U.S. patent application number 17/613817 was filed with the patent office on 2022-07-28 for baffle constructs for insulative fill materials.
The applicant listed for this patent is The North Face Apparel Corp.. Invention is credited to Alford H. Lee.
Application Number | 20220232917 17/613817 |
Document ID | / |
Family ID | 1000006301966 |
Filed Date | 2022-07-28 |
United States Patent
Application |
20220232917 |
Kind Code |
A1 |
Lee; Alford H. |
July 28, 2022 |
BAFFLE CONSTRUCTS FOR INSULATIVE FILL MATERIALS
Abstract
The inventive subject matter is directed to an assembly of a
plurality of baffle constructs which each include: a primary
baffle, comprising a pliable textile, and a secondary baffle. 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 and a secondary baffle. 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 of the second volume of insulative fill
material is contained above most of the first insulative material
when the primary baffle is maintained in an intended vertical
orientation. The secondary baffles are mainly responsible for
filling the primary baffle to its intended shape in an upper
portion of the primary baffle.
Inventors: |
Lee; Alford H.; (Berkeley,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The North Face Apparel Corp. |
Wilmington |
DE |
US |
|
|
Family ID: |
1000006301966 |
Appl. No.: |
17/613817 |
Filed: |
June 5, 2019 |
PCT Filed: |
June 5, 2019 |
PCT NO: |
PCT/US19/35498 |
371 Date: |
November 23, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62852633 |
May 24, 2019 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A41D 31/065 20190201;
A47G 9/10 20130101 |
International
Class: |
A41D 31/06 20060101
A41D031/06; A47G 9/10 20060101 A47G009/10 |
Claims
1. An assembly of a plurality of baffle constructs, each baffle
construct comprising: a primary baffle, comprising a pliable
textile, and one or more secondary baffles, the baffle constructs
configured to be alignable along a vertical axis relative to the
ground; each primary baffle defining 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; and each secondary baffle defining 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.
2. The assembly of claim 1 wherein the primary baffle has a bottom
and the secondary baffle has a bottom, the bottom of the secondary
baffle being spaced a predetermined height above the bottom of the
primary baffle.
3. The assembly of claim 1 wherein 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, 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.
4. The assembly of claim 1 wherein 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.
5. The assembly of claim 1 wherein the primary baffle has a height
H and a secondary baffle has a height H' and the ratio H/H' is
between 1.25 and 10.
6. The assembly of claim 5 wherein a single secondary baffle is
enclosed in the primary baffle and an upper end of the secondary
baffle is pendulously appended to an upper end of the primary
baffle.
7. The assembly of claim 1 wherein the secondary baffle has an
oblong shaped configuration.
8. The assembly of claim 1 wherein the secondary baffle has a
pendulous configuration.
9. The assembly of claim 8 wherein the secondary baffle has a
generally teardrop or piriform shape.
10. The assembly of claim 1 wherein the assembly has 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.
11. The assembly of claim 10 wherein the secondary baffle(s) is/are
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).
12. The assembly of claim 10 wherein each secondary baffle has a
pendulous profile.
13. The assembly of claim 1 wherein the primary baffle in an
expanded condition has sides that converge at upper and lower ends
when moving from an intermediate section.
14. The assembly of claim 1 wherein an upper-most secondary
baffle(s) has a first edge of the secondary baffle 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.
15. The assembly of claim 14 further comprising a second secondary
baffle 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.
16. The assembly of claim 7 wherein the secondary baffle(s)
has/have a pendulous profile.
17. The assembly of claim 7 wherein the secondary baffle(s) is/are
disposed on an inner surface of the back layer and are not
connected to the back layer so that the face layer does not show
any seams or joints for the secondary baffles, the wall with which
the second edge of the secondary baffle merges with being the back
layer.
18. The assembly of claim 1 wherein when the secondary baffle(s)
and is/are in an expanded condition, the primary baffle in an
expanded profile can receive fill material below the bottom of the
secondary baffle(s) and along at least one vertical side of the
secondary baffle(s).
19. The assembly of claim 10 wherein at least two secondary baffles
are disposed in the primary baffle and are arranged at different
heights in the primary baffle.
20. The assembly of claim 1 wherein at least three secondary
baffles are disposed in the primary baffle and are arranged at
different heights in the primary baffle.
21. The assembly of claim 19 wherein the secondary baffles are each
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 baffles.
22. The assembly of claim 19 wherein one of the secondary baffles
stacks in partial overlap with the lower one of the secondary
baffles.
23. A garment comprising, a panel configured to cover a torso area
of a wearer, the panel comprising: an assembly of a plurality of
baffle constructs, each baffle construct comprising: a primary
baffle, comprising a pliable textile, and one or more secondary
baffles, the baffle constructs configured to be alignable along a
vertical axis relative to the ground; each primary baffle defining
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; and each secondary
baffle defining 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.
24. The garment of claim 23 further comprising an insulative fill
material disposed in each primary baffle and secondary baffle, the
insulative fill material filling the primary baffle and secondary
baffles to a desired profile.
25. A method of producing an insulative panel, comprising:
providing an assembly of a plurality of baffle constructs, each
baffle construct comprising: a primary baffle, comprising a pliable
textile, and one or more secondary baffles, the baffle constructs
configured to be alignable along a vertical axis relative to the
ground; each primary baffle defining 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; and each secondary baffle defining 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; and
filling each primary baffle and secondary baffle with an insulative
fill material to a desired profile.
Description
BACKGROUND
[0001] 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.
[0002] 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.
[0003] 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.
[0004] 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.
[0005] 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
[0006] 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.
[0007] 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.
[0008] 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.
[0009] 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.
[0010] 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.
[0011] 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.
[0012] 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.
[0013] In the foregoing and other embodiments, the secondary baffle
may have an oblong shaped configuration.
[0014] In the foregoing and other embodiments, may have the
secondary baffle has a fully pendulous configuration.
[0015] In the foregoing and other embodiments, the secondary baffle
may have a generally teardrop or piriform shape.
[0016] 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.
[0017] 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).
[0018] 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.
[0019] 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.
[0020] 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.
[0021] 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).
[0022] 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.
[0023] 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.
[0024] In the foregoing and other embodiments, the secondary
baffles may stack in partial overlap with the lower one of the
secondary baffles.
[0025] 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 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.
[0026] 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.
[0027] 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.
[0028] 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.
[0029] 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
[0030] The appended figures show embodiments according to the
inventive subject matter, unless noted as showing prior art.
[0031] FIG. 1 shows a side, cross-section of an individual
baffle.
[0032] FIG. 2A shows a side, cross-section of an assembly of
baffles like the baffle of FIG. 1.
[0033] FIG. 2B shows a perspective view of the assembly of FIG. 2
from a face layer.
[0034] FIG. 2C shows a perspective view of the assembly of FIG. 2
from a face layer.
[0035] FIG. 4 shows a side, cross-section of a first alternative
embodiment an individual baffle.
[0036] FIG. 5 shows a side, cross-section of a second alternative
embodiment an individual baffle.
[0037] FIG. 6 shows a side, cross-section of a third alternative
embodiment an individual baffle.
[0038] FIG. 7 shows a garment incorporating panels of baffles
according to one of the foregoing embodiments or any other
embodiment contemplated herein.
[0039] FIG. 8 shows a side, cross-section of an alternative
embodiment of an individual baffle.
DETAILED DESCRIPTION
[0040] Representative embodiments according to the inventive
subject matter are shown in FIGS. 1-8, wherein the same or
generally similar features share common reference numerals.
[0041] 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.
[0042] 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 depressions in the surrounding primary baffle, thus creating a
taller, more continuously plumped or expanded primary baffle.
[0043] 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.
[0044] 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.
[0045] 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.
[0046] In some embodiments, the baffle constructs have a height of
at least 5 cm, 8 cm, 11 cm, 12 cm, 13 cm, 14 cm, 15 cm, 16 cm, 17
cm, 18 cm, 19 cm, 20 cm, 25 cm, 30 cm, 35 cm, 40 cm, 45 cm, 50 cm,
or thereabout any such number, for supporting a column of fill
material.
[0047] 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.
[0048] 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 11a of the space, and (2) a
secondary baffle 12 in a second part 11b of the space.
[0049] 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.
[0050] 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 Thermoball.TM. 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.
[0051] 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.
[0052] 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 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 11a (volume not
occupied by secondary baffle 12) and the space 11b of the secondary
baffle 13.
[0053] 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.
[0054] 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 H/H' is between 1.25
and 5.
[0055] 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.
[0056] 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 11a is filled with fill material.
[0057] 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 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.
[0058] 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.
[0059] 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.
[0060] 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).
[0061] 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.
[0062] 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.
[0063] 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.
[0064] 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.
[0065] 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.
[0066] 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 vertical wall 24, and the face layer 36 is
the same as vertical wall 26.
[0067] 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).
[0068] 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.
[0069] 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.
[0070] 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.
[0071] 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 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.
[0072] 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.
[0073] 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.
[0074] 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.).
[0075] 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.
[0076] 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.
[0077] 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.
[0078] 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.
[0079] 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 10 cm, 15 cm, 20 cm
25 cm, 30 cm, 35 cm, 40 cm, 50, cm, 75 cm, 100 cm, 150 cm, or 200
cm.
[0080] 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.
[0081] 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. 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.
[0082] 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.
[0083] 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.
[0084] 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.
[0085] 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.
[0086] 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 Thermoball.TM. (available in products from The North
Face.RTM., a division of VF Outdoor, Inc., Alameda, Calif., USA),
which is based on round fiber clusters from Primaloft.TM., Inc.,
Latham, N.Y., 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.
[0087] 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.
[0088] 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.
[0089] 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.
[0090] 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.
[0091] 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.idfl.com, with a current test at
http://www.idfl.com/media/pdfs/IDFL%20Downproof%20vs%20Air%20Permeability-
.pdf.
[0092] 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.
[0093] 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.
Rating System:
[0094] 5=Pass (little or no leakage through fabric)
[0095] 4=Pass (minimal or normal leakage through fabric)
[0096] 3=Borderline
[0097] 2=Fail (above average leakage through fabric)
[0098] 1=Extreme Fail (significant leakage through fabric)
[0099] 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.
[0100] 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 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".
[0101] 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.
* * * * *
References