US20150159366A1

US20150159366A1 - Collapsible Cellular Insulation

Info

Publication number: US20150159366A1
Application number: US14/099,772
Authority: US
Inventors: Paul E. Guerard; Jeffrey Scott Lassegard; Linden D. Bolisay
Original assignee: LGarde Inc
Current assignee: LGarde Inc
Priority date: 2013-12-06
Filing date: 2013-12-06
Publication date: 2015-06-11

Abstract

Multi-layered insulation is disclosed for having a collapsed configuration in which one dimension of the insulation is minimized to reduce the volume for storage. The multi-layered insulation has an expanded configuration in which the dimension is maximized to separate outer layers of the insulation. The insulation layer is composed of internal connecting membranes between outer surfaces. The MLI lattice is configured such that, when properly deployed, creates a cellular structure, thus providing the air gap between the outer surfaces.

Description

BACKGROUND

Outdoor camping is an activity that over 40 million people in the U.S. participate in each year. However, camping is usually limited from late spring to early fall because camping equipment is normally not well-equipped to handle extreme temperatures. For example, commercially available recreational camping tents are constructed from thin polyester or nylon fabric which does not insulate well. Their primary goal is to shield the occupant from elemental weather conditions such as rain, wind, etc., but do not protect against the variation in temperature. Therefore, many shelters can become extremely hot internally when exposed to the hot sun during summer months and very cold during winter nights.
U.S. Pat. No. 7,169,459 describes the fundamental concept of a multi-layer insulation (MLI). The multilayer insulation provides cells that trap air and reduce convective currents to provide a lightweight, deployable insulation. The cells are created through the interconnection of adjacent intermediate layers, which are deployed by laterally moving one outer layer longitudinally with respect to the opposing outer layer. The relative lateral movement of the outer layers may limit the deployment of the MLI. The configuration of the intermediate layers also may provide difficulties for mass production as adjacent intermediate layers are connected at multiple positions along their length. The multiple positions may overlap such that each connection length must be isolated from other intermediate layers and individually adhered. The manufacturing process of the disclosed MLI is therefore time and personnel intensive and not readily subject to mass production.
The present description provides a design and materials that allow for greater performance and manufacturability. The MLI design of the present description can be applied to camping tents while maintaining similar volume, weight, stowability and ease of deployment compared to unmodified camping tents. The design can also be constructed using a wide range of materials.

SUMMARY

Apparatus and systems are described herein for insulation. Methods of manufacturing and deploying the disclosed insulation are also provided. Innovative methods and/or materials to improve the insulation properties of outdoor recreational equipment, such as tents and sleeping pads, are also disclosed. Devices incorporating the described insulation may achieve extended utility into the colder seasons and make hot weather more tolerable. Embodiments may alternatively or additionally permit easy removal and efficient storage when not needed.

DRAWINGS

FIGS. 1A-1C illustrate an exemplary embodiment of the multilayer insulation (MLI).

FIG. 1A is a side view of the MLI in a collapsed configuration, FIG. 1B is a side view in an expanded configuration, and FIG. 1C is a perspective view in an expanded configuration.

FIGS. 2A-2D illustrate exemplary configurations with corresponding perpendicular planes in dashed lines.

FIGS. 3A-3E illustrate exemplary cellular structures defined by the MLI layers and membrane.

FIGS. 4A-4B illustrates an exemplary MLI including more than two layered cells between outer layers, in a collapsed and expanded configuration, respectively.

FIGS. 5-10 illustrate exemplary embodiments of different exemplary multi-cellular structures forming the MLI.

FIGS. 11-14 illustrate exemplary methods of deploying embodiments of the MLI as described herein.

FIG. 15 illustrates an exemplary method of manufacture based on the configuration of FIG. 5 in which successive seams are accessible during the bonding process.

DESCRIPTION

The following detailed description illustrates by way of example, not by way of limitation, the principles of the invention. This description will clearly enable one skilled in the art to make and use the invention, and describes several embodiments, adaptations, variations, alternatives and uses of the invention, including what is presently believed to be the best mode of carrying out the invention. It should be understood that the drawings are diagrammatic and schematic representations of exemplary embodiments of the invention, and are not limiting of the present invention nor are they necessarily drawn to scale. For example, the material thickness is greatly exaggerated relative to the cellular structure to illustrate the attachment of the respective layers and membranes. However, the relative orientation, position, and spacing of layers and/or membranes exemplify preferred configurations.
Embodiments described herein are generally provided in terms of outdoor recreational equipment, such as tents and sleeping pads. However, embodiments are not so limited and may be applied to any application desiring additional insulation, such as make-shift or low construction buildings and housing, roofs, canopies, mats, blankets, shelters, walls, etc. Embodiments may also be incorporated into older construction buildings to add, improve, supplement, and/or replace insulation cheaply and efficiently. Exemplary embodiments for select applications are provided herein. It is understood that the features and configurations of the respective embodiments may be combined in various ways and still be within the scope of the present disclosure. Accordingly, features may be combined, duplicated, added, deleted, etc.
The disclosed multi-layer cellular insulation takes advantage of the low thermal conductivity of air by providing multiple air gaps between the tent wall and the interior of the tent. The insulation layer is composed of internal connecting membranes between two planar outer sheets and one intermediate planar sheet. The MLI lattice is configured such that, when properly deployed, creates a cellular structure, thus providing the air gap between the outer surfaces.
In an exemplary embodiment, the outer sheets, intermediate sheet, and connecting membranes are configured to reduce a storage profile. Each of the layers are configured to generally lay without wrinkles, folds, or bunching within the respective material layers such that each surface of each layer fully faces one or more adjacent layers. Thus, surfaces of a given layer are not self-facing or facing another portion of the same layer. Accordingly, the respective layers may lie generally flat in the compact configuration. In a deployed configuration, the outer sheets expand directly away from each other, generally perpendicular to the opposing outer sheet. The intermediate planar sheet translates generally perpendicularly away from the respective outer surfaces, while translating longitudinally generally parallel to the outer surfaces. The longitudinal translation permits the membranes to open and creates the respective cells within the insulation layer. The MLI may be retained in a deployed configuration through gravity, externally applied retention force, internally applied retention force, or internal/external inflation pressure.
FIG. 1 illustrates an exemplary embodiment of the multilayer insulation (MLI). The MLI 100 includes opposing outer layers 102, 104 and at least one intermediate layer 106. A first plurality of membranes 108 connect the first outer layer 102 to the intermediate layer 106, while a second plurality of membranes 110 connect the second outer layer 104 to the intermediate layer 106. The plurality of membranes 108, 110 directly connect the outer layers 102, 104 to the intermediate layer 106.
The membranes may connect to the respective outer layers and/or intermediate layer through various known connection techniques. As shown, one end of the membrane 122 may be oriented generally parallel to the outer layer 102 extending from an intermediate section 121 of the membrane in a first direction 124. The membrane may then be oriented generally parallel to the intermediate layer 106 extending from the intermediate section 121 in a second direction 125 opposite the first direction. The sections of the membrane extending generally parallel to the respective layers may be used to couple the membrane to the layer. The intermediate section 121 of the membrane may be variably positioned from generally parallel to the intermediate and outer layers, in a collapsed configuration, to generally perpendicular thereto, in an expanded configuration. The membranes may also terminate at the respective layers without being generally aligned thereto, such that the membrane generally comprises only intermediate section 121. It is noted that the general orientation is dependent on the flexibility of the material of the respective layers and/or membranes, such that the orientation of any layer or membrane may smoothly transition between the disclosed orientations thus creating serpentine orientations instead of the clearly delineated segments as illustrated.
A first plurality of membranes 108 may be coupled and positioned between the first outer layer 102 and the intermediate layer 106 in a first direction 126. A second plurality of membranes 110 may be coupled and positioned between the second outer layer 104 and the intermediate layer 106 in a second opposing direction 127 such that the membranes 108 and 110 extend outwardly from the intermediate layer 106 on opposing sides in the same direction 124 along the intermediate layer. In an exemplary embodiment, the membranes 108 and 110 are positioned to create mirrored reflections across the intermediate layer 106. Accordingly, the membranes 108 and 110 may extend from the intermediate layer 106 on opposing sides of the intermediate layer aligned across the intermediate layer. This configuration permits the respective connections or seams of the respective membranes to be created simultaneously across the intermediate layer if desired. The membranes may also be staggered on opposing sides of the intermediate layer such that the membranes do not share a common connection or seam plane.
Membranes 108 and 110 generally extend across the outer and intermediate layers in one direction 128, with adjacent membranes spaced along the layers 102, 104, 106 in a second direction 129. Successively adjacent membranes may be separated by generally the same separation distance x1, or may include one or more separation distances such as x1, x2, x3 repeated or variable along the length. For example, a larger separation distance may be between adjacent membranes at one end while sequentially successive membranes are progressively closer together toward the opposing end, or any combination thereof. The height of the membrane z1 may be the same for opposing sides of the intermediate layer or may be different.
The MLI 100 has a collapsed configuration in which at least one outer dimension of the MLI is minimized to permit the MLI to be stored in a reduced volume. As seen in FIG. 1A, the thickness (z) of the MLI may be minimized by translating the intermediate layer 106 longitudinally to compress the outer layers 102 and 104 toward each other. In the collapsed configuration, the outer layers, intermediate layer, and membranes are oriented generally parallel without substantial wrinkling, bending, or out of plane displacement. Given the flexibility of the material and possible overlap of different layers or membranes, some out of plane displacement may be expected. However, the layers and membranes are configured to minimize the thickness of the stored configuration by minimizing the overlapping of one layer or membrane upon itself. Thus, generally parallel or minimized out of plane displacement is understood to include slight deformations of the layers and membranes. However, the layers and membranes are configured such that when stored the layer or membrane does not overlap itself in a plane generally perpendicular to the surface of the layer or membrane. FIGS. 2A-2D illustrate exemplary configurations with corresponding perpendicular planes in dashed lines. As seen in FIGS. 2A and 2B, slight variations may be achieved without the overlapping of the material upon itself, even when adjacent layers or membranes may overlap (FIG. 2B). In contrast, FIGS. 2C and 2D illustrate exemplary configurations in which substantial variations are experienced, thus adding to the dimensions in a collapsed configuration.
As seen in FIG. 1B, the MLI 100 has an expanded configuration creating cells 140 defined by adjacent membranes, one of the outer layers, and the intermediate layer. The cells are filled with air in the expanded configuration. The membranes impede convection currents, thus creating a lightweight insulation with a low storage volume.
The MLI has an expanded configuration in which the minimized dimension of the collapsed configuration is now maximized, i.e. the outer layers 102 and 104 are fully separated. To deploy the MLI 100, the outer layers 102, 104 are retained in relative position over each other such that they do not generally move longitudinally along a surface of each other. The outer layers 102, 104 translate perpendicular to the opposing outer layer 104, 102 directly away from each other. Therefore, the outer layers 102, 104 move relatively away from the intermediate layer 106. The intermediate layer 106 simultaneously translates in a direction generally parallel to the outer layers, or longitudinally along a surface of the outer layer. During deployment, the outer layers generally do not translate parallel relative to each other. It is understood that given the material flexibility some longitudinal translation between the outer layers may be observed and is within the scope of the present invention. However, the layers and membranes are configured such that the outer layers need not translate longitudinally relative to each other to fully deploy the MLI.
Accordingly, a first outer layer 102 may generally be planar in an x, y coordinate system. In a stored configuration, the intermediate layer 106 and opposing outer layer 104 may be generally planar and parallel to the first outer layer 102. Membranes 108 and 110 may lie generally flat against the first outer layer 102, intermediate layer 106, or opposing outer layer 104. The configuration minimizes the out of plane, i.e. vertical or z direction, displacement of the MLI 100 in the collapsed configuration. In an exemplary embodiment, the thickness of the MLI in the collapsed configuration is 3 to 15 times the thickness of a respective or average layer thickness, and more preferably of 3 to 10 times a layer thickness. In an exemplary embodiment, the stored configuration has an out of plane (i.e. z direction) thickness at any one or more points along the MLI less than twice the sum of the individual material layers traversed at that point in the z direction in the collapsed configuration. In exemplary embodiments, the MLI thickness in the contracted state at any one point is generally the thickness of the sum of the layers traversed at the point. An error associated with the material thickness may be on the order of the thickness of 1-2 materials layers, or 5-10% of the overall MLI thickness. The MLI 100 translates to the deployed configuration by moving the outer layers 102, 104 relative to each other in the z direction only. The intermediate layer 106 moves away from the respective outer layers (i.e. z-direction) and along the outer layers (i.e. x-y plane).
The outer layers 108 and 110 and/or the intermediate layer 106 may include an exterior border 150 along one or more edges that extends beyond an extent of the membrane. The border may be configured to removably or permanently attach to a border of an opposing outer and/or intermediate layer, such as for example, by tying, lacing, snapping, Velcro, hook and loop, adhesive, rivet, hooking, bonding, welding, etc. The border 150 may be used to support the MLI in a deployed configuration. The attachment may further be used to retain the MLI in either an expanded or collapsed configuration. With or without attachment to another border, the border may be used to enclose one or more ends of the cellular structure in the expanded configuration, thus further reducing air flow through the MLI and increasing the insulative effects. In an exemplary embodiment, the border 150 may be an extension of the one or more layers that simply overlaps and/or wraps around the end of the expanded MLI to reduce air flow through the cellular structure. In another exemplary embodiment, the border may be separately attached between one more layers and/or one or more membranes.
The membranes, outer layers, and intermediate layer may be coupled through various techniques. For example, the membrane and layers may be bonded, adhered, glued, stitched, welded, stapled, sewn, punched, riveted, buttoned, snapped, radio frequency (RF) welded, heat sealed, etc. Other methods may be used of attaching the two outer sheets in a way that, when properly deployed, creates a cellular structure, thus providing the air gap between the outer surfaces.
Relative terms such as “approximately” or “generally” are used herein to describe the disclosed features. Even when a description of an orientation or dimension is provided, it is understood to include the approximate values and equivalent values thereto based on the intended function of the respective component. These terms are used to suggest normal deviations from those disclosed based on the understanding of a person of skill in the art, the method of manufacture, and variations in materials and components. For example, “approximate” when describing the thickness of the MLI in either the collapsed or expanded configuration is understood to be equal thereto and encompass a reasonable error corresponding to the connecting method used to include seam thicknesses and minor variation corresponding to trapped air pockets or kinking/creasing of the respective layers and membranes, while “generally” flat or planar is understood to be planar with deviations related to the material thickness of overlapping layers and/or minor kinking/creasing of the respective layers and membranes.
FIGS. 3A-3E illustrate exemplary cellular structures defined by the MLI layers and membrane. It is understood that the described configurations are exemplary only, in which one or more feature of the configurations may be combined in various ways, all of which are within the scope of the present disclosure. The separation between adjacent membranes and between adjacent layers may be determined to improve insulation effects for various applications. For example, smaller cells can be created by positioning adjacent membranes closer together. Thus, the smaller membranes may be used on one side or one end of the MLI as opposed to another end, depending on the desired insulation.
FIG. 3A illustrates an exemplary configuration in which the separation between adjacent membranes is generally equidistant and approximates the separation between the layers in a deployed configuration. In an exemplary embodiment, a first plurality of membranes 108 may extend across a first surface in a first direction of the intermediate layer and be spaced generally equidistantly along the first surface in a second direction generally perpendicular to the first direction. A second plurality of membranes 110 may extend across a second surface opposite the first surface in the first direction of the intermediate layer and be spaced generally equidistantly along the second surface in the second direction. The membranes 108 and 110 may extend from opposing sides of the intermediate layer at approximately the same position. The separation between adjacent membranes may also be larger than the layer separation distance to compensate for the overlap created at the seam of the membranes. The separation distance between adjacent membranes may therefore be selected such that adjacent membranes do not overlap in the collapsed configuration. Alternatively, the distance may be selected such that the membranes overlap in a uniform manner such that the number of layers traversed in the collapsed configuration is consistent across the layer.
FIG. 3B illustrates an exemplary embodiment in which adjacent membranes may be equidistantly spaced, but be offset on opposing sides of the intermediate layer. Therefore, the membranes 108 on a first side of the intermediate layer may be staggered from the membranes on the second opposing side of the intermediate layer. For example, the membranes 110 may occur generally halfway between the 108 membranes along the second direction of the intermediate layer. The membranes 108 and 110 may be sufficiently spaced such that the membranes do not overlap in a collapsed configuration. The membranes may be positioned such that membranes on opposing sides of the intermediate layer do not overlap, but generally create a uniform material thickness across the layers in the collapsed configuration. Alternatively, the membranes may be positioned such that the membranes on opposing sides of the intermediate layer do overlap and create a regular pattern or constant material thickness in the collapsed configuration.
FIG. 3C illustrates an exemplary configuration in which the separation of adjacent members may be uniform or variable, and may be different on opposing sides of the intermediate layer; the separation distance between the intermediate layer and the respective outer layer may also be different. For example, one side of the intermediate layer may have a generally uniform separation between adjacent membranes, x, and a constant separation distance between the intermediate layer and the first outer layer, y. The opposing side of the intermediate layer may have a variable separation, u or v, between adjacent membranes, while having a different separation height, w, between the intermediate layer and the second outer layer. The membrane separation across one or more adjacent cells may be subdivided such that a recurrent number of membranes align at a given interval. Thus, as shown, three cells, or every fourth membrane from one side of the intermediate layer aligns with every two cells, or every other membrane of the opposing side. The separation distance between the membranes need not however align such that one or more membranes align on opposing sides of the intermediate layer. The separation distance between the intermediate layer and the respective outer layer, y and w, although not necessary, is preferably kept approximately equal such that the outer layers translate minimally relative to one another within the plane of the membrane from the collapsed to the deployed configurations.
FIG. 3D illustrates an exemplary embodiment in which the membranes connect to the respective layers at a terminal end thereof, and have an adjacent separation distance between adjacent membranes less than the separation distance between adjacent layers. The membranes may be positioned such that one or more adjacent membranes overlap in the stored configuration. For example, the separation of adjacent membranes may be approximately half the length of the membrane such that the two adjacent membranes overlap the same middle membrane along opposing ends of the middle membrane.
FIG. 3E illustrates an exemplary embodiment in which the separation distance between adjacent membranes varies along the length of the MLI. As shown, the separation distance between adjacent membranes may be progressively reduced, thus creating smaller cells at one end of the MLI than at the opposing end. The respective membrane separation may be progressively variable, such as either reduced or increased by a linear or non-linear amount between sequentially adjacent membranes. Alternatively, a set of membranes may be separated by a generally uniform separation distance, while adjacent sets of membranes may have variable separation distances. This configuration may be used to increase the insulation at one section or one end of the MLI. The additional membrane layers may increase the overall thickness dimension in the collapsed configuration, but does permit the overall stowage volume to be reduced by removing membranes and corresponding material thickness for sections not requiring as much insulation. The variable separation of adjacent membranes need not be progressive in one direction, but may be any variation of separation distances.
FIG. 4 illustrates an exemplary MLI 400 including more than two layered cells between outer layers. The embodiments of FIGS. 1-3 included two cellular layers, one per opposing side of the intermediate layer. The embodiments of FIG. 4 configure the membrane or include additional membrane sections such that more than two cells traverse the separation between the outer layers.
As seen in FIG. 4A, the MLI 400 has a collapsed configuration and, as seen in FIG. 4B, an expanded configuration. The layers and membranes are configured such that they generally lie parallel, flat, planar, or along each other as described above. Accordingly, no one layer or membrane generally has a portion that crosses itself in a plane perpendicular to that layer or membrane surface at any given location in the collapsed configuration.
As shown in the expanded configuration, FIG. 4B, four cells 440 traverse the MLI from outer layer 402 to outer layer 404—two cells on each side of the intermediate layer 406. The MLI 400 deploys in a similar manner as that of MLI 100 described above. The outer layers 402 and 404 generally move away from each other perpendicular to the plane of the respective layers, but translate minimally within the plane relative to each other. Thus, the MLI 400 deploys by merely expanding the outer layers. The intermediate layer 406, however, translates along the plane of the layers such that it traverses longitudinally along the MLI. The respective relative motion of each of the layers is indicated by arrows on FIG. 4B. It should be noted that the indicated motion is relative, such that it is understood that the intermediate layer 406 may be kept stationary and the outer layers translate longitudinally in the same direction by approximately the same displacement, or other corresponding combinations of relative motion. The cellular configurations as described above and herein may be incorporated with the multiple cellular configuration of FIG. 4. Therefore, the layers and membranes may comprise different adjacent separation distances resulting in different insulative qualities and corresponding collapsed or storage dimensions and volumes.
FIGS. 5-9 illustrate exemplary embodiments to create the multi-cellular layered MLI of FIG. 4. FIGS. 5-9 illustrate only one side of the MLI from the intermediate layer 406 to the outer layer 402; the opposing side may be the mirror image of that shown to create the MLI illustrated in FIG. 4, duplicated and translated across the intermediate layer 406, or may be offset or substituted by any other disclosed embodiment. Therefore, the embodiments of FIGS. 5-9 may be used alone, in conjunction, combination, or sub-combination, with any of the described embodiments. For example, to one side of the MLI may be a single layer cell configuration of FIGS. 1-3, while the opposing side of the MLI may be any one of the FIGS. 5-8 embodiments. The membranes and/or layers may be configured such that the outermost layers are separated from the intermediate layer by an approximately equal amount, thus maintaining the outer layers relatively stationary in-plane during deployment. Other separation distances may similarly achieve the preferred relative in-plane stationary configuration of the outer layers. However, the outer layers need not necessarily deploy outwardly only, but may translate in an in-plane direction as well.
FIG. 5 illustrates an exemplary embodiment in which the multi-layered cells on one side of the intermediate layer 406 are created by a separate membrane 409 a connecting adjacent membranes 408. Accordingly, FIG. 5 is similar to FIG. 1 described above, but with the extra connecting membrane between adjacent membranes.
In the expanded configuration, the outer layers 402 and intermediate layer 406 are generally planar and parallel. Membranes 408, 410 extend from opposing sides of the intermediate layer generally perpendicular thereto in opposing out of plane directions but in the same in plane direction. The connecting membrane 408 connects adjacent membranes and is generally parallel to the outer and intermediate layers. Each of the membranes 408, and 409 a may have opposing end portions that run along and overlap the layer or membrane in which it connects. Therefore, for connecting membrane 409 a, end portions extend generally along the surface of adjacent membranes 408. The end portions of the respective membranes may be used as the connecting surfaces to connect the membrane to the respective layer and/or membrane. The separation of the membranes 408 from an adjacent membrane may be approximately half the length of the membrane or distance between the intermediate layer 406 and the outer layer 402. The connecting membrane 409 a may approximately bisect the membrane 408 to create cells of approximately equal cross-sectional shape and size.
In the contracted configuration, each of the layers and membranes generally align and overlap to minimize the out of plane dimension and reduce the overall storage volume of the MLI. The connecting ends of the membranes extend in opposing directions on adjacent layers and/or membranes such that when contracted, the membrane flattens along its length. The thickness, or out of plane dimension of the MLI in the contracted state in an exemplary embodiment is 5-15 times the thickness of any one layer or the average of the layers. In exemplary embodiments, the MLI thickness in the contracted state at any one point is generally the thickness of the sum of the layers traversed at the point. An error associated with the material thickness may be on the order of the thickness of 1-2 materials layers, or 5-10% of the overall MLI thickness.
Additional cell layers may be added by incorporating more connecting membranes 409 a between adjacent membranes 408. The thickness or out of plane dimension in the contracted configuration is preferably less than three times the number of cell layers between outer layers times the material thickness of any one layer or the average material thickness.
Alternative configurations are contemplated consistent with the disclosures above in which cellular sizes and/or cross sectional shapes are not uniform across the MLI. For example, the outer cellular layer toward the outer layer may be larger or smaller than a cellular layer toward the intermediate layer. The cellular sizes may also vary across the MLI and/or outwardly. Thus, various combinations of cellular sizes are contemplated and incorporated herein as necessitated by the application, material and dimensional constraints, etc.
FIG. 6 illustrates an exemplary embodiment in which multiple cellular layers are created by interconnecting membranes 408 along their length to adjacent membranes. This configuration reduces the overall out of plane dimension in the contracted configuration as compared to FIG. 5 by eliminating the additional material overlap created by the connecting membrane 409 a. Thus, a portion of the membrane 409 b acts as the connecting membrane 409 a described above with respect to FIG. 5. In the deployed configuration, the membrane 408 forms a stepped cross section such that portions of the membrane 408 extends out of plane from the intermediate layer 406 and portions of the membrane 409 b extend generally parallel with the intermediate layer 406. When expanded, the end of the membrane connected to the intermediate layer is displaced longitudinally from the end of the membrane connected to the outer layer. The number of attachments to adjacent membranes dictates the number of cellular layers. As described above, the cells may have any configuration of size and/or shape across the MLI. However, the attachment locations between adjacent membranes preferably do not overlap in a collapsed configuration to permit access during manufacturing. By sufficiently spacing the adjacent attachment positions relative to the length of the membrane, the attachment positions may be accessible when the inner cellular structure is collapsed. The attachment of adjacent membranes may then be achieved to create the inner cellular structure without needing to move portions of the membrane material out of the way during attachment of individual locations. Therefore, mass manufacturing can be more easily achieved.
FIG. 7 illustrates an exemplary embodiment similar to FIG. 1, but with the membranes 408 and outer layer 402 duplicated around the intermediate layer 406. Therefore, the membrane 409 c separating cellular layers is another layer between the intermediate layer 406 and the outer layer 402. The intermediate layer 406 is connected by membranes 408 to the separation layer 409 c, which is then connected by membranes 408′ to the outer layer 402. The membranes 408, 408′ extend outwardly from the separation layer 409 c and along the separation layer 409 c in opposing longitudinal directions. Alternatively the membranes 408, 408′ extend outwardly from the intermediate layer 406 in the same in-plane, longitudinal direction. Therefore, to deploy the MLI from the collapsed configuration, the intermediate layer 406 translates in plane in one direction, while the separation layer 409 c and outer layer 402 translated outwardly away from the intermediate layer 406 and in plane in a direction opposite the first direction, as indicated by the arrows on FIG. 7.
The membranes 408, 408′ may be aligned across the separation layer 409 c such that the seams align and can be simultaneously bonded. Alternatively, the membranes 408, 408′ may be offset and configured in various configurations, with any combination of separation distances between intermediate layer and separation layer, separation layer and outer layer, or adjacent membranes 408, 408′.
FIG. 8 illustrates a multilayer cellular MLI in which a separation layer 409 d is added similar to FIG. 7 above. However, the connecting membranes 408, 408′ are in the same in plane direction around the separation layer 409 d. Accordingly, to deploy the MLI of FIG. 8, the outer layers 402, 404 and the intermediate layer 406 are translated in a first direction, while the separation layer 409 d is translated in an opposing direction, as indicated by the arrows. As the MLI is traversed from one outer layer 402 to the opposing outer layer, connecting membranes of sequential cellular layers are directed in opposing in-plane directions. Similar to other embodiments discussed herein, the separation distances between connecting membranes or between layers may be tailored as desired to create one or more unique cellular patterns within one or more unique cellular layers. The separation distance between layers is preferably selected such that the outer layers 402, 404 need not translate in plane with respect to one another during deployment. The separation layers and intermediate layer may translate by differing amounts to accommodate the cellular structure, while maintaining the outer layers relatively longitudinally stationary.
FIG. 9 illustrates an exemplary embodiment in which each of the membranes 408, 408′ and 409 e comprise individually and separately connected segments. This configuration permits optimal material selections as each segment may be independently configured. However, the overlapping seam is thicker and therefore adds to the overall out of plane dimension in the collapsed configuration. The seams may be offset such that membranes 408, 408′ may be coupled to an intermediate portion of connecting membrane 409 d, thus reducing the out of plane dimension in the collapsed configuration. In one embodiment, the seams may be staggered such that the out of plane dimension is maintained generally uniform across the MLI. Separating the membranes and/or layers into discrete sections between cells may be applied to any of the disclosed embodiments to one or more cellular structures, layers, membranes, etc.
The configurations of FIGS. 5-8 generally have adjacent membranes along the outer layer directed in the same linear direction with respect to the outer layer. For example, each membrane has an attachment segment that is coupled to the outer layer. The attachment segment has a terminal end and an opposing end extending into the connecting portion of the membrane. The connecting portion either traverses between layers or between adjacent membranes. As shown, each terminal end of each membrane connected to an outer layer is directed in a first direction. The connecting portion then extends from the attachment segment in a second direction opposite the first direction. In an exemplary embodiment, the MLI may have two outside layers, and the membranes coupled to an interior surface of the outside layers have a terminal end of the attachment segment in a first direction, which extends to a connecting portion from the outside layer toward the interior of the MLI in a second direction, generally opposite the first direction. In an exemplary embodiment, at least one intermediate layer includes membranes coupled to opposing sides directed in the same direction. Therefore, the respective terminal ends of the attachment segment coupled to the intermediate layer on opposing sides of the intermediate layer are in a third direction, while the opposing end extending into the connecting portion of the membrane is in a fourth direction opposite the third direction. This uniformity of direction assists in deploying the MLI by encouraging interior layers and/or membranes to translate with respect to the outer layers, while maintaining the outer layers relatively stationary with respect to each other. The described movement and directions are linear directions along a plane of the MLI, such as, for example, the axis x, from FIG. 1A. The translations of the membranes may have components in other directions, including out of plane directions, as well as the directions disclosed.
FIG. 10 illustrates an exemplary embodiment in which each of the membranes 408″ are integrally connected. Therefore, spaced first portions of the membrane 408″ are directed generally perpendicular to the outer layers 402, 410 and intermediate layer 406, while second portions disposed between adjacent first portions are aligned with a corresponding portion of either the outer layer 402 or intermediate layer 406. The first and second portions being integrally formed and linear extensions of the same material sheet. This configuration permits easier manufacturing as the layers and membranes may be spooled and joined at respective locations sequentially. This membrane 408″ is configured to be generally aligned with the respective outer layers and intermediate layer in the collapsed configuration in an overlapping manner. Therefore, adjacent segments of the membrane lay flat along the respective segment in the collapsed configuration, but overlap adjacent segments.
This configuration is unique from the other configurations in that adjacent connecting membranes are not orientated in the same direction along the outer layer. If the connecting portions of the membrane are considered individually, e.g. the section within oval of FIG. 10, then the attachment portions of adjacent connecting membranes extend in opposing directions between adjacent membranes from the outer layer. This configuration therefore, may benefit from the deployment methods using outside force, deployment retention structures, or supporting segments to transition and maintain the MLI to and in the deployed configuration.
Given the flexibility of the MLI in an exemplary embodiment, it is understood that the directions and orientations described herein may be approximations. If the MLI is sufficiently rigid, the membranes and/or layers may maintain sections that are generally linear along portions thereof in either the collapsed or deployed configuration. Alternatively, if the MLI is more flexible, then the membranes may transition between orientations in a more smooth or serpentine manner. Therefore, the description of zig-zag, linear, planar, parallel, and/or perpendicular, for example, is intended to encompass an MLI of more linear segments or more serpentine transitions. Therefore, it is understood that if one section of the MLI transitions through or approximates the given orientation, it is intended to be encompassed within that description. Variations depending on the flexibility of the material and the transitions between configurations is intended to be broad and within the scope of the present description.
FIGS. 10-13 illustrate exemplary methods of deploying embodiments as described herein. Embodiments of the MLI may be deployed passively or actively. The MLI may be deployed and maintained in a given configuration by gravity, an externally applied force, an internal support, inflation, etc. The various methods may be used in conjunction to deploy and/or maintain the MLI in a chosen configuration. FIGS. 10-12 illustrate exemplary applications for insulating one or more surfaces of a tent, while FIG. 13 illustrates an exemplary application to a sleeping mat. The applications are not intended to be limiting, as embodiments as described herein may be used in various applications for reusable or single use insulation with a low storage volume. The exemplary deployment methods are provided in terms of the MLI of FIG. 1. It is understood that the below description depends on the configuration of the various layers and membranes, such that different layers would be translated or held stationary as dictated by the given configuration. Thus, for example, the configuration of FIG. 8 would translate the intermediate layer 406 in the same manner as the outer layers described below, while the separation layer of 409 d is translated in an opposing manner, i.e. in the same manner as the intermediate layer described below.
When in the relaxed or storage state, the panel lies flat with no observable cellular structure. However, when deployed (by translating the outer surfaces in one direction and the inner sheet in the opposite direction, the insulation is deployed) the cellular structure can be seen. Exemplary multi-layer insulation panels in the relaxed or stored state and in the deployed state are provided herein. The disclosed deployment method differs from the previous known MLI structures. In prior MLI structures, the inner panel is absent such that deployment occurs when the outer two surfaces are translated in opposite directions.
FIG. 11 illustrates an exemplary method of deploying the MLI using gravity. This method is particularly suited when the MLI is used for a vertical, or highly sloped surface, such that one end of the MLI is higher than an opposing end of the MLI. In this configuration, the intermediate layer is coupled to an external support. The external support may be part or attached to the tent or structure to be insulated or separate therefrom. The intermediate layer may include a connection system, to attach the intermediate layer to the external support. The connection system may include tether, snaps, buttons, cord, hook and/or loop, Velcro®, etc. The outer layer toward the support structure is maintained generally stationary through the frictional contact with the support structure, while the intermediate layer is pulled upward and connected to the support structure. The movement of the intermediate layer deploys the MLI against the support structure. Alternatively, the intermediate layer may be connected to the support structure, while the outer layers are drawn downward by gravity. The MLI is then deployed when the outer layers translate downwardly.
FIG. 12 illustrates an exemplary embodiment in which external forces are applied to deploy and maintain the MLI in an expanded configuration. The MLI may include a connection system at opposing ends at the intermediate layer and/or outer layers such that the relative in plane position of the intermediate layer and outer layers may be maintained. This configuration is particularly suited for horizontal surfaces or in conditions that may interfere with the gravitational orientation of FIG. 10, such as high winds, etc. As shown, the outer layers may be individually or jointly connected to a support structure at one end. The intermediate layer may then be translated in an in-plane direction opposite the connection end of the outer layers. The translation of the intermediate layer raises the intermediate layer and the top outer layer, thereby expanding the MLI. The intermediate layer may then be connected at an opposing end to that of the outer layer connections to maintain the MLI in the deployed configuration. The connection system may be configured to apply an external force by pulling or pushing on the respective layers. The connection system may be on the same end or opposing ends of the MLI for each layer depending on the configuration. The membranes and/or layers may be sufficiently rigid to support the MLI in the expanded configuration. Preferably, the membranes and/or layers are also relatively flexible to permit manipulation, such as rolling or contouring of the MLI to the structure to be insulated, in either the collapsed or expanded configuration.
FIG. 13 illustrates an exemplary embodiment in which the MLI includes an internal support structure to deploy and/or maintain the MLI in an expanded configuration. For example, connecting supports may be included between the intermediate layer and the outer layer to maintain the relative position of the layers in the deployed configuration.
As seen on the right side of FIG. 13, a first support 1220 may connect between the outer layers 1202, 1204. The support may bend as indicated by the dotted line in the collapsed configuration. As shown, the interior portion of the support is positioned away from the intermediate layer in the collapsed configuration. When the support 1220 is extended, the support structure may be configured such that it does not bend in a direction opposite the stowed direction. Thus, the support structure has two configurations, a collapsed, bent configuration and an extended straight configuration. The support structure is therefore not configured to bend in an opposing direction from the collapsed configuration. The support structure therefore maintains a generally linear cross section when extended. The support 1220 may include one or more structures to attach to the intermediate layer 1206. The intermediate layer 1206 may also or alternatively include one or more corresponding connection structures. The intermediate layer 1206 may impose a force of the support structure, thereby maintaining the support structure in the expanded configuration, and maintains the relative in-plane configuration of the layers in the deployed configuration. The structure 1220 may provide the support to maintain the relative in-plane orientation of the layers with respect to one another to maintain the MLI in the deployed configuration and/or may provide support to the outer layers to maintain the out of plane separation of the one or more layers.
The support structure 1220 may be permanently or removably attached to the outer layers and/or intermediate layer. For example, the support structure may be bonded, welded, sewn, glued, or otherwise permanently attached to the outer layers. The intermediate layer may be removably coupled through buttons, snaps, hook and loop, Velcro®, etc., or may be permanently but variably coupled through, for example, an elastic tether, pull cord, or tightenable threaded seam.
As seen on the left side of FIG. 13, an exemplary support structure may include a frame 1222 may be used to support the MLI in the expanded configuration. The frame may be inflatable such that it expands and separates the outer layers when inflated. The frame may include one or more connection systems to maintain the intermediate layer relative to the outer layers in the deployed configuration. The frame may also be separately connectable to the one or more layers of the MLI. The frame may extend along one or more sides of the MLI, or may inscribe the entire perimeter of the MLI to support the MLI along all edges.
The support structures may also be connected or connectable between adjacent layers. The support structures may be, for example, removably attached and/or permanently attached to one or more layers. The support structures may be sufficiently rigid to separate adjacent layers in the deployed configuration. The support structures may include one or more features to maintain the support structure in the desired orientation. The features may interact with other support structure features or may be configured to engage the layer directly. One or more locking mechanisms may also be included to provide additional support or to retain the support structures in the desired configuration. For example, a tether may be used between the outer layers that is sufficiently sized to traverse between the outer layers in the expanded configuration, but does not permit the outer layers to translate away from the end of the MLI with the tether. The locking feature may be between support structures to lock the intermediate layer in relative position with respect to the outer layers with the supports separating the respective layers.
The support structures may extend along the length of the MLI to provide a continuous support across the MLI. Alternatively or in conjunction, one or more discrete support structures may be positioned along or throughout the MLI at accessible locations to retain and support the MLI in a deployed configuration. The support structures may also be used to maintain the MLI in the collapsed configuration, or in a stowed configuration. For example, the connection of the support structure to one or more layers may be disengaged to collapsed the MLI and re-engaged with a separate or the same corresponding connection when the MLI is collapsed and or configured in a stowed configuration, for example, rolled up.
The support structures may be integrated into one or more of the membrane structures, such that the membranes translate between a collapsed configuration parallel to the layers to an expanded configuration generally perpendicular to the layers. The membranes may be sufficiently rigid to support the layers in the expanded configuration. The membranes may include one or more locking mechanisms to maintain the membranes in the expanded configuration. The layers may also be made flexibility rigid to assist in deploying and or maintaining the MLI in the expanded configuration while permitting the MLI to be reconfigured in a stowed configuration separate from the collapsed configuration. For example, the stowed configuration may comprise the collapsed configuration roll-up to reduce a second dimension of the MLI volume.
FIG. 14 illustrates an exemplary MLI deployed through inflation. The outer layers may be directly or indirectly connected to seal the interior of the MLI and maintain an inflation pressure to deploy and maintain the MLI in the expanded configuration. The MLI may include one or more ports 1320 to inject air or other suitable gas. The port 1320 may include a cap or closable structure to seal the interior of the MLI. In an exemplary embodiment, the outer layers may include a border that extends past the intermediate layer in both the collapsed and expanded configuration around the perimeter of the MLI. The outer layers are then directly connected at the perimeter of the outer layer border regions. The intermediate layer is free to translate in plane, when the outer layers separate out of plane. The in-plane relative position of the outer layers is maintained from the collapsed to the expanded configuration. The outer layers separate out of plane to deploy the MLI when air is injected through the port. In the collapsed configuration, the respective layers and membranes are configured generally planar and parallel, thus reducing the out of plane dimension of the MLI.
In an exemplary embodiment, the outer layers and/or membranes may inflate, providing the support pressure for the MLI. Therefore, instead of air pressure within the cellular structure used to maintain the layers and membranes in the expanded configuration, the air pressure is within the membrane and/or layers directly.
Embodiments as described herein permit an easier assembly process and the use of different materials. For example, exemplary MLI geometries disclosed herein permit the inner matrix to be made from polymer-coated nylon (PCN) with an adhesive film because the individual seams are accessible during assembly for techniques such as heat sealing or RF welding. Previous known designs include overlapping and alternating seams that are inaccessible during assembly making these sealing techniques more difficult. Instead, these configurations require individual gluing of seams that is labor and time intensive. The configuration of FIG. 5 is particularly suitable for mass manufacturing as the individual seams are easily accessible during assembly for techniques such as heat sealing or RF welding.
Embodiments as described herein incorporate a cellular insulation design based on the theory that air is a good insulator (poor conductor) and heat travels poorly within an air medium. Additionally, the cellular walls formed within the panel serve to break up the convective eddies which transfer heat from one side of the structure to the other. The thin membranes offer a very small conductive path from the inner and outer surface, further retarding energy flow and enhancing the insulation capabilities. The metalized membranes also reflect heat, substantially limiting radiational heating. The matrix is easily formed and lends itself well to mass production and automated manufacturing processes, such as heat sealing, RF welding, and other techniques.
The manufacturing and assembly process of the MLI structure increases the number of possible materials used in its construction; namely polyurethane (and other polymers) coated rip-stop nylon (PCN), silicon-coated nylon, as well as other heat sealable and RF weldable materials. PCN is used extensively in recreational camping products on the market due to its durability and lightweight characteristics. The polymer coating makes the nylon impermeable to air, water repellant and heat sealable (uncoated nylon is used when breathability is required). These characteristics are ideal for inflatables, such as sleeping pads, and resisting air flow as used in the MLI structure. Disposable embodiments are also contemplated in which the MLI may be configured from disposable, cheap, and/or lightweight materials, such as paper or cardboard. Exterior and or interior surfaces of the MLI may also comprise different materials or coatings for added functionality, such as weather resistance, wind resistance, water-proofing, easy cleaning, reflective, etc.
In an exemplary embodiment, the layers are comprised of a PCN material with a density ranging from 1-12 grams (gm)/square yard(yd²), with a preferred density of 1.5 to 3 gm/yd²for the inner layer and 3 to 6 gm/yd²for the outer layers, depending on strength and durability requirements. The nylon is also available in many different colors for different aesthetic designs. The cellular structure between the nylon layers is comprised of a metalized polymer film in the range of 0.5 to 5 millimeters (mils) (12 to 127 microns). The metal coating is typically aluminum, but other reflective metal coatings are possible; the metallization acts as a reflector of radiation, reducing heat transfer. The polymer film can be mylar, kapton, polyurethane, polypropylene, etc. The insulation value of the MLI structure with thickness consisting of 4 cells of aluminized mylar has been measured at R-9.6, where units of R are: ft²hours ° F./Btu. The total thickness in the collapsed configuration of the 4 cell construction is preferably approximately 1 mm or less, 2 mm or less, or may be 0.5-5 mm.
FIG. 15 illustrates an exemplary method of manufacture based on the configuration of FIG. 5 in which successive seams are accessible during the bonding process. In a first step, 1402, the inner matrix may be configured by bonding connecting membranes between adjacent membranes. An adhesive material may be applied along an exterior edge of one or both facing surfaces of adjacent membranes. Alternatively or in addition thereto, the membranes may be aligned and then heat sealed, RF welded or otherwise bonded along the seam. In an exemplary embodiment, the membrane lengths are selected such that membranes overlapping at the seam are intended to be coupled as part of the seam. Therefore, individual orientation of membranes to access a given seam is unnecessary. Although, the configuration of FIG. 1 MLI is used to illustrate the present method of manufacturing, the other embodiments may similarly take advantage of the present method. For example, as described above with respect to FIG. 6, the inner cellular matrix may be made by attaching adjacent membranes together in which the attachment location is accessible by selecting the bonding location relative to the membrane length. At step 1404, the inner matrix may then be coupled to an outer layer sequentially. As illustrated, the first bond may occur at A and proceed to C such that the bonding surface is directly accessible by separating the inner matrix from the outer layer and bringing successive membranes into contact with the outer layer. At step 1406, the intermediate layer may be coupled to the inner matrix on opposing sides in a similar fashion such that sequential seams are directly accessible during manufacturing. Steps 1404 and 1406 can be switched and still provide the same accessibility to the respective seams during manufacturing.
The MLI may be configured such that the membranes and/or layers are self supporting. Therefore, the translation of the one or more layers with respect to each other orients the one or more membrane out of plane from the one or more layers. The out of plane membrane may be sufficiently stiff such that the membrane supports the separation of the layers and does not fold, or buckle, thereby creating the internal cellular structure. Alternatively, an internal or external frame or support structure may be imposed to separate the respective layers. The required stiffness of the membranes may be dictated by the respective applications. For example, an MLI supported vertically such that gravity translates the respective layers into the deployed configuration requires less rigid membranes than an MLI deployed horizontally, in which the membranes must support the full weight of the respective one or more layers. As such, the material selection may depend on the desired application, required storage volume, and insulation requirements. Accordingly, the membranes and/or layers may be rigid such that they translate from the collapsed configuration to the expanded configuration without much flexibility along the surface. The connections between layer and membrane may comprise segments that act like hinges to deploy the MLI. The rigid material therefore self-supports the structure in both the collapsed and/or expanded configuration. The MLI material may also be semi-rigid such that it can support the MLI in either the collapsed or expanded configuration but still provide flexibility to the MLI to conform to a structure to be insulated or to be reconfigured into different storage configurations such as by folding or rolling. The MLI material may also be flexible and not self-supporting such that the MLI material can be fully manipulated, folding, oriented, configured, conformed, rolled, etc. The MLI may therefore use a deployment structure to support the MLI in a given collapsed and/or expanded configuration.
The MLI may also be biased in either the collapsed or expanded configuration to maintain a desired orientation. Alternatively, the MLI may be passive in that it maintains whatever configuration positioned and does not tend to transition to a biased configuration. The MLI may also include one or more external or internal mechanism to lock or maintain the MLI in a chosen configuration.
In an exemplary application, the thermal insulation described herein may be used with camping tents and sleeping pads that are collapsible to a flat form factor for easy packing and transport. The module is lightweight and can be expanded and folded thousands of times without degradation. It can be designed for utilization with any shape tent since modules can conform to the interior walls.
For smaller, lightweight tents, the MLI can be designed to replace the traditional rain fly to provide thermal protection as well as moisture and wind protection. In this application, the MLI would use the existing tent structure as support and tent stakes to keep the MLI structure deployed. The deployment of the structure is very easy, allowing for a quick single person setup. This replacement would slightly increase weight and packaging size of the tent. However, it would afford the possibility of converting an existing three season tent into a comfortable lightweight four season tent.
For larger recreational and commercial tents, the MLI can be designed to be modular to insulate the inner lining of the tent. The modular panels may attach to the inner wall of existing tent structures, as well as each other, with, by way of example, light weight plastic buckles or Velcro®. In some embodiments, a lightweight webbing system would be used to accommodate large tent structures. For some applications, it may be useful for the MLI modules to be permanently integrated into the tent walls.
The MLI structure can be formed into a sleeping pad to provide comfort and insulation for camping and other activities. The edges of the module will be hermetically sealed to maintain air pressure, and the pad is inflated with either an air pump or by blowing into a connective air tube.
MLI modules can be used to control internal conditions during extreme temperatures in portable structures, such as pop-up campers, temporary buildings at construction sites and outdoor events like surfing competitions, marathons, golf tournaments, ceremonies and festivals. In particular, pop-up campers are not comfortable on extremely hot or cold days, when additional deployable insulation could make conditions inside much more livable. The low storage volume and ease of deployment of custom-shaped MLI modules can make pop-up campers comfortable year round. Similarly, MLI can be modified to form insulating boat tops or covers, ice fishing shanties, portable latrines, etc.
In addition to applications for tents and sleeping pads, the MLI has other numerous applications where the thermal environment needs to be controlled. In the area of packaging, compact foldable MLI containers can be used to keep produce, drinks, and frozen foods cool during transport, for example, from market to home, to picnics, for boating excursions, school bag lunches, etc. Conversely, MLI containers can keep hot foods warm, for example, for pizza delivery or take-out food orders. Such containers are compact and lightweight enough that they can be easily folded away after usage, kept in auto glove compartments, trunks or under seats, and carried in purses or backpacks.
The MLI design can be modified for outdoor wearing apparel, such as gloves, hats, pants, parkas, etc. It can also be used to construct emergency blankets and small shelters for people stranded on the roadside or hikers in the wilderness during extreme weather. Possible modifications to make the MLI self-expanding, self-inflatable or air-inflatable to maintain a specific deployed shape can be used to make it practical for many of these applications. Alternatively, the MLI could be fixed or stabilized in the deployed, expanded state, by way of example, with supports, springs, hinges, or other various devices and materials in order to maintain its deployed shape during use. Such devices can include an air bladder system that would form a frame around the panel to keep it deployed. One method would be to utilize compressed gas like small CO₂canisters used in the bicycle and paintball industries for such inflation.
MLI modules can be adapted for use in the construction industry to replace existing insulation products where installation can be difficult or costly. For example, MLI modules can be attached with fasteners to the underside of the roof in attics, instead of laying rolls of fiberglass batts between the joists, or between studs in outside exposed walls. Removable MLI modules can also keep doghouses cooler in the summer and warmer in the winter, but are easily removed during temperate seasons.
Although embodiments of this invention have been fully described with reference to the accompanying drawings, it is to be noted that various changes and modifications will become apparent to those skilled in the art. Such changes and modifications are to be understood as being included within the scope of embodiments of this invention as defined by the appended claims. Specifically, a number of exemplary configurations are disclosed, which may be used in any combination, recombination, subcombination, in which elements may be duplicated, repeated, added, and/or removed. As such, different layers of the MLI may include configurations of different embodiments, or a cellular structure between outer layers may include for example, 2-6 cellular layers by duplicating or incorporate different cellular layers around, for example, one or more intermediate layers. A single cellular layer may also be composed between outer layers in configurations consistent with embodiments described herein. For example, the intermediate layer of the disclosed MLI is configured essentially as the outer layer and the second or additional cellular layers are removed.
Moreover, exemplary embodiments are generally described herein in terms of layers and membranes, where layers constitute a substantial size or orientation of the Mil, with the membranes being intermediate or connecting portions between layers or between other membranes. However, the terms membrane and layer may be used interchangeably such that a membrane may compose a described layer or a layer may be composed of membranes. As such, no distinction is intended in terms of thickness, size, or orientation with respect to the usability of the terms membrane and layer. Also, as used in the claims, numerical references are provided for a first, section, third, and fourth objects. These references are intended only to distinguish one object or function from another and does not denote an actual numerical requirement of objects. Therefore, if the same feature otherwise meets the recitations of the claims, it is intended to be encompassed by the claims without requiring different numerical objects, unless otherwise specifically required.

Claims

What is claimed is:

1. An insulation panel, comprising:

two outer surfaces; and

a plurality of membranes connected to the outer surfaces, the insulation panel configured to translate from a stored configuration, in which the outer surfaces and plurality of membranes are generally aligned, to a deployed configuration, wherein the panel is configured to deploy by translating the outer surfaces outwardly from one another without an associated relative in-plane translation relative to the other.

2. The insulation panel of claim 1, wherein the outer surfaces and membranes are aligned generally flat in a collapsed configuration to minimize the thickness of the insulation panel and reorient to form a layered cellular structure in a deployed configuration.

3. The insulation panel of claim 2, further comprising an intermediate layer between two outer layers defining the two outer surfaces.

4. The insulation panel of claim 3, wherein a plurality of membranes connect the intermediate layer to the outer layers, the membranes configured to translate the intermediate layer generally parallel to the two outer layers when transitioning from the collapsed configuration to the deployed configuration.

5. The insulation panel of claim 4, wherein the plurality of membranes are coupled to the intermediate layer at one end of the membrane and extend out of plane, away from the intermediate layer on opposing sides of the intermediate layer to an outer end of the membrane in the deployed configuration; and in the stored configuration, the membranes extend in the same in plane direction relative to the intermediate layer from the one end to the outer end.

6. The insulation panel of claim 5, wherein the inner cellular structure is formed from thin flexible membranes which form two to six air cell layers between the outer surfaces.

7. The insulation panel of claim 6, further comprising one or more connecting membranes between adjacent membranes to create the inner cellular structure of four to six air cell layers.

8. The insulation panel of claim 7, wherein each of the outer layers, intermediate layer, membranes, and connecting membranes are configured to not overlap itself in a plane perpendicular to a plane of the panel.

9. The insulation panel of claim 8, wherein each of the outer layers, intermediate layer, membranes, and connecting membranes are configured to not overlap itself in a plane perpendicular to its own surface.

10. A multiple layered cellular insulation structure comprising:

a first outer layer;

a second outer layer;

an intermediate layer between the first outer layer and second outer layer;

a first plurality of membranes connected between the intermediate layer and the first outer layer;

a second plurality of membranes connected between the intermediate layer and the second outer layer;

the multiple layered cellular insulation configured to translate from a collapsed configuration to an expanded configuration by a relative movement of the first and second outer layers in a first direction, and the relative movement of the intermediate layer in a second direction opposite the first direction, wherein an inner cellular structure is defined by the first outer layer, second outer layer, first plurality of membranes, second plurality of membranes, and intermediate layer in the deployed configuration.

11. The multiple layered cellular insulation structure of claim 10, wherein the first outer layer, second outer layer, first plurality of membranes, second plurality of membranes, and intermediate layer are configured to lay generally flat in the collapsed configuration.

12. The multiple layered cellular insulation structure of claim 10, further comprising a third plurality of membranes connected between adjacent first plurality of membranes, and a fourth plurality of membranes connected between adjacent second plurality of membranes.

13. The multiple layered cellular insulation structure of claim 12, wherein each of the first, second, third, and fourth plurality of membranes are configured to lay adjacent another layer or membrane along its entire length and not contact itself along its length.

14. The multiple layered cellular insulation structure of claim 13, wherein the first and second plurality of membranes are oriented in a generally zig-zag shape in the deployed configuration, such that a first and second terminal end of each membrane is aligned with the intermediate layer, and an interior section of the membrane is directed generally perpendicular thereto; wherein the first and second terminal ends and the interior section of each of the membranes are generally parallel in the collapsed configuration, with the first terminal end connected to the intermediate section and the second terminal end extending in the same direction along the intermediate layer.

15. The multiple layered cellular insulation structure of claim 10, further comprising a second and third intermediate layer between the intermediate layer and the first outer layer such that the multiple layered cellular insulation structure is configured to translate from the collapsed configuration to the deployed configuration by translating the first and second outer layers and the second intermediate layer in a first direction and the intermediate layer and third intermediate layer in a second direction opposite the first direction, the intermediate layer positioned between the second outer layer and the second intermediate layer and the third intermediate layer positioned between the first outer layer and the second intermediate layer.

16. The multiple layered cellular insulation structure of claim 10, further comprising a second intermediate layer between the intermediate layer and the first outer layer and a third intermediate layer between the intermediate layer and the second outer layer, the multiple layered cellular insulation structure configured to translate from the collapsed configuration to the deployed configuration by moving the first and second outer layers and the second and third intermediate layers in a first direction and the intermediate layer in a second direction opposite the first direction.

17. A method of insulating an area, comprising:

providing an insulation panel comprising two outer layers, and intermediate layer, and membranes connected between the intermediate layer and outer layers to form a layered cellular structure in a deployed configuration;

collapsing the insulation panel to a collapsed configuration in which the outer layers, intermediate layer, and membranes generally align such that a thickness of the insulation panel is minimized in the collapsed configuration; and

expanding the insulation panel to a deployed configuration by separating the outer layers to form the cellular structure.

18. The method of insulating the area of claim 17, wherein the insulation panel is expanded by separating the outer layers out of plane away from each other without needing to translate the outer layers in a plane relative to each other, and translating the intermediate layer in a direction parallel to the outer layers.

19. The method of insulating the area of claim 18, wherein the outer layers, intermediate layer, and membranes are configured in the collapsed configuration such that each does not cross a plane perpendicular to its own surface.

20. The method of insulating an area of claim 17, wherein the insulation panel is deployed by imposing an outside force to translate the intermediate layer relative to the outer layer.

21. The method of insulating an area of claim 17, wherein the insulation panel is deployed by gravity.

22. The method of insulating an area of claim 17, wherein the insulation panel is deployed by inflating the panel.