WO2019222457A1 - Composite materials and methods of manufacture - Google Patents

Composite materials and methods of manufacture Download PDF

Info

Publication number
WO2019222457A1
WO2019222457A1 PCT/US2019/032600 US2019032600W WO2019222457A1 WO 2019222457 A1 WO2019222457 A1 WO 2019222457A1 US 2019032600 W US2019032600 W US 2019032600W WO 2019222457 A1 WO2019222457 A1 WO 2019222457A1
Authority
WO
WIPO (PCT)
Prior art keywords
textile layer
composite material
article
filler
baffle structures
Prior art date
Application number
PCT/US2019/032600
Other languages
French (fr)
Inventor
John Ly
Original Assignee
The North Face Apparel Corp.
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
Application filed by The North Face Apparel Corp. filed Critical The North Face Apparel Corp.
Publication of WO2019222457A1 publication Critical patent/WO2019222457A1/en

Links

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
    • B32B3/02—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 features of form at particular places, e.g. in edge regions
    • B32B3/08—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 features of form at particular places, e.g. in edge regions characterised by added members at particular parts
    • B32B3/085—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 features of form at particular places, e.g. in edge regions characterised by added members at particular parts spaced apart pieces on the surface of a layer
    • 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
    • B32B5/02—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
    • B32B5/026—Knitted 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
    • B32B5/06—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 characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • 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
    • B32B7/02—Physical, chemical or physicochemical properties
    • 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
    • B32B7/02—Physical, chemical or physicochemical properties
    • B32B7/027—Thermal properties
    • 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
    • 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
    • B32B7/09—Interconnection of layers by mechanical means by stitching, needling or sewing
    • 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
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • 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
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/02—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising animal or vegetable substances, e.g. cork, bamboo, starch
    • 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
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/047—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material made of fibres or filaments
    • 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
    • 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
    • B32B2250/02—2 layers
    • 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
    • B32B2250/03—3 layers
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • 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
    • B32B2262/0253—Polyolefin 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
    • B32B2262/02—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
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    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B32B2262/08—Animal fibres, e.g. hair, wool, silk
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/00—Properties of the layers or laminate
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    • B32B2307/724—Permeability to gases, adsorption
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    • B32B2307/00—Properties of the layers or laminate
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    • B32B2307/724—Permeability to gases, adsorption
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    • B32B2307/7246—Water vapor barrier
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B32B2307/7265—Non-permeable
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/00—Properties of the layers or laminate
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    • B32B2307/73—Hydrophobic
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2437/00—Clothing
    • 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
    • B32B2437/00—Clothing
    • B32B2437/02—Gloves, shoes
    • 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
    • B32B2437/00—Clothing
    • B32B2437/04—Caps, helmets

Definitions

  • a material comprising a filler may comprise stitching configured to prevent movement of the filler within the material.
  • the stitching may comprise stitched compartments. Stitching the material and filling the stitched compartments with the filler may account for inefficiencies in the manufacture of the material. Additionally, the material comprising filled stitched compartments may not have a uniform thermal insulation and/or may not maintain a uniform temperature throughout the material.
  • a composite material may comprise a plurality of baffles.
  • the plurality of baffles may be arranged in a pattern within the composite material.
  • the plurality of baffles may be configured to control movement of a filler within the composite material.
  • An article comprising the composite material may be manufactured.
  • the last step of manufacturing the article may comprise inserting the filler in the composite material.
  • the filler may fill gaps between the plurality of baffles and textile layers of the composite material.
  • FIG. 1 shows an example composite material.
  • FIG. 2 shows an example composite material
  • FIG. 3 shows an example method.
  • FIG. 4 shows an example article.
  • FIG. 5 shows an example article.
  • FIG. 1 shows an example composite material 100.
  • the composite material 100 may comprise a first textile layer 101, a filler 102, a second textile layer 103, and a plurality of baffle structures 104.
  • the plurality of baffle structures 104 may be disposed between the first textile layer 101 and the second textile layer 103.
  • the filler 102 may be disposed between the first textile layer 101 and second textile layer 103.
  • the filler 102 may be disposed between the plurality of baffle structures 104.
  • the composite material 100 may be configured to control movement of the filler 102, such as between the first textile layer 101 and the second textile layer 103.
  • the composite material 100 may be configured to control movement of the filler 102 when an article comprising the composite material 100 is in normal use.
  • the body of a jacket may be made of the composite material 100 and the filler 102 may comprise down.
  • the composite material 100 may be configured to prevent the down from moving to the bottom of the jacket when the jacket is worn.
  • the first textile layer 101 and the second textile layer 103 may comprise the same material or different material.
  • the first textile layer 101 and/or the second textile layer 103 may comprise a woven material, such as nylon taffeta woven or polyester taffeta woven.
  • the first textile layer 101 and/or the second textile layer 103 may comprise a fiber proof material.
  • the first textile layer 101 and/or the second textile layer 103 may comprise a knit material.
  • the first textile layer 101 and/or the second textile layer 103 may comprise a synthetic material, such as polyester, polypropylene, or a blend.
  • the first textile layer 101 and/or the second textile layer 103 may comprise a non-synthetic material, such as cotton or wool.
  • the first textile layer 101 and/or the second textile layer 103 may comprise a blend of fibers.
  • the first textile layer 101 and/or the second textile layer 103 may comprise a wind-resistant or windproof material.
  • Wind resistance of a material may be described by an amount of cubic feet per minute (CFM) of about a 30-mile-per-hour wind that can pass through one square foot of the material. Wind resistance may be determined using a standardized test such as ASTM D737.
  • the first textile layer and/or the second textile layer may comprise a windproof material having a permeability of 0-2 or 3-4 CFM.
  • the first textile layer and/or the second textile layer may comprise a wind-resistant material having a permeability of 5-20 CFM.
  • the first textile layer and/or the second textile layer may comprise a waterproof material.
  • the waterproof material may comprise a material treated with a durable water- repellant (DWR) finish.
  • the DWR finish may cause the material to repel water, such as by causing the water to bead up and roll of a surface of the material.
  • Waterproofing may be based on a water column test that measures water permeability under pressure.
  • the water column test may comprise placing a one-inch diameter column of water over the material for a time period of twenty-four hours. Waterproofness may describe the height of a column that may be filled before water permeates the material within the time period. Waterproofness may be determined using a standardized test, such as AATCC 127, AATCC 35, AATCC 22, or ISO 811.
  • the material may comprise a super waterproof material having a water column test rating of greater than 20,000 mm/24 hours.
  • the material may comprise a very waterproof material having a water column test rating of greater than 15,000 mm/24 hours and up to 20,000 mm/24 hours.
  • the material may comprise a waterproof material having a water column test rating of greater than 10,000 mm/24 hours and up to 15,000 mm/24 hours.
  • the material may comprise a somewhat waterproof material having a water column test rating of greater than 5,000 mm/24 hours and up to 10,000 mm/24 hours.
  • the material may comprise a water resistant material having a water column test rating of around 5,000 mm/24 hours.
  • the first textile layer 101 and/or the second textile layer 103 may comprise a non-breathable material or a breathable material. Breathability of a material may be described by an amount of water vapor that can pass through a square meter of the material during a time frame of twenty -four hours. Breathability may be determined using a standardized test, such as BS7209 or ASTM E96.
  • the non-breathable material may have a breathability of 5,000 g/m 2 - 9,000 g/m 2 , for example.
  • the breathable material may have a breathability of 10,000 g/m 2 - 25,000 g/m 2 , for example.
  • the first textile layer 101 and/or the second textile layer 103 may comprise a downproof material. Downproofness of a material may be described by a rating determined by a standardized test, such as EN 12131-1, EN 12131-2, GB/T 12705.1, GB/T 12705.2, GB/T 14272, or“International Rotating Box” test (TMS or IDFL-20). As measured by the
  • the downproof material may have a number of total particles escaped or protruding of 0-5, 6-11, or 12-22.
  • the downproof material may prevent the escape or movement of the filler 102, such as to the exterior of the composite material 100.
  • the material of the first textile layer 101 and/or the second textile layer 103 may be selected based on an article to be manufactured with the composite material 100.
  • the material may be selected based on desired properties of the article, such as strength, elasticity, size, cost, appearance, weight, insulation, comfort of the article.
  • the material may be selected based on the type of article, such as sports equipment, athletic apparel, cold weather apparel, luggage, etc.
  • the material may be selected based on properties of the material, such as softness, strength, modulus of elasticity, insulation, water resistance, or wind resistance, etc.
  • the first textile layer 101 and/or the second textile layer 103 may be configured to form an exterior or an interior of an article.
  • the interior may comprise a side of the article that is in contact with a body of a user when the apparel is worn or a side of the article that is closer to the body of the user when the apparel is worn.
  • the exterior may comprise a side of the article that is exposed to the environment outside the apparel when the apparel is worn.
  • the material comprising the first textile layer 101 and/or the material comprising the second textile layer 103 may be selected based on whether the layer will form the exterior or the interior of the article. For example, a material that is water-resistant or wind-resistant may be selected for the exterior layer. As another example, a soft or breathable material may be selected for the interior layer. A material that is less water-resistant and/or less wind-resistant than the material selected for the exterior layer may be selected for the interior layer.
  • the first textile layer 101 and the second textile layer 103 may each comprise a sheet.
  • the sheets may have perimeters. At least a portion of the perimeter of the first textile layer 101 sheet may be joined to at least a portion of the perimeter of the second textile layer 103 sheet, such as by sewing, gluing, weaving, or welding.
  • the joining of the sheets may be configured to hold the filler between the sheets.
  • the joining of the sheets may be configured to hold the filler between the plurality of baffle structures.
  • the filler 102 may comprise an insulating material.
  • the insulating material may be configured to maintain a thermal temperature, such as between the first textile layer 101 and the second textile layer 103.
  • the filler 102 may a natural fiber, such as down or wool.
  • the filler 102 may comprise fleece or shelled microfleece.
  • the filler 102 may comprise a synthetic material, such as a synthetic microfiber blend (e.g., Primaloft, Thinsulate, Thermolite, or Quallofil).
  • the filler 102 may comprise a thermoball insulation, such as polyester balls. The thermoballs may be blown into the spaces between the first textile layer 101 and the second textile layer 103.
  • the filler 102 may have an insulation value of .1-.8 clo, as measured by the ASHRAE-55 standard test.
  • the filler 102 may have an R-value of 1.6-2.9 per inch, as defined by ASTM C168.
  • FIG. 2 shows a plurality of baffle structures 104.
  • the baffle structures 104 may be coupled to the first textile layer 101.
  • the baffle structures 104 may be coupled to the second textile layer 103.
  • the baffle structures 104 may be coupled to the first textile layer 101 and/or the second textile layer 103 by bonding, such as with adhesive or with welding.
  • the baffle structures 104 may be arranged in a pattern.
  • the pattern may be configured to control movement of the filler 102.
  • the pattern may be configured to minimize movement of the filler 102 within the composite material 100.
  • the filler 102 may rest on the baffle structures 104.
  • the baffle structures 104 may comprise barriers that prevent the filler 102 from moving in the direction of the force of gravity or in a direction of force acting upon the composite material 100 or an article comprising the composite material 100.
  • the baffle structures 104 may prevent the filler 102 from migrating from one portion of the article to another portion of the article.
  • the baffle structures 104 may prevent filler from a thigh portion of a pant from moving to a knee portion of the pant.
  • the pattern may be configured to control movement of the filler 102 when an article comprising the composite material 100 is in use.
  • the baffle structures 104 may maintain the filler 102 in a fixed position to maintain a uniform distribution of the filler 102 throughout the composite material 100.
  • the uniform distribution of the filler 102 may result in a uniform temperature or thermal insulation throughout the composite material 100.
  • the pattern may be selected based on the type of filler 102.
  • the pattern may be selected based on a weight or thickness of the filler 102.
  • the pattern may be selected based on a type of article to be manufactured using the composite material 100.
  • the pattern may comprise a distance between the plurality of baffle structures.
  • FIG. 2 shows baffle structures 104 that are evenly spaced. However, other distances or spacing is possible.
  • the pattern may comprise rows and/or columns of the plurality of baffle structures.
  • FIG. 2 shows columns of baffle structures 104 that are staggered. However, other arrangements of rows and/or columns of baffle structures 104 are possible.
  • the pattern of the baffle structures 104 may be selected based on the shape of the baffle structures 104.
  • the baffle structures 104 may have a shape. As an example, FIG. 2 shows baffle structures 104 having a biconcave shape. However, other baffle structure 104 shapes are possible. Non-limiting examples of baffle structure 104 shapes include biconvex shapes, plano- concave shapes, plano-convex shapes, polygonal shapes, circular shapes, triangular shapes, quadrilateral shapes, wave shapes, linear shapes, crescent shapes, and/or arc shapes.
  • the composite material 100 may comprise baffle structures 104 of a same shape or of different shapes. For example, different regions of the composite material 100 may comprise baffle structures 104 of different shapes.
  • the shape of the baffle structures 104 may be configured and/or selected to control movement of the filler 102. The shape may be selected based on the type of the filler, a type of article to be manufactured using the composite material 100, as examples. The shape of the baffle structures 104 may be selected based on the pattern of the baffle structures 104.
  • FIG. 3 shows an example method 300.
  • the baffle structures 104 may be coupled to the first textile layer 101. Coupling the baffle structures 104 may comprise bonding the baffle structures 104, such as with adhesive. Coupling the baffle structures 104 may comprise welding the baffle structures 104 to the first textile layer 101. Coupling the baffle structures 104 may comprise nailing, screwing, or stapling the baffle structures 104 to the first textile layer 101.
  • the baffle structures 104 may be coupled to the second textile layer 103. Coupling the baffle structures 104 may comprise bonding the baffle structures 104, such as with adhesive. Coupling the baffle structures 104 may comprise welding the baffle structures 104 to the second textile layer 103, such as sonically welding the baffle structures 104 to the second textile layer 103. Coupling the baffle structures 104 use a sonic coupling technology. Coupling the baffle structures 104 may use a radio frequency (RF) technology. Coupling the baffle structures 104 may comprise stitching the baffle structures 104 to the second textile layer 103. Coupling the baffle structures 104 may comprise nailing, screwing, or stapling the baffle structures 104 to the second textile layer 103.
  • RF radio frequency
  • At least a portion of the first textile layer 101 may be coupled to at least a portion of the second textile layer 103.
  • the portion of the first textile layer 101 may be stitched or woven with the portion of the second textile layer 103.
  • the filler 102 may be inserted between the first textile layer 101 and the second textile layer 103.
  • the filler 102 may be inserted between the baffle structures 104. Inserting the filler 102 may comprise injecting the filler 102. Inserting the filler 102 may comprise blowing the filler 102 into the spaces between the layers 101, 103 and the baffle structures 104.
  • the filler 102 comprises thermoballs or another blowable material, the thermoballs may be blow into the spaces.
  • the inserting the filler 102 in the composite material 100 may be more efficient.
  • filler may be inserted in each compartment, individually.
  • the filler 102 may be inserted in the composite material 100 at once. The filler 102 may disperse and fill the gaps between the first textile layer 101, the second textile layer 103, and the filler 102.
  • the composite material 100 may be used to manufacture an article.
  • the article may comprise a blanket or a covering.
  • the article may comprise sporting equipment or outdoor equipment.
  • the article may comprise sporting equipment lining, such a lining of a helmet.
  • the article may comprise an article of apparel, such as a jacket, pants, a hat, gloves, a jumpsuit, or other outerwear.
  • the filler 102 of the composite material 100 may be more uniformly distributed throughout the material 100. If filler is inserted in compartments, the amount of filler, such as the volume of filler, inserted in each compartment may vary. In contrast, when the filler 102 is injected in the composite material 100, the filler 102 may be forced into the cavities between the two layers 101, 103 and the baffle structure 104 until the cavities are full. Thus, the areas between the layers 101, 103 and the baffle structure 104 may hold the same or similar amounts or volumes of the filler 102. As a material comprising compartments is used, the filler may accumulate towards one area or side of the compartments.
  • the filler may fall to the bottom of the compartments due to gravity or motion or the user.
  • the baffle structure 104 may keep the filler 102 from changing position within the material 100.
  • the filler 102 may be more evenly distributed throughout the material 100, such as along a width, length or surface area of the material 100.
  • the distribution of the filler 102 may affect thermal insulation or temperature of the material 100.
  • the composite material 100 may be have a more uniform thermal insulation throughout the composite material 100.
  • FIG. 4 shows an example pattern 400 for an article comprising the composite material 100.
  • FIG. 4 shows an example pattern 400 for an article comprising a jacket, however a similar pattern may be used for a different type of article comprising the composite material 100.
  • the pattern 400 may comprise a differential in dimensions of the first textile layer 101 and the second textile layer 103, wherein one of the layers may comprise an interior layer 405 and an exterior layer 406.
  • the differential may be configured to provide space for the baffle structures 104 and/or the filler 102 between the interior layer 405 and the exterior layer 406.
  • the differential may be configured to facilitate the inserting of the filler 102 between the interior layer 405 and the exterior layer 406, such as in a last step of the process of manufacturing the article and/or inserting the filler 102 throughout the composite material 100 at once.
  • the interior layer 105 may have a circumference that is less than a circumference of the exterior layer.
  • FIG. 4 shows a pattern 400a of a 10.5 inch sleeve opening portion of the jacket.
  • the pattern 400a comprises circular patterns of an interior layer 405 and an exterior layer 406 having a warmth differential of 1.497.
  • the warmth differential may comprise a temperature or insulation of a portion of the composite material 100 relative to temperatures or insulations of other portions of the composite material 100.
  • FIG. 4 shows a pattern 400b of a 21 inch bicep portion of the jacket.
  • the pattern 400b comprises circular patterns of an interior layer 405 and an exterior layer 406 having a warmth differential of 1.622.
  • FIG. 4 shows a pattern 400c of a 30 inch hood portion of the jacket.
  • the pattern 400c comprises circular patterns of an interior layer 405 and an exterior layer 406 having a warmth differential of 1.531.
  • other dimensions, portions of the article, and warmth differentials are possible.
  • FIG. 5 shows an example pattern 500 for an article comprising the composite material 100.
  • Z-axis pieces 519 may correspond to dimensions of one or more side walls of a garment comprising the composite material 100.
  • the side walls may be configured to eliminate compression of filler in particular areas of the garment, such as at openings.
  • Interior layers 509, 510, 511, 512, and 513 have different dimensions than exterior layers 514, 515, 516, 517, and 518.
  • Exterior layers 514, 515, 516, 517, and 518 have greater dimensions than interior layers 509, 510, 511, 512, and 513.
  • the dimensions may be selected based on a desired warmth differential between the exterior layers 514, 515, 516, 517, and 518 and the interior layers 509, 510, 511, 512, and 513.
  • the warmth differentials may be based on a portion of the pattern of the article to be formed with the layers.
  • Examples of a portion of a pattern for a jacket, sweater, shirt, dress, or vest may comprise a sleeve, a forearm portion of a sleeve, an elbow portion of a sleeve, a bicep portion of a sleeve, a shoulder portion of a sleeve, a hood, a pocket portion, or an abdominal portion, as examples.
  • Examples of a portion of a pattern for pants or shorts may comprise an ankle portion, a calf portion, a knee portion, a thigh portion, a crotch portion, a waist portion, or a pocket portion, as examples.
  • the present disclosure comprises at least the following aspects.
  • a composite material comprising: a first textile layer; a second textile layer; and a plurality of baffle structures coupled to the first textile layer and the second textile layer, wherein the plurality of baffle structures are positioned to control movement of a filler disposed between the first textile layer and the second textile layer.
  • Aspect 2 The composite material of aspect 1, further comprising the filler.
  • Aspect 3 The composite material of aspect 2, wherein the filler comprises down.
  • Aspect 4 The composite material of aspect 2, wherein the filler comprises an insulative material.
  • Aspect 5 The composite material of aspect 1, wherein the plurality of baffle structures are bonded to the first textile layer and the second textile layer.
  • Aspect 6 The composite material of aspect 1, wherein the first textile layer comprises a first material and the second textile layer comprises a second material different than the first material.
  • Aspect 7 The composite material of aspect 6, wherein the first material and the second material have a different at least one of water resistance, wind resistance, or permeability.
  • Aspect 8 The composite material of aspect 1, wherein at least one of the first textile layer or the second textile layer comprises a synthetic material.
  • Aspect 9 The composite material of aspect 1, wherein at least a portion of the first textile layer and at least a portion of the second textile layer are coupled.
  • Aspect 10 The composite material of aspect 9, wherein the at least a portion of the first textile layer and the at least a portion of the second textile layer are coupled by stitching. [0043] Aspect 11. An article of manufacture comprising the composite material of any of aspects 1-10.
  • Aspect 12 The article of manufacture of aspect 11, wherein the article of apparel comprises an interior and an exterior each comprising the composite material of any of aspects 1-10.
  • Aspect 13 The article of manufacture of aspect 12, wherein the interior has a first dimension and the exterior has a second dimension, wherein the first dimension and the second dimension are different.
  • Aspect 14 The article of manufacture of aspect 13, wherein the second dimension is greater than the first dimension.
  • Aspect 15 The article of manufacture of any of aspects 13-14, wherein the first dimension comprises a first circumference and the second dimension comprises a second circumference.
  • Aspect 16 The article of manufacture of any of aspects 13-15, wherein the article of apparel has a length; and wherein the first dimension and the second dimension vary along the length of the article of apparel.
  • Aspect 17 The article of manufacture of any of aspects 13-16, wherein the article of apparel comprises a plurality of sections; and wherein the first dimension and the second dimension vary in one or more of the plurality of sections.
  • Aspect 18 The article of manufacture of aspect 17, wherein the article of apparel comprises at least one of a jacket, a sweater, a shirt, a dress, or a vest; and wherein the plurality of sections comprise one or more of a wrist portion of a sleeve, a forearm portion of a sleeve, an elbow portion of a sleeve, a bicep portion of a sleeve, a shoulder portion of a sleeve, a hood, a pocket portion, or an abdominal portion of the at least one of the jacket, the sweater, the shirt, the dress, or the vest.
  • Aspect 19 The article of manufacture of aspect 17, wherein the article of apparel comprises at least one of pants or shorts; and wherein the plurality of sections comprise one or more of an ankle portion, a calf portion, a knee portion, a thigh portion, a crotch portion, a waist portion, or a pocket portion of the at least one of the pants or the shorts.
  • a method comprising: coupling a plurality of baffle structures to a first textile layer, wherein the plurality of baffle structures are positioned to control movement of a filler; coupling the plurality of baffle structures to a second textile layer; and inserting the filler between the first textile layer, the second textile layer, and the plurality of baffle structures.
  • Aspect 21 The method of aspect 20, wherein the coupling the plurality of baffle structures to the first textile layer comprises bonding the plurality of baffle structures to the first textile layer.
  • Aspect 22 The method of aspect 20, wherein the method further comprises coupling at least a portion of the first textile layer and at least a portion of the second textile layer.
  • Aspect 23 The method of aspect 22, wherein the coupling the at least a portion of the first textile layer and the at least a portion of the second textile layer comprises stitching at least a portion of a perimeter of the first textile layer to at least a portion of a perimeter of the second textile layer.
  • Aspect 24 A composite material manufactured by the method of any of aspects
  • Aspect 25 An article comprising the composite material of aspect 24.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Laminated Bodies (AREA)

Abstract

A composite material may comprise a first textile layer coupled to a plurality of baffle structure. The composite material may comprise a second textile layer coupled to the plurality baffle structures. The composite material may comprise a filler between the first textile layer and the second textile layer. The plurality of baffles may be positioned to control movement of the filler within the composite material.

Description

COMPOSITE MATERIALS AND METHODS OF MANUFACTURE
BACKGROUND
[0001] A material comprising a filler may comprise stitching configured to prevent movement of the filler within the material. The stitching may comprise stitched compartments. Stitching the material and filling the stitched compartments with the filler may account for inefficiencies in the manufacture of the material. Additionally, the material comprising filled stitched compartments may not have a uniform thermal insulation and/or may not maintain a uniform temperature throughout the material.
SUMMARY
[0002] A composite material may comprise a plurality of baffles. The plurality of baffles may be arranged in a pattern within the composite material. The plurality of baffles may be configured to control movement of a filler within the composite material. An article comprising the composite material may be manufactured. The last step of manufacturing the article may comprise inserting the filler in the composite material. The filler may fill gaps between the plurality of baffles and textile layers of the composite material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] The following drawings illustrate generally, by way of example, but not by way of limitation, various examples discussed in the present disclosure. In the drawings:
[0004] FIG. 1 shows an example composite material.
[0005] FIG. 2 shows an example composite material.
[0006] FIG. 3 shows an example method.
[0007] FIG. 4 shows an example article.
[0008] FIG. 5 shows an example article.
DETAILED DESCRIPTION
[0009] FIG. 1 shows an example composite material 100. The composite material 100 may comprise a first textile layer 101, a filler 102, a second textile layer 103, and a plurality of baffle structures 104. The plurality of baffle structures 104 may be disposed between the first textile layer 101 and the second textile layer 103. The filler 102 may be disposed between the first textile layer 101 and second textile layer 103. The filler 102 may be disposed between the plurality of baffle structures 104. The composite material 100 may be configured to control movement of the filler 102, such as between the first textile layer 101 and the second textile layer 103. The composite material 100 may be configured to control movement of the filler 102 when an article comprising the composite material 100 is in normal use. As an example, the body of a jacket may be made of the composite material 100 and the filler 102 may comprise down. The composite material 100 may be configured to prevent the down from moving to the bottom of the jacket when the jacket is worn.
[0010] The first textile layer 101 and the second textile layer 103 may comprise the same material or different material. The first textile layer 101 and/or the second textile layer 103 may comprise a woven material, such as nylon taffeta woven or polyester taffeta woven. The first textile layer 101 and/or the second textile layer 103 may comprise a fiber proof material.
The first textile layer 101 and/or the second textile layer 103 may comprise a knit material. The first textile layer 101 and/or the second textile layer 103 may comprise a synthetic material, such as polyester, polypropylene, or a blend. The first textile layer 101 and/or the second textile layer 103 may comprise a non-synthetic material, such as cotton or wool. The first textile layer 101 and/or the second textile layer 103 may comprise a blend of fibers.
[0011] The first textile layer 101 and/or the second textile layer 103 may comprise a wind-resistant or windproof material. Wind resistance of a material may be described by an amount of cubic feet per minute (CFM) of about a 30-mile-per-hour wind that can pass through one square foot of the material. Wind resistance may be determined using a standardized test such as ASTM D737. The first textile layer and/or the second textile layer may comprise a windproof material having a permeability of 0-2 or 3-4 CFM. The first textile layer and/or the second textile layer may comprise a wind-resistant material having a permeability of 5-20 CFM.
[0012] The first textile layer and/or the second textile layer may comprise a waterproof material. The waterproof material may comprise a material treated with a durable water- repellant (DWR) finish. The DWR finish may cause the material to repel water, such as by causing the water to bead up and roll of a surface of the material. Waterproofing may be based on a water column test that measures water permeability under pressure. The water column test may comprise placing a one-inch diameter column of water over the material for a time period of twenty-four hours. Waterproofness may describe the height of a column that may be filled before water permeates the material within the time period. Waterproofness may be determined using a standardized test, such as AATCC 127, AATCC 35, AATCC 22, or ISO 811. The material may comprise a super waterproof material having a water column test rating of greater than 20,000 mm/24 hours. The material may comprise a very waterproof material having a water column test rating of greater than 15,000 mm/24 hours and up to 20,000 mm/24 hours.
The material may comprise a waterproof material having a water column test rating of greater than 10,000 mm/24 hours and up to 15,000 mm/24 hours. The material may comprise a somewhat waterproof material having a water column test rating of greater than 5,000 mm/24 hours and up to 10,000 mm/24 hours. The material may comprise a water resistant material having a water column test rating of around 5,000 mm/24 hours.
[0013] The first textile layer 101 and/or the second textile layer 103 may comprise a non-breathable material or a breathable material. Breathability of a material may be described by an amount of water vapor that can pass through a square meter of the material during a time frame of twenty -four hours. Breathability may be determined using a standardized test, such as BS7209 or ASTM E96. The non-breathable material may have a breathability of 5,000 g/m2- 9,000 g/m2, for example. The breathable material may have a breathability of 10,000 g/m2- 25,000 g/m2, for example.
[0014] The first textile layer 101 and/or the second textile layer 103 may comprise a downproof material. Downproofness of a material may be described by a rating determined by a standardized test, such as EN 12131-1, EN 12131-2, GB/T 12705.1, GB/T 12705.2, GB/T 14272, or“International Rotating Box” test (TMS or IDFL-20). As measured by the
International Rotating Box test, the downproof material may have a number of total particles escaped or protruding of 0-5, 6-11, or 12-22. The downproof material may prevent the escape or movement of the filler 102, such as to the exterior of the composite material 100.
[0015] The material of the first textile layer 101 and/or the second textile layer 103 may be selected based on an article to be manufactured with the composite material 100. For example, the material may be selected based on desired properties of the article, such as strength, elasticity, size, cost, appearance, weight, insulation, comfort of the article. The material may be selected based on the type of article, such as sports equipment, athletic apparel, cold weather apparel, luggage, etc. The material may be selected based on properties of the material, such as softness, strength, modulus of elasticity, insulation, water resistance, or wind resistance, etc.
[0016] The first textile layer 101 and/or the second textile layer 103 may be configured to form an exterior or an interior of an article. For example, if the article comprises apparel, the interior may comprise a side of the article that is in contact with a body of a user when the apparel is worn or a side of the article that is closer to the body of the user when the apparel is worn. The exterior may comprise a side of the article that is exposed to the environment outside the apparel when the apparel is worn. The material comprising the first textile layer 101 and/or the material comprising the second textile layer 103 may be selected based on whether the layer will form the exterior or the interior of the article. For example, a material that is water-resistant or wind-resistant may be selected for the exterior layer. As another example, a soft or breathable material may be selected for the interior layer. A material that is less water-resistant and/or less wind-resistant than the material selected for the exterior layer may be selected for the interior layer.
[0017] The first textile layer 101 and the second textile layer 103 may each comprise a sheet. The sheets may have perimeters. At least a portion of the perimeter of the first textile layer 101 sheet may be joined to at least a portion of the perimeter of the second textile layer 103 sheet, such as by sewing, gluing, weaving, or welding. The joining of the sheets may be configured to hold the filler between the sheets. The joining of the sheets may be configured to hold the filler between the plurality of baffle structures.
[0018] The filler 102 may comprise an insulating material. The insulating material may be configured to maintain a thermal temperature, such as between the first textile layer 101 and the second textile layer 103. The filler 102 may a natural fiber, such as down or wool. The filler 102 may comprise fleece or shelled microfleece. The filler 102 may comprise a synthetic material, such as a synthetic microfiber blend (e.g., Primaloft, Thinsulate, Thermolite, or Quallofil). The filler 102 may comprise a thermoball insulation, such as polyester balls. The thermoballs may be blown into the spaces between the first textile layer 101 and the second textile layer 103. The filler 102 may have an insulation value of .1-.8 clo, as measured by the ASHRAE-55 standard test. The filler 102 may have an R-value of 1.6-2.9 per inch, as defined by ASTM C168. [0019] FIG. 2 shows a plurality of baffle structures 104. The baffle structures 104 may be coupled to the first textile layer 101. The baffle structures 104 may be coupled to the second textile layer 103. The baffle structures 104 may be coupled to the first textile layer 101 and/or the second textile layer 103 by bonding, such as with adhesive or with welding.
[0020] The baffle structures 104 may be arranged in a pattern. The pattern may be configured to control movement of the filler 102. For example, the pattern may be configured to minimize movement of the filler 102 within the composite material 100. The filler 102 may rest on the baffle structures 104. The baffle structures 104 may comprise barriers that prevent the filler 102 from moving in the direction of the force of gravity or in a direction of force acting upon the composite material 100 or an article comprising the composite material 100. The baffle structures 104 may prevent the filler 102 from migrating from one portion of the article to another portion of the article. As an example, the baffle structures 104 may prevent filler from a thigh portion of a pant from moving to a knee portion of the pant. The pattern may be configured to control movement of the filler 102 when an article comprising the composite material 100 is in use. The baffle structures 104 may maintain the filler 102 in a fixed position to maintain a uniform distribution of the filler 102 throughout the composite material 100. The uniform distribution of the filler 102 may result in a uniform temperature or thermal insulation throughout the composite material 100.
[0021] The pattern may be selected based on the type of filler 102. For example, the pattern may be selected based on a weight or thickness of the filler 102. The pattern may be selected based on a type of article to be manufactured using the composite material 100. The pattern may comprise a distance between the plurality of baffle structures. For example, FIG. 2 shows baffle structures 104 that are evenly spaced. However, other distances or spacing is possible. The pattern may comprise rows and/or columns of the plurality of baffle structures. As an example, FIG. 2 shows columns of baffle structures 104 that are staggered. However, other arrangements of rows and/or columns of baffle structures 104 are possible. The pattern of the baffle structures 104 may be selected based on the shape of the baffle structures 104.
[0022] The baffle structures 104 may have a shape. As an example, FIG. 2 shows baffle structures 104 having a biconcave shape. However, other baffle structure 104 shapes are possible. Non-limiting examples of baffle structure 104 shapes include biconvex shapes, plano- concave shapes, plano-convex shapes, polygonal shapes, circular shapes, triangular shapes, quadrilateral shapes, wave shapes, linear shapes, crescent shapes, and/or arc shapes. The composite material 100 may comprise baffle structures 104 of a same shape or of different shapes. For example, different regions of the composite material 100 may comprise baffle structures 104 of different shapes. The shape of the baffle structures 104 may be configured and/or selected to control movement of the filler 102. The shape may be selected based on the type of the filler, a type of article to be manufactured using the composite material 100, as examples. The shape of the baffle structures 104 may be selected based on the pattern of the baffle structures 104.
[0023] FIG. 3 shows an example method 300. At step 301, the baffle structures 104 may be coupled to the first textile layer 101. Coupling the baffle structures 104 may comprise bonding the baffle structures 104, such as with adhesive. Coupling the baffle structures 104 may comprise welding the baffle structures 104 to the first textile layer 101. Coupling the baffle structures 104 may comprise nailing, screwing, or stapling the baffle structures 104 to the first textile layer 101.
[0024] At step 302, the baffle structures 104 may be coupled to the second textile layer 103. Coupling the baffle structures 104 may comprise bonding the baffle structures 104, such as with adhesive. Coupling the baffle structures 104 may comprise welding the baffle structures 104 to the second textile layer 103, such as sonically welding the baffle structures 104 to the second textile layer 103. Coupling the baffle structures 104 use a sonic coupling technology. Coupling the baffle structures 104 may use a radio frequency (RF) technology. Coupling the baffle structures 104 may comprise stitching the baffle structures 104 to the second textile layer 103. Coupling the baffle structures 104 may comprise nailing, screwing, or stapling the baffle structures 104 to the second textile layer 103.
[0025] At least a portion of the first textile layer 101 may be coupled to at least a portion of the second textile layer 103. For example, the portion of the first textile layer 101 may be stitched or woven with the portion of the second textile layer 103.
[0026] At step 303, the filler 102 may be inserted between the first textile layer 101 and the second textile layer 103. The filler 102 may be inserted between the baffle structures 104. Inserting the filler 102 may comprise injecting the filler 102. Inserting the filler 102 may comprise blowing the filler 102 into the spaces between the layers 101, 103 and the baffle structures 104. For example, if the filler 102 comprises thermoballs or another blowable material, the thermoballs may be blow into the spaces. Compared to materials that comprise compartments, such as stitched compartments, between one or more layers configured to hold filler, the inserting the filler 102 in the composite material 100 may be more efficient. For example, filler may be inserted in each compartment, individually. In contrast, the filler 102 may be inserted in the composite material 100 at once. The filler 102 may disperse and fill the gaps between the first textile layer 101, the second textile layer 103, and the filler 102.
[0027] The composite material 100 may be used to manufacture an article. The article may comprise a blanket or a covering. The article may comprise sporting equipment or outdoor equipment. The article may comprise sporting equipment lining, such a lining of a helmet. The article may comprise an article of apparel, such as a jacket, pants, a hat, gloves, a jumpsuit, or other outerwear.
[0028] Compared to filler in compartments of a material, such as stitched
compartments, the filler 102 of the composite material 100 may be more uniformly distributed throughout the material 100. If filler is inserted in compartments, the amount of filler, such as the volume of filler, inserted in each compartment may vary. In contrast, when the filler 102 is injected in the composite material 100, the filler 102 may be forced into the cavities between the two layers 101, 103 and the baffle structure 104 until the cavities are full. Thus, the areas between the layers 101, 103 and the baffle structure 104 may hold the same or similar amounts or volumes of the filler 102. As a material comprising compartments is used, the filler may accumulate towards one area or side of the compartments. For example, as a jacket comprising the material is worn, the filler may fall to the bottom of the compartments due to gravity or motion or the user. In contrast, the baffle structure 104 may keep the filler 102 from changing position within the material 100. As a result, the filler 102 may be more evenly distributed throughout the material 100, such as along a width, length or surface area of the material 100.
[0029] The distribution of the filler 102 may affect thermal insulation or temperature of the material 100. Compared to materials that comprise compartments, such as stitched compartments, between one or more layers configured to hold filler, the composite material 100 may be have a more uniform thermal insulation throughout the composite material 100.
Compared to materials that comprise compartments, such as stitched compartments, between one or more layers configured to hold filler, the composite material 100 may maintain a more uniform temperature throughout the composite material 100. [0030] FIG. 4 shows an example pattern 400 for an article comprising the composite material 100. FIG. 4 shows an example pattern 400 for an article comprising a jacket, however a similar pattern may be used for a different type of article comprising the composite material 100. The pattern 400 may comprise a differential in dimensions of the first textile layer 101 and the second textile layer 103, wherein one of the layers may comprise an interior layer 405 and an exterior layer 406. The differential may be configured to provide space for the baffle structures 104 and/or the filler 102 between the interior layer 405 and the exterior layer 406. The differential may be configured to facilitate the inserting of the filler 102 between the interior layer 405 and the exterior layer 406, such as in a last step of the process of manufacturing the article and/or inserting the filler 102 throughout the composite material 100 at once. For example, as shown in FIG. 4, the interior layer 105 may have a circumference that is less than a circumference of the exterior layer. FIG. 4 shows a pattern 400a of a 10.5 inch sleeve opening portion of the jacket. The pattern 400a comprises circular patterns of an interior layer 405 and an exterior layer 406 having a warmth differential of 1.497. The warmth differential may comprise a temperature or insulation of a portion of the composite material 100 relative to temperatures or insulations of other portions of the composite material 100. A higher warmth differential may indicate a higher temperature or more insulation. A higher warmth differential may indicate more filler in the portion of the material than in other portions of the material. FIG. 4 shows a pattern 400b of a 21 inch bicep portion of the jacket. The pattern 400b comprises circular patterns of an interior layer 405 and an exterior layer 406 having a warmth differential of 1.622. FIG. 4 shows a pattern 400c of a 30 inch hood portion of the jacket. The pattern 400c comprises circular patterns of an interior layer 405 and an exterior layer 406 having a warmth differential of 1.531. However, other dimensions, portions of the article, and warmth differentials are possible.
[0031] FIG. 5 shows an example pattern 500 for an article comprising the composite material 100. Z-axis pieces 519 may correspond to dimensions of one or more side walls of a garment comprising the composite material 100. The side walls may be configured to eliminate compression of filler in particular areas of the garment, such as at openings. Interior layers 509, 510, 511, 512, and 513 have different dimensions than exterior layers 514, 515, 516, 517, and 518. Exterior layers 514, 515, 516, 517, and 518 have greater dimensions than interior layers 509, 510, 511, 512, and 513. The dimensions may be selected based on a desired warmth differential between the exterior layers 514, 515, 516, 517, and 518 and the interior layers 509, 510, 511, 512, and 513. The warmth differentials may be based on a portion of the pattern of the article to be formed with the layers. Examples of a portion of a pattern for a jacket, sweater, shirt, dress, or vest may comprise a sleeve, a forearm portion of a sleeve, an elbow portion of a sleeve, a bicep portion of a sleeve, a shoulder portion of a sleeve, a hood, a pocket portion, or an abdominal portion, as examples. Examples of a portion of a pattern for pants or shorts may comprise an ankle portion, a calf portion, a knee portion, a thigh portion, a crotch portion, a waist portion, or a pocket portion, as examples.
[0032] The present disclosure comprises at least the following aspects.
[0033] Aspect 1. A composite material comprising: a first textile layer; a second textile layer; and a plurality of baffle structures coupled to the first textile layer and the second textile layer, wherein the plurality of baffle structures are positioned to control movement of a filler disposed between the first textile layer and the second textile layer.
[0034] Aspect 2. The composite material of aspect 1, further comprising the filler.
[0035] Aspect 3. The composite material of aspect 2, wherein the filler comprises down.
[0036] Aspect 4. The composite material of aspect 2, wherein the filler comprises an insulative material.
[0037] Aspect 5. The composite material of aspect 1, wherein the plurality of baffle structures are bonded to the first textile layer and the second textile layer.
[0038] Aspect 6. The composite material of aspect 1, wherein the first textile layer comprises a first material and the second textile layer comprises a second material different than the first material.
[0039] Aspect 7. The composite material of aspect 6, wherein the first material and the second material have a different at least one of water resistance, wind resistance, or permeability.
[0040] Aspect 8. The composite material of aspect 1, wherein at least one of the first textile layer or the second textile layer comprises a synthetic material.
[0041] Aspect 9. The composite material of aspect 1, wherein at least a portion of the first textile layer and at least a portion of the second textile layer are coupled.
[0042] Aspect 10. The composite material of aspect 9, wherein the at least a portion of the first textile layer and the at least a portion of the second textile layer are coupled by stitching. [0043] Aspect 11. An article of manufacture comprising the composite material of any of aspects 1-10.
[0044] Aspect 12. The article of manufacture of aspect 11, wherein the article of apparel comprises an interior and an exterior each comprising the composite material of any of aspects 1-10.
[0045] Aspect 13. The article of manufacture of aspect 12, wherein the interior has a first dimension and the exterior has a second dimension, wherein the first dimension and the second dimension are different.
[0046] Aspect 14. The article of manufacture of aspect 13, wherein the second dimension is greater than the first dimension.
[0047] Aspect 15. The article of manufacture of any of aspects 13-14, wherein the first dimension comprises a first circumference and the second dimension comprises a second circumference.
[0048] Aspect 16. The article of manufacture of any of aspects 13-15, wherein the article of apparel has a length; and wherein the first dimension and the second dimension vary along the length of the article of apparel.
[0049] Aspect 17. The article of manufacture of any of aspects 13-16, wherein the article of apparel comprises a plurality of sections; and wherein the first dimension and the second dimension vary in one or more of the plurality of sections.
[0050] Aspect 18. The article of manufacture of aspect 17, wherein the article of apparel comprises at least one of a jacket, a sweater, a shirt, a dress, or a vest; and wherein the plurality of sections comprise one or more of a wrist portion of a sleeve, a forearm portion of a sleeve, an elbow portion of a sleeve, a bicep portion of a sleeve, a shoulder portion of a sleeve, a hood, a pocket portion, or an abdominal portion of the at least one of the jacket, the sweater, the shirt, the dress, or the vest.
[0051] Aspect 19. The article of manufacture of aspect 17, wherein the article of apparel comprises at least one of pants or shorts; and wherein the plurality of sections comprise one or more of an ankle portion, a calf portion, a knee portion, a thigh portion, a crotch portion, a waist portion, or a pocket portion of the at least one of the pants or the shorts.
[0052] Aspect 20. A method comprising: coupling a plurality of baffle structures to a first textile layer, wherein the plurality of baffle structures are positioned to control movement of a filler; coupling the plurality of baffle structures to a second textile layer; and inserting the filler between the first textile layer, the second textile layer, and the plurality of baffle structures.
[0053] Aspect 21. The method of aspect 20, wherein the coupling the plurality of baffle structures to the first textile layer comprises bonding the plurality of baffle structures to the first textile layer.
[0054] Aspect 22. The method of aspect 20, wherein the method further comprises coupling at least a portion of the first textile layer and at least a portion of the second textile layer.
[0055] Aspect 23. The method of aspect 22, wherein the coupling the at least a portion of the first textile layer and the at least a portion of the second textile layer comprises stitching at least a portion of a perimeter of the first textile layer to at least a portion of a perimeter of the second textile layer.
[0056] Aspect 24. A composite material manufactured by the method of any of aspects
20-23.
[0057] Aspect 25. An article comprising the composite material of aspect 24.

Claims

CLAIMS What is claimed:
1. A composite material comprising:
a first textile layer;
a second textile layer; and
a plurality of baffle structures coupled to the first textile layer and the second textile layer, wherein the plurality of baffle structures are positioned to control movement of a filler disposed between the first textile layer and the second textile layer.
2. The composite material of claim 1, further comprising the filler disposed between the first textile layer and the second textile layer.
3. The composite material of any one of claims 1-2, wherein the plurality of baffle
structures are bonded to the first textile layer and the second textile layer.
4. The composite material of any one of claims 1-3, wherein the first textile layer comprises a first material and the second textile layer comprises a second material different than the first material.
5. The composite material of claim 4, wherein the first material and the second material have a different at least one of water resistance, wind resistance, or permeability.
6. The composite material of any one of claims 1-5, wherein at least a portion of the first textile layer and at least a portion of the second textile layer are coupled together.
7. The composite material of claim 6, wherein the at least a portion of the first textile layer and the at least a portion of the second textile layer are coupled by stitching.
8. The composite material of any one of claims 1-7, wherein the plurality of baffle
structures are positioned in a pattern to control movement of a filler disposed between the first textile layer and the second textile layer, and wherein the pattern is selected based on one or more of a weight of the filler, a thickness of the filler, a type of article to be manufactured using the composite material, or a shape of the baffle structures.
9. A method of making the composite material of any one of claims 1-8.
10. An article of manufacture comprising the composite material of any of claims 1-9.
11. The article of manufacture of claim 10, wherein the article of apparel comprises an
interior and an exterior each comprising the composite material of any one of claims 1-9.
12. The article of manufacture of claim 11, wherein the interior has a first dimension and the exterior has a second dimension, wherein the first dimension and the second dimension are different, and wherein the first dimension comprises a first circumference and the second dimension comprises a second circumference.
13. The article of manufacture of any one of claims 10-12, wherein the article of apparel comprises at least one of a jacket, a sweater, a shirt, a dress, or a vest; and wherein the plurality of sections comprise one or more of a wrist portion of a sleeve, a forearm portion of a sleeve, an elbow portion of a sleeve, a bicep portion of a sleeve, a shoulder portion of a sleeve, a hood, a pocket portion, or an abdominal portion of the at least one of the jacket, the sweater, the shirt, the dress, or the vest.
14. The article of manufacture of any one of claims 10-12, wherein the article of apparel comprises at least one of pants or shorts; and wherein the plurality of sections comprise one or more of an ankle portion, a calf portion, a knee portion, a thigh portion, a crotch portion, a waist portion, or a pocket portion of the at least one of the pants or the shorts.
15. A method of making the article of manufacture of any one of claims 10-14.
PCT/US2019/032600 2018-05-18 2019-05-16 Composite materials and methods of manufacture WO2019222457A1 (en)

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CN115012120A (en) * 2022-06-14 2022-09-06 西安工程大学 Composite material three-dimensional preform piercing weaving device and weaving method

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US20090155543A1 (en) * 2007-07-18 2009-06-18 Rick Fowler Insulating materials and methods of making the same
WO2016073691A1 (en) * 2014-11-07 2016-05-12 The North Face Apparel Corp. Constructs for distribution of fill material
US20170099898A1 (en) * 2015-10-07 2017-04-13 Nike, Inc. Vented garment

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