Note: Descriptions are shown in the official language in which they were submitted.
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BAFFLE CONSTRUCTS FOR INSULATIVE FILL MATERIALS
Inventor: Alford H. Lee
Background
The inventive subject matter is generally directed to textile constructs that
provide
thermal insulation in consumer products. Products like jackets and other
garments often have a
multi-layered construction made up of an assembly of fabrics and insulation
materials. One
common construct for colder climates is an assembly of baffles. For example,
baffles may be
provided between the two outer-most layers of a garment to create chambers
that hold insulative
fill material, such as natural or synthetic down.
Gravity and use can cause fill material to settle, compact or compress at the
bottom of a
baffle, creating voids at the top portion of a baffle. Because of this,
conventional baffles have a
limited height that helps prevent settling and compression of fill material.
In other words, as the
columnar height of fill material increases, so does its weight and compressive
force. Hence,
because of the increased weight, there is more pronounced compression and
settling of the fill
material in taller baffles. In such cases, the voiding of material at the top
of the baffle flattens,
indents, or depresses the upper portion of the baffle.
These kinds of changes in the baffle are problematic for at least two reasons:
(1) the
flattened areas cause cold spots in the panel of baffles, and (2) the
flattened areas are unsightly
and do not provide the intended aesthetic of plump, uniformly filled baffles.
Typically, baffles have a height of a height of less than 15 cm in garments
such as a
jacket. Disadvantageously, relatively short baffles require more seams or
joints between baffles
over a given area. The seams or joints result in potential cold spots. Having
many seams or
joints also restricts the aesthetics of a panel of baffles and does not free
the designer to reduce the
number of seams or joints for a cleaner or less busy appearance to the baffle
panel.
In short, conventional baffles have the foregoing and other disadvantages, and
there is a
need for improved baffle constructions that allow for uniform fill
distribution, elimination of
cold spots, reduction in seams or other joints, and/or greater design
flexibility, for example.
SUMMARY
The inventive subject matter generally relates to baffle constructs for use in
consumer
products, such as garments and sleeping bags. In certain aspects, the
inventive subject matter
provides an innovative solution to the problem of settling and compacting of
fill material, which
limits the height of baffles and consequently baffle performance and
aesthetics.
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In one possible embodiment, the inventive subject matter is directed to an
assembly of a
plurality of baffle constructs. Each baffle construct includes: a primary
baffle, comprising a
pliable textile, and one or more secondary baffles, which may also comprise a
pliable textile.
The baffle constructs are configured to be alignable along a vertical axis
relative to the ground.
Each primary baffle defines a bounded, volumetric space for enclosing a first
volume of
insulative fill material in a first part of the space and a secondary baffle
in a second part of the
space. Each secondary baffle defines a bounded, volumetric space for enclosing
a second
volume of fill material. One or more of the secondary baffle are disposed in
the primary baffle
so that most (i.e., more than 50%) of the second volume of insulative fill
material of the
secondary baffle(s) is contained above most of the insulative material in the
first part of the space
when the main baffle is maintained in an intended vertical orientation. In
other words, the
secondary baffle or baffles are mainly responsible for filling the primary
baffle to its intended
shape in an upper portion of the primary baffle.
In the foregoing and other embodiments, the primary baffle has a bottom and a
secondary
baffle has a bottom, the bottom of the secondary baffle being spaced a
predetermined height
above the bottom of the primary baffle.
In the foregoing and other embodiments, the primary baffle may have a
predetermined
profile in a desired expanded condition and the secondary baffle has a
predetermined desired
profile in the expanded condition, and wherein the primary baffle's profile in
the expanded
condition is supported and not disrupted by the secondary baffle when the
secondary baffle's
profile in the expanded condition.
In the foregoing and other embodiments, the primary baffle may have a height H
and the
secondary baffle has a height H' and the ratio H/H' is at least 1.25.
In the foregoing and other embodiments, the primary baffle may have a height H
and a
secondary baffle has a height H' and the ratio H/H' is between 1.25 and 10.
In the foregoing and other embodiments, a single secondary baffle may be
enclosed in the
primary baffle and an upper end of the secondary baffle is pendulously
appended to an upper end
of the primary baffle.
In the foregoing and other embodiments, the secondary baffle may have an
oblong
shaped configuration.
In the foregoing and other embodiments, may have the secondary baffle has a
fully
pendulous configuration.
In the foregoing and other embodiments, the secondary baffle may have a
generally
teardrop or piriform shape.
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In the foregoing and other embodiments, the assembly may have a face layer and
a back
layer, and the primary baffles are defined in part by horizontal seam or
joints connecting the face
layer and back layer and which define a top and the bottom for a given baffle.
In the foregoing and other embodiments, the secondary baffle(s) may be
disposed on an
inner surface of the back layer and are not connected to the back layer so
that the face layer is
free of any seams or joints for the secondary baffle(s).
In the foregoing and other embodiments, the primary baffle in an expanded
condition
may have sides that converge at upper and lower ends when moving from an
intermediate
section.
In the foregoing and other embodiments, an upper-most secondary baffle(s) may
have a
first edge of the secondary baffle that merges into the upper end of a primary
baffle, and a
second edge is downwardly spaced apart from the upper edge and merges into a
vertical wall of
the primary baffle, such that the secondary baffle's bounded space is defined
in part by a wall of
the primary baffle.
In the foregoing and other embodiments, a second secondary baffle may be
spaced, at
least in part, below the upper-most secondary baffle, a first edge of the
secondary baffle merges
into the vertical wall of the primary baffle, and a second edge is downwardly
spaced apart from
the second secondary baffle's upper edge and merges into the vertical wall of
the primary baffle,
such that the second secondary baffle's bounded space is defined in part by a
wall of the primary
baffle.
In the foregoing and other embodiments, when the secondary baffle(s) is/are in
an
expanded condition, the primary baffle in an expanded profile may receive fill
material below
the bottom of the secondary baffle(s) and along at least one vertical side of
the secondary
baffle(s).
In the foregoing and other embodiments, at least two secondary baffles may be
disposed
in the primary baffle and arranged at different heights in the primary baffle.
In the foregoing and other embodiments, at least three secondary baffles may
be disposed
in the primary baffle and arranged at different heights in the primary baffle.
In the foregoing and other embodiments, the secondary baffles may stack in
partial
overlap with the lower one of the secondary baffles.
In another possible embodiment, the inventive subject matter is directed to a
garment
having a panel configured to cover a torso area of a wearer. The panel
includes an assembly of a
plurality of baffle constructs. Each baffle construct includes a primary
baffle consisting of a
pliable textile, and one or more secondary baffles. The baffle constructs are
configured to be
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alignable along a vertical axis relative to the ground. Each primary baffle
defines a bounded,
volumetric space for enclosing a first volume of insulative fill material in a
first part of the space
and a secondary baffle in a second part of the space. Each secondary baffle
defines a bounded,
volumetric space for enclosing a second volume of fill material, the secondary
baffle being
disposed in the primary baffle so that most of the second volume of insulative
fill material is
contained above most of the insulative material in the first part of the space
when the main baffle
is maintained in an intended vertical orientation.
In the foregoing and other embodiments, an insulative fill material may be
disposed in
each primary baffle and secondary baffle, the insulative fill material filling
the primary baffle
and secondary baffles to a desired profile.
In another possible embodiment, the inventive subject matter is directed to a
method of
producing an insulative panel. The method includes the steps of: providing an
assembly of a
plurality of baffle constructs, each baffle construct including a primary
baffle, consisting of a
pliable textile, and one or more secondary baffles. The baffle constructs are
configured to be
alignable along a vertical axis relative to the ground. Each primary baffle
defines a bounded,
volumetric space for enclosing a first volume of insulative fill material in a
first part of the space
and a secondary baffle in a second part of the space. Each secondary baffle
defines a bounded,
volumetric space for enclosing a second volume of fill material, the secondary
baffle being
disposed in the primary baffle so that most of the second volume of insulative
fill material is
contained above the height of most of the insulative material in the first
part of the space when
the main baffle is maintained in an intended vertical orientation; and filling
each primary baffle
and secondary baffle with an insulative fill material to a desired profile.
The foregoing is not intended to be an exhaustive list of embodiments and
features of the
inventive subject matter. Persons skilled in the art can appreciate other
embodiments and
features from the following detailed description in conjunction with the
drawings. These and
other embodiments are described in more detail in the following detailed
descriptions and the
figures.
The following is a description of various inventive lines under the inventive
subject
matter. The appended claims, as originally filed in this document, or as
subsequently amended,
are hereby incorporated into this Summary section as if written directly in.
BRIEF DESCRIPTION OF THE DRAWINGS
The appended figures show embodiments according to the inventive subject
matter,
unless noted as showing prior art.
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FIG. 1 shows a side, cross-section of an individual baffle.
FIG. 2A shows a side, cross-section of an assembly of baffles like the baffle
of FIG. 1.
FIG. 2B shows a perspective view of the assembly of FIG. 2 from a face layer.
FIG. 2C shows a perspective view of the assembly of FIG. 2 from a face layer.
FIG. 4 shows a side, cross-section of a first alternative embodiment an
individual baffle.
FIG. 5 shows a side, cross-section of a second alternative embodiment an
individual
baffle.
FIG. 6 shows a side, cross-section of a third alternative embodiment an
individual baffle.
FIG. 7 shows a garment incorporating panels of baffles according to one of the
foregoing
embodiments or any other embodiment contemplated herein.
FIG. 8 shows a side, cross-section of an alternative embodiment of an
individual baffle.
DETAILED DESCRIPTION
Representative embodiments according to the inventive subject matter are shown
in
Figures 1-8, wherein the same or generally similar features share common
reference numerals.
The inventive subject matter generally relates to baffle constructs for use in
consumer
products, such as garments and sleeping bags. In certain aspects, baffles are
arranged as a panel
of a plurality of primary baffles 10, each primary baffle has a selected
theoretical profile when in
an expanded condition that defines an enclosed main volumetric space for
holding fill material.
Each primary baffle has one or more secondary baffles, e.g., baffles 12, 112,
212, 312, 412 each
with an enclosed secondary baffle volumetric space, disposed within the
primary baffle's
enclosed main volumetric space. A secondary baffle is disposed at at least a
top portion of a
primary baffle's volumetric space. The void of the main volumetric space and
the void for the
secondary baffle each receive fill material. Because the secondary baffle's
volumetric space is
disposed at the top portion of the main volumetric space, the fill material in
the secondary baffle
is suspended above the lower void of the main volumetric space and does not
compress the fill
material below it. Consequently, the main volumetric space does deflate,
compact or flatten out
when used. The secondary baffles serve to keep the top portion of the primary
baffles in a
plumped, inflated, or expanded state. Thereby, the primary baffle may be
better presented and
maintained according to its theoretical profile or other desired expanded
state.
Advantageously, the inventive subject matter allows for apparel and other
products with a
panel of baffles to have vertically taller baffles and to prevent the down or
other fill material
from migrating to the bottom of the baffle. To maintain loft in the baffle,
the innovative baffle
constructs include an internal or secondary baffle that does not create any
indentations or
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depressions in the surrounding primary baffle, thus creating a taller, more
continuously plumped
or expanded primary baffle.
The baffle constructs can be formed into a predetermined assembly of multiple
baffles.
For example, they can be assembled as a plurality of adjacent, consecutive
baffles forming a flat
panel. Other constructions are possible too. For example, the baffles can be
arranged to overlap
or nest in multiple layers.
As used herein, the term "panel" means there is a section that generally
extends over at
least one plane. For example, in the case of garments, a panel may extend over
some or all the
front abdomen of a wearer. A panel may extend over multiple planes. For
example, in the case
of garments, the panel may extend over and from the front abdomen over the
other sides of the
wearer's body. The panel may extend partly or fully over one or both sides of
the wearer. It may
extend from one or both sides partly or fully over the back of the wearer.
FIGs. 1-8 show baffle 10 for holding a fill material, typically an insulative
fill material of
discrete particles, such as natural down. The baffles may be used in a variety
of products,
including garments, sleeping bags, sleeping pads, footwear uppers, gloves,
headwear, pillows,
cushions, beds, bed toppings, and other such objects. However, the baffle
constructs are
particularly suited for use in panels that have a vertical orientation
(height) relative to the ground,
i.e., an orientation wherein there is a column of fill material that is acted
on by gravity. The
inventive subject may benefit not only garments and other products that are
primarily oriented
vertically in use but also products that are primarily oriented horizontally
in use. For example,
sleeping bags or comforters may be hung and stored vertically, so the
inventive subject matter
may benefit such products.
In some embodiments, the baffle constructs have a height of at least 5cm, 8cm,
11cm,
12cm, 13cm, 14cm, 15cm, 16cm, 17cm, 18cm, 19cm, 20cm, 25cm, 30cm, 35cm, 40cm,
45cm,
50cm, or thereabout any such number, for supporting a column of fill material.
Looking at one possible embodiment, FIGs. 2A-2C show a panel 1 formed from an
assembly of a plurality of baffle constructs. Each baffle construct consists
of a primary baffle 10
and one or more secondary baffles 12 contained within the primary baffles. The
baffle
constructs are configured to be alignable along a vertical axis relative to
the ground. For
example, they would stack vertically when integrated into a garment and when
the garment is
worn as intended, as seen in FIG. 7, for example.
Each primary baffle defines a bounded, volumetric space 11, i.e, a
compartment, for
enclosing: (1) a first volume of insulative fill material 2 in a first part ha
of the space, and (2) a
secondary baffle 12 in a second part llb of the space.
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Each secondary baffle defines the bounded, volumetric space (11b) and is a
compartment
for enclosing a second volume of fill material 3. The secondary baffle is
disposed in the primary
baffle so that the second volume of insulative fill material is contained
above the height of the
insulative material in the first part of the space when the main baffle is
maintained in an intended
vertical orientation. This keeps the second volume of material from settling
to a lower portion of
the main space 11. Thereby, the fullness of the upper portion may be
maintained under
conditions that would otherwise result in settling or compaction of the fill
material. As discussed
below, the upper portion can be maintained in a desired degree of fullness,
resistant to settling by
a single, appropriately-sized secondary baffle, or by a series of secondary
baffles that are
arranged in the part of the primary baffle that is susceptible to deflation or
flattening.
In embodiments for which naturally down is the intended fill material, the
height of each
stacking compartment for holding fill material is equal to or less than 15.24
cm, otherwise the
down may unacceptably settle and compact, producing substantial dead space at
the top of the
compartment. Under the inventive subject matter, the foregoing height may be
referred to herein
as the "maximum stacking height" of down or another fill material. For other
fill materials like
ThermoballTm insulation, the maximum stacking height may be less than 6.35 cm,
or less than
15.24 cm, or less than 30.48 cm, depending on how high the material can be
stacked without
unacceptable compacting. Unacceptable compacting occurs where the material
after a period of
reasonable intended use has primary baffles that perceptibly lose their
intended overall form.
Accordingly, prior art baffles are limited to a maximum stacking height, if
they are to
maintain substantial fullness when oriented vertically. However, the inventive
subject matter is
not so limited. By using stackable compartments, a primary baffle may be
formed that has a
height that is multiples of the maximum stacking height.
Looking at the embodiment of FIGs. 1-2C as generally representative, the
primary baffle
10 has a height H between a bottom 14 and top 21. The secondary baffle has a
height H' between
bottom 16 and top 19. The bottom of the secondary baffle 12 is spaced a
predetermined height
H" 14 above the bottom of the primary baffle. The intermediate space between
the bottoms may
therefore be filled with fill material 2. The height H' of the intermediate
space may represent the
height to which a fill material is naturally resistant to settling and
compaction, e.g., the maximum
stacking height. The height H' from the bottom of the secondary baffle to its
top may also
represent such a height. Accordingly, the sum total columnar height of fill
material 2 in the
intermediate space, and fill material 3 in the secondary baffle, is more than
what would resist
settling and compaction normally, if there was no suspension of fill material
by secondary baffle
14. However, by dividing the main space 11 into a main compartment and a sub-
compartment
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via the secondary baffle, the main compartment holds its full height in fill
material, with the
bottom of the secondary baffle serving to suspend the fill material and divide
the total height into
sub-compartments that individually provide non-settling or compacting columns
of fill material.
Notably, the stacking heights of each sub-compartment may be about the same if
the same fill
material is used in space 11 a (volume not occupied by secondary baffle 12)
and the space llb of
the secondary baffle 13.
In other embodiments, the void at the bottom of the main baffle and a series
of stacking,
secondary baffles may effectively allow for a total stacking of fill material
to a height that is a
multiple of the maximum stacking height for fill material used. For example,
FIG. 4 shows a
primary baffle 10 with three vertically stacking secondary baffles 112a, 112b,
112c. While the
height of each stacking secondary baffle does not necessarily have to be
limited to a maximum
stacking height for a fill material, if each were configured to such a height,
the primary baffle 10
could have a height that is about three times the maximum stacking height of
the fill material,
adding the height of each secondary baffle, and factoring in that there is
some minor overlapping
of secondary baffles, and there is an intermediate space between the bottom of
the primary
baffle and the bottom of the lowermost secondary baffle 112c.
In some embodiments, the primary baffle has a height H and the secondary
baffle has a
height H' and the ratio H/H' is at least 1.25. In some embodiments, the
primary baffle has a
height H and a secondary baffle has a height H' and the ratio HIH' is between
1.25 and 5.
As seen in Figures, the primary baffle has a predetermined profile in a
desired expanded
condition, and the secondary baffle has a predetermined desired profile in the
expanded
condition. The primary baffle has an oblong profile in the illustrated
examples, but other profiles
are also contemplated. The secondary baffle also has an oblong profile in the
illustrated
examples, but other profiles are also contemplated.
The secondary baffle, or combination of secondary baffles, may be expanded
with fill
material so that it generally follows or complements the predetermined profile
of the primary
baffle in its predetermined expanded profile. In other words, the secondary
baffle 12 or baffles
in the main compartment of a primary baffle 10 are configured to expand to a
profile that
supports and maintains the fullness of the predetermined profile of the main
baffle when space
1 la is filled with fill material.
In any of the embodiments disclosed herein, the secondary baffle can be
connected to an
inner surface of the primary baffle in a variety of ways. The Figures show a
few different
possibilities. For example, FIGs. 1-4 and 6 show a "J" connection where a top
edge 18 of
secondary baffle 12 is connected to the top, inner surface 20 of the primary
baffle 10 at or about
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the upper apex or end 21 of the primary baffle. The edge connects to the inner
surface at a joint
19, which may coincide with apex or top 21. The secondary baffle 12 has a
vertically oriented
wall 22 that extends downwardly from the top edge 18. The wall runs generally
parallel to the
opposing vertical walls 24, 26 of the primary baffle. The wall 22 terminates
in a bottom edge 28
that connects to vertical wall 24. Accordingly, wall 22 is expandable or
displaceable from the
wall 24, providing an intermediate space for fill material. Similarly, wall 22
spaces apart from
wall 26 as fill material is added, and fill material may be disposed in the
space between the
walls.
Although the edge 18 is shown connecting at the top 20 of the primary baffle,
in other
embodiments, it could connect into vertical wall 24 of the primary baffle. For
example, as seen
for example in the case of secondary baffles 112b and 112c in FIG. 4.
In the embodiment shown, wall 22 may be made of a sheet material that has a
length that
is greater than the distance between joint 19 and a joint 29 where bottom edge
28 joins vertical
wall 24. By using a drapable sheet material for the wall, a pendulous portion
30 of secondary
.. baffle 12 is created, which hangs downwardly below where joint 29 is
disposed on wall 24. The
pendulous portion has opposing sides 32, 34 that are vertically oriented and
not connected to
wall 24. The pendulous section's bottom is the bottom 16 of the secondary
baffle. In this
example, the inner surface of secondary baffle 12 is defined in part by
primary baffle's wall 24
and the inner surface of wall 22 (both the vertical and bottom, horizontal
portions). In FIG. 4, a
series of secondary baffles 112a, 112b, and 112c may be vertically arranged
along wall 24. The
secondary baffles may partially overlap.
From the foregoing discussion, when secondary baffle(s) and are in an expanded
condition, the remaining space of the primary baffle can hold fill material
below the bottom of
the secondary baffle(s) and along at least one vertical side (e.g., wall 22)
of the secondary
.. baffle(s).
A secondary baffle can have a fully pendulous configuration. A fully pendulous
configuration is one where the vertically oriented sidewalls of the secondary
baffle are free from
the walls of the primary baffle so that the secondary baffle is suspended just
from a top
connection. An example of a fully pendulous configuration is seen in FIG. 5.
In secondary baffle
212 the opposing edges of a sheet wall material connect to or near the top of
the primary baffle
10. The portion of the sheet material in between the edges hangs downwardly
and forms the
closed bottom 16 of the secondary baffle. In other words, the sheet material
hangs in a generally
U-shaped form. Fill material in the primary baffle can surround the vertical
sides 32, 34 and
bottom side 16 of the secondary baffle 212.
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In other embodiments, the secondary baffle can have a non-pendulous form where
the
bottom 16 does not hang below joint 29. For example, FIG. 8 shows primary
baffle 10 with a
secondary baffle 412 in a C-shaped form that has bottom 16 coinciding with
joint 29. This form
of baffle is relatively shorter than a pendulous one and may be suited for use
at the top of a
primary baffle, as seen in FIG. 8.
In other embodiments, the primary baffle's main space can include not only a
first
secondary baffle 312a in an upper portion but also a second secondary baffle
312b in a lower
portion, as seen in FIG. 6. The two secondary baffles collectively have a
configuration that
mirrors the primary baffle and is concentrically disposed within the primary
baffle. Accordingly,
based on the teachings herein, the main compartment of the primary baffle can
be subdivided
into any number of sub-compartments via secondary baffles, from 1, 2, 3, 4, 6
or more sub-
compartments are possible. The arrangement of baffles collectively mimics the
shape of the
primary baffle such that they sufficiently maintain its intended profile when
sufficiently filled
with fill material. The secondary baffles may do this without a need for the
primary baffle to
have fill material other than what is provided in the secondary baffle(s), as
seen in the case of
FIG. 6.
In any embodiment, the cross-sectional profile of the main and secondary
baffles, taken
across a vertical orientation may vary. (In all cases, baffles are assumed to
be in an expanded
condition representing the desired profile). Typically, they will have an
oblong profile, namely a
height that is greater than width, using major axes. The height to width ratio
may be 1.2:1, 1.5:1,
2:1, 2.5:1, 3:1; 4:1, 5:1, 6:1, 7:1, 8:1, 9:1, 10:1, or higher. In the
Figures, primary baffle 10 has
an elliptical profile. And the secondary baffles of FIGs. 1-5 generally
resemble a tear drop or
piriform shape, with walls that diverge going from a top end toward a rounded
bottom. Another
way to characterize some of the many possible profiles that a primary or
secondary baffle may
have is that the profile converges at upper and lower ends when moving from an
intermediate
section of maximum width. Possible profiles under this description include,
ellipse, oval, tear
drop, piriform, and circle.
The baffle constructs contemplated under the inventive subject matter can be
assembled
into a panel. The baffles may all have the same configuration or they may have
a mix of
configurations. The inventive panels can be used in any application in which
conventional
baffles are used.
In one possible assembly of baffles, the primary baffles are defined in part
by horizontal
seams or joints 19 connecting a panel's face layer 36 and back layer 38 and
which define a top
and the bottom for a given baffle 10. In some embodiments, the back layer 38
is the same as
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vertical wall 24, and the face layer 36 is the same as vertical wall 26.
Advantageously, by disposing all the secondary baffles on and vertically
spaced along the
same inner surface 24 of the back layer 38, free from the face layer 36, the
face layer is free of
any seams or other joints for the sub baffle(s). This is seen in FIGs. 1-7
which show the face
.. layer 36 of panel 1 having just joints 19, free of any seems or other
joints for the secondary
baffles contained within the primary baffles. For example, looking at back
layer 38 in FIG. 2C,
seams 19 for the primary baffles are visible; seams 29 for secondary baffles
12 are also visible.
In contrast, FIG. 2B shows face layer 36 on the opposite side of back layer
38. Only seams 19
are visible because secondary baffles 12 are all aligned on wall 24 (back
layer 38 in this case),
and all the secondary baffles are disconnected from the wall 26 (face layer 36
in this case).
As generally shown in FIG. 7, any panel contemplated herein may be used as a
portion of
a garment 4, such as an upper body covering or lower body covering. Panels can
cover a
wearer's torso, in whole or part, including chest areas, stomach areas,
shoulder areas, upper back
areas, lower back areas. Panels can be included in the pelvic region and/or
leg regions of
garments and cover various areas of those regions.
The baffles constructs may be formed of separate pieces of woven or nonwoven
textiles
or fabrics, which are joined together. The baffles could also be formed of non-
textiles that have
textile properties and are suitable for use in garments and other applications
contemplated herein,
e.g., drapable or pliable thin sheets, webs, films, and membranes of material,
such as plastic or
.. elastomeric materials. Joints where one section of material merges into
another section can be
seams formed by stitching, adhesives, thermal bonding or fusion. The joints
can also be based
on seamless weaving or knitting, and other known or hereafter discovered
joining techniques.
The inventive baffle constructs contemplated herein may be in whole or part a
unitary
woven or nonwoven article with different sides, sections, or layers seamlessly
joined. In other
words, all portions are formed, for example, in the same weaving or knitting
process, and are not
separate panels that are joined together after each section is woven or knit.
For instance, baffle
panels having a unitary woven construction are disclosed in U.S. Publ. No.
US20170172240,
which is hereby incorporated by reference in its entirety for all it
discloses.
As indicated above, panel 1 has a multilayer construction for the primary
baffles of a first
or face layer 36 and a back layer 38. The labeling of layers 36, 38 is
arbitrary, as either may be
deemed one or the other. The labeling will have significance in the context of
end products or
components for end products: (i) the face layer normally faces outwardly
towards the
environment, and (ii) the back layer faces inwardly against a substrate, e.g.,
in the case of a
jacket or sleeping bag, the face layer faces away from the user's body and the
back layer faces
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the user's body. The panels with baffle constructs may also have intermediate
layers of baffle
constructs to form multi-layer panels, such as shown in U.S. Publ. No.
US20170172240.
The layers may have the same or different compositions of yarns or other woven
filament. The face layer 36 may be selected to provide desired performance
and/or aesthetic
attributes. For example, it may be a lightweight material such as taffeta. Or
it may be a durable
or wear resistant material, such as 40D polyester or ripstop nylon; a weather
resistant material
that blocks water or wind; an elastic material; or a material that provides a
combination of such
attributes. The face can be woven in various Dobby patterns.
The back layer 38 may be a comfort material, such as a taffeta; a material
that wicks
moisture; or a material that provides a combination of such attributes. An
interlayer (not shown)
may be the same or different from the other layers, or a combination of
materials used in the
other layers. The face and/or can have finishes such as DWR for water
repellency or CIRE to
make the fabric downproof and less air permeable.
In one representative, non-limiting example, face layer 36 has a woven
construction such
as Dobby, jacquard, etc., to produce a desired weave type (e.g., ripstop,
twill, etc.), while the
back layer 38 may have a basic taffeta construction. The interlayer 14 may
also have a basic
taffeta construction like the back layer. Alternatively, it may be like the
face layer (e.g., ripstop,
twill, etc.).
Various conventional materials with known attributes may be selected to
provide desired
attributes, such as those listed above, including nylon, polyester,
polypropylene, rayon, elastane,
silk, cotton, wool, acetate, acrylic, aramid, hemp, jute, lyocell, cashmere,
triexta, polyethylene,
rayon, and blends of the foregoing, and all recycled versions of any of the
foregoing or blends of
the foregoing. Deniers for the layers may be 5D or higher, and any layer may
be a blend of
deniers. For example, deniers of 10D, 15D, 20D, 30D, 40D, 50D, 60D, 70D, 75D,
80D, 90D,
100D, 120D, 140D, 150D, 160D, 180D, or 200D for typical sleeping bag and
apparel
applications, and a ripstop construction, or other known or discovered Dobby
patterns, may be
used with any layer to impart additional tear resistance and strength.
A given layer may also have varying attributes in different zones, and there
may be
transition zones between different zones that allow for a progressive change
in attributes, as
disclosed in more detail below.
FIGs. 1-7 show a theoretical or desired shape of the baffles when each is
filled properly.
However, as persons in the art will appreciate, in the field baffle shapes can
vary from a desired
shape as a result of use, and the theoretical or desired shape is a general
representation of a
desired condition, which is obtainable by person skilled in the art using the
teachings herein.
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Each baffle 10 in the illustrated examples has a generally oval-like or
elliptical-like cross-
sectional profile, following a longitudinal axis of the multi-layer fabric
construct. In other
embodiments, baffles may have other volumetric shapes like triangles,
pentagons, hexagons, or
other polygons, circles and other shapes defining a bounded area. Because of
their drapable,
pliable, fabric nature, the baffles may have some variation in shape if the
baffles are
incompletely filled or are filled with, for example, clumpy material that does
not uniformly
distribute within a baffle. Taking the structures shown in the Figures, the
variation can be from
flattened, with no filling in the baffles, to round with overstuffing of the
baffles. The theoretical
shape of the baffles is generally the volumetric shape that the baffle
construct would take in the
intermediate shape between flat and overstuffed to a round shape (in the case
of the baffles
shown). In the case of baffles structured in other shapes, e.g., polygons, as
the baffle expands
from an expected intermediate shape generally representing or recognizable as
a polygon, the
corners will curve creating a rounder shape. Another way to view the
theoretical shape is to
imagine an array of the baffles to be made of an inelastic, air impermeable
fabric that was
inflated with air until it just reached tautness. This should be the oval-like
structure shown. In the
following discussion, references to baffle shapes and geometries assume that
baffle construct is
in its theoretical expanded state unless indicated otherwise.
Each baffle 10, 12, 112, 212, 312, 412 in a vertical orientation, extends
latitudinally
(widthwise) through the construct as a hollow compartment for receiving a fill
material 2, 3. The
.. width of a baffle typically is as least 10cm, 15cm, 20cm 25cm, 30cm, 35cm,
40cm, 50, cm,
75cm, 100cm, 150cm, or 200cm.
The baffles may also have rectilinear forms that approximate an oval or
ellipsis such as a
rhombus or rhomboidal form. The Figures show representative geometries for
primary baffles
consistent with the foregoing description. However, the inventive subject
matter is not limited to
oval-like or elliptical-like geometries. It also contemplates, for example,
any version of a
trapezoid up to a rectangle and down to a triangle may be used and substituted
in for the oval-
like baffles shown in the Figures. And, as noted, shapes representing any
desired bounded area
may be used in certain embodiments.
In each baffle construct, the baffles may be woven to have varying
configurations, i.e.,
size, shape, or volume, based on differences in the length, height, cross-
section, or volume of a
baffle. One advantage of varying baffle parameters is that the construct can
be tuned for
performance needs. For example, for a parka, higher volume baffles could be
positioned at a
user's chest where more insulation may be desirable. Lower volume baffles
could be positioned
at a user's arms or underarms, where less insulation is needed, allowing for
more mobility.
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Lower volume baffles may be positioned at joint areas where more flexibility
is needed. Baffles
configured with fabrics allowing for more weatherproofness (water and/or wind)
or breathability
can also be mapped to body zones. For example, the baffles mapping to a user's
underarm area
may be made of layers of fabric that are more porous and breathable.
FIG. 7 shows a representative product, namely a parka, which may incorporate a
baffle
construction shown in the Figures or otherwise disclosed and contemplated
herein. The baffles
according to the inventive subject matter may be incorporated partially or
fully through such end
products.
Once the baffle is formed, a fill material 2, 3 may be placed in the baffle
compartments.
First, openings at one side of baffle construct are closed using known means.
For example, the
openings can be closed by stitching along one selvedge edge of the baffle
construct. This is just
one representative, non-limiting approach for a closure. For example, in
addition to stitching,
the baffle ends may be woven closed.
Loose fill material, such as natural or synthetic down may be blown in using
known
techniques for filling baffles. In general, a blowing system includes a supply
of fill material, one
or more tubes from the blowing system are placed in in openings on the
unsealed side of the
baffle construct. The fill material is then blown into the compartments to
partially or fully fill the
compartments. Alternatively, synthetic, non-blown insulative material may be
placed into the
baffles. After the fill material is supplied, the unsealed side of the baffle
construct may be sealed
by stitching, or other known means.
After filling and sealing, the baffle construct may be assembled with other
materials to
make a finished end-product or component thereof. Additional layers of
material may be added
to the baffle construct. For example, a layer of durable or wear resistant
material may be added.
A layer of waterproof/breathable material may be added. A comfort liner may be
added. The
baffle construct may be used as a shoe upper and a sole or sole component may
be added.
The loose fill contemplated for use with the baffle constructs disclosed and
contemplated
herein may be any natural fill material such as down or feathers, vegetable or
animal fibers or
fur, or combinations of the foregoing. One example of synthetic down is
ThermoballTm
(available in products from The North Face , a division of VF Outdoor, Inc.,
Alameda,
California, USA), which is based on round fiber clusters from PrimaloftTM,
Inc., Latham, New
York, USA. The insulative may also consist of synthetic/down blends, general
synthetics, foam,
or any other insulate material know or discovered insulative material suitable
for use in baffles
for apparel, sleeping bags and other end products contemplated herein.
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Fill power (or the equivalent for synthetic insulation) may be any desired
range from 100,
200, 300, 400, 500, 550, 600, 650, 700, 750, 800, 850, 900, or more, or any
range in between
based on any generally accepted industry protocol for determining fill power.
In some applications, a baffle construct may have varying thread densities
across layers
or zones. For example, in many applications, the only layers that need to be
completely
downproof are the outer layers. An interlayer or secondary baffle fabric, only
needs to be dense
enough to hold the majority of the down in place (i.e., if some feathers
transfer from baffle to
baffle, it is generally not an issue). Removing density from the interlayer
allows for higher
density in the outer layers and reduction of the overall weight of the
construct. Accordingly, in
this example, the reduction of density in the interlayer is for weight saving
purposes, not for the
downproof purpose described above. As a weight saving measure, it is
contemplated that the
interlayer can be a low-density taffeta or a lattice-like structure like an
open mesh.
The foregoing approaches of selectively varying yarn denier, yarn material
(e.g.,
hydrophobic, hydrophilic, elastic, etc.), or fabric density may be used in
other applications. For
example, the foregoing principles may be used to provide selective
breathability, windproofness,
waterproofness, thermal insulation, moisture transport, elasticity, abrasion
resistance, cut/tear
resistance, anti-compression resistance, increased compressibility, purely
aesthetic features, such
as color amongst others, and other desired attributes in one layer or zone
versus another.
In addition to the foregoing approaches for providing downproofness,
independent or
supplemental approaches include external finishing techniques such as a cire
finishes, coatings,
and/or laminates.
One standard for assessing downproofness has been set by the International
Down and
Feather Laboratory Institute (IDFL), and may be found on their website
www.idtl.com, with a
current test at
lutp;//www.kal.cointmediaixdfs/IIva.%20Downpro4.4.%20vs%20Air%20Permeabilitv.pd
f.
Under the 2008 test at the above link, downproofness is the fabric's ability
to contain
down and feathers. The test involves placing a test pillow into a tumbling box
where it is
tumbled for 30 minutes, during which time it is struck by rubber stoppers
(complete procedure is
available upon request). This procedure attempts to mimic the actual use of
the product.
Downproofness is considered poor when many fibers and/or feathers can pass
through the fabric.
The rating is based on a scale from 1-5 (with 1 being the worst and 5 being
the best). The
rating is based on the number of fibers and/or feathers that pass through the
fabric of a test
pillow.
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RATING SYSTEM:
= Pass (little or no leakage through fabric)
4 = Pass (minimal or normal leakage through fabric)
3 = Borderline
5 2 = Fail (above average leakage through fabric)
1 = Extreme Fail (significant leakage through fabric)
Another standard for evaluating the suitability of a fabric to contain fill
material is
fiberproofness. This is an analogous evaluation to downproofness but applies
to synthetic fiber
fills. A fiberproof fabric may be slightly more air permeable than downproof
but still prevents
the migration of synthetic insulations like basic Primaloft insulation.
As used herein, "and/or" means "and" or or, as well as "and" and "or."
Moreover, all
patent and non-patent literature cited herein is hereby incorporated by
references in its entirety
for all purposes. The principles described above in connection with any
particular example can
be combined with the principles described in connection with any one or more
of the other
examples. Accordingly, this detailed description shall not be construed in a
limiting sense, and
following a review of this disclosure, those of ordinary skill in the art will
appreciate the wide
variety of fluid heat exchange systems that can be devised using the various
concepts described
herein. Moreover, those of ordinary skill in the art will appreciate that the
exemplary
embodiments disclosed herein can be adapted to various configurations without
departing from
the disclosed principles.
The previous description of the disclosed embodiments is provided to enable
any person skilled
in the art to make or use the disclosed innovations. Various modifications to
those embodiments
will be readily apparent to those skilled in the art, and the generic
principles defined herein may
be applied to other embodiments without departing from the spirit or scope of
this disclosure.
Thus, the disclosed inventions are not intended to be limited to the
embodiments shown herein,
but are to be accorded the full scope consistent with the language of this
disclosure, wherein
reference to an element in the singular, such as by use of the article "a" or
an is not intended to
mean one and only one unless specifically so stated, but rather one or more.
All structural
and functional equivalents to the elements of the various embodiments
described throughout the
disclosure that are known or later come to be known to those of ordinary skill
in the art are
intended to be encompassed by the elements of the claims. Moreover, nothing
disclosed herein is
intended to be dedicated to the public regardless of whether such disclosure
is explicitly recited
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in the claims. No element is to be construed under the provisions of 35 USC
112, sixth
paragraph, unless the element is expressly recited using the phrase "means for
or "step for.
Thus, in view of the many possible embodiments to which the disclosed
principles can be
applied, it should be recognized that the above-described embodiments are only
examples and
should not be taken as limiting in scope. All rights to claim the subject
matter disclosed herein
are reserved, including the right to claim any and all combinations of subject
matter described
herein, including but not limited to all that comes within the scope and
spirit of the following
claims.
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