Baffle constructs for insulative fill materials

Patent metadata

Field	Value
Publication number	US-11457682-B2
Application number	US-201615125925-A
Country	US
Kind code	B2
Filing date	Feb 29, 2016
Priority date	Apr 30, 2015
Publication date	Oct 4, 2022
Grant date	Oct 4, 2022

Abstract

The inventive subject matter generally relates to shaped battle constructs for use in consumer products, such as garments and sleeping bags. In certain aspects, the shaped baffles are arranged in a multi-level construction of baffles wherein the baffles are offset in two or more levels. In certain aspects, the entire construct is a unitary woven, seamless construction.

First claim

The invention claimed is:

1. A baffle construct, comprising:
a drapable, pliable multilayer construction of a first layer, one or more interlayers, and a third layer, the interlayer being disposed between the first and third layers, the layers all being part of a unitary, seamlessly woven fabric construct, the layers being joined so as to define a plurality of baffles, and
wherein an elongate flat woven section comprising a closure is disposed in the baffle construct, the closure comprising sections that can separate from one another, thereby dividing multiple rows of baffles into two sections of baffles on either side of the closure, with the closure sections and the baffle sections being seamlessly woven with each other, the closure being suitable for forming an opening in the construct on separation of the separable closure sections.

2. A baffle construct comprising:
a drapable, pliable multilayer construction of a first layer, one or more interlayers, and a third layer, the one or more interlayers being disposed between the first and third layers, the layers all being part of a unitary, seamlessly woven fabric construct, the layers being joined so as to define a plurality of baffles, and wherein the baffles are expandable from a first collapsed configuration to a second expanded configuration; and
wherein at least one layer is downproof or fiberproof, and one of the interlayers has an overall fabric density that is lower than the overall fabric density of the first and/or the third layers, the first layer and/or the third layer being downproof or fiberproof based on its overall fabric density.

3. The baffle construct of claim 2 wherein the baffle construct has a flat form when in the first collapsed configuration, with the first layer being adjacent one side of the interlayer and the third layer being adjacent to an opposite side of the interlayer the layers being disconnected from one another except at spaced apart joints at (i) top side of the interlayer where the first layer merges therewith and (ii) at the bottom side of the interlayer where the third layer merges therewith.

4. The baffle construct of claim 2 wherein the length/height aspect ratio of the baffle is at least 1, the length being the separation between joints along the X-axis, and the height being the maximum separation of the adjacent layers along the Y-axis.

5. The baffle construct of claim 2 wherein the height/length aspect ratio of the baffle is at least 1, the length being the separation between joints along the X-axis, and the height being the maximum separation of the adjacent layers along the Y-axis.

6. The baffle construct of claim 2 wherein the baffles are aligned on a first level and a second level, the levels being in parallel planes arranged along two levels, and wherein the first level of baffles comprises baffles having a first configuration and the second level of baffles comprises a second configuration in a nested arrangement with the baffles of the first configuration, the baffles in the second configuration each overlying fully multiple baffles in the first configuration.

7. The baffle construct of claim 6 wherein the baffles at one level nest with baffles at the other level.

8. The baffle construct of claim 2 wherein there are at least 5 or more baffles.

9. A baffle construct, comprising:
a drapable, pliable three-layer construction of a first layer, a second interlayer below the first layer, and a third layer below the interlayer, the layers all being part of unitary, seamlessly woven fabric construct, the layers being joined so as to define at least four expandable baffles, the baffles being expandable from a first collapsed configuration to a second expanded configuration;
the baffle construct having a theoretical longitudinal cross-sectional profile such that the first, second, and third layers each have a sinusoidal form with maxima or peaks and minima or troughs, with the first layer and third layer generally being in phase with each other, and the interlayer being out of phase by about 180 degrees;
for the first and third layers, the minima or troughs of the first layer merging with maxima or peaks of the interlayer to form joints, and the maxima or peaks of the third layer merging with minima or troughs of the interlayer to form joints; and
wherein the first, second, and third layers are disconnected between the joints so as to define the expandable baffles; and
wherein at least one layer is downproof or fiberproof and one of the interlayers has an overall fabric density that is lower than the overall fabric density of the first and/or the third layers, the first layer and/or the third layer being downproof or fiberproof based on its overall fabric density.

10. A baffle construct of claim 2 further comprising a fill material that expands the baffle towards the theoretical profile, the baffle construct being sealed to contain the fill material.

11. An end product comprising a baffle construct of claim 10 , the end product being selected from the group of: garments, sleeping bags, sleeping pads, footwear uppers, gloves, headwear, pillows, cushions, beds, or bed toppings.

12. The baffle construct of claim 2 wherein the layers of material vary from one another or within a given layer in terms of materials, weave types, and/or material properties.

13. The baffle construct of claim 12 wherein at least one layer has varying zones across the warp and/or weft direction, and a transition zone is disposed between zones so as to provide a progressive transition of the attributes of one zone to another.

14. The baffle construct of claim 2 wherein one of the first or third layers comprises a durability zone and the other of the first or third layers comprises a light-weight, breathable, moisture wicking, or comfort fabric layer.

15. A baffle construct, comprising:
a drapable, pliable multilayer construction of a first layer, one or more interlayers, and a third layer, the one or more interlayers being disposed between the first and third layers, the layers all being part of a unitary, seamlessly woven fabric construct, the layers being joined so as to define a plurality of baffles,
the baffles being expandable from a first collapsed configuration to a second expanded configuration, wherein the baffle construct has a flat form when in the first collapsed configuration, with the first layer being adjacent one side of the interlayer and the third layer being adjacent to an opposite side of the interlayer, the layers being disconnected from one another except at spaced apart joints at (i) a top side of the interlayer where the first layer merges therewith and (ii) at a bottom side of the interlayer where the third layer merges therewith; and
wherein the baffle construct has a theoretical longitudinal cross-sectional profile in the second, expanded configuration such that the first, second, and third layers each have an undulating or sinusoidal form with (1) maxima or peaks and (2) minima or troughs, which are configured and arranged so that the baffles are arranged in a nested configuration along two or more levels; and
wherein at least one layer is downproof or fiberproof and one of the interlayers has an overall fabric density that is lower than the overall fabric density of the first and/or the third layers, the first layer and/or the third layer being downproof or fiberproof based on its overall fabric density.

16. The baffle construct of claim 2 wherein the layers being disconnected from one another except at spaced apart joints at (i) a top side of the interlayer where the first layer merges therewith

Assignees

• North Face Apparel Corp

Inventors

• Massey Ryan Taylor
• Olson Cory Michael

Classifications

• B32B2307/558

  Impact strength, toughness · CPC title

• A41D31/125

  Moisture handling or wicking function through layered materials · CPC title

• A41D31/04

  characterised by special function or use (protective clothing affording protection against heat or harmful chemical agents or for use at high altitudes A62B17/00; composition of materials for coverings or clothing affording protection against harmful chemical agents A62D5/00) · CPC title

• B32B5/02 Primary

  characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)} · CPC title

• B32B2262/0276

  Polyester fibres · CPC title