# US 7,943,225 B2 · Vented insulating liner method and apparatus > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,943,225 B2 - Document ID: US7943225B2 - Status: Granted - Kind: B2 - Application number: 11/277,591 - Filed: 2006-03-27 - Published: 2007-09-27 - Granted: 2011-05-17 - Earliest claimed: 2006-03-27 - Assignees: Polar Wrap, LLC - Inventors: Bruce McCormick - Web page: https://patentgrep.com/patent/US7943225B2 ## CPC - B32B 3/266: {characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12} - B32B 3/04: characterised by {at least one} layer folded at the edge, e.g. over another layer {; characterised by at least one layer enveloping or enclosing a material} - B32B 3/08: characterised by added members at particular parts {(layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18)} - B32B 3/10: characterised by a discontinuous layer, i.e. formed of separate pieces of material - B32B 7/05: the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection (using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14) - B32B 27/08: of synthetic resin - B32B 27/12: next to a fibrous or filamentary layer - B32B 27/30: comprising vinyl {(co)polymers; comprising acrylic (co)polymers} - B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF} - B32B 2260/021: Fibrous or filamentary layer - B32B 2260/046: Synthetic resin - B32B 2262/0276: Polyester fibres - B32B 2262/062: Cellulose fibres, e.g. cotton - B32B 2262/106: Carbon fibres, e.g. graphite fibres - B32B 2307/304: Insulating - B32B 2437/00: Clothing - Y10T 428/231: Filled with gas other than air; or under vacuum - Y10T 428/239: Complete cover or casing - Y10T 428/24322: Composite web or sheet - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract An insulating liner for an article of clothing includes an insulating layer including an aerogel material and having opposite sides with passages extending therebetween, and a cover encapsulating the insulating layer. The cover includes vent holes aligned with the passages of the insulating layer, and has portions that extend into the passages of the insulating layer from the opposite sides of the insulating layer, with the portions having vent holes therethrough and being sealed about the periphery of the vent holes. A valve may be provided with the liner to allow gas to be withdrawn or expelled from the liner. Methods of forming the insulating liner(s) are also provided. ## Claims ### Claim 1 An insulating liner for an article of clothing, comprising: an insulating layer comprising a dust generating aerogel composite that includes a fibrous substrate carrying an aerogel material, said insulating layer having opposite sides with a plurality of passages extending therebetween; and a cover hermetically encapsulating said insulating layer and including a plurality of vent holes aligned with said plurality of passages of said insulating layer, said cover having portions that extend into said plurality of passages of said insulating layer from said opposite sides of said insulating layer, with said portions having vent holes therethrough and being sealed about the periphery of said vent holes. ### Claim 2 (depends on 1) An insulating liner as defined in claim 1, wherein said cover comprises: a first layer disposed on one of said opposite sides of said insulating layer; and a second layer disposed on said other of said opposite sides of said insulating layer, wherein said first and second layers are affixed together within said plurality of passages of said insulating layer and include said plurality of vent holes therethrough at said plurality of passages of said insulating layer. ### Claim 3 (depends on 2) An insulating liner as defined in claim 2, wherein said fibrous substrate further comprises a polymeric, fibrous, carbon-based substrate and said aerogel material is composed of a nonporous silica matrix, and wherein said first and second layers are structural layers composed of a vinyl material and are hermetically sealed together about the periphery of said insulating layer and about the periphery of said plurality of vent holes. ### Claim 4 (depends on 2) An insulating liner as defined in claim 2, wherein said first and second layers are impermeable to air and are hermetically sealed together about the periphery of said insulating layer and about the periphery of said plurality of vent holes to thereby hermetically seal said insulating layer while permitting air flow through said vent holes. ### Claim 5 (depends on 4) An insulating liner as defined in claim 4, wherein said first and second layers are structural layers that comprise a vinyl material welded together about the periphery of said insulating layer. ### Claim 6 (depends on 1) An insulating liner as defined in claim 1, wherein said fibrous substrate further comprises a polymeric, fibrous substrate and said aerogel is composed of a nonporous silica matrix. ### Claim 7 (depends on 6) An insulating liner as defined in claim 6, wherein said fibrous substrate further comprises a carbon-based substrate or a polyester substrate. ### Claim 8 (depends on 1) An insulating liner as defined in claim 1, wherein said cover includes a sealed valve. ### Claim 9 (depends on 8) An insulating liner as defined in claim 8, wherein said sealed valve enables gas to be displaced from within said liner to at least reduce said gas pressure in said cover. ### Claim 10 (depends on 9) An insulating liner as defined in claim 9, wherein said sealed valve enables gas to be displaced from within said liner to yield a negative pressure condition therein. ### Claim 11 (depends on 9) An insulating liner as defined in claim 9, and adapted for use in an insulation assembly comprising permeable insulation layers disposed on opposite sides of said insulating liner, wherein said permeable insulation layers are sewn together at the periphery thereof and through the periphery of said insulating liner. ### Claim 12 An insulating liner for an article of clothing comprising: an insulating layer comprising a dust generating aerogel composite that includes a fibrous substrate carrying an aerogel material, said insulating layer having opposite sides with a plurality of passages extending therebetween; and a cover hermetically encapsulating said insulating layer and including a valve to allow gas within said liner to pass therethrough. ### Claim 13 (depends on 12) An insulating liner as defined in claim 12, wherein said valve includes a body affixed to said cover and includes a resilient seal carried within said body that may be pierced to allow gas to be withdrawn from said liner. ### Claim 14 (depends on 12) An insulating liner as defined in claim 12 wherein said valve is a check valve and said liner is compressible to allow gas to be expelled from said liner through said check valve. ### Claim 15 A method of forming an insulating liner for an article of clothing, comprising the steps of: providing at least one insulating layer comprising a dust generating aerogel composite that includes a fibrous substrate carrying an aerogel material, said aerogel composite having a plurality of passages therethrough; providing first and second sheets of an impermeable polymeric material; encapsulating said at least one insulating layer between said first and second sheets; cutting said first and second sheets to a desired shape; and forming a plurality of vent holes through said first and second sheets at said plurality of passages. ### Claim 16 (depends on 15) A method as defined in claim 15, wherein said fibrous substrate further comprises a carbon-based substrate or a polyester substrate. ### Claim 17 (depends on 15) A method as defined in claim 15, wherein said encapsulating step is carried out by the following steps: hermetically sealing said first and second sheets together within said passages of said at least one insulating layer; and hermetically sealing said first and second sheets together about the periphery of said insulating layer disposed therebetween. ### Claim 18 (depends on 15) A method as defined in claim 15, wherein said step of providing said at least one insulating layer comprises cutting and punching said at least one insulating layer from a bulk supply of insulation material to define a size and shape of said at least one insulating layer and said plurality of passages therethrough. ### Claim 19 (depends on 18) A method as defined in claim 18, wherein said encapsulating step comprises: laying said at least one insulating layer over said first sheet; disposing said second sheet over said at least one insulating layer; and hermetically sealing said first and second sheets together about the periphery of said at least one insulating layer and about the periphery of said plurality of vent holes. ### Claim 20 (depends on 18) A method as defined in claim 18, wherein said encapsulating step comprises: laying said at least one insulating layer over said first sheet; disposing said second sheet over said at least one insulating layer; positioning said sheets and said insulating layer in a high frequency ultrasonic welder below a die plate thereof having a die cutting surface and on a platen thereof, wherein said lower platen and upper die plate have said preferred contours and features of said insulating liner; pressing said die plate against said platen with said sheets and insulating layer disposed therebetween while applying a high frequency to weld said sheets together about the periphery of said insulating layer and at said passages of said insulating layer to thereby encapsulate said insulating layer between said sheets; and die-cutting the periphery of said sheets as well as said portions of said sheets that extend into said passages of said insulating layer, thereby forming said plurality of vent holes. ### Claim 21 (depends on 15) An insulating liner for an article of clothing produced by the method as defined in claim 15. ### Claim 22 (depends on 15) A method as defined in claim 15 wherein said encapsulating step is carried out in a vacuum chamber. ### Claim 23 A method of forming an insulating liner for an article of clothing, comprising the steps of: providing at least one insulating layer comprising a dust generating aerogel composite that includes a fibrous substrate carrying an aerogel material, said aerogel composite having a plurality of passages therethrough; providing a cover of an impermeable polymeric material; encapsulating said at least one insulating layer within said cover; cutting said cover to a desired shape; providing a valve in said cover; and displacing gas from within said insulating liner through said valve to reduce gas pressure therein. ### Claim 24 (depends on 23) A method as defined in claim 23, wherein said displacing step comprises inserting a needle of a syringe through said valve in communication with the interior of said insulating liner, and actuating said syringe to withdraw said gas to yield a reduced pressure condition within said liner to enhance the insulative properties thereof. ### Claim 25 (depends on 23) A method as defined in claim 23, wherein said valve is a check valve and said displacing step comprises applying a compression force to said liner to expel gas through said valve and thereby reduce the interior volume of said liner to substantially the external size of the now-compressed said at least one insulating layer, and also comprises subsequently releasing the compression force to allow the compressed said at least one insulating layer to at least partially recover its original size and shape thereby tending to at least slightly increase the interior volume of said liner and thus yield a reduced pressure condition within said liner to enhance the insulative properties thereof. ### Claim 26 (depends on 25) A method as defined in claim 25, further comprising a step of using a welding machine to at least partially carry out said encapsulating and cutting steps as well as said displacing step. ### Claim 27 (depends on 23) A method as defined in claim 23, wherein said displacing step yields a reduction in gas pressure of about 25 to 75 Torr. ### Claim 28 (depends on 23) A method as defined in claim 23, wherein said encapsulating step is carried out in a vacuum chamber.