U.S. patent application number 15/611902 was filed with the patent office on 2017-12-07 for thermal- and moisture-regulating duvet inserts.
The applicant listed for this patent is Casper Sleep Inc.. Invention is credited to Jeff Chapin, Jesse Menayan.
Application Number | 20170347813 15/611902 |
Document ID | / |
Family ID | 60477857 |
Filed Date | 2017-12-07 |
United States Patent
Application |
20170347813 |
Kind Code |
A1 |
Chapin; Jeff ; et
al. |
December 7, 2017 |
Thermal- And Moisture-Regulating Duvet Inserts
Abstract
An apparatus is disclosed with a substantially rectangular duvet
insert comprising a plurality of substantially rectangular pockets,
wherein each of the plurality of substantially rectangular pockets
comprises a substantially rectangular top cotton shell, a
substantially rectangular bottom cotton shell, and duck down
between the substantially rectangular top cotton shell and the
substantially rectangular bottom cotton shell. The duck down is
placed between the substantially rectangular top cotton shell and
the substantially rectangular bottom cotton shell after the top
long left edge is secured to the bottom long left edge by stitching
and after the top long right edge is secured to the bottom long
right edge by stitching and before the top short front edge is
secured to the bottom short front edge by stitching and before the
top short rear edge is secured to the bottom short rear edge by
stitching.
Inventors: |
Chapin; Jeff; (Providence,
RI) ; Menayan; Jesse; (Sausalito, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Casper Sleep Inc. |
New York |
NY |
US |
|
|
Family ID: |
60477857 |
Appl. No.: |
15/611902 |
Filed: |
June 2, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62345249 |
Jun 3, 2016 |
|
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|
62450728 |
Jan 26, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A47G 9/0207 20130101;
A47G 9/0261 20130101 |
International
Class: |
A47G 9/02 20060101
A47G009/02 |
Claims
1. An apparatus comprising: a substantially rectangular duvet
insert comprising a plurality of substantially rectangular pockets,
wherein each of the plurality of substantially rectangular pockets
comprises a substantially rectangular top cotton shell, a
substantially rectangular bottom cotton shell, and duck down
between the substantially rectangular top cotton shell and the
substantially rectangular bottom cotton shell; wherein the
substantially rectangular top cotton shell has a top long left
edge, a top long right edge, a top short front edge, a top short
rear edge; wherein the substantially rectangular bottom cotton
shell has a bottom long left edge, a bottom long right edge, a
bottom short front edge, a bottom short rear edge; wherein the top
long left edge is secured to the bottom long left edge by
stitching; wherein the top long right edge is secured to the bottom
long right edge by stitching; wherein the top short front edge is
secured to the bottom short front edge by stitching; wherein the
top short rear edge is secured to the bottom short rear edge by
stitching; wherein the duck down is placed between the
substantially rectangular top cotton shell and the substantially
rectangular bottom cotton shell after the top long left edge is
secured to the bottom long left edge by stitching and after the top
long right edge is secured to the bottom long right edge by
stitching; and wherein the duck down is placed between the
substantially rectangular top cotton shell and the substantially
rectangular bottom cotton shell before the top short front edge is
secured to the bottom short front edge by stitching and before the
top short rear edge is secured to the bottom short rear edge by
stitching.
2. The apparatus as in claim 1, wherein the duck down has a minimum
90% white duck down clusters, no more than 3% dark clusters and has
approximately 750 fill power white duck down by volume.
3. The apparatus as in claim 1, wherein the substantially
rectangular duvet insert has a short front edge, a short rear edge,
a long left edge and a long right edge; and further comprising a
piped edge attached to the short front edge, attached to the short
rear edge, attached to the long left edge and attached to the long
right edge.
4. The apparatus as in claim 1, wherein the substantially
rectangular duvet insert has a topside and has an underside and
further comprising four corner loops, wherein each of the corner
loops is secured to one of the corners of the underside of the
substantially rectangular duvet insert.
5. The apparatus as in claim 1, further comprising a substantially
rectangular wool batting layer attached to the substantially
rectangular duvet insert.
6. The apparatus as in claim 1, further comprising a duvet cover
encompassing the substantially rectangular duvet insert, a top
sheet attached to the duvet cover and a bottom sheet attached to
the duvet cover.
7. The apparatus as in claim 1 further comprising: a substantially
rectangular barrier fabric between the substantially rectangular
top cotton shell and the substantially rectangular bottom cotton
shell by being secured between the top long left edge and the
bottom long left edge, by being secured between the top long right
edge and the bottom long right edge, by being secured between the
top short front edge and the bottom short front edge, and by being
secured between the top short rear edge and the bottom short rear
edge; wherein the duck down is placed between the substantially
rectangular top cotton shell and the substantially rectangular
barrier fabric; wherein wool is placed between the substantially
rectangular bottom cotton shell and the substantially rectangular
barrier fabric.
8. The apparatus as in claim 7 wherein the wool is in the form of
wool batting.
9. The apparatus as in claim 8, wherein the wool comprises
approximately 85% Merino Wool and 15% Low Melt Polyester.
10. The apparatus as in claim 7, wherein the substantially
rectangular duvet insert has a short front edge, a short rear edge,
a long left edge and a long right edge; and further comprising a
piped edge attached to the short front edge, attached to the short
rear edge, attached to the long left edge and attached to the long
right edge.
11. The apparatus as in claim 7, wherein the substantially
rectangular duvet insert has a topside and has an underside and
further comprising four corner loops, wherein each of the corner
loops is secured to one of the corners of the underside of the
substantially rectangular duvet insert.
12. The apparatus as in claim 7, further comprising a duvet cover
encompassing the substantially rectangular duvet insert and a
bottom sheet attached to the duvet cover.
13. The apparatus as in claim 7, further comprising a duvet cover
encompassing the substantially rectangular duvet insert, a top
sheet attached to the duvet cover and a bottom sheet attached to
the duvet cover.
14. A method comprising: creating a duvet insert--the duvet insert
having a top portion with a top portion left long side, a top
portion right long side, a top portion front short side, a top
portion rear short side, and the duvet insert having a bottom
portion with a bottom portion left long side, a bottom portion
right long side, a bottom portion front short side, a bottom
portion rear short side--by stitching the edge of the top portion
left long side with the bottom portion left long side to create a
left-edge stitch and by stitching the edge of the top portion right
long side with the bottom portion right long side to create a
right-edge stitch; stitching a plurality of long-side stiches
running from the top portion front short side and the bottom
portion front short side to the top portion rear short side and the
bottom portion rear short side, the plurality of long-side stitches
being substantially parallel with the left-edge stitch and the
right-edge stitch, so as to create a plurality of long-side
contiguous channels within the duvet insert; inserting insulating
material into the plurality of long-side contiguous channels;
stitching the edge of the top portion front short side with the
bottom portion front short side to create a front-edge stitch and
stitching the edge of the top portion rear short side with the
bottom portion rear short side to create a rear-edge stitch;
stitching a plurality of short-side stiches running from the top
portion left long side and the bottom portion left long side to the
top portion right long side and the bottom portion right long side,
the plurality of short-side stitches being substantially parallel
with the front-edge stitch and the rear-edge stitch, so as to
create a plurality of substantially rectangular pockets within the
duvet insert; wherein the number of the plurality of short-side
stiches is less than the number of the plurality of long-side
stitches.
15. The method as in claim 14 wherein the insulating material is
duck down.
16. The method as in claim 14 wherein the insulation material is
duck down and wool.
17. The method as in claim 16 wherein the wool is in the form of
wool batting.
18. The apparatus as in claim 16, wherein the wool comprises
approximately 85% Merino Wool and 15% Low Melt Polyester.
19. The method as in claim 14 wherein the step of inserting
insulating material into the plurality of long-side contiguous
channels uses blowers.
20. The method as in claim 15 where the duck down has a minimum 90%
white duck down clusters, no more than 3% dark clusters and has
approximately 750 fill power white duck down by volume.
Description
REFERENCE TO PRIOR APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 62/345,249, filed on Jun. 3, 2016 and
U.S. Provisional Patent Application Ser. No. 62/450,728, filed on
Jan. 26, 2017.
FIELD OF THE DISCLOSURE
[0002] The present invention relates to the field of a duvet insert
for quilts, bedspreads and the like. The duvet insert provides
thermal insulation and/or moisture regulation while sleeping.
BACKGROUND
[0003] A duvet insert provides the major insulation layer in a
bedding sleep environment. The duvet insert is designed to regulate
temperature and humidity. A more consistent temperature results in
better sleep with less disruptive waking. As the temperature rises,
humidity also increases. Inconsistent humidity regulation can also
lead to poor sleep and more waking.
[0004] Current duvet inserts typically use large sewn square
chambers to hold insulating duck/goose down clusters between layers
of woven fabric. The larger the square chamber, the more likely the
down will shift and migrate within the chamber. This leaves empty
areas of no insulation, ultimately creating cold spots and poor
temperature regulation while sleeping.
[0005] To handle down migration within duvets, it is common for the
size of the sewn box to be made smaller. The smaller the box, the
better at holding the insulation materials. But the smaller box
tends to produce a more expensive product. Further, the additional
sewing adds labor time and the stitching process may trap down
between the stitching. This trapped down is compressed and does not
provide proper insulation.
[0006] Accordingly, there is an opportunity to help users sleep
better by ensuring consistent temperature and humidity regulation,
calibrating insulation to known room temperature ranges, and
constructing down holding chambers in a unique manner. This
prevents the insulation from moving/migrating and ensuring
consistent insulation across the entire duvet insert.
BRIEF DESCRIPTION OF THE FIGURES
[0007] The accompanying figures, where like reference numerals
refer to identical or functionally similar elements throughout the
separate views, together with the detailed description below, are
incorporated in and form part of the specification, and serve to
further illustrate embodiments of concepts that include the claimed
invention, and explain various principles and advantages of those
embodiments.
[0008] FIG. 1 shows a duvet insert in accordance with the present
invention.
[0009] FIG. 2 is an inset view of the duvet insert in accordance
with the present invention.
[0010] FIG. 3 shows the use of a duvet insert in accordance with
the present invention.
[0011] FIG. 4 shows a cross-section of a duvet insert in accordance
with the present invention.
[0012] FIG. 5A shows a method of inserting material in a duvet
insert with sewn-through pockets in accordance with the present
invention.
[0013] FIG. 5B shows a method of inserting material in a duvet
insert with baffle boxes in accordance with the present
invention.
[0014] FIG. 6 shows a stitching method of a duvet insert in
accordance with the present invention.
[0015] FIG. 7 is an exploded view of a first embodiment of a duvet
insert in accordance with the present invention.
[0016] FIG. 8 is an exploded view of a second embodiment of a duvet
insert in accordance with the present invention.
[0017] Skilled artisans will appreciate that elements in the
figures are illustrated for simplicity and clarity and have not
necessarily been drawn to scale. For example, the dimensions of
some of the elements in the figures may be exaggerated relative to
other elements to help to improve understanding of embodiments of
the present invention.
[0018] The apparatus and method components have been represented
where appropriate by conventional symbols in the drawings, showing
only those specific details that are pertinent to understanding the
embodiments of the present invention so as not to obscure the
disclosure with details that will be readily apparent to those of
ordinary skill in the art having the benefit of the description
herein.
DETAILED DESCRIPTION
[0019] Most people sleep in a temperature-controlled environment
(the bedroom) where temperature is managed by a thermostat. In
addition, human bodies thermoregulate, which is a process that
maintains internal core temperature. Humans have discreet
biological mechanisms that happen automatically whenever the body
gets too cold or too hot. When the body's core temperate drops and
the person becomes cold, blood vessels contract, extremities get
cold, the body shivers the heart rate increases. These mechanisms
disrupt sleep. When the body's core temperate rises and the person
becomes hot, the body sweats (typically above 98.6.degree.), the
person turns and kick the covers away. These mechanisms also
disrupt sleep.
[0020] Insulation plays an important part of finding the right
temperature. If there is too little insulation, the cooler ambient
temperature sucks away all the heat from under the covers. If there
is too much insulation, heat gets trapped underneath the covers
with no way to escape. (It should be noted that the bedding
industry markets towards overly fluffy duvets. These are
over-insulated and almost always sleep too hot.) This may be
further aided by providing specific temperature ratings for
specific products. For example, high-end sleeping bags are
typically rated for a specific temperature range.
[0021] Maintaining proper core temperature is key to good sleep.
This involves a balancing act between body temperature, ambient
temperature, insulation, and material permeability. The ideal duvet
creates the proper sleep envelope; providing a lightweight and
adaptable layer of insulation to help the body maintain temperature
and get a good night's sleep.
[0022] The current marketplace provides a plethora of insulation
options based on pre-determined seasonal temperature variations.
For example, in Europe, it is common for duvets to be sold as a
system. There are different weights that may be used separately or
combined together to give the user the ability to control the
amount of insulation. Alternatively, some manufacturers offer a
"winter duvet insert," "spring duvet insert," or "summer duvet
insert." Some manufacturers have their own proprietary system (L1,
L2, L3). Some manufacturers offer an all-season duvet insert which
claim proper temperature regulation for year-round use.
[0023] Some companies sell a "smaller box" duvet. The smaller the
box, the less chance of down migrating around and creating cold
spots. Some companies sell moisture wicking bed linens that attempt
to proactively manage heat and moisture.
[0024] Despite the claims of superior performance throughout the
industry, there are no objective guidelines that justify claims of
optimal performance. This leaves the consumer no choice but to "buy
and then try" and hope for a satisfactory result.
[0025] The present invention involves calibrating duvet insulation
to a specific room temperature range. Since most people sleep in
temperature controlled environments (air-conditioned in summer and
heated in winter), calibrating insulation to an ideal ambient sleep
temperature may eliminate the guessing when purchasing a duvet.
Typical bedding already consists of several layers; bottom sheet,
top sheet, duvet cover, and duvet insert. Each of these layers
provides measurable amounts of insulation. The disclosed bedding
system (including the duvet insert) allow for users to customize
insulation by just using their existing bedding. One example is the
following:
[0026] For coldest situations: Use bottom sheet, top sheet, duvet
insert and duvet cover.
[0027] For medium situations: Use bottom sheet, no top sheet, duvet
insert and duvet cover.
[0028] For hot situations: Use bottom sheet and top sheet.
[0029] Moreover, temperature regulation for one person in a bed is
different than two people in a bed. This is because some people
sleep hot and others sleep cold. The customization is configurable
to take this into account by forming different configurations on
different sides.
[0030] The various choices for choosing material for a duvet are
described herein.
[0031] Insulation. Temperature regulation is typically managed by
fill type, fill power, and fill weight. There are 3 main fill
types; duck down, goose down, and synthetic polyester filling. For
down, fill power is a measure of how big each individual down
cluster is. The larger the cluster, the greater its insulation
value is per weight of material. The higher the fill power, the
less weight of insulation is needed to achieve the same insulation
value. Higher fill power is perceived as better insulating.
[0032] Duck down clusters offer the best insulation per weight.
Down traps air incredibly well. Its lightweight nature allows for a
comfortable drape over the body while sleeping. The down cluster is
unique to waterfowl birds. It is a collected from a remarkable
inner coat that helps keep them warm, buoyant, and keeps eggs warm
during nesting. The cluster has no hard quills (like feathers) and
has many filaments growing in all directions. Down is the best
insulator per weight in the world.
[0033] Down clusters are blown into a duvet and form a light matrix
of structural filaments and air pockets. Air gets trapped in down
"puff balls" to help maintain temperature while still allowing for
moisture and excess heat to pass through.
[0034] Down clusters are sorted by puff ball size. "Fill power"
refers to how large a volume 1 oz. of puff balls will hold. The
larger the cluster, the larger 1 oz. of that material will hold.
"Fill weight" refers to the total amount (by weight) of down
clusters blown into a duvet. Identical insulation values may be
created by varying fill power and fill weight.
[0035] Shell. The duvet shell needs to be lightweight, breathable,
and not too crunchy. Breathable fabrics (like lightweight cotton)
perform better than synthetic fabrics for a duvet shell. Their
increased permeability allows for heat and moisture to pass through
into the ambient environment, preventing a hot and muggy sleep
microclimate.
[0036] A lightweight cotton shell may be used to help the overall
weight of the duvet become lighter. Cotton is a natural material
that has optimal breathability and permeability performance. Using
cotton allows for moisture vapor generated by the user to easily
pass through the assembly and out into the ambient environment;
preventing a hot and muggy sleep environment. Typical synthetic
fabrics are far less breathable and tend to trap heat and moisture
within the sleep environment.
[0037] The fabric shell often weighs more than the insulating down
material inside. The lighter the total assembly, the lighter it is
on the body; increasing comfort by not weighing down and
compressing the insulation material. A lighter assembly also has
less thermal mass for the user's body to warm up. Thus, the user is
able to reach a comfortable temperature faster.
[0038] The permeability of the duvet shell fabric must be
"down-proof" to prevent leakage of the down our of the shell. Down
"proofness" may be achieved a number of ways and in particular, by
decreasing the yarn diameter and increasing the woven density of
the fabric. In so doing, a tighter barrier is created that prevents
the down from escaping form the shell.
[0039] Duvet boxes. The boxes that contain the down in the duvet
insert are important in regulating the performance of the duvet.
The larger the box, the more room for down to move around within.
When down migrates or clumps up, it leaves areas of bare fabric
with no insulation. These create cold spots which could disrupt a
cozy night of sleep.
[0040] Turning to FIG. 1, shown is a duvet insert 100 in accordance
with the present invention. The duvet insert 100 shown herein is
divided into ninety (90) rectangular channels formed by short
channels 101-116 and long channels 121-125. The long ends of the
rectangular channels run along the length of the duvet insert 100
and the short ends of the rectangular channels run along the width
of the duvet insert 100. The duvet insert 100 may have any number
of rectangular channels depending on the number of short channels
101-116 and long channels 121-125 in the particular duvet insert
100. The number of rectangular channels will also depend on what
bedding size the duvet insert is for, e.g., a king, queen, full or
twin duvet.
[0041] Turning to FIG. 2, shown is an inset of the underside of a
corner of a duvet insert 100. Cutting across the underside corner
edge 210 of the duvet insert 100 is a corner loop 220. The corner
loop 220 may be elastic or inelastic. The corner loop 220 may be
repeated on all four sides of the duvet insert 100. The corner loop
220 is designed to secure the duvet insert 100 to a duvet cover
(not shown) having ties or snaps on each corner.
[0042] Turning to FIG. 3, shown is a mock-up 300 of the duvet
insert 320 draped over a human 310. The mock-up 300 shows that the
long side of the channels of the duvet insert 320 are draped over
the length of the human 310, while the short side of the channels
of the duvet insert 320 are draped over the width of the duvet
insert 320. The reason that the long side (rather than the short
side) is draped over the length of the human body is to ensure that
there is optimal distribution of down over the body. Even if the
down moves along the channels, there will still be more down-filled
portions covering the body. Moreover, if the channels were
horizontal, the insulation could migrate to the sides and leave
more cold spots over the body than if the channels were
vertical.
[0043] Turning to FIG. 4, shown is a cross-section 400 of a single
portion of a duvet insert having both down and wool. Shown is a
cross-section of a top shell 405 and a cross-section of a bottom
shell 410. The top shell 405 and bottom shell 410 are secured by a
first stitching 442 and a second stitching 444. A cross-section of
a first region 420 may be filled with down, including duck down. A
cross section of a second region 410 may be filled with wool in the
form of a wool batting. In between the first region 410 and second
region 420 is a barrier 415 to keep the down in the first region
420 from mixing with the wool in the second region 410. Like the
top shell 405 and the bottom shell 415, the barrier 415 is also
secured by a first stitching 442 and a second stitching 444.
[0044] There are two possible methods of constructing a duvet:
baffle boxes or sewn-through regions. Baffle box-based duvets are a
grid of square boxes with internal baffles (or gussets) that helps
create a consistent thickness to the construction. They are complex
and are the predominant construction of duvets. They also allow for
overly puffy aesthetics. Sewn-through region duvets are much
simpler. Stitching joins two layers of fabric together to create
pockets (usually square) for down to be held within. In a typical
duvet, if all stitching happens after filling, down is often
trapped between the stitching.
[0045] FIGS. 5A and 6 show a method of filling a duvet insert using
sewn-through regions with down in a manner to limit trapped down in
the stitching. Turning to FIG. 5A, shown is a first step of a
method 500 of filling down into a partially-completed duvet insert
520. The partially-completed duvet insert 520 comprises a series of
sewn-through channels after the stitching has been done along the
long side but before the stitching has been done along the short
side. As shown in the inset, to accomplish the filling of down,
blowers 501, 502, 503, 504 push the down 505, 506, 507, 508 into
the channels 509, 510, 511, 512. Turning to FIG. 6, shown is a
second step of a method 600 of filling the now-completely stitched
duvet 606. The completion is caused by the stitching 601, 602, 603,
604, 605 across the short side of the duvet insert 606.
[0046] Thus, all of the vertical stitching is done first, which is
followed by filling the vertical channels of the duvet cover, which
is then followed by the horizontal stitching. This minimizes the
trapped down and maximizes the insulation.
[0047] More specifically, creating a duvet insert--the duvet insert
having a top portion with a top portion left long side, a top
portion right long side, a top portion front short side, a top
portion rear short side, and the duvet insert having a bottom
portion with a bottom portion left long side, a bottom portion
right long side, a bottom portion front short side, a bottom
portion rear short side--may occur in several steps.
[0048] First, the duvet insert may be formed by stitching the edge
of the top portion left long side with the bottom portion left long
side to create a left-edge stitch and by stitching the edge of the
top portion right long side with the bottom portion right long side
to create a right-edge stitch.
[0049] The next step is stitching a plurality of long-side stiches
running from the top portion front short side and the bottom
portion front short side to the top portion rear short side and the
bottom portion rear short side, the plurality of long-side stitches
being substantially parallel with the left-edge stitch and the
right-edge stitch, so as to create a plurality of long-side
contiguous channels within the duvet insert.
[0050] The next step is inserting insulating material into the
plurality of long-side contiguous channels
[0051] The next step is stitching the edge of the top portion front
short side with the bottom portion front short side to create a
front-edge stitch and stitching the edge of the top portion rear
short side with the bottom portion rear short side to create a
rear-edge stitch.
[0052] The next step is stitching a plurality of short-side stiches
running from the top portion left long side and the bottom portion
left long side to the top portion right long side and the bottom
portion right long side, the plurality of short-side stitches being
substantially parallel with the front-edge stitch and the rear-edge
stitch, so as to create a plurality of substantially rectangular
pockets within the duvet insert.
[0053] In the duvet insert, the number of the plurality of
short-side stiches may be less than the number of the plurality of
long-side stitches.
[0054] The preceding steps may occur in a different order.
[0055] FIG. 5B shows an alternative method of filling a duvet
insert via baffle boxes. Baffle box duvets are a grid of square
boxes with internal baffles (or gussets) that helps create
consistent thickness to the construction. FIG. 5B shows a filling
method 550 of filling baffles with a tube. Specifically, baffles
551, 552, 553 are attached to each other and have baffle doors 556,
557, 558 to allow access between them. To fill the baffles, a tube
554 is inserted into the baffle doors 556, 557, 558 and down 555 is
blown into the first baffle 551. The tube 554 is then pulled
through the first door 556 and down is blown into the second baffle
552. The tube 554 is then pulled through the second door 557 and
down is blown into the third baffle 553. The tube 554 is then
withdrawn from the third door 558.
[0056] Also shown in FIG. 5B is are filled baffle boxes 590 that
result from the filling method 550. Shown are three filled baffle
boxes 559, 560, 561 with doors between them 563, 565, 567. Down
562, 564, 566 is now resident within each of the baffle boxes 559,
560, 561. Baffle doors my leak because they are held shut by the
pressure of the filled down. Down can move between boxes fairly
easily.
[0057] Although three baffle boxes are shown in FIG. 5B, any number
of baffle boxes may be used.
[0058] In the industry, it is believed that a duvet insert with
baffle boxes provides better performance than a duvet insert with
sewn-through regions. The theory is that there is less heat leakage
in baffle boxes than sewn-through regions. Several experiments were
conducted to verify this hypothesis.
[0059] Experiment 1
[0060] A duvet insert mockup was constructed by combining 4
portions of other duvet inserts and stitching them together to form
one duvet insert with 4 regions:
[0061] 1. Top Left Region: duvet insert with large baffle box
construction (large baffle box region).
[0062] 2. Bottom Left Region: duvet insert with small baffle box
construction (small baffle box region).
[0063] 3. Top Right Region: duvet insert with large sewn-through
construction (large sewn-through region).
[0064] 4. Bottom Right Region: duvet insert with small sewn-through
construction (large sewn-through region).
[0065] The duvet insert mockup was placed over a fitted sheet and
an electric blanket. For the sewn-through regions (large and
small), temperature measurements were made on the seams of the
sewn-through regions and in the center of the sewn-through regions.
For the baffle box regions (large and small), temperature tests
were made on the seams of the baffle boxes and in the center of the
baffle boxes. Testing took place without a top sheet. The
temperature for each region without a top sheet was measured and
the results are in Table 1.
TABLE-US-00001 TABLE 1 Variance without a top sheet. Type of duvet
Temperature at Temperature at insert the center (.degree. F.) the
seam (.degree. F.) Variance (.degree. F.) Small sewn- 76.4 81.9 5.5
through Large sewn- 74.6 80.4 5.8 through Small baffle box 76.4
78.8 2.4 Large baffle box 76.3 77.3 1.0
[0066] The differences in baffle boxes temperature for the center
and seam (2.4 and 1.0) are less than the differences in the
sewn-through temperature for the center and seam (5.8 and 5.5).
This demonstrates that baffle boxes may retain heat in a duvet
better than sewn-through region when no top sheet is used.
[0067] Experiment 2
[0068] The duvet insert mockup used in Experiment 1 was placed over
a fitted sheet and an electric blanket and a top sheet was added on
top. For the sewn-through regions (large only), temperature
measurements were made on the seams of the sewn-through regions and
in the center of the sewn-through regions. For the baffle boxes
(large only), temperature tests were made on the seams of the
baffle boxes and in the center of the baffle boxes. The temperate
for each region with a top sheet was measured and the results are
in Table 2.
TABLE-US-00002 TABLE 2 Variance with a top sheet. Type of duvet
Temperature at Temperature at insert the center (.degree. F.) the
seam (.degree. F.) Difference (.degree. F.) Large baffle box 77.2
77.8 0.6 Large sewn- 76.0 77.1 1.1 through
[0069] Here, the differences in baffle boxes from center to seam
(0.6.degree. F.) are functionally equivalent to the differences in
the sewn-through regions from center to seam (1.1.degree. F.). The
0.5.degree. F. difference is negligible in real-world situations.
This demonstrates that any advantages that baffle boxes have in
retaining heat in a duvet better than sewn-through region becomes
essentially irrelevant when a top sheet is used. Thus, a tentative
conclusion was reached that the temperature variances between
baffle box and sewn-through regions are negligible for indoor
climate controlled environments.
[0070] Experiment 3
[0071] To confirm the foregoing, a certified lab was retained using
a temperate controlled guarded hot plate device.
[0072] Methodology: The insulation value of the fabrics was
measured using the constant temperature method specified in ASTM D
1518, Standard Test Method for Thermal Resistance of Batting
Systems Using a Hot Plate (option #1) (ASTM, 2015). This method
uses a box hood to produce still air conditions. There was no air
velocity over the plate and sample.
[0073] Apparatus: A Dynatech hot plate apparatus Model TCB-TX was
used in an environmental chamber. The plate measurement section was
a 25.4.times.25.4 cm (10.times.10 in.) square surrounded by a guard
section which increased the total size of the plate to a
50.8.times.50.8 cm (20.times.20 in.) square. The function of the
guard heater was to eliminate lateral heat flow to or from the main
heater. A second bucking heater located beneath the main heater
eliminated the heat flow in the axial direction away from the test
sample. These two heaters thereby forced all of the heat generated
in the main heater to flow in the direction of the test sample. The
side of the test sample away from the heater plate assembly was
exposed to still air conditions inside a fabric box hood. The
heater controllers and readout instrumentation for the various
sensors in the apparatus were located in a separate cabinet outside
the environmental chamber. The hot plate also included a data
acquisition and control system which is interfaced to a
computer.
[0074] Procedures for Measuring Thermal Resistance (Insulation):
One 50.8.times.50.8 cm (20.times.20 in.) square specimen was
prepared for each type of fabric/duck down/fabric system. The
construction varied among the specimen types.
[0075] The specimen types were the following:
[0076] 1. Sewn-thru region with stitching on center without fabric
cover.
[0077] 2. Sewn-thru region with box on center without fabric
cover.
[0078] 3. Baffle-box with stitching on center without fabric
cover.
[0079] 4. Baffle-box with box on center without fabric cover.
[0080] 5. Sewn-thru region with stitching on center with fabric
cover.
[0081] 6. Baffle-box with stitching on center with fabric
cover.
[0082] The samples were stored on a shelf inside the environmental
chamber to "condition." The samples were randomized for testing for
each replication of the test method.
[0083] The air temperature in the chamber was 2.degree. C.
(35.degree. F.). The air layer resistance (bare plate value) was
0.085 m.sup.2.degree. C./Watt. The relative humidity was not
controlled at a specific level, but it was stable between 30-70% as
specified in the standard. The plate temperature was maintained at
35.degree. C. (95.degree. F.). Each fabric system was placed on the
horizontal, flat plate so that the code number was visible on the
top. Then it was covered by the box hood. When the temperatures
were within their tolerance limits and the system had reached
steady-state (defined as a less than 1% change in R.sub.t,
insulation value), data were collected every 30 seconds for 30
minutes. The data collected included plate surface temperature
(T.sub.s), air temperature (T.sub.a), air dew point temperature
(T.sub.dp), and current and voltage to the test section. Four air
temperature sensors hanging 508 mm (20 in.) above the center of the
plate were averaged to determine the mean air temperature. Power
(H) to the test section was determined from the voltage and current
readings. Three replications of the test were conducted on each
fabric type and on the bare plate.
[0084] First, the total resistance to dry heat transfer
(R.sub.t)--or insulation value--for the fabric system including the
air film resistance was calculated. Data from three replications of
the dry hot plate tests were averaged to determine the mean R.sub.t
for each fabric system and for the bare plate.
[0085] The thermal resistance (insulation) values for the fabric
systems are given in Table 3. The higher the dry resistance value,
the higher the insulation provided by the fabric system.
TABLE-US-00003 TABLE 3 Total Insulation R.sub.t (m.sup.2 .degree.
C./Watt) I.sub.t (clo) Sewn-thru with 0.696 4.489 stitching on
center without fabric cover Sewn-thru with 0.823 5.308 box on
center without fabric cover Baffle-box with 0.772 4.979 stitching
on center without fabric cover Baffle-box with 0.787 5.076 box on
center without fabric cover Sewn-thru with 0.864 5.573 stitching on
center in pillow case Baffle-box with 0.914 5.895 stitching on
center in pillow case
[0086] The general conclusions from the data comparisons were:
[0087] The constructions where the stitching was in the center of
the plate (i.e., over the thermocouple), had slightly lower
insulation values than similar constructions with the puffy thick
box part in the center of the sample.
[0088] The baffle box construction provided more insulation than
the sewn-thru region construction--particularly when each specimen
was tested alone.
[0089] The use of a fabric cover on both sides of the specimens
added insulation primarily because the thin fabric trapped still
air between the top surface of the comforter specimen and the
fabric (i.e., tenting effect). This minimized the differences
between the types of constructions.
[0090] Thus, these experiments demonstrate that there is little
difference between sewn-through regions and baffle box constriction
in real-world conditions, i.e., when the duvet insert is used with
a top sheet or the equivalent.
[0091] The duvet insert of the present invention may have two
embodiments. The first embodiment includes down only. The second
embodiment includes down and wool. The third embodiment includes
down and wool in a different construction.
[0092] Shown in FIG. 7 is an exploded view of the first embodiment,
which is a down duvet 700 with the stitching forming the narrow
channels (not shown). A top cotton shell 705 and a bottom cotton
shell 720 have a piped edge 715 along all four sides. Within the
top cotton shell 705 and the bottom cotton shell 720 is the duck
down layer 710. Four corner loops 725 (three are shown) are
attached to the underside of the bottom cotton shell 720. As shown
in FIG. 2, the corner loops are designed to secure the duvet insert
to a duvet cover having ties or snaps on each corner. A legal label
730 is also attached to the bottom cotton shell 720.
[0093] The down-only embodiment may consist of an outer shell,
piping and corner loop fabric consisting of 100% Cotton and having
a 370 thread count (200.times.170) and a percale weave with 86
grams per square meter and 100'' roll width.
[0094] The details of the duck down itself may be as follows:
Minimum 75% white duck down clusters (no more 3% dark clusters) and
having a 600 Fill Power: +/-10% (by volume).
[0095] The Thread/Stitching for the shell may comprise white, 100%
polyester thread with double-Needle Stitched Edge at 10 stitches
per inch and Single Needle Channel Stitching having 9 stitches per
inch.
[0096] The shell closing may be white, 100% polyester thread with
poly core/poly wrap, T35 for closing duvet, T60 for cross stitching
and 12 stitches per inch.
[0097] The piping cord may consist of 100% cotton, braided, white
with a 0.125'' diameter (3 mm).
[0098] Shown in FIG. 8 is an exploded view of the second
embodiment, which is a wool and down duvet 800 with the stitching
forming the narrow channels (not shown). A top cotton shell 805 and
a bottom cotton shell 830 have a piped edge 825 along all four
sides. Within the top cotton shell 805 and the bottom cotton shell
830 is the duck down layer 810, a barrier layer 815 and a wool
batting layer 820. Four corner loops 835 (three are shown) are
attached to the underside of the bottom cotton shell 830. As shown
in FIG. 2, the corner loops are designed to secure the duvet insert
to a duvet cover having ties or snaps on each corner. A legal label
840 is also attached to the bottom cotton shell 830.
[0099] Wool is a natural material that can absorb up to 1/3 of its
weight in moisture vapor. Wool also has natural insulating, odor
control, and anti-microbial properties. Thus, integrating a layer
or prescribed area of wool inside the duvet construction offers
increased humidity and temperature regulation. Other materials that
are capable of moisture wicking may be used as well, such as
cotton, linen, bamboo, rayon, silk and the like.
[0100] In the duck down and wool embodiment, the outer shell,
piping & corner loop fabric may consist of 100% Cotton having a
370 thread count (200.times.170), percale weave, 90 grams per
square meter and 100'' roll width.
[0101] The outer shell top may be white. The outer shell bottom may
be gray.
[0102] The shell top, piping, and corner straps may all be from the
same dye lot
[0103] The wool batting may consist of 85% Merino Wool and 15% Low
Melt Polyester, with tolerances of +/-5%. It may weigh 100 g/sq.
meter +/-10 grams and have approximately 1/2'' (12 mm) thickness
+/-10%.
[0104] The wool fiber diameter may be 30 micron+/-1 micron, be
shrink-resist treated and having 100'' roll width.
[0105] The piping cord may be 100% cotton, braided, white and
0.125'' diameter (3 mm).
[0106] The duck down may have the following properties: 1) a
minimum 90% white duck down clusters (no more 3% dark clusters); 2)
750 fill power white duck down: +/-10% (by volume).
[0107] The barrier fabric may consist of 100% polyester, 35 grams
per square meter.
[0108] The Thread/Stitching for the shell may comprise white, 100%
polyester thread with double-Needle Stitched Edge at 10 stitches
per inch and Single Needle Channel Stitching having 9 stitches per
inch.
[0109] The shell closing may be white, 100% polyester thread with
poly core/poly wrap, T35 for closing duvet, T60 for cross stitching
and 12 stitches per inch.
[0110] A third embodiment presents an alternative version of the
down-only duvet with a separate wool layer In this third
embodiment, the wool batting layer 820 is not placed within the top
cotton shell 805 and a bottom cotton shell 830. Instead the wool
batting layer 820 is secured to the bottom or top of the down duvet
700 so that it is a separate layer. The securing may take place by
using snaps.
[0111] Thus, the present invention provides the following
significant benefits:
[0112] Sewing the majority of the stitched lines prior to filling
with insulation traps less down and leads to greater insulation. If
all stitching happens otherwise after filling, down is often
trapped between the stitching.
[0113] The rectangular shaped boxes contain down better than
traditional square boxes and are oriented to work and drape of a
sleeping body, while preventing cold spots.
[0114] Calibrating the insulation value to a known room
temperature/humidity levels. This will take the majority of
confusion around knowing whether the duvet will be warm enough.
[0115] It is contemplated that any optional feature of the
inventive variations described may be set forth and claimed
independently, or in combination with any one or more of the
features described herein. Reference to a singular item, includes
the possibility that there is a plurality of the same items
present. More specifically, as used herein and in the appended
claims, the singular forms "a," "an," "said," and "the" include
plural referents unless specifically stated otherwise. In other
words, use of the articles allow for "at least one" of the subject
item in the description above as well as the to be appended claims.
It is further noted that the appended claims may be drafted to
exclude any optional element. As such, this statement is intended
to serve as antecedent basis for use of such exclusive terminology
as "solely," "only" and the like in connection with the recitation
of claim elements, or use of a "negative" limitation.
[0116] Without the use of such exclusive terminology, the term
"comprising" in the to be appended claims shall allow for the
inclusion of any additional element irrespective of whether a given
number of elements are enumerated in the to be appended claim, or
the addition of a feature could be regarded as transforming the
nature of an element set forth in the to be appended claims. Except
as specifically defined herein, all technical and scientific terms
used herein are to be given as broad a commonly understood meaning
as possible while maintaining to be appended claim validity.
[0117] The breadth of the present invention is not to be limited to
the examples provided and/or the subject specification, but rather
only by the scope of the to be appended claim language. Use of the
term "invention" herein is not intended to limit the scope of the
appended claims in any manner. Rather it should be recognized that
the "invention" includes the many variations explicitly or
implicitly described herein, including those variations that would
be obvious to one of ordinary skill in the art upon reading the
present specification. Further, it is not intended that any section
of this specification (e.g., the Summary, Detailed Description,
Abstract, Field of the Invention, etc.) be accorded special
significance in describing the invention relative to another or the
to be appended claims. All references cited are incorporated by
reference in their entirety. Although the foregoing invention has
been described in detail for purposes of clarity of understanding,
it is contemplated that certain modifications may be practiced
within the scope of the to be appended claims.
[0118] In the foregoing specification, specific embodiments have
been described. However, one of ordinary skill in the art
appreciates that various modifications and changes can be made
without departing from the scope of the invention as set forth in
the claims below. Accordingly, the specification and figures are to
be regarded in an illustrative rather than a restrictive sense, and
all such modifications are intended to be included within the scope
of present teachings.
[0119] The benefits, advantages, solutions to problems, and any
element(s) that may cause any benefit, advantage, or solution to
occur or become more pronounced are not to be construed as a
critical, required, or essential features or elements of any or all
the claims. The invention is defined solely by the appended claims
including any amendments made during the pendency of this
application and all equivalents of those claims as issued.
[0120] Moreover, in this document, relational terms such as first
and second, top and bottom, and the like may be used solely to
distinguish one entity or action from another entity or action
without necessarily requiring or implying any actual such
relationship or order between such entities or actions. The terms
"comprises," "comprising," "has", "having," "includes",
"including," "contains", "containing" or any other variation
thereof, are intended to cover a non-exclusive inclusion, such that
a process, method, article, or apparatus that comprises, has,
includes, contains a list of elements does not include only those
elements but may include other elements not expressly listed or
inherent to such process, method, article, or apparatus. An element
proceeded by "comprises . . . a", "has . . . a", "includes . . .
a", "contains . . . a" does not, without more constraints, preclude
the existence of additional identical elements in the process,
method, article, or apparatus that comprises, has, includes,
contains the element. The terms "a" and "an" are defined as one or
more unless explicitly stated otherwise herein. The terms
"substantially", "essentially", "approximately", "about" or any
other version thereof, are defined as being close to as understood
by one of ordinary skill in the art. The term "coupled" as used
herein is defined as connected, although not necessarily directly
and not necessarily mechanically. A device or structure that is
"configured" in a certain way is configured in at least that way,
but may also be configured in ways that are not listed.
[0121] The Abstract of the Disclosure is provided to allow the
reader to quickly ascertain the nature of the technical disclosure.
It is submitted with the understanding that it will not be used to
interpret or limit the scope or meaning of the claims. In addition,
in the foregoing Detailed Description, it can be seen that various
features are grouped together in various embodiments for the
purpose of streamlining the disclosure. This method of disclosure
is not to be interpreted as reflecting an intention that the
claimed embodiments require more features than are expressly
recited in each claim. Rather, as the following claims reflect,
inventive subject matter lies in less than all features of a single
disclosed embodiment. Thus the following claims are hereby
incorporated into the Detailed Description, with each claim
standing on its own as a separately claimed subject matter.
* * * * *