U.S. patent application number 11/381245 was filed with the patent office on 2006-11-16 for thermal liner for an article of clothing.
Invention is credited to Bruce McCormick.
Application Number | 20060254088 11/381245 |
Document ID | / |
Family ID | 38668507 |
Filed Date | 2006-11-16 |
United States Patent
Application |
20060254088 |
Kind Code |
A1 |
McCormick; Bruce |
November 16, 2006 |
THERMAL LINER FOR AN ARTICLE OF CLOTHING
Abstract
A thermal liner for an article of clothing includes a housing
having a top and a bottom, with a thermal material layer interposed
therebetween, and a perimeter portion substantially peripherally
enclosing the thermal material layer. The perimeter portion can be
defined, for example, by peripheral margins of the top and bottom
that are sealed together, or by a separate frame interposed between
the top and bottom, or by a frame integral with the top and
bottom.
Inventors: |
McCormick; Bruce; (Santa Fe,
NM) |
Correspondence
Address: |
JAMES D. STEVENS;REISING, ETHINGTON, BARNES, KISSELLE, P.C.
P.O. BOX 4390
TROY
MI
48099
US
|
Family ID: |
38668507 |
Appl. No.: |
11/381245 |
Filed: |
May 2, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11156890 |
Jun 20, 2005 |
|
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|
11381245 |
May 2, 2006 |
|
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|
60580933 |
Jun 19, 2004 |
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Current U.S.
Class: |
36/44 |
Current CPC
Class: |
A43B 7/34 20130101; A41D
31/065 20190201; A43B 17/14 20130101 |
Class at
Publication: |
036/044 |
International
Class: |
A43B 13/38 20060101
A43B013/38 |
Claims
1. A thermal liner for an article of clothing, comprising: a
thermal material layer; and a housing having a top and a bottom
wherein the thermal material layer is interposed therebetween, and
further having a perimeter portion substantially peripherally
enclosing the thermal material layer.
2. The thermal liner of claim 1, wherein the perimeter portion is
defined by peripheral margins of the top and bottom, wherein the
peripheral margins are sealed together.
3. The thermal liner of claim 1, wherein the perimeter portion is
defined by a separate frame interposed between the top and
bottom.
4. The thermal liner of claim 1, wherein the perimeter portion is
defined by a frame integral with the top and bottom.
5. The thermal liner of claim 1, wherein the thermal material layer
is an insulating layer sealed between the top and bottom, wherein
the insulating layer comprises an aerogel material.
6. The thermal liner of claim 5, wherein the bottom is an
impermeable first layer, the top includes an impermeable second
layer, and the frame is sealingly attached therebetween.
7. The thermal liner of claim 6, wherein the second layer includes
an impermeable polymeric material and a wearing material applied
thereto.
8. The thermal liner of claim 6, wherein the second layer includes
an encapsulated phase change material.
9. The thermal liner of claim 1, wherein the housing is injection
molded such that the top, bottom, and frame are integral and the
housing defines a cavity.
10. The thermal liner of claim 9, wherein the housing also includes
a closure member and the frame of the housing includes an opening
to receive the thermal material layer into the cavity and a closure
member to close the housing.
11. The thermal liner of claim 10, wherein the closure member is
sealingly attached to corresponding portions of the top, bottom,
and frame.
12. The thermal liner of claim 9, wherein the thermal material
layer is at least one of an aerogel-containing insulating material
or a phase change material.
13. A thermal liner for an article of clothing, comprising: an
insulating layer; and a housing including a first layer and a
second layer, and a frame interposed therebetween, wherein the
insulating layer is interposed between the first and second layers
and peripherally enclosed by the frame.
14. The thermal liner of claim 13, wherein the bottom is an
impermeable first layer, the top includes an impermeable second
layer, the frame is sealingly attached therebetween, and the
insulating layer comprises an aerogel material.
15. The thermal liner of claim 13, further comprising a frontal
region defined by portions of the first and second layers bonded
together without said insulating layer therebetween and including
contour lines identifying cut lines along which the liner may be
trimmed to various sizes.
16. The thermal liner of claim 13, wherein the second layer
includes an encapsulated phase change material.
17. A thermal liner for an article of clothing, comprising: a
thermal material layer; and an injection molded housing including
an integral top, bottom, and frame defining an opening through
which the thermal material layer is inserted and further defining a
cavity in which the thermal material layer is disposed, and further
including a closure member to close the opening.
18. The thermal liner of claim 17, wherein the closure member is
sealingly attached to corresponding portions of the top, bottom,
and frame.
19. The thermal line of claim 17, wherein the thermal material
layer is separately encapsulated before being inserted into the
housing.
20. The thermal liner of claim 17, wherein the thermal material
layer is at least one of an aerogel-containing insulating liner or
a phase change material.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of, and claims
priority to, U.S. application Ser. No. 11/156,890, filed Jun. 20,
2005, which claims the benefit of U.S. Provisional Application No.
60/580,933, filed Jun. 19, 2004, the complete disclosures of which
are hereby incorporated by reference.
TECHNICAL FIELD
[0002] This invention relates generally to clothing and garment
articles and, more particularly, to insulating garments as well as
insulating garment articles such as shoe liners or other clothing
inserts that are used in conjunction with an article of
clothing.
BACKGROUND OF THE INVENTION
[0003] Incorporation of insulating liners with the use of an
article of clothing is known. As used herein, "clothing",
"garment", or "article of clothing" includes not only under and
outer wear (shirts, blouses, pants, shorts, skirts, underwear,
etc.), but also such things as footwear, gloves, blankets, sleeping
bags, and other articles used to provide protection or comfort
against the elements. Such insulating liners when used in
combination with the overlaying article of clothing shields the
user against uncomfortably cold or hot temperatures and high levels
of moisture. Various insulating materials for insulating liners
that have been used in the textile industry include felt, fleece,
flannel, wool, various forms of latex foam, or the like.
[0004] Although flexible and readily adaptable for textile
applications, such materials are often provided in relatively thick
slabs that can be bulky, thereby requiring the user, for example,
to use a larger sized garment in order to fit the insulating insert
or liner. Also, such materials often do not exhibit effective
insulative properties in extremely high or extremely low
temperature-related environments.
[0005] Silica aerogels have been known to exhibit excellent thermal
insulation performance and have been readily adapted for use in
high temperature thermal insulation and cryogenic thermal
insulation applications including, for example, advanced space suit
designs by NASA. Aerogels, as that term is used herein, include
polymers with pores with less than 50 nanometers in porous
diameter. In a process known as sol-gel polymerization, monomers
are suspended in solution and react with one another to form a sol,
or collection, of colloidal clusters. The larger molecules then
become bonded and cross-linked, forming a nearly solid and
transparent sol-gel. An aerogel of this type can be produced by
carefully drying the sol-gel so that the fragile network does not
collapse.
[0006] Thermal insulation blankets using aerogels have been
developed, and aerogel materials are now commercially available in
which the aerogel is impregnated or otherwise incorporated into a
carbon-based media. One difficulty with using silica aerogels is
that the aerogel tends to be dusty, even when supported by a
carrier material. If the aerogel material is not properly contained
and sealed within the liner assembly, the dust particles may escape
the liner and into the atmosphere thereby diminishing the effective
insulative life of the insulating liner.
[0007] Thus, it is an object of the present invention to provide an
insulating lining for an article of clothing that effectively
insulates against hot and cold temperature conditions as well as
against moisture, while reducing or even eliminating the loss of
the aerogel dust.
SUMMARY OF THE INVENTION
[0008] In accordance with one aspect of the present invention, a
thermal liner for an article of clothing includes a housing having
a top and a bottom wherein a thermal material layer is interposed
therebetween, and further having a perimeter portion substantially
peripherally enclosing the thermal material layer.
[0009] In accordance with another aspect of the present invention,
a thermal liner for an article of clothing includes a housing
including a first layer and a second layer, and a frame interposed
therebetween, wherein an insulating layer is interposed between the
first and second layers and is peripherally enclosed by the
frame.
[0010] In accordance with a further aspect of the present
invention, a thermal liner for an article of clothing includes an
injection molded housing including an integral top, bottom, and
frame defining an opening through which a thermal material layer is
inserted and further defining a cavity in which the thermal
material layer is disposed. The thermal liner further includes a
closure member to close the opening.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Preferred exemplary embodiments of the invention will
hereinafter be described in conjunction with the appended drawings,
wherein like designations denote like elements, and wherein:
[0012] FIG. 1 is a top view of an insulating liner for a shoe;
[0013] FIG. 2 is a cross-sectional view taken along line 2-2 of the
insulating liner shown in FIG. 1;
[0014] FIG. 3 is an exploded, perspective view of the formation of
the insulating liner using the formation process of the present
invention;
[0015] FIG. 4 is an alternative cross-sectional view taken along
line 2-2 of the insulating liner shown in FIG. 1;
[0016] FIG. 5 is a cross-sectional view of a boot taken
transversely through a toe end thereof,
[0017] FIG. 6 is an alternative cross-sectional view of the boot of
FIG. 5;
[0018] FIG. 7 is another alternative cross-sectional view of the
boot of FIG. 5;
[0019] FIG. 8 is a top view of a thermal liner for a shoe;
[0020] FIG. 9A is a cross-sectional view taken along line 9-9 of
the thermal liner shown in FIG. 8;
[0021] FIG. 9B is a cross-sectional view of an alternative thermal
liner;
[0022] FIG. 10 is an exploded top view of another thermal liner for
a shoe; and
[0023] FIG. 11 is a side view of a portion of the thermal liner of
FIG. 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] With reference to the drawings, FIGS. 1 and 2 depict a
multiple layer insulating shoe liner 10 comprising an
aerogel-containing insulation layer 12 encapsulated within two
support layers 14, 16 by a hermetic seal. The insulation layer 12
is a relatively thin layer of material that is composed of a dust
generating aerogel composite including a nonporous silica matrix
supported or carried by a polymeric, fibrous substrate. The
insulation layer 12 is die-cut and then disposed on an upper
surface 13 of the first support layer 14. The liner 10 is completed
by disposing the second support layer 16, having a wearing material
18 laminated on an upper surface 22 of a polymeric material layer
20, over the insulation layer 12. The periphery of the first and
second support layers 14, 16 are hermetically sealed by a high
frequency or ultrasonic welder for encapsulating the insulation
layer 12 between the support layers 14, 16. The insulating shoe
liner 10 can include a frontal region 25 which comprises the upper
and lower layers 14, 16 bonded together without any insulating
material 12 therebetween. This frontal region includes raised
contour ridges 27 that comprise cut lines along which the liner 10
can be trimmed to fit various sized shoes.
[0025] The insulation layer 12 is composed of a carrier material
impregnated with an aerogel composite. Studies have shown that
aerogel composites demonstrate superior insulative properties as
opposed to other insulators conventionally used in textile, garment
and footwear applications. Based upon their chemical structures,
aerogels can have low bulk densities of about 0.15 g/cm.sup.3 or
less, and more preferably of about 0.03 to 0.3 g/cm.sup.3, very
high surface areas of generally from about 400 to 1,000 m.sup.2/g
and higher, and more preferably of about 700 to 1000 m.sup.2/g,
high porosity of about 95% and greater, and more preferably greater
than about 97% porosity, and relatively large pore volume with more
than about 3.8 mL/g, and more preferably with about 3.9 mL/g and
higher. The combination of these properties in an amorphous
structure provides low thermal conductivity values of about 9 to 16
mW/m-K at 37.degree. C. and 1 atmosphere of pressure for any
coherent solid material.
[0026] The carrier used in insulation layer 12 is a polymeric
fibrous material that effectively carries the aerogel composite
material with it. The carrier itself can be a carbon-based
material, such as a carbon felt or other fibrous material, or can
be formed from polyester or any other material suitable for
supporting and retaining the aerogel within the carrier. The
fibrous material may include a single type of polymer fiber or may
include a combination or matrix of fibers and is somewhat bulky, as
compared to the aerogel, and includes some resilience preferably
with some bulk recovery. The use of the carrier minimizes the
volume of unsupported aerogel while avoiding degradation of the
thermal performance thereof. Also, the carrier permits the aerogel
to be available in the form of a sheet or a roll that contains one
continuous sheet or strip that may be easily cut to any desirable
size and/or shape using conventional textile cutting tools such as
die cutting machines, for example. The carrier further provides the
aerogel material in a very flexible state that is very manageable
for textile, footwear and other similar applications. Suitable
aerogel materials for use in the present invention include the
Spaceloft.RTM. AR3101, AR3102 and AR3103 materials as well as
Pyrogel.RTM. AR5401, all of which are manufactured by Aspen
Aerogels, Inc. of Marlborough, Mass.
[0027] The first support layer 14 is generally composed of an
organic polymeric material, such as nylon, polystyrene,
polypropylene, polyvinyl chloride (PVC), or the like. Specifically,
the PVC material is structurally intact, yet flexible, can be
easily cut to a desired size and shape and further provides a
somewhat sticky or gripping-like surface that is particularly
advantageous for footwear applications. The lower surface 23 of the
first support layer 14 readily grips and temporarily adheres to the
insole of the shoe. For other textile-like applications, other
materials such as nylon, for example, provides a similar
structurally integral material suitable for the support layer 14
but does not exhibit such a gripping property, thereby making the
liner 10 more adaptable for clothing inner linings and for outer
linings where a non-grip surface is desired. In footwear
applications, the support layer 14 for the liner 10 is preferably
composed of PVC foam having a thickness in the range of about 1.5
mm to 2.5 mm, and more preferably of about 2.0 mm in thickness.
[0028] The second support layer 16 comprises the wearing material
18, about 1.0 mm or less in thickness, secured on the upper surface
22 of the polymeric material layer 20 by lamination, for example.
The wearing material 18 is preferably made of a knitted or woven
polyester material that can be easily cut to the desired size
and/or shape of the liner 10, is readily adherable to the polymeric
material 20, and further provides a comfortable wearing surface for
the user. The polymeric material 20 is preferably the same PVC foam
material that is used for the first structural layer 14 depending,
of course, on the application (e.g., footwear application) in which
the liner will be used.
[0029] In the illustrated embodiment, both the first and second
support layers 14, 16 are structural layers that not only seal the
aerogel material into an enclosed space, but also provide
structural features such as cushioning to the shoe insert. Where
such structural features are not needed, the layers 14, 16 can
instead be implemented in other ways that will be apparent to those
skilled in the art.
[0030] In reference now to FIGS. 1-3, the insulating liner 10 is
formed by the following process. First, the insulation layer 12 is
cut into a suitable size and shape and laid over an upper surface
24 of a PVC sheet 26. The PVC sheet 26, after the forming process
of the liner 10 provides the first structural layer 14. Since the
PVC sheet 26 may be provided in various sizes, more than one
insulation layer 12 may be provided on the upper surface 24 to
thereby form multiple liner assemblies 10 during a single
insulation liner manufacturing process.
[0031] Second, a PVC sheet 28 is pre-preprocessed by laminating a
sheet 30 of the knitted or woven polyester material 18 thereon. The
combined PVC/polyester panel is then disposed over the insulating
layer 12, thereby forming the second structural layer 16 of the
insulating liner 10.
[0032] Third, a high frequency (HF) or ultrasonic welder (not
shown) is provided including a lower platen 31 and upper die plate
32 having the contours of the shoe liner 10, including the shape,
size, and embossments such as dimples 34 (as shown in FIGS. 1 and
3), a logo or the like. The die plate 32 includes one, two, or more
outer die-cutting surfaces 36 (only one die cutting surface 36
shown in FIG. 3) for forming one, two or more simultaneous
insulating liner assemblies 10. The sheet 26 having the insulating
layer 12 thereover as well as the sheet 28 with the laminated
material 30 thereon are then positioned on the platen 31 below the
die plate 32, and the die-cutting surface 36 is aligned with the
insulating layer 12. The die plate 32 then engages the wearing
material 30, and presses the two sheets 26, 28 with the insulating
layer 12 disposed between them together against the platen 31 while
applying a high frequency of about 10-30 KHz to weld the sheets 26,
28 together just outside the periphery of insulating layer 12 to
thereby encapsulate the insulating layer 12 therebetween. The die
plate 32 further die-cuts the sheets 26, 28 with suitable pressure
exerted on the layers 14, 16 from the welder and further
simultaneously embosses the wearing material 18. A hermetic seal is
thus formed between the PVC sheets 26, 28 and the insulting liner
10 is cut and formed having the dimples 34 and contour ridges 27,
as well as manufacturers' logos or other embossments formed
thereon. PVC foam is just one example of a suitable material that
is impermeable to air and capable of being hermetically sealed to
another layer of the same material about its periphery. Other
suitable materials will be known to those skilled in the art. The
welder can be a high frequency plastic welding machine such as is
available from Weldech Electric Industry Co., Ltd. of Taichung,
Taiwan (www.weldech.com).
[0033] The dimples 34 can comprise areas where the PCV and
insulating layers are compressed tightly together such that the
dimples comprise indentations in the upper surface. Alternatively,
the dimples can be raised areas formed from recesses in the die
plate 32. In this latter arrangement, the dimples help provide air
flow between the shoe liner and wearer's foot. These dimples can be
formed on the first layer 14 as well, thereby allowing airflow
between the insert and insole of the shoe. This latter arrangement
is also advantageous during manufacturing since the layers 12, 14,
16 can be tightly compressed by the die plate 32 to squeeze out
excess air before hermetically sealing the layers 14, 16 during
welding. This helps minimize the amount of air trapped in the shoe
liner. Furthermore, this manufacturing approach facilitates use of
thicker foam layers such as, for example, a 5 mm foam layer. During
compression and welding, the foam can be significantly compressed
leaving dimples that protrude by several millimeters.
[0034] Turning now to FIG. 4, there is illustrated another
embodiment of an insulating liner for an article of clothing in the
form of a shoe liner 110. This embodiment is similar in many
respects to the embodiment of FIG. 2 and like numerals that are
offset by 100 between the embodiments generally designate like or
corresponding elements throughout the several views of the drawing
figures. Additionally, features of shoe liner 110 that are not
explicitly described hereafter can be implemented in the same
manner as described above for the first embodiment. The shoe liner
110 includes an aerogel-containing insulation layer 112
encapsulated within two support layers 114, 116 by a hermetic seal.
As with the embodiment shown in FIG. 2, a wearing material 118 is
disposed against an upper surface 122 of a polymeric material layer
120. Additionally, however, a thermally reflective layer 121 such
as metal foil is disposed between the wearing material 118 and the
polymeric material layer 120.
[0035] The manufacturing process for the liner 110 may be
substantially similar to that described above, except that the
thermally reflective layer 121 may be sandwiched between the
wearing material 118 and the polymeric material layer 120 before
the wearing material 118 is laminated or otherwise attached to the
polymeric material layer 120. Alternatively, the wearing material
118 may be welded to the polymeric material layer 120 about the
periphery of the insulation layer 112 with the thermally reflective
layer 121 trapped therebetween. In any case, the thermally
reflective layer 121 is provided between the insulating layer 112
and the wearer of the article of clothing. Accordingly, it is also
contemplated that the thermally reflective layer 121 could be
positioned between the polymeric material layer 120 and the
insulation layer 112 if desired.
[0036] In general, FIGS. 5 through 7 illustrate embodiments of an
article of clothing generally including an insulating liner
integrated into a boot or shoe. As used herein, the terms boot and
shoe are interchangeable footwear articles of clothing.
Specifically, in FIG. 5 an insulating liner is integrated into a
boot 200, wherein an aerogel material is contained and sealed
within the boot upper to prevent aerogel dust particles from
escaping the insulating liner. The boot 200 includes a molded sole
202 to provide a foundation for the boot 200 and an outer
structural layer such as a leather upper 204 molded into the sole
202. Disposed on the sole 202 within the confines of the leather
upper 204, the boot 200 further includes a foam layer or insert 206
that is preferably composed of PVC, and a cushion layer or insert
208 disposed on the foam insert 206 that is preferably composed of
cork. The boot 200 further includes an aerogel upper or layer 212
disposed within the confines of the leather upper 204, between the
leather upper 204 and another structural layer such as an open-cell
foam upper 214 that is also disposed within the confines of the
leather upper 204. The insulating liner or lining is thus defined
by the aerogel layer 212 and open-cell foam upper 214, with the
aerogel layer 212 being sealed between the leather upper 204 and
foam layer 214. Aerogel layer 212 can be the same aerogel/carrier
material as insulation layer 12 of the first embodiment. An
open-cell foam insert 216 is disposed on top of the cushion layer
208 within the confines of the open-cell foam upper 214. A
thermally reflective layer 221 may be disposed on either or both
sides of the aerogel layer 212. Finally, a thin liner or wearing
material 218 is preferably composed of polyester material and is
applied to inside surfaces of the open cell foam upper 214 and
insert 216.
[0037] In general, FIG. 6 illustrates an alternative embodiment of
a boot including an insulating liner. Specifically, a boot 300 is
composed of the same components and materials as described above,
except that the cushion layer 208 of the boot 200 of FIG. 5 is
replaced with an aerogel insert or layer 308. Accordingly, the boot
300 provides a substantially circumferential aerogel layer defined
by the aerogel upper 212 and the aerogel insert 308, wherein the
aerogel layer is contained and sealed within the boot to prevent
aerogel dust particles from escaping the insulating liner.
[0038] FIG. 7 illustrates another embodiment of a boot including an
insulating liner. Specifically, a boot 400 is composed of the same
components and materials as described above, except that the foam
insert 206 of the boot 200 of FIG. 5 is replaced with an aerogel
insert or layer 406. Accordingly, the boot 400 provides a
circumferential aerogel layer defined by the aerogel upper 212 and
the aerogel insert 406, wherein the aerogel layer is again
contained and sealed within the boot to prevent aerogel dust
particles from escaping the insulating liner.
[0039] Also, with reference back to FIG. 5, both the insole layers
206 and 208 can comprise aerogel material. Alternatively, one or
more aerogel layers could be added adjacent to one or both of the
layers 206 and 208. In yet another embodiment, the upper aerogel
layer 212 can be eliminated and instead the aerogel layer can be
used in the insole only forming, in effect, an integrated shoe
liner placed beneath at least the uppermost layer 218.
[0040] FIGS. 8 through 9B illustrate other embodiments of thermal
liners. These embodiments are similar in many respects to the
embodiment of FIGS. 1 through 3 and like numerals between the
embodiments generally designate like or corresponding elements
throughout the several views of the drawing figures. Additionally,
the description of the previous embodiments are incorporated by
reference and the common subject matter may generally not be
repeated here.
[0041] FIGS. 8 and 9A depict a thermal liner 510 comprising an
aerogel-containing insulation layer 512 encapsulated within a
housing 511. The thermal liner 510 is preferably a thermal shoe
liner 510 but may be any suitable type of clothing liner. The
housing 511 is defined by two support layers 514, 516, and by a
frame 515 interposed therebetween. The insulation layer 512 is
sandwiched between the support layers 514, 516 and is substantially
peripherally enclosed by the frame 515, which defines a perimeter
portion of the housing 511.
[0042] But the perimeter portion need not be a separate component,
such as the frame 515. Instead, for example, the perimeter portion
could be defined by peripheral margins of the support layers 514,
516 that are fused together or otherwise attached to one another.
For example, such a perimeter portion is defined by peripheries of
the first and second support layers 14, 16, which are hermetically
sealed together to define a housing to enclose the insulation layer
12 of the liner 10 of FIGS. 1 and 2. In another example, the
perimeter portion could be a unitary portion integral with both of
the support layers 514, 516, as will be described below with regard
to FIGS. 10 and 11.
[0043] Referring again to FIGS. 8 and 9A, the insulation layer 512
is a relatively thin layer of material that is composed of a dust
generating aerogel composite including a nonporous silica matrix
supported or carried by a polymeric, fibrous substrate. As
similarly described above with respect to FIGS. 1-3, the frame 515
is die cut and disposed on an upper surface 513 of the first
support layer 514. Then, the insulation layer 512 is die-cut and
disposed on the upper surface 513 of the first support layer 514
within the peripheral confine of the frame 515. The liner 510 is
completed by disposing the second support layer 516, having a
wearing material 518 laminated or otherwise carried on an upper
surface 522 of a polymeric material layer 520, over the insulation
layer 512 and frame 515.
[0044] The insulation layer 512 is encapsulated and hermetically
sealed within the frame 515 and between the support layers 514, 516
of the housing. For example, the upper and lower surfaces of the
frame 515, and/or corresponding peripheral portions of the upper
and lower surfaces 513, 521 of the support layers 514, 516, are
preferably provided with liquid adhesive or pressure sensitive
adhesive, wherein heat and pressure are applied to the frame 515
and support layers 514, 516 during assembly to create a hermetic
seal therebetween. This process does not result in a liner 510 with
impressions, which are typically created during radio frequency
welding. Alternatively, the periphery of the first and second
support layers 514, 516 can be hermetically sealed to the upper and
lower surfaces of the frame 515 using a high frequency or
ultrasonic welder. This alternative process is similar to the
process described above with reference to FIGS. 1-3 with an
exception; the lower sheet 26 would also have the frame 515
thereon, in addition to the insulating layer 512 and upper sheet
28, before being positioned on the platen 31. In addition to, or
instead of, the sealing techniques above, the housing can be
fastened by sewing the support layers 514, 516 together through the
frame 515. In any case, the insulating liner 512 can also be
adhered to one or both of the layers 514, 516, or can loosely
placed therebetween without attachment.
[0045] The thermal shoe liner 510 can include a frontal region 525,
which comprises the lower and upper support layers 514, 516 bonded
to a frontal region of the frame 515 without any insulating
material 512 therebetween. This frontal region includes raised
contour ridges 527 that comprise cut lines along which the liner
510 can be trimmed to fit various sized shoes. Moreover, the
frontal region 525 is but a portion of a peripheral margin
surrounding the insulating layer 512 that can be trimmed to a
desired size without penetrating, cutting, or otherwise breaking
the seal around the insulating layer 512. Accordingly, the liner
510 can be manufactured for a broad range of shoe sizes such as
Men's 7-12 or the like.
[0046] The liner 510 materials can be the same or similar to that
described above with regard to FIGS. 1 through 3. For example, the
insulation layer 512 is composed of a carrier material impregnated
with an aerogel composite, wherein the carrier used in the
insulation layer 512 is a polymeric fibrous material that
effectively carries the aerogel composite material with it.
Preferably, the carrier is an odor-absorbing carbon-based material.
The support layers 514, 516 are generally composed of an
impermeable organic polymeric material, such as polyurethane,
ethylene vinyl acetate co-polymer (EVA), polyvinyl chloride (PVC),
or the like. In footwear applications, the support layers 514, 516
are preferably composed of a vinyl polymer material having a
thickness in the range of about 1.5 mm to 4.0 mm in thickness. The
layers 514, 516 are preferably formed from relatively thin
materials to produce a liner 510 that is as thin as possible to
provide comfort for a user. The bottom or first layer 514 can be
composed of a relatively durable EVA foam material, which resists
tearing and provides cushioning. An anti-microbial finish can be
applied to the liner 510 to resist growth of bacteria on the
product.
[0047] Preferably, the support layers 514, 516 are composed of PVC
and the frame is composed of a PVC or EVA material to provide a
relatively thin product. The second support layer 516 can include
the wearing material 518, which can be natural pigskin or leather,
synthetic pigskin or leather, or the like carried or secured on the
upper surface 522 of the polymeric material layer 520 by
lamination, for example. If the wearing material 518 is
impermeable, then the support layer 516 can include just the
wearing material 518 in place of the polymeric material layer 520,
which can be omitted.
[0048] In the illustrated embodiment, both the first and second
support layers 514, 516 are structural layers that, together with
the frame 515, not only seal the aerogel material 512 into an
enclosed space, but also provide structural features such as
cushioning to the shoe liner 510. Where such structural features
are not needed, the layers 514, 516 can instead be implemented in
other ways that will be apparent to those skilled in the art. As an
alternative, more than one insulating layer 512 can be used to
obtain greater insulating performance. When two or more insulating
layers 512 are used, the thickness of the frame 515 is preferably
also correspondingly increased.
[0049] Alternatively, as shown in FIG. 9B, a thermal liner 510' can
include an upper support layer 516' comprising an encapsulated
phase change material. The encapsulated phase change material can
be used in hot or cold weather and has the ability to slowly
release energy as it changes from a solid to a liquid. For example,
the encapsulated phase change material can be a cold pack. An
exemplary phase change material is available from Frisby
Technologies and is known as Thermasorb.TM. 95, which is made from
paraffin wax, transforms from solid to liquid at about 35 degrees
C., and has a latent heat capacity of about 180 J/g. Accordingly,
the liner 510' can be stored inside a freezer prior to use and,
once placed inside a shoe, the phase change material absorbs heat
from a user's foot to help keep the foot more comfortable during
hot weather. The encapsulated phase change material can include a
phase change material that is encapsulated and sealed between
impermeable polymeric layers 518' and 520, one of which can be the
polymeric material layer 520. The polymeric layers 518', 520 can be
composed of any suitable material(s) including those mentioned
above with respect to the previously described embodiments. The
layers 518, 520 can be hermetically sealed about the periphery of
the phase change material, such as by applying liquid adhesive or
pressure sensitive adhesive, or using high frequency, ultrasonic,
or radio frequency welding, or the like. Those of ordinary skill in
the art are familiar with encapsulated phase change materials and a
detailed discussion is, thus, omitted here.
[0050] FIGS. 10 and 11 illustrate another embodiment of a thermal
liner. This embodiment is similar in many respects to the
embodiment of FIGS. 1 through 3, and FIGS. 8 through 9B, and like
numerals between the embodiments generally designate like or
corresponding elements throughout the several views of the drawing
figures. Additionally, the description of the previous embodiments
are incorporated by reference and the common subject matter may
generally not be repeated here.
[0051] FIGS. 10 and 11 depict a thermal liner 610 comprising a
thermal material layer 612 encapsulated within a housing 611
defined by two integral support layers 614, 616 and a partially
integral frame 615 interposed therebetween. The thermal liner 610
is preferably a thermal shoe liner, but may be any suitable type of
clothing liner. The housing 611 is a hollow structure defining a
cavity 619 for receiving the thermal material layer 612, and
includes a removable closure member 617 that is adapted to be fit
into a corresponding opening 623 in the frame 615 of the housing
611.
[0052] In contrast to the embodiments described above, the housing
611 and its closure member 617 are preferably injection molded from
an impermeable polymeric material. Then, the thermal material layer
612 is provided and, as shown, inserted within the cavity 619
defined by the housing 611 between an upper surface 613 of the
first support layer 614 and a lower surface 621 of the second
support layer 616 within the peripheral confine of the frame 615.
The liner 610 is completed by positioning the closure member 617 in
place and sealingly attaching it to corresponding portions of the
support layers 614, 616, and frame 615.
[0053] The thermal material layer 612 is encapsulated and
hermetically sealed within the frame 615 and between the support
layers 614, 616 of the housing 611. For example, the closure member
617 can be provided with liquid adhesive or pressure sensitive
adhesive, wherein heat and pressure are applied to the closure
member 617, frame 615 and support layers 614, 616 during assembly
to create a hermetic seal therebetween. Alternatively, the closure
member 617 can be hermetically sealed to corresponding portions of
the frame 615 and upper and lower surfaces of the housing 611 using
high frequency, ultrasonic, or radio frequency welding.
Alternatively, the thermal material layer 612 can be separately
encapsulated and hermetically sealed prior to being assembled
within the housing 611. In this case, the closure member 617 would
not have to be hermetically sealed to the rest of the housing 611.
Instead, the closure member 617 could be mechanically connected to
the housing 611, interference fit to the housing 611, or the
like.
[0054] The liner 610 materials can be the same or similar to that
described above with regard to FIGS. 1 through 3 and/or FIGS. 8
through 9B. For example, the housing 611 is preferably composed of
an impermeable organic polymeric material, such as silicone,
polyvinyl chloride (PVC), or the like. Also, an anti-microbial
finish can be applied to the liner 610 to resist growth of bacteria
on the product. In another example, the thermal material layer 612
can be an insulation layer such as a relatively thin layer of
material that is composed of a dust generating aerogel composite
including a nonporous silica matrix supported or carried by a
polymeric, fibrous substrate. More specifically, such an insulation
layer can comprise a carrier material impregnated with an aerogel
composite, wherein the carrier is a polymeric fibrous material that
effectively carries the aerogel composite material with it.
Alternatively, the thermal material layer 612 can be a phase change
material. Those skilled in the art will recognize that thermal
materials include phase change materials and insulation materials.
Accordingly, the insulation layer and phase change material layer
are interchangeable within any given liner housing design.
[0055] The liner 610 can be manufactured according to any suitable
method. For example, the thermal material layer 612 can be
encapsulated between impermeable polymeric materials and provided
as a sub-assembly to be assembled into the housing 611, or can be a
loose component that is assembled into the housing 611. In another
example, the thermal material layer can be an aggregate that is
injected, poured, or otherwise introduced into the cavity of the
housing 611. In a further example, an over-molding process can be
used wherein the thermal material layer 612 may first be inserted
into a mold of a molding machine, and then the housing 610 is
injection molded therearound. Generally, over-molding methods are
well known to those of ordinary skill in the art.
[0056] In the illustrated embodiment, both the first and second
support layers 614, 616 are structural layers that, together with
the frame 615 and closure member 617, not only seal the thermal
material layer 612 into an enclosed space, but also provide
structural features such as cushioning to the shoe liner 610. As an
alternative, more than one thermal material layer 612 can be used
to obtain greater insulating performance. When two or more thermal
material layers 612 are used, the thickness of the frame 615 is
preferably also correspondingly increased.
[0057] It is to be understood that the foregoing description is not
a description of the invention itself, but of one or more preferred
exemplary embodiments of the invention. The invention is not
limited to the particular embodiment(s) disclosed herein, but
rather is defined solely by the claims below. Furthermore, the
statements contained in the foregoing description relate to
particular embodiments and are not to be construed as limitations
on the scope of the invention or on the definition of terms used in
the claims, except where a term or phrase is expressly defined
above or where the statement specifically refers to "the
invention." Various other embodiments and various changes and
modifications to the disclosed embodiment(s) will become apparent
to those skilled in the art. For example, the insulating liner 10
can further include a cushion layer disposed between the structural
layers 14, 16 in addition to the insulating layer 12. Also,
although the above description refers to both aerogels and aerogel
composites, it will be appreciated by those skilled in the art that
the aerogel composites comprise aerogels that have been formed with
another substance, and that either aerogels per se or aerogel
composites can be used without departing from the scope of the
invention. All such other embodiments, changes, and modifications
are intended to come within the scope of the appended claims.
[0058] As used in this specification and appended claims, the terms
"for example" and "such as," and the verbs "comprising," "having,"
"including," and their other verb forms, when used in conjunction
with a listing of one or more components or other items, are each
to be construed as open-ended, meaning that that the listing is not
to be considered as excluding other, additional components or
items. Other terms are to be construed using their broadest
reasonable meaning unless they are used in a context that requires
a different interpretation.
* * * * *