Insulated paneling for active sports
An active-insulation paneling component and garments including an active-insulation paneling component are disclosed. The active-insulation paneling component includes insulated panels separated by gussets. The gussets are configured to expand upon an outward pulling force to allow the active-insulation paneling component and/or garment to expand even where the active-insulation paneling component and/or garment are not manufactured from elastic materials.
1. A method of manufacturing an active-insulation paneling component for incorporation into a garment, the method comprising:
applying formation stitch lines to partially join two fabric layers together, wherein the formation stitch lines define insulation-panel-formation sections and gusset-formation sections located between the insulation-panel-formation sections, wherein each gusset-formation section is defined by at least two formation stitch lines;
filling the insulation-panel-formation sections with insulation;
folding the gusset-formation sections to bring borders of adjacent insulation-panel-formation sections together, the borders of the adjacent insulation-panel-formation sections defined by the formation stitch lines; and
applying, substantially orthogonal to the formation stitch lines, at least one finishing stitch line to seal ends of the insulation-panel-formation sections and fix the folding of the gusset-formation sections to form the active-insulation paneling component, wherein the active-insulation paneling component is configured to expand when a pulling force is applied in a direction orthogonal to the formation stitch lines.
2. The method of claim 1 , wherein the two fabric layers are made from an inelastic material having a weight less than or equal to 50 grams per square meter (gsm).
3. The method of claim 1 , wherein the insulation is blown-in insulation.
4. The method of claim 1 , wherein, prior to the step of folding the gusset-formation sections, the insulation-panel-formation sections have a width (D3), the gusset-formation sections have a width (D4), the widths D3 and D4 satisfy the inequality D3>2*D4.
5. The method of claim 4 , wherein each gusset-formation section includes a central stitch line, and the step of folding the gusset-formation sections is performed along the central stitch line.
6. The method of claim 1 , wherein folding the gusset-formation sections causes the borders of the adjacent insulation-panel-formation sections to partially overlap.
7. The method of claim 1 , further comprising, joining the active-insulation paneling component to a jacket.
8. A method of manufacturing an active-insulation paneling component for incorporation into a garment, the method comprising:
applying formation stitch lines to partially join two fabric layers together, wherein the formation stitch lines include a first formation stitch line, a second formation stitch line, a third formation stitch line, and a fourth formation stitch line, wherein:
the first formation stitch line and the second formation stitch line define borders of a first insulation-panel-formation section;
the second formation stitch line and the third formation stitch line define borders of a gusset-formation section; and
the third formation stitch line and the fourth formation stitch line define borders of a second insulation-panel-formation section;
filling the first and second insulation-panel-formation sections with insulation;
folding the gusset-formation section to bring the second formation stitch line and the third formation stitch line together; and
applying, substantially orthogonal to the formation stitch lines, at least one finishing stitch line to seal ends of the insulation-panel-formation sections and fix the folding of the gusset-formation section to form the active-insulation paneling component, wherein the active-insulation paneling component is configured to expand when a pulling force is applied in a direction orthogonal to the formation stitch lines.
9. The method of claim 8 , further comprising attaching a binding around a periphery of the active-insulation paneling component.
10. The method of claim 8 , attaching the active-insulation paneling component to an upper back side of a jacket such that the formation stitch lines extend in a head-to-toe direction.
11. The method of claim 10 , wherein the active-insulation paneling component is attached to a collar and a sleeve of the jacket.
12. The method of claim 8 , wherein, prior to the step of folding the gusset-formation section, the first insulation-panel-formation section has a width (D3), the gusset-formation section has a width (D4), the widths D3 and D4 satisfy the inequality D3>2*D4.
13. The method of claim 12 , wherein the widths D3 and D4 satisfy the inequality 0.1*D3<D4.
14. The method of claim 12 , wherein:
prior to the step of folding the gusset-formation section, the active-insulation paneling component has a width D1 and a length D2;
the width D4 is less than one third of the width D1; and
the formation stitch lines extend at least 90% of the width D1.
15. The method of claim 8 , wherein:
the gusset-formation section is a first gusset-formation section;
the formation stitch lines further include a fifth formation stitch line; and
the fifth formation stitch line and the fourth formation stitch line define a second gusset-formation section.
16. A method of manufacturing a jacket with an active-insulation paneling component, the method comprising:
applying formation stitch lines to partially join two fabric layers together, wherein the formation stitch lines include a first formation stitch line, a second formation stitch line, a third formation stitch line, and a fourth formation stitch line, wherein:
the first formation stitch line and the second formation stitch line define borders of a first insulation-panel-formation section;
the second formation stitch line and the third formation stitch line define borders of a gusset-formation section; and
the third formation stitch line and the fourth formation stitch line define borders of a second insulation-panel-formation section;
filling the first and second insulation-panel-formation sections with insulation;
folding the gusset-formation section to bring the second formation stitch line and the third formation stitch line together;
applying, substantially orthogonal to the formation stitch lines, at least one finishing stitch line to seal ends of the insulation-panel-formation sections and fix the folding of the gusset-formation section to form the active-insulation paneling component, wherein the active-insulation paneling component is configured to expand when a pulling force is applied in a direction orthogonal to the formation stitch lines; and
attaching the active-insulation paneling component to an upper back side of a jacket such that the formation stitch lines extend in a head-to-toe direction.
17. The method of claim 16 , wherein the active-insulation paneling component is attached to a collar of the jacket.
18. The method of claim 17 , wherein the active-insulation paneling component is attached to a sleeve of the jacket.
19. The method of claim 16 , wherein the active-insulation paneling component is attached to an insulated segment on the lower back of the jacket, the insulated segment extending laterally.
20. The method of claim 16 , further comprising attaching a lateral-extending elastic band to the gusset-formation section, wherein the elastic band is configured to stretch when the pulling force is applied in the direction orthogonal to the formation stitch lines.