Adjustably insulative construct

• US 20050144696A1
• Filed: 11/30/2004
• Published: 07/07/2005
• Est. Priority Date: 08/29/2002
• Status: Abandoned Application

• Current Assignee: W. L. Gore & Associates (W.L. Gore & Associates)
• Original Assignee: W. L. Gore & Associates (W.L. Gore & Associates)
• Inventors: Farnworth, Brian, Lack, Craig D.
• Application Number:
  US10/999,816
• Publication Number:
  US 20050144696A1
• Time in Patent Office: Days
• US Class Current: 2/69
• CPC Class Codes: A41D 2400/10 Heat retention or warming
• CPC Class Codes: A41D 2400/14 inflatable
• CPC Class Codes: A41D 31/065 using layered materials
• CPC Class Codes: A41D 31/102 Waterproof and breathable
• CPC Class Codes: A47G 2009/003 with inflatable members
• CPC Class Codes: A47G 9/0207 Blankets; Duvets
• CPC Class Codes: A47G 9/086 for outdoor sleeping
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 7/04 Interconnection of layers

Abstract

A multi-layered, composite, inflatable and deflatable article of manufacture is provided. The article includes at least two layers of a flexible, waterproof, air impermeable, optionally water-vapor-penneable material, the two layers forming at least one inflatable compartment therebetween. The two layers have at least one additional layer of a porous insulating material, e.g., batting, disposed between them within the compartment. The layers are all adhesively bonded together about the periphery of the compartment and, optionally, at discrete locations within the periphery of the compartment. The porous insulating layer is otherwise unattached to either of the waterproof layers, and preferably is not otherwise attached to either. The compartment has at least one sealable opening therein through which air may be injected into or removed from the compartment, as desired, to thereby inflate or deflate the compartment to a desired volume and to thereby control its insulative value. The construct of the invention is useful, inter alia, in garments, in air mattresses, in sleeping bags, or in a combination air mattress and sleeping bag, and in various bed covers.

Claims

1. A multi-layered composite construct having at least one inflatable and deflatable compartment therein, said construct comprising:

at least two layers of a flexible, waterproof, air impermeable, optionally water-vapor-permeable material, the two layers forming at least one compartment therebetween,

at least one additional layer of a porous insulating material disposed between said two layers and within said compartment, and

a waterproof, airtight adhesive seal extending around the periphery of said compartment,

wherein said at least two layers and said additional layer are adhesively bonded together about the periphery of said compartment and, optionally, at discrete locations within the periphery of said compartment, and wherein said adhesive penetrates the pores of the porous insulating material and bonds the at least two layers and the at least one additional layer together to form the adhesive seal,

said porous additional insulating material layer being otherwise unattached to at least one of said at least two layers, said compartment having at least one sealable opening therein through which air may be injected into or removed from said compartment, as desired, thereby inflating or deflating said compartment to a desired volume.

2. The construct of claim 1 wherein said at least two layers are of a water-vapor permeable material.

3. The construct of claim 1 wherein said porous additional insulating material layer is otherwise unattached to either of said at least two layers.

4. The construct of claim 1 being a garment.

5. The garment of claim 4 being a vest.

6. The garment of claim 4 being a jacket.

7. The garment of claim 4 being a pant.

8. The garment of claim 4 being a glove.

9. The garment of claim 4 being a coat.

10. The garment of claim 4 being a hat.

11. The garment of claim 4 being a sock.

12. The garment of claim 4 being a boot.

13. The construct of claim 1 being a mattress.

14. The construct of claim 1 being a sleeping bag.

15. The construct of claim 1 being a combination mattress and sleeping bag.

16. The construct of claim 1 being a bed cover.

17. The construct of claim 1 wherein said waterproof, air impermeable, water-vapor-permeable material is a membrane of a thermoplastic polyurethane.

18. The construct of claim 1 wherein said waterproof, air impermeable, water-vapor-permeable material is a membrane of a thermoplastic polyester.

19. The construct of claim 17 wherein at least one of said at least two layers has a moisture-vapor-transmission rate therethrough in the range of 2000 to greater than 5000 gm/m²/24 hours.

20. The construct of claim 18 wherein at least one of said at least two layers has a moisture-vapor-transmission rate therethrough in the range of 2000 to greater than 5000 gm/m²/24 hours.

21. The construct of claim 19 wherein said at least one of said at least two layers has a moisture-vapor-transmission rate exceeding 5000 gm/m²/24 hours.

22. The construct of claim 20 wherein said at least one of said at least two layers has a moisture-vapor-transmission rate exceeding 5000 gm/m²/24 hours.

23. The construct of claim 17 wherein said polyurethane is the reaction product of 4,4′

-diphenylmethane diisocyanate, poly(oxylene) glycol and 1,4-butanediol.

24. The construct of claim 1 wherein said at least one additional layer of insulating material is a layer of a batting material.

25. The construct of claim 24 wherein the batting material is a fibrous batting material.

26. The construct of claim 25 wherein the batting material is Primaloft®

batting.

27. The construct of claim 1 adhesively bonded by an adhesive selected from the class consisting of polyurethane, reactive polyurethane, thermoplastic polyurethane, silicone, flexible epoxy and PVC adhesives.

28. The construct of claim 27 wherein said adhesive is a thermoplastic polyurethane.

29. The construct of claim 1 including at least one reinforcing layer affixed to each of said at least two layers of waterproof, air impermeable, water-vapor-permeable material.

30. The construct of claim 29 wherein said reinforcing layer is a textile fabric.

31. The construct of claim 29 wherein said reinforcing layers are disposed internally of said at least two layers.

32. The construct of claim 29 wherein said reinforcing layers are disposed externally of said at least two layers.

33. The construct of claim 29 wherein said reinforcing layers are disposed both internally and externally of said at least two layers.

34. The construct of claim 30 wherein said textile fabric is selected from the class consisting of woven, knit or nonwoven fabrics.

35. The construct of claim 30 wherein said textile fabric is selected from the class consisting of nylon, polyester, polypropylene, polyaramid and cotton textile fabrics.

36. The construct of claim 30 wherein said textile fabric is nylon.

37. The construct of claim 1 wherein said at least two layers are composite layers of (a) a flexible first layer of hydrophobic material having a moisture vapor transmission rate exceeding 1000 gms/m²/24 hours and an advancing water contact angle exceeding 90 degrees;

and

(b) a continuous hydrophillic layer attached to the inner face of said first layer, said hydrophilic layer having a moisture-vapor-transmission rate exceeding 1000 gms/m²/24 hours.

38. The construct of claim 37 wherein said hydrophobic layer is microporous, expanded polytetrafluoroethylene.

39. The construct of claim 37 wherein said hydrophilic layer is a polyether-polyurethane.

40. The construct of claim 1 having a plurality of said additional porous insulating layers.

41. The construct of claim 1 wherein said layers form multiple compartments therein.

42. The construct of claim 1 wherein said sealable opening is a valved opening.

43. The construct of claim 42 including, in combination, an air supply.

44. The construct of claim 43 wherein said air supply is affixed to said construct.

45. The construct of claim 44 wherein said air supply is removably affixed to said construct.

46. The construct of claim 43 wherein said air supply includes a pump for pumping ambient air into said compartment.

47. The construct of claim 46 wherein said pump is a reversible pump capable of pumping air into or out of said compartment.

48. The construct of claim 42 wherein the valve of said valved opening is directional.

49. The construct of claim 42 wherein the valve of said valved opening is bi-directional.

50. The construct of claim 42 wherein the valve of said valved opening is multi-directional.

51. The construct of claim 46 wherein said pump is a bellows pump and the valve of said valved opening is directional.

52. The construct of claim 42 wherein said valve is a one-way valve.

53. The construct of claim 52 wherein air is injected into said compartment manually, by blowing into a tube affixed to said opening.

54. The construct of claim 1 inflated.

55. The construct of claim 1 deflated.

56. The construct of claim 1 having multiple valved openings.

63. The combination sleeping bag and air mattress of claim 15 wherein the air mattress component thereof comprises:

at least two layers of a flexible, waterproof, air impermeable, optionally water-vapor-permeable material, the two layers forming at least one compartment therebetween, the two layers having at least one additional layer of a porous insulating material disposed between said two layers, and within said compartment,

wherein said at least two layers and said additional layer are adhesively bonded together about the periphery of said compartment and, optionally, at discrete locations within the periphery of said compartment, and wherein said adhesive penetrates said porous insulating material and bonds said layers together to form a waterproof, airtight seal for said compartment extending around the periphery of said compartment,

said porous additional insulating material layer being otherwise unattached to at least one of said at least two layers,

said compartment having at least one sealable opening therein through which air may be injected into or removed from said compartment as desired,

thereby inflating or deflating said compartment to a desired volume,

wherein the sleeping bag component comprises a layered composite of an outer layer of an optionally air permeable, waterproof material, a middle layer of a porous insulating material, and an inner layer of an optionally waterproof, optionally air permeable material, this sleeping bag component also optionally including an external shell,

the air mattress component and the sleeping bag component being in registry, one to the other, and being adhesively bonded, one to the other, about the periphery of said sleeping bag component except at the access opening to the sleeping bag.

64. The combination sleeping bag and air mattress of claim 63 wherein said porous insulating material layer is otherwise unattached to either of said at least two layers.

57. A sleeping bag having an access opening allowing entry by a user, said sleeping bag comprising:

an upper panel of at least two layers of a flexible, breathable, optionally air permeable material, at least one layer being waterproof, the two layers forming at least one compartment therebetween, the two layers having at least one additional layer of a porous insulating material disposed between said two layers and within said compartment,

said upper panel being in registry with

a lower panel of at least two layers of a flexible, breathable, optionally air-impermeable material, at least one layer being waterproof, the two layers forming at least one compartment therebetween, the two layers having at least one additional layer of a porous insulating material disposed between said two layers and within said compartment,

said sleeping bag also having an optional outer-shell layer external to both upper and lower panels,

wherein all layers of all panels are adhesively and sealingly bonded together about the periphery of said sleeping bag, except at said access opening thereof.

58. The sleeping bag of claim 57 wherein said outer shell is a textile fabric.

59. The sleeping bag of claim 58 wherein said textile fabric is selected from the class consisting of woven, knit or nonwoven fabrics.

60. The sleeping bag of claim 58 wherein said textile fabric is selected from the class consisting of nylon, polyester, polypropylene, polyaramid and cotton textile fabrics.

61. The sleeping bag of claim 58 wherein said textile fabric is nylon.

62. The sleeping bag of claim 57 wherein said porous insulating material is a porous batting.