WO2008124414A1 - Materiau d'isolation mince possedant une structure cellulaire remplie de gaz - Google Patents

Materiau d'isolation mince possedant une structure cellulaire remplie de gaz Download PDF

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Publication number
WO2008124414A1
WO2008124414A1 PCT/US2008/059078 US2008059078W WO2008124414A1 WO 2008124414 A1 WO2008124414 A1 WO 2008124414A1 US 2008059078 W US2008059078 W US 2008059078W WO 2008124414 A1 WO2008124414 A1 WO 2008124414A1
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WIPO (PCT)
Prior art keywords
gas
cells
insulative
cell
article
Prior art date
Application number
PCT/US2008/059078
Other languages
English (en)
Inventor
Nate Alder
Brady Woolford
Benjamin Maughan
Original Assignee
Argon Technologies, Inc.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from US12/013,326 external-priority patent/US20080249276A1/en
Application filed by Argon Technologies, Inc. filed Critical Argon Technologies, Inc.
Priority to CA002682982A priority Critical patent/CA2682982A1/fr
Priority to EP08744895.7A priority patent/EP2136989A4/fr
Publication of WO2008124414A1 publication Critical patent/WO2008124414A1/fr

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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
    • 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
    • B32B3/10—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 discontinuous layer, i.e. formed of separate pieces of material
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • 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
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D13/00—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches
    • A41D13/002—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches with controlled internal environment
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D2400/00—Functions or special features of garments
    • A41D2400/10—Heat retention or warming
    • A41D2400/14—Heat retention or warming inflatable

Definitions

  • the present invention is in the field of thermal insulation materials. More particularly, embodiments of the present invention relate to articles (e.g., ski jackets and other outdoor gear and apparel) in which a dry gas is disposed in a cellular structure and used as a thermal insulator.
  • articles e.g., ski jackets and other outdoor gear and apparel
  • a dry gas is disposed in a cellular structure and used as a thermal insulator.
  • Thermal insulators have long been important for human survival and comfort in cold climates.
  • the primary function of any thermal insulator is to reduce heat loss (i.e., heat transfer) from a heat source to a cold sink.
  • heat transfer There are three forms of heat transfer: convection, conduction, and radiation.
  • Heat loss through convective mixing of gases is caused by the tendency of a gas to form a rotational mixing pattern between a warmed (i.e., less dense) region and a cooler (i.e., more dense) region.
  • warmed gas is constantly being exchanged for cooler gas.
  • One of the primary ways in which thermal insulators work is through suppressing convection by trapping or confining a volume of a gas within the insulative material. For example, one of the reasons that a fiber-filled parka feels warm is that the air near the wearer's skin is warmed by body heat and the fibers act to prevent or at least slow convective mixing of the warmed layer of the air with the cold air outside.
  • Conduction involves heat flow through a material from hot to cold in the form of direct interaction of atoms and molecules.
  • the phenomenon of conduction is one of the reasons why a thin layer of insulation does not insulate as well as a thicker layer.
  • Radiation involves direct net energy transfer between surfaces at different temperatures in the form of infrared radiation. Radiation is suppressed by using materials that reflect infrared radiation. For example, the glass surface of a vacuum flask is coated with silver to reflect radiation and prevent heat loss through the vacuum region.
  • thermal insulators prevent heat loss through convection, conduction, and radiation in different ways.
  • fiber-based thermal insulators like polyester fiber fill or fiberglass insulation utilize fairly low conductivity fibers in a stack or batt with a volume of air trapped or confined amongst the fibers.
  • conduction is reduced by the random orientation of the fibers across the stack or batt, and radiative heat loss is somewhat reduced because the radiation is scattered as it passes through the fibers.
  • thermal insulators includes closed cell structures, such as foams or microspheres. Closed cell structures are generally comprised of a polymer matrix with many small, mostly closed cavities. As with fiber-based insulations, these insulators conserve heat by trapping a volume of air in and amongst the cells. In fact, convection is effectively eliminated inside the small, closed cells. Furthermore, conduction is reduced by using low conductivity materials, and radiation is low because the cells are typically very small and there is little temperature difference between cavity walls and hence low driving force for radiative heat transfer.
  • thermal insulators present a tradeoff between insulative value (i.e., prevention of convection, conduction, and radiation), bulk, and cost.
  • insulative value i.e., prevention of convection, conduction, and radiation
  • bulk, and cost i.e., because of the bulkiness of fiber- or foam-based insulation, achieving a sufficient degree of insulation for a given set of conditions can be difficult without also making the article too bulky for practical use.
  • adding additional fiber- or foam-based insulation inevitably adds weight.
  • Such insulative materials are also static in that the amount of insulative material cannot be changed or adjusted as the user's needs change. For example, if a person is wearing a fiber filled parka or sleeping in a fiber filled sleeping bag, the amount of insulation cannot be increased or decreased as environmental or activity conditions change.
  • many typical insulative materials produce toxic and/or environmentally damaging byproducts in the process of manufacture.
  • thermal insulators such as polyester fibers or foams produces CFCs and/or greenhouse gases.
  • thermal insulators also continue to outgas toxic chemicals long after their manufacture.
  • fiberglass insulation is typically manufactured with formaldehyde compounds that continue to outgas long after the insulation is placed in a wall or other structure.
  • typical insulators, such as fiberglass or polyester fiber fill produce loose fibers that can be harmful if they are inhaled.
  • the present invention is directed to a lightweight, gas-filled, highly insulative material and methods for manufacturing the material.
  • the insulative material has a cellular structure that can be filled with an insulative gas (e.g., argon).
  • the insulative material can be incorporated into outdoor gear and apparel to make the outdoor gear or apparel warm, while still maintaining a desired thinness and flexibility.
  • the volume of the insulative gas in the cellular structure can be adjustable such that the insulation provided by the outdoor gear or apparel can be selectable. Because the insulative component is a gas, the insulation value of the article can be adjusted by increasing or decreasing the amount of gas, without appreciably affecting the weight of the article.
  • the cellular structure can be used to insulate a variety of outdoor clothing and gear.
  • the present invention includes a lightweight, gas-filled, highly insulative material with a cellular structure.
  • the cell structure can be formed from a plurality of cells that are configured to minimize thermal convection.
  • the cell structure is formed from first and second sheets of a gas impermeable material that are joined together to form a chamber between the sheets.
  • the chamber is subdivided into cells that are in fluid communication with one another.
  • a dry insulating gas e.g., argon
  • a reservoir of a dry gas is coupled to the cells to allow the insulating gas to be introduced, and optionally removed, from the cells.
  • the volume and dimensions of the cells and type of insulative gas are selected such that free convective mixing of the insulating gas disposed within the cells is minimized.
  • the convective mixing of the insulative gas in the cells has a Rayleigh value of less than 300,000 (based on a temperature difference of body temperature to 0 0 C.
  • the first and second sheets that form the cellular structure comprise a fabric, such as nylon, polyester, or spandex, that is bonded or laminated to a gas impermeable material.
  • gas impermeable materials include, but are not limited to, polyethylene, polypropylene, polyurethane, urethane, silicone rubber, latex rubber, polytetrafluoroethylene (PTFE), expanded PTFE, butyl rubber, and Mylar.
  • the water content of the insulative gas used in the cellular structure can be limited to prevent accumulation of condensed water vapor.
  • the water content of the insulative gas in the cellular structure is less than about 4 percent by weight, more preferably less than about 2 percent by weight and most preferably less than 1 percent by weight.
  • suitable gasses include argon, krypton, xenon, carbon dioxide, sulfur hexafluoride, and combinations thereof.
  • atmospheric air can be used. However, atmospheric air is typically less desirable if the water content is difficult to control since excess water vapor has been found to lead to pooling of condensed water vapor in the cellular structure, which substantially reduces the insulative properties of the cellular structure and substantially increases weight.
  • the cell volume and cell dimension for the plurality of cells in the insulative article are selected such that heat loss through convective mixing is minimized.
  • One way to minimize heat loss though convective mixing is to select a cell volume and cell dimensions such that the Rayleigh value of the cell is less than about 300,000. More preferably, the Rayleigh value of the cell is in a range from about 50,000 to about 275,000. Most preferably, the Rayleigh value of the cell is in a range from about 125,000 to about 250,000.
  • a preferred example of a cell configuration with a Rayleigh value below about 300,000 has a cell volume less than about 300 cm 3 with dimensions of about 3 cm by about 14 cm by about 7 cm.
  • a more preferred example of a cell configuration with a Rayleigh value below about 300,000 has a cell volume less than about 145 cm 3 with dimensions of about 3 cm by about 12 cm by about 4 cm.
  • a most preferred example of a cell configuration with a Rayleigh value below about 300,000 has a cell volume less than about 100 cm 3 with dimensions of less than about 3 cm by about 8 cm by about 4 cm.
  • the insulative cell structure of the present invention may be used to insulate outdoor apparel.
  • Exemplary outdoor apparel items include, but are not limited to, coats, parkas, jackets, vests, gloves, mittens, hats, liners, waders, snow boots, work boots, ski boots, and snowboard boots.
  • the cell structure of the present invention may be used to insulate outdoor gear.
  • Exemplary outdoor gear items include, but are not limited to, tents, sleeping bags, bivouac bags, and sleeping pads.
  • the present invention includes a method for manufacturing a lightweight, gas-filled, highly insulative material.
  • the method comprises steps of (1) providing a first sheet of a gas impermeable material and a second sheet of a gas impermeable material; (2) welding the first and seconds sheets of gas impermeable material together to form a chamber having a cell structure comprising a plurality cells that are in fluid communication; (3) filling the plurality of cells with a dry insulating gas selected from the group consisting of argon, krypton, xenon, carbon dioxide, sulfur hexafluoride, and combinations thereof, wherein the insulating gas has a moisture content less than about 4 percent by weight.
  • the insulative material can then be incorporated into an article of outdoor apparel or outdoor gear.
  • the first and second sheets that form the cellular structure comprise a fabric, such as nylon, polyester, or spandex, bonded or laminated to a gas impermeable material.
  • a gas impermeable material Preferably the materials used to form the insulative material are flexible such that the insulative material can be wearable or useable next to a person's body.
  • suitable gas impermeable materials include, but are not limited to, polyethylene, polypropylene, polyurethane, urethane, silicone rubber, latex rubber, polytetrafluoroethylene (PTFE), expanded PTFE, butyl rubber, and Mylar.
  • the method further comprises choosing a volume and cell dimensions for each of the plurality of cells such that the Rayleigh value of each of the plurality of cells is less than about 300,000.
  • the insulative material can be incorporated into an article of outdoor apparel and/or outdoor gear.
  • suitable articles of outdoor apparel and/or outdoor gear include, but are not limited to, coats, parkas, jackets, vests, gloves, mittens, hats, liners, snow boots, work boots, ski boots, snowboard boots, tents, sleeping bags, bivouac bags, and sleeping pads.
  • the use of a selectable volume of gas to control the insulative value of the article is particularly beneficial for use with outdoor gear and outdoor apparel since it allows a person to dynamically control heating adjacent the body, thereby ensuring greater likelihood that a desired comfort level can be achieved.
  • Figure 1 illustrates a schematic of single insulating gas cell having X, Y, and Z dimensions, a gas reservoir, and a valve;
  • Figure 2 illustrates an arrangement of a plurality of insulating gas cells as in
  • Figure 1 that are in fluid connection with one another and with a gas reservoir
  • Figure 3 illustrates an alternate arrangement of a plurality of insulating gas cells that are in fluid connection with one another
  • Figure 4 illustrates yet another alternate arrangement of a plurality of insulating gas cells that are in fluid connection with one another
  • Figure 5 illustrates even yet another alternate arrangement of a plurality of insulating gas cells that are in fluid connection with one another.
  • the present invention is directed to a lightweight, gas-filled, highly insulative material having a cellular structure and methods for manufacturing the material.
  • the cellular structure can be incorporated into outdoor gear and apparel to make the outdoor gear or apparel warm, while still maintaining a desired thinness and flexibility.
  • the insulative material takes advantage of the superior insulative properties of dry gases and preferably highly insulative gasses such as argon.
  • the volume of the insulative gas in the insulative material can be adjustable such that the insulation provided by the outdoor gear or apparel can be selectable. Because the insulative component is a gas, the insulation value of the article can be adjusted by increasing or decreasing the amount of gas, without appreciably affecting the weight of the article.
  • the cellular structure can be used to insulate a variety of outdoor clothing and gear.
  • Figure 1 illustrates a schematic of single insulating gas cell 10 having X, Y, and Z dimensions.
  • X, Y, and Z dimensions are selected to reduce heat transfer by means of convection.
  • Convective heat transfer consists of both forced and natural convection. Forced convection is due to the induced movement of the gas in the gas-filled cell. For example, in the case of a gas-filled cell that is incorporated into a garment, forced convection can be caused by movement of the wearer. Natural convection is a rotational flow pattern of gas caused by the temperature differential between warm and cool regions of the cell and gas buoyancy. For example, in a gas filled insulating cell 10 like the one depicted in Figure
  • the gas adjacent to the cell 10 surface nearest to a source of heat is typically at a higher temperature and lower density than the gas at the surface of the cell closest to atmospheric conditions.
  • the hotter gas will rise and the cooler gas will replace the hotter gas thus setting off convective mixing of the gas within the cell 10.
  • This will increase the heat transfer through the cell 10, which is undesirable for insulation.
  • heat transfer is enhanced as the length of the free flowing path of the gas is increased. This is because convective mixing of the gas is allowed to more fully develop in these free flowing paths and thus heat transfer by convection is increased. This means that increasing the XYZ dimensions of the cell 10 depicted in Figure 1 will tend to increase the tendency of convection coils to form inside the cell 10, which increases heat loss.
  • the cell 10 structure is specifically designed to reduce both free and forced convection of the gas inside the cell 10. Free and forced convection are minimized by choosing cell volume and dimensions that break up the free flow path of the gas inside the cell 10 and thus reduce convective mixing or rotational motion of the gas in the cell 10.
  • a heat transfer model was developed that allows one to predict preferred cell dimensions (i.e., X, Y, and Z dimensions) in order to minimize natural convection and increase the insulating capabilities of the cell 10. These preferred cell dimensions for natural convection will also reduce heat transfer due to forced convection.
  • the model is developed by using both the Rayleigh value and the Nusselt number to predict the convective coefficient for the cell 10 under static conditions
  • the Rayleigh value is a correlation between the buoyancy and viscous forces of the gas inside the cell 10.
  • the Rayleigh value can be expressed as the following for the geometry used for the cell structure.
  • Equation 1 g represents gravity, B is the expansion coefficient for the gas, ⁇ is the thickness of the cell structure when inflated with the gas, P r is the Prandtl number, v is the kinematic viscosity of the gas, T B - T 0 is the temperature difference between the inner and outer wall of the cell 10.
  • the Rayleigh value is calculated using a value of 37 0 C for T B and -40 0 C for T 0 .
  • the Rayleigh value is used in turn to predict the Nusselt number, which quantifies convective heat transfer from the surfaces of the cell 10.
  • the Nusselt number is then used to calculate the total heat transfer through the cell 10.
  • Empirical correlations for the average Nusselt number for natural convection in enclosures were used to determine the Nusselt number based on the Rayleigh value and cell geometry.
  • the Rayleigh value is significantly influenced by the thickness (i.e., the Z dimension depicted in Figure 1) of the cell 10 and also the temperature difference between the inner and outer wall of the cell 10. Increasing the thickness will increases the free flowing path of the gas. When either the cell thickness or the temperature difference is increased than the Rayleigh value is increased which also causes the Nusselt number to increase. Equation 2 shows that as the Nusselt number is increased the total heat transfer in the cell is also increased. (T B - T 0 )
  • the equation for heat transfer also shows the importance of the thermal conductivity value, k of the gas used in the cell structure. The smaller the thermal conductivity of the gas the lower the total heat transfer through the cell structure. Thermal conductivity of the gas is a function of the gas type (i.e., some gases are better insulators than other gases), the moisture content of the gas (i.e., increased water content increases the thermal conductivity of the gas), and on the temperature.
  • the preferred dimensions for minimal heat transfer through the cell 10 occur at a preferred Rayleigh value less than 300,000. More preferably, the Rayleigh value of the cell is in a range from about 50,000 to about 275,000. Most preferably, the Rayleigh value of the cell is in a range from about 125,000 to about 250,000. Rayleigh values greater than 300,000 will cause the insulative cell to perform less optimally due to convective heat transfer. This will reduce the effectiveness of the gas cell 10 as an insulator.
  • the present invention includes a gas-filled, highly insulative cell 10.
  • the cell 10 includes a first sheet of a gas impermeable material and a second sheet of a gas impermeable material joined together to form a cell 10.
  • the cell 10 depicted in Figure 1 is attached to a dry gas reservoir 12 and a valve mechanism 16 configured to allow the dry insulating gas to the introduced into and removed from the cell 10.
  • valve 12 can be a Schrader valve or similar valve for controlling the flow of a gas.
  • the cell 10, the gas reservoir 12, and the valve mechanism are connected to the cell 10 by means of a gas line 14.
  • the volume and XYZ dimensions of the cell are chosen such that free and forced convective mixing of gas inside the cell is minimized.
  • the cell 10 includes a dry insulative gas disposed within the cell 10.
  • the identity of the insulating gas is an important factor is determining the insulative properties of the cell 10.
  • dry gases insulate better than moist gases
  • monatomic gases insulate better than diatomic or polyatomic gases
  • heavy, viscous gases insulate better than lighter, less viscous gases.
  • the gas disposed within the cell 10 has a moisture content less than about 4 percent by weight. More preferably, the gas disposed within the cell 10 has a moisture content less than about 2 percent by weight. Most preferably, the gas disposed within the cell 10 has a moisture content less than about 1 percent by weight.
  • the insulating gas can be selected from the group consisting of atmospheric air, argon, krypton, xenon, carbon dioxide, sulfur hexafluoride, and combinations thereof. In one embodiment, the preferred Rayleigh value for the cell 10 is less than
  • the Rayleigh value of the cell is in a range from about 50,000 to about 275,000. Most preferably, the Rayleigh value of the cell is in a range from about 125,000 to about 250,000. Based on a preferred Rayleigh value of less than 300,000, preferred X, Y, and Z dimensions for the cell 10 depicted in Figure 1 were determined.
  • the cell volume is less than about 300 cm 3 with XYZ dimensions of less than about 7 cm by about 14 cm by about 3 cm. More preferably, the cell volume is less than about 145 cm 3 with XYZ dimensions of less than about 4 cm by about 12 cm by about 3 cm.
  • the cell volume is less than about 100 cm 3 with XYZ dimensions of less than about 4 cm by about 8 cm by about 3 cm. These dimensions minimize heat transfer due to both forced and natural convection.
  • INSULATIVE MATERIAL HAVING CELLULAR STRUCTURE In one embodiment of the present invention, a plurality of insulative cells as depicted in Figure 1 are grouped together to form an insulative cell structure. Figures 2-5 depict various arrangements of the plurality of cells 10 that form a cell structure.
  • the cell structure 20 comprises a first sheet of a gas impermeable material and a second sheet of a gas impermeable material that are joined together to form a chamber there between.
  • the chamber is subdivided into a cellular structure comprising a plurality cells 10.
  • the first and second sheets are bonded together such that there are open sections that form the cells 10.
  • the cells 10 are in fluid communication with one another.
  • the cells 10 are in fluid connection with one another via short connector tubes 26 and 28 that allow gas to flow between cells 10. It should be mentioned, however, that the connector tubes 26 and 28 do not enhance convection within the cells 10. That is, the connector tubes 26 and 28 are sufficiently small and they are placed such that convection currents do not form between adjacent cells 10.
  • a dry insulating gas is disposed within the plurality of cells 10.
  • the identity of the insulating gas is an important factor is determining the insulative properties of the insulative article 20.
  • dry gases insulate better than moist gases, monatomic gases insulate better than diatomic or polyatomic gases, and heavy, viscous gases insulate better than lighter, less viscous gases.
  • the gas disposed within the cells 10 has a moisture content less than about 4 percent by weight. More preferably, the gas disposed within the cells 10 has a moisture content less than about 2 percent by weight. Most preferably, the gas disposed within the cells 10 has a moisture content less than about 1 percent by weight.
  • the insulating gas is selected from the group consisting of atmospheric air, argon, krypton, xenon, carbon dioxide, sulfur hexafluoride, and combinations thereof.
  • the insulative article 20 depicted in Figure 2 is depicted as it may be attached to a dry gas reservoir 12 and a valve mechanism 16 configured to allow the dry insulating gas to be introduced into and removed from the cells 10 comprising the insulative article 20.
  • the insulative article 20 is connected to the gas reservoir 12, and the valve mechanism 16 via a gas line 14.
  • the connector tubes 26 and 28 depicted in Figure 2 allow gas introduced into one cell 10 to fill all cells 10 in the insulative article 20.
  • the volume and X dimension 22, Y dimension 24, and Z dimension (not shown) of the cells 10 are chosen such that free and forced convective mixing of gas inside the cell is minimized. Minimizing free and forced convection of the gas inside the plurality of cells 10 increases the insulative efficiency of the insulative article 20.
  • the preferred Rayleigh value for the each of the plurality of cells 10 is less than about 300,000. More preferably, the Rayleigh value of the cell is in a range from about 50,000 to about 275,000. Most preferably, the Rayleigh value of the cell is in a range from about 125,000 to about 250,000.
  • the cell volume is less than about 300 cm 3 with XYZ dimensions of about 7 cm by about 14 cm by about 3 cm. More preferably, the cell volume is less than about 145 cm 3 with XYZ dimensions of about 4 cm by about 12 cm by about 3 cm. Most preferably, the cell volume is less than about 100 cm 3 with XYZ dimensions of about 4 cm by about 8 cm by about 3 cm. These dimensions minimize heat transfer due to both forced and natural convection.
  • the first and second sheets of material that form the plurality of cells 10 that comprise the insulative article 20 are comprised of a fabric, such as nylon, polyester, or spandex, bonded to a gas impermeable material.
  • gas impermeable materials include, but are not limited to, polyethylene, polypropylene, polyurethane, urethane, silicone rubber, latex rubber, polytetrafluoroethylene (PTFE), expanded PTFE, butyl rubber, and Mylar.
  • Figure 3 depicts an alternate arrangement of a plurality of cells 10 to form an insulative article 30.
  • the cells 10 are formed as open space between two sheets of gas impermeable material that are bonded together to form a plurality of cells 10. Bonded regions 36 are formed between the cells 10.
  • the cells 10 are arranged in a zigzag fashion with adjacent cells 10 arranged at substantially right angles relative to one another.
  • Each cell 10 has an X dimension 32, a Y dimension 34, and a Z dimension (not shown).
  • the Y dimension 34 is depicted in part by an imaginary line that extends into the adjacent cell.
  • the cell is bounded by the dotted lines because gas atoms traveling through the center of the cell have a free motion that is essentially bounded by these dimensions since most the gas atoms bouncing off the walls will stay within this space.
  • each of the cells 10 are chosen such that heat loss through convection is minimized. Even though the cells are connected, the formation of convection currents that lead to heat loss are minimized because the right angles break up the free flow path of any convection currents that may form. That is, rotational convection currents generally cannot form around right angles. Heat loss through convection is minimized if the Rayleigh value for the each of the plurality of cells 10 is preferably less than about 300,000. More preferably, the Rayleigh value of the cell is in a range from about 50,000 to about 275,000. Most preferably, the Rayleigh value of the cell is in a range from about 125,000 to about 250,000.
  • the cell volume is less than about 300 cm 3 with XYZ dimensions of about 7 cm by about 14 cm by about 3 cm. More preferably, the cell volume is less than about 145 cm 3 with XYZ dimensions of about 4 cm by about 12 cm by about 3 cm. Most preferably, the cell volume is less than about 100 cm 3 with XYZ dimensions of about 4 cm by about 8 cm by about 3 cm. These dimensions minimize heat transfer due to both forced and natural convection.
  • Figure 4 depicts another alternate arrangement of a plurality of cells 10 to form an insulative article 40.
  • the arrangement is similar to the arrangement depicted in Figure 2.
  • the cells 10 are formed as open space between two sheets of gas impermeable material that are bonded together to form a plurality of cells 10. Bonded regions 49 are formed between the cells 10.
  • the cells are in fluid connection with one another via connector tubes (46 and 48) between the cells.
  • each of the plurality of cells 10 have an X dimension 42, a Y dimension 44, and a Z dimension (not shown).
  • the XYZ dimensions are chosen according to the preferred Rayleigh value of less than 300,000 so as to minimize heat loss through convection of the gas within the cells 10.
  • Figure 5 depicts another alternate arrangement of a plurality of cells 10 to form an insulative article 50.
  • the arrangement is similar to the arrangement depicted in Figure 3.
  • the cells 10 are formed as open space between two sheets of gas impermeable material that are bonded together to form a plurality of cells 10. Bonded regions 58 are formed between the cells 10.
  • the cells are in fluid connection with one another via connector tubes 56 between the cells.
  • each of the plurality of cells 10 have an X dimension 52, a Y dimension 54, and a Z dimension (not shown).
  • the XYZ dimensions are chosen according to the preferred Rayleigh value of less than 300,000 so as to minimize heat loss through convection of the gas within the cells 10.
  • the insulative articles depicted in Figures 2-5 may be used to insulate outdoor apparel.
  • Exemplary outdoor apparel items include, but are not limited to, coats, parkas, jackets, vests, gloves, mittens, hats, liners, and boots.
  • the insulative articles depicted in Figures 2-5 may be used to insulate outdoor gear.
  • Exemplary outdoor gear items include, but are not limited to, tents, sleeping bags, bivouac bags, and sleeping pads.
  • the present invention includes a method for manufacturing a lightweight, gas-filled, highly insulative material.
  • the method comprises steps of (1) providing a first sheet of a gas impermeable material and a second sheet of a gas impermeable material; (2) welding the first and seconds sheets of gas impermeable material together to form a chamber having a cell structure comprising a plurality cells that are in fluid communication; (3) providing a valve mechanism configured to allow an insulating gas to be introduced into and removed from the plurality of cells; and (4) filling the plurality of cells with a dry insulating gas selected from the group consisting of argon, krypton, xenon, carbon dioxide, sulfur hexafluoride, and combinations thereof.
  • dry atmospheric air can also be used, although the foregoing dry gases are preferred.
  • the insulating gas used to fill the plurality of cells has a moisture content less than about 4 percent by weight. More preferably, the insulating gas used to fill the plurality of cells has a moisture content less than about 2 percent by weight. Most preferably, the insulating gas used to fill the plurality of cells has a moisture content less than about 1 percent by weight.
  • the first and second sheets that form the cellular structure comprise a fabric, such as nylon, polyester, or spandex, bonded or laminated to a gas impermeable material.
  • a gas impermeable material Preferably the materials used to form the insulative material are flexible such that the insulative material can be wearable or useable next to a person's body.
  • suitable gas impermeable materials include, but are not limited to, polyethylene, polypropylene, polyurethane, urethane, silicone rubber, latex rubber, polytetrafluoroethylene (PTFE), expanded PTFE, butyl rubber, and Mylar.
  • Exemplary techniques to welding the first and seconds sheets of gas impermeable material together to form a chamber having a cell structure comprising a plurality cells that are in fluid communication include, but are not limited to, ultrasonic welding, laser welding, stamp heat welding, hot plate welding, gluing, taping, sewing, and other fabric joining techniques known by those having skill in the art.
  • the repeating patterns of cells examples of which are depicted in Figures 2-5, can be formed by welding two sheets if gas impermeable fabric together with an ultrasonic welding drum or a hot plate welding drum that is machined to impress the pattern into the sheets of fabric.
  • the method further comprises choosing a volume and cell dimensions for each of the plurality of cells such that the Rayleigh value of each of the plurality of cells is less than about 300,000. Based on a preferred Rayleigh value of less than about 300,000, preferred dimensions for each of the plurality of cells 10 depicted in Figure 3 were determined.
  • the cell volume is less than about 300 cm 3 with XYZ dimensions of about 7 cm by about 14 cm by about 3 cm.
  • the cell volume is less than about 145 cm 3 with XYZ dimensions of about 4 cm by about 12 cm by about 3 cm. Most preferably, the cell volume is less than about 100 cm 3 with XYZ dimensions of about 4 cm by about 8 cm by about 3 cm. These dimensions minimize heat transfer due to both forced and natural convection.
  • the method disclosed herein further comprises incorporating the insulative material into an article of outdoor apparel and/or outdoor gear.
  • articles of outdoor apparel and/or outdoor gear include, but are not limited to, coats, parkas, jackets, vests, pants, gloves, mittens, hats, liners, snow boots, work boots, ski boots, snowboard boots, tents, sleeping bags, bivouac bags, and sleeping pads.
  • the insulative material can be an integral component of the article of outdoor gear or apparel.
  • the insulative material can form part of the wall of a jacket or ski pant.
  • the insulative material can be used to make a hat where all or part of the hat is the insulative material with a cellular structure.
  • the insulative material can be used as a liner in a sleeping bag or it can be sewn such that the insulative material is a permanent component of the sleeping bag.
  • the liner can be used as the fabric portion of the wall of a tent.
  • the insulative material can be used in the floor of the tent to provide a barrier between a person and the ground.
  • the insulative material can be used as a sleeping pad to provide insulated separation between a person and the ground.
  • the insulative material can be overlaid or attached as a liner to the article of outdoor gear or apparel.
  • the insulative material can be attached using a zipper, snaps, hook and loop fastener (i.e., Velcro), or any other suitable connection means.
  • the insulative material can be incorporated into a vest or jacket that can zip into the shell of a coat. This mechanism allows the insulative material to be selectively used or removed depending on weather condition.

Landscapes

  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Professional, Industrial, Or Sporting Protective Garments (AREA)

Abstract

L'invention concerne une structure cellulaire légère, remplie de gaz et hautement isolante et des procédés de fabrication de la structure cellulaire. La structure cellulaire peut être intégrée dans un équipement ou un vêtement de plein air pour chauffer l'équipement ou le vêtement de plein air, tout en maintenant la finesse et la souplesse souhaitées. L'article d'isolation a l'avantage de posséder les propriétés isolantes supérieures des gaz secs et, de préférence, des gaz hautement isolants tels que l'argon. De plus, la dimension et la forme des cellules de la structure cellulaire sont sélectionnées de manière à minimiser la convection.
PCT/US2008/059078 2007-04-06 2008-04-02 Materiau d'isolation mince possedant une structure cellulaire remplie de gaz WO2008124414A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
CA002682982A CA2682982A1 (fr) 2007-04-06 2008-04-02 Materiau d'isolation mince possedant une structure cellulaire remplie de gaz
EP08744895.7A EP2136989A4 (fr) 2007-04-06 2008-04-02 Materiau d'isolation mince possedant une structure cellulaire remplie de gaz

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
US91048507P 2007-04-06 2007-04-06
US60/910,485 2007-04-06
US12/013,326 US20080249276A1 (en) 2007-04-06 2008-01-11 Thin insulative material with gas-filled cellular structure
US12/013,326 2008-01-11
US3875208P 2008-03-22 2008-03-22
US61/038,752 2008-03-22

Publications (1)

Publication Number Publication Date
WO2008124414A1 true WO2008124414A1 (fr) 2008-10-16

Family

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Application Number Title Priority Date Filing Date
PCT/US2008/059078 WO2008124414A1 (fr) 2007-04-06 2008-04-02 Materiau d'isolation mince possedant une structure cellulaire remplie de gaz

Country Status (3)

Country Link
EP (1) EP2136989A4 (fr)
CA (1) CA2682982A1 (fr)
WO (1) WO2008124414A1 (fr)

Cited By (2)

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Publication number Priority date Publication date Assignee Title
US9756955B2 (en) 2009-11-09 2017-09-12 Argon Technologies, Inc. Inflatable pad and methods for using same
WO2022125156A3 (fr) * 2020-08-27 2022-10-27 Liqui-Box Corporation Sacs souples et produits contenus à l'intérieur à durée de conservation prolongée

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US5270092A (en) * 1991-08-08 1993-12-14 The Regents, University Of California Gas filled panel insulation
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US4547906A (en) * 1983-06-27 1985-10-22 Kanebo, Ltd. Heat retaining article
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US4336292A (en) * 1980-07-11 1982-06-22 Rohr Industries, Inc. Multi-layer honeycomb thermo-barrier material
US4678693A (en) * 1986-01-29 1987-07-07 J. E. Morgan Knitting Mills, Inc. Insulating fabric and method of manufacture thereof
US5270092A (en) * 1991-08-08 1993-12-14 The Regents, University Of California Gas filled panel insulation
US6114003A (en) * 1997-09-04 2000-09-05 No Fire Technologies, Inc. Insulation blanket having an inner metal core air cell and adjoining outer insulation layers
US7169459B2 (en) * 2002-05-15 2007-01-30 L'garde, Inc. Collapsible cellular insulation

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See also references of EP2136989A4 *

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9756955B2 (en) 2009-11-09 2017-09-12 Argon Technologies, Inc. Inflatable pad and methods for using same
US10799031B2 (en) 2009-11-09 2020-10-13 Argon Technologies, Inc. Inflatable pad and methods for using the same
WO2022125156A3 (fr) * 2020-08-27 2022-10-27 Liqui-Box Corporation Sacs souples et produits contenus à l'intérieur à durée de conservation prolongée

Also Published As

Publication number Publication date
CA2682982A1 (fr) 2008-10-16
EP2136989A1 (fr) 2009-12-30
EP2136989A4 (fr) 2016-01-20

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