e.g. wrapped, coiled, crimped or covered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)
  • Laminated Bodies (AREA)

Abstract

A method for producing a casing for insulation material comprising providing a first layer of material, a second layer of material, and a third layer of material positioned between the first and second layers; joining the first layer to the third layer by formation of a first joint and joining the second layer to the third layer by formation of a second joint, wherein the first and second joints are offset relative to each other. There may be a plurality of first and second joints, all the first joints may be offset relative to all the second joints and there may be no points of intersection between any of the first and second joints, the joints may be elongate and may extend along all or part of the length or width of the layers or material. The joints may be formed by any suitable means such as sewing, lamination, welding and bonding. There may be formed a plurality of open ended chambers formed between the first layer and third layer of material and the second and third layers of material formed by said joints. These chambers may be filled with insulation material, which may be fibrous fill, and then sealed. The first and second materials may be a woven nylon fabric, the third material may be the same or may be a non-woven scrim comprising aluminium. Fourth and fifth layers of material may also be present contacting the first and/or second material. Also include are claim to the casing made by such a method.

Description

CASING FOR INSULATION MATERIAL AND METHOD OF MANUFACTURE
The present invention relates to a method for producing a casing for an insulation material, particularly a fibrous fill insulation material. The invention also relates to a casing for an insulation material, particularly a fibrous fill insulation material and the combination of a casing and an insulation material, particularly a fibrous fill insulation material Outdoor pursuits including climbing, mountaineering, hiking and skiing demand that a person can insulate themselves and that their clothing and shelter are easy to carry, making lightweight equipment necessary.
Fibrous fill insulation materials such as down, down and feather mixes, synthetic insulation materials and blends of the aforementioned offer improvements over other insulating materials. These improvements include their loft and subsequently high thermal resistance, their low weight for a given thermal resistance, their compressibility, and their recovery from compression. However, these insulation materials must be contained to remain effective.
Numerous commonplace methods exist for encasing fibrous fill insulation materials, including fabric casings having stitch-through baffles, box wall baffles, V-block baffles, slanted box baffles, and trapezoid baffles. in the case of stitch through baffles, stitch lines where the two faces of the fabric casings are adjoined, thickness between them tends to zero and so cold spots arise. The stitch lines may also permit water and/or wind ingress. The remaining methods of baffle construction mentioned are complex to manufacture, their use of internal stripping increases weight and stiffness, and increases cost.
Thus, there is need for a method of encasing insulation materials, particularly fibrous fill insulation materials, which combines benefits of stitch through baffle construction, including the low weight, good drape, and ease of manufacture, while reducing or removing the undesirable effects of stitch lines.
The invention relates to a method for producing a casing for insulation material such as fibrous insulation material, as well as the casing and the combination of casing and insulation material. The casing in combination with an insulation material may be used in the manufacture of items such as garments of clothing, sleeping bags, or inflatable mattresses.
In an aspect of the invention there is provided method requiring a first layer of material, a second layer of material, and a third layer of material; the third layer of material being positioned between the first layer of material and the second layer of material; the method comprising joining the first layer of material to the third layer of material by formation of a first joint and joining the second layer of material to the third layer of material by formation of a second joint, wherein the first and second joints are offset relative to each other.
The method may be repeated such that a plurality of first joints between the first layer of material and the third layer of material are formed and a plurality of second joints I5 between the second layer of material and third layer of material are formed.
Ideally all of the first joints are offset in relation to all of the second joins.
Ideally all the first joints are offset in relation to all of the second joins and there are no points of intersection between any of the first joints and any of the second joints.
The first layer of material may be joined to a first surface of the third layer of material or may be joined to the third layer of material such that it is adjacent to a first surface of the third layer of material.
The second layer of material may be joined to a second surface of the third layer of material or may be joined to the third layer of material such that it is adjacent to a second surface of the third layer of material.
The plurality of first joints between the first layer of material and the third layer of material gives rise a plurality of open ended chambers formed between the first laver of material and the third layer of material.
The plurality of second joints between the second layer of material and the third layer of material gives rise a plurality of open ended chambers formed between the second layer of material and the third layer of material.
The method further comprises filling some or all, preferably all, of the chambers with insulation material, for example, fibrous fill insulation material. The method further comprises dosing the chambers in any suitable manner known in the art.
In a further aspect of the invention there is provided a casing for an insulation material, the casing comprising a first layer of material, a second layer of material, and a third layer of material; the third layer of material being positioned between the first layer of material and the second layer of material; the first layer of material is joined to the third layer of material by a plurality of first joints and the second layer of material is joined to the third layer of material by a plurality of second joints, wherein the first joints and second joints are offset relative to each other.
Ideally all of the plurality of first joints are offset in relation to all the plurality of second joints and more ideally there is also no point of intersection between any of the first joints and any of the second joints.
The plurality of first joints gives rise a plurality of open ended chambers between the first layer of material and the third layer of material. The plurality of second joints between the second layer of material and the third layer of material gives rise a plurality of open ended chambers between the second laver of material and the third layer of material.
One or both open ends of the chambers may be closed.
In a still further aspect of the invention there is provided a combination of the casing of the present invention and an insulation material, for example, a fibrous fill insulation.
In the combination some or all, preferably all, of the chambers between the first layer of material and the third layer of material and the chambers between the second layer of material and the third layer of material are filled with insulation material and the open ends of the chambers are closed.
The below relate to features applicable to any of the method, casing and combination of the invention.
The first, second and third layers of materials may have the same length and/or width.
Ideally the first,second and third layers of material are co-extensive.
The first and second materials may be the same or different.
The first material may be a first fabric. The second material may be a second fabric.
The first and second fabrics may each be composed of fibres which may be synthetic or natural. The natural or synthetic fibres may be virgin or recycled in origin.
The fibres may be coated with or may contain membranes composed or partly composed of polyurethane (PU), thermoplastic polyurethane (TPU), expanded polytetrafluoroethylene (ePTFE), or polyester (PES) The first and/or second material may comprise a woven nylon fabric. The woven nylon fabric may be a densely woven nylon fabric with polyurethane coating. Examples include (i) a 40 denier nylon fabric with polyurethane coating that affords a hydrostatic head in excess of 1500mm and weighs 56g ml2; and (ii) a 20 denier nylon fabric with polyurethane coating that affords a hydrostatic head in excess of 1500mm and weighs 36g m-2.
The first and/or second material may comprise a recycled nylon fabric. The recycled nylon fabric may be a densely wovcn recycled nylon fabric. Examples include a 20 denier recycled nylon fabric that is both downproof and fibre proof by means of its high weave density.
The third material may be the same or different to one or both of the first and second 35 materials The third material may be a third fabric. The third fabric may be composed of fibres which may be synthetic or natural. The fibres may be woven, knitted or made using a nonwoven processing technique The third material may be a nonwoven scrim with an aluminium component for example the nonwoven scrim can be made from the XReflex scrim product from He i Q. The first material and the second material may be joined to the third material by any suitable means including sewing, lamination, welding, and bonding The first and/or second joints may be elongate. The first and/or second joints may extend along all or part, preferably all, of the length or width of the first, second and third layers of material.
Ideally the first and second joints may be elongate. Ideally the first and second joints may extend along all or part, preferably all, of the length or width of the first, second and third layers of material The first and/or second joints may run in straight lines, in zig-zags, in curves, or in any other regular or irregular shape. The joints may run parallel to each other.
The distance between the first joints may be any suitable distance. The distance between the second joints may be any suitable distance. The distance may be from 1 cm to 100 cm, more preferably from 2 to 50 cm, more preferably still from 3 cm to 20 cm, and more preferably still from 4 cm to 10 cm, for example 5 to 8cm.
The distance between the joints may be equal or different across the length or width of the casing.
Open ends of the chambers may be dosed in any manner familiar to one skilled in the art.
The fibrous fill insulation material may comprise any suitable material such as down feather, feather, wadding containing down feathers, synthetic wadding insulation, loose fill synthetic insulation, or a blend or combination of any of the aforementioned.
The insulation material may comprise 700 or 800 fill power duck down, though alternative grades of duck down or goose down could be used, or the fill could be synthetically derived.
If down is to be used then ideally it should be washed and cleaned according to methods known by someone skilled in the art. Fill power of the washed down and measured by IDFB testing following steam conditioning should ideally be in excess of 300 cubic inches per ounce, more preferably in excess of 500 cubic inches per ounce, and more preferably yet, equal to or in excess of 700 cubic inches per ounce. Down: flight feather ratios of 10:90 to 97:3, but most preferably from 80:20 to 93:7 may be I5 used.
A fourth layer of material may be provided adjacent and/or contacting one of the first or second layers of material. Furthermore, a fifth layer of material may be provided adjacent and/or contacting the other of the first or second layer of material.
The fourth and/or fifth layers of material are preferably adjacent and/or contacting a surface of the first or second layer of material facing away from the third layer of material.
The fourth and fifth layers of material may be the same of different.
The fourth material may be a fourth fabric. The fifth material may be a fifth fabric.
The fourth and fifth fabrics may be one or more of windproof, breathable and downproof. A suitable example fabric is a Gore-Tex Infiniumm fabric, more specifically a 10 denier 39g m-2 densely woven nylon iteration Gore-Tex InfiniumTM.
Example 1
The first material comprises a densely woven nylon fabric with polyurethane coating, more specifically a 40 denier nylon fabric with polyurethane coating that affords a hydrostatic head in excess of 1500mm and weighs 56g in-2 The second material comprises a densely woven recycled nylon fabric, more specifically a 20 denier recycled nylon fabric that is both downproof and fibre proof by means of its high weave density.
The third material is a nonwoven scrim with an aluminium component, as a non-limiting example the nonwoven scrim can be made from the XReflex scrim product from He i(It In this example the first, second and third layers of material are co-extensive. The woven nylon fabric (first material) is stitched to the nonwoven scrim (third material) to form an elongate first joint. Then the recycled nylon fabric (second material) is stitched to the nonwoven scrim (third material) to form an elongate second joint.
The first and second joints extend along the length of the layers of material from one side to the opposing side. The elongate joints between the first and third materials are offset in relation to those between the second and third materials and do not meet or cross.
This process is repeated across the full width of the three materials so that there are formed a number of elongate joints between first and third lavers and a number of elongate joints between second and third layers each extending along the length of the three layers of material from one side to the opposing side. The joints are parallel and spaced apart by approximately 8cm. The chambers that are formed between the third material and each of the first and second materials therefore measure approximately 8 cm between the joint lines.
As a non-limiting example the chambers might be filled with 700 fill power duck down, though alternative grades of duck down or goose down could be used, or the fill could be synthetically derived.
Example 2
The first material comprises a densely woven nylon fabric with polyurethane coating, more specifically a 20 denier nylon fabric with polyurethane coating that affords a hydrostatic head in excess of 1500mm and weighs 36g in-2 The second material comprises a densely woven recycled nylon fabric, more specifically a 20 denier recycled nylon fabric that is both downproof and fibre proof by means of its high weave density.
The third material is a nonwoven scrim with an aluminium component, as a non-limiting example the nonwoven scrim can be made from the XReflex scrim product from He i().® In this example the first, second and third layers of material are co-extensive. The woven nylon fabric (first material) is stitched to the nonwoven scrim (third material) to form an elongate first joint. Then the recycled nylon fabric (second material) is stitched to the nonwoven scrim (third material) to form an elongate second joint.
The first and second joints extend along the length of the layers of material from one side to the opposing side. The elongate joints between the first and third materials are offset in relation to those between the second and third materials and do not meet or cross.
This process is repeated across the full width of the three materials so that there are formed a number of elongate joints between first and third layers and a number of elongate joints between second and third layers each extending along the length of the three layers of material from one side to the opposing side. The joints are parallel and spaced apart by approximately 5cm. The chambers that are formed between the third material and each of the first and second materials therefore measure approximately 5 cm between the joint lines.
As a non-limiting example they might be filled with 700 fill power duck down, though alternative grades of duck down or goose down could be used, or the fill could be synthetically derived.
Example 3
In another example, a design akin to that described in example 1 above is made, and then a separate fabric is overlaid on an outer surface of one of the first and second materials.
This overlaid fabric is a windproof and breathable downproof fabric such as a Gore-Tex infiniumm fabric, more specifically a 10 denier 39g m-2 densely woven nylon iteration Gore-Tex infiniumTm.
In this example the chambers are filled with, as a non-limiting example, 800 fill power goose down, though alternative grades of duck down or goose down could be used, or the fill could be synthetically derived.
In this example the overlaid fabric is attached around the edges of the easing by I5 stitching.
The invention is further exemplified by the attached figures in which: Figure 1 shows a cross-section through a casing of the presentinvention; Figure 2 shows a perspec e view of the casing of figure 1 and Figure 3 shows the casing of figures 1 and 2 containing insulation material.
The figures show a casing 100 for an insulation material. The casing 100 comprises a first layer of material 1, a second laver of material 2, and a third layer of material 3.
The third layer of material 3 is positioned between the first layer of material 1 and the second layer of material.
The first, second and third layers of material are co-extensive In the casing 100 the first layer of material 1 is joined to the third layer of material 3 by a sewing, giving rise to plurality of elongate first stitch lines 4.
The second layer of material 2 is joined to the third layer of material 3 by sewing, giving risc to a plurality of elongate second stitch lines 5.
In this example first and second stitch lines are straight and parallel and spaced apart across the width of the casing W. The figures show a spacing of 14cm between first stitch lines 4. The spacing is the same between second stitch lines 5.
The first and second stitch lines 4 and 5 are offset relative to each other across the width of the casing so there is no point of contact between the first and second stitch lines 4, 5.
In this example the elongate stitch lines each extend along the complete length L of the casing 100 as can be best seen in figure 2.
IS The elongate first stitch lines 4 between the first layer of material I and the third layer of material 3 gives rise a plurality of open ended chambers 6 formed between the first layer of material 1 and the third layer of material 3 The elongate second stitch lines 5 between the second layer of material 2 and the third layer of material 3 gives rise a plurality of open ended chambers 7 formed between the second layer of material 2 and the third layer of material 3.
The chambers 6, 7 are all filled with insulation material 8, for example, fibrous fill insulation material as shown in figure 3. The chambers arc closed in any suitable manner known in the art, for example by sewing.
To make the casing of figures I to 3 the third layer of material 3 is positioned between the first layer of material 1 and the second layer of material 2.
The first layer of material 1 is joined to the third layer of material 3 by means of an elongate stitch line 4 extending along the length of the first and third layers of material.
The second layer of material 2 is joined to the third layer of material 3 by means of an elongate stitch line 5 extending along the length of the second and third layers of material.
The first stitch lines 4 between the first and third layers of material and the second stitch lines 5 between the second and third layers of material are offset relative to each other.
The above step is repeated such that a plurality of elongate first stitch lines 4 between the first layer of material 1 and the third laver of material 3 are formed and a plurality of elongate second stitch lines 5 between the second layer of material 2 and third layer of material 3 are formed extending across the width of the first, second and third layers of material The elongate stitch lines 5 between the first layer of material 1 and the third layer of material 3 give rise a plurality of open ended chambers 6 formed between the first layer of material 1 and the third layer of material 3.
The plurality of elongate stitch lines 7 between the second layer of material 2 and the third layer of material 3 give rise a plurality of open ended chambers 7 formed between the second layer of material and the third layer of material.
The method further comprises filling the chambers 6, 7 with insulation material, for example, fibrous fill insulation material.
The method further comprises closing the chambers 6. 7 in any suitable manner known in the art such as sewing.
The casing filled with insulation material according to the invention can be used in the manufacture of any type of insulated garment such as coats (including for example parkas), jackets, trousers, shorts, skirts, jumpers, hats, gloves (including mittens), scarves; and also outdoor equipment such as sleeping bags and sleeping mats/mattresses.

Claims (25)

  1. CLAIMS1. A method for producing a casing for nsulation material such as fibrous insulation material, the method comprising: providing a first layer of material, a second layer of material, and a third layer of material, the third layer of material being positioned between the first layer of material and the second layer of material; joining the first layer of material to the third layer of material by formation of a first joint and joining the second layer of material to the third layer of material by formation of a second joint, wherein the first and second joints are offset relative to each other.
  2. 2. The method of claim 1, wherein the method is repeated such that a plurality of first joints between the first layer of material and the third layer of material are formed and a plurality of second joints between the second layer of material and third layer of material are formed.
  3. 3. The method of claims 1 or 2, wherein all of the first joints are offset in relation to all of the second joints.
  4. 4. The method of any one of claims 1 to 3, wherein there are no points of intersection between any of the first joints and any of the second joints.
  5. 5. The method of any one of the preceding claims, wherein the plurality of first joints between the first layer of material and the third layer of material gives rise a plurality of open ended chambers formed between the first layer of material and the third layer of material.
  6. 6. The method of any one of the preceding claims, wherein the plurality of second joints between the second layer of material and the third layer of material gives rise a plurality of open ended chambers formed between the second layer of material and the third layer of material.
  7. 7. The method of claim 5 or 6, wherein the method further comprises filling some or all of the chambers with insulation material; and closing the chambers.
  8. 8. A casing for an insulation material, the casing comprising a first layer of material, a second layer of material, and a third layer of material; the third layer of material being positioned between the first layer of material and the second layer of material; the first layer of material is joined to the third layer of material by a plurality of first joints and the second layer of material is joined to the third layer of material by a plurality of second joints, wherein the first joints and second joints are offset relative to each other.
  9. 9. The casing of claim 8, wherein there is no point of intersection between any of the first joints and any of the second joints.
  10. 10. The casing of claims 8 or 9, wherein the plurality of first joints gives rise a plurality of open ended chambers between the first layer of material and the third layer of material.
  11. 11. The casing of any of claims 8 to 10, wherein the plurality of second joints between the second layer of material and the third layer of material gives rise a plurality of open ended chambers between the second layer of material and the third layer of 20 material.
  12. 12. The casing of either of claims 10 or 11 wherein one or both of the open ends of the chambers is closed.
  13. 13. A combination of the casing according to any one of claims 8 to 12 and an insulation material, for example, a fibrous fill insulation.
  14. 14. The combination of claim 13, wherein some or all of the chambers between the first layer of material and the third layer of material are filled with insulation material.
  15. 15. The combination of claim 13 or 14, wherein some or all of the chambers between the second layer of material and the third layer of material are filled with insulation material.
  16. 16. The combination of any of claims 13 to 15, wherein the open ends of the chambers are closed.
  17. 17. The method, casing or combination of any one of the preceding claims, wherein the first and/or second joints are elongate.
  18. 18. The method, casing or combination of any one of the preceding claims, wherein the first and/or second joints extend along all or part, preferably all, of the length or width of the first, second and third layers of material.
  19. 19. The method, casing or combination of any one of the preceding claims, wherein the first material and the second material are joined to the third material by any suitable means including sewing, lamination, welding, and bonding.
  20. 20. The method, casing or combination of any one of the preceding claims, wherein the fibrous fill insulation material comprises any suitable material such as down feather, feather, wadding containing down feathers, synthetic wadding insulation, loose fill synthetic insulation, or a blend or combination of any of the aforementioned.
  21. 21. The method, casing or combination of any one of the preceding claims wherein the first and/or second material comprises a woven nylon fabric or a recycled nylon fabric.
  22. 22. The method, casing or combination of any one of the preceding claims wherein the third material is the same as one or both of the first and second materials.
  23. 23. The method, casing or combination of any one of claims I to 21 wherein the third material is a nonwoven scrim with an aluminium component.
  24. 24. The method, casing or combination of any one of the preceding claims wherein a fourth layer of material is provided adjacent and/or contacting one of the first or second layers of material.
  25. 25. The method, casing or combination of claim 23 wherein a fifth layer of material is provided adjacent and/or contacting the other of the first or second layers of material
GB2116332.4A 2020-11-13 2021-11-12 Casing for insulation material and method of manufacture Pending GB2604211A (en)

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GB2604211A true GB2604211A (en) 2022-08-31

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016175917A1 (en) * 2015-04-30 2016-11-03 The North Face Apparel Corp. Baffle constructs for insulative fill materials
WO2018130751A2 (en) * 2017-05-04 2018-07-19 Dewellton Oy A 3-fabric layer insulation material and a method and an arrangement for producing the same
US20210138763A1 (en) * 2018-07-17 2021-05-13 Denso Corporation Bonded structure and method for producing same, and heat exchanger

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016175917A1 (en) * 2015-04-30 2016-11-03 The North Face Apparel Corp. Baffle constructs for insulative fill materials
WO2018130751A2 (en) * 2017-05-04 2018-07-19 Dewellton Oy A 3-fabric layer insulation material and a method and an arrangement for producing the same
US20210138763A1 (en) * 2018-07-17 2021-05-13 Denso Corporation Bonded structure and method for producing same, and heat exchanger

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Publication number Publication date
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GB202017928D0 (en) 2020-12-30

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