Patent Description:
Insulating panels in blankets and garments may include a layer of insulating particles. The insulating particles may comprise feathers, down, natural and synthetic fibers or combinations thereof. Laundering of the blanket or garment may result in the insulating particles escaping or protruding through stitch openings or other openings of the panels.

<CIT> discloses a baffled insulating garment panel according to the preamble of claim <NUM>, including a vacuum heat insulating material that is heat-welded so that a jacket material follows a core shape.

An aspect of the present disclosure relates to a baffled insulating garment/blanket panel comprising:.

The fourth wall may be secured to a trough bottom of the first wall. The fifth wall may be secured to a trough bottom of the third wall.

The trough top of the second wall may be secured in a closed state.

The trough top of the second wall may be concealed, for example by the third layer. The fourth wall may have a trough bottom. The fourth wall may have a trough top. The trough top of the fourth wall may be secured in a closed state.

The trough top of the fourth wall may be concealed, for example by a fourth layer of the baffled insulating garment/blanket panel.

The baffled insulating garment/blanket panel may further comprise a second insulating particle layer. The second insulating particle layer may have a portion continuously extending between the fourth wall and the fifth wall. The portion of the second insulating particle layer may be sandwiched between the second layer and the third layer. The portion of the second insulating particle layer may span the trough top of the second wall.

The insulating particle layer may have a first thickness. The second insulating particle layer may have a second thickness. The second thickness may be less than the first thickness.

The first wall, the second wall, the third wall, the fourth wall and the fifth wall may be parallel.

The first wall, the second wall, the third wall, the fourth wall and the fifth wall may be configured to be horizontal when a garment comprising said baffled insulating garment/blanket panel is being worn.

The folds of the second layer may form a sixth wall. The sixth wall may have a trough bottom. The sixth wall may have a trough top. The sixth wall may be located between the second wall and the third wall. The insulating particle layer may comprise a third portion. The third portion may be between the second wall and the third wall. The third portion may be between the second wall and the sixth wall. The third portion may be sandwiched between the first layer and the second layer. The trough bottom of the sixth wall may be secured adjacent to the first layer. A portion of the third layer may span across the trough top of the sixth wall.

As noted above, the second insulating particle layer may have a portion continuously extending between the fourth wall and the fifth wall. The portion of the second insulating particle layer may be sandwiched between the second layer and the third layer. The portion of the second insulating particle layer may span the trough top of the second wall and the trough top of the sixth wall.

The second wall and the sixth wall of the second layer may be spaced from one another by at least <NUM>. The second wall and the sixth wall of the second layer may be spaced from one another by no greater than <NUM>.

The walls of the second layer may have a height of at least <NUM>. The walls of the second layer may have a height of no greater than <NUM>.

The fourth wall and the fifth wall may be spaced by at least <NUM>. The fourth wall and the fifth wall may be spaced by no greater than <NUM>.

One or more of the first wall, the second wall and the third wall may be secured to the first layer, for example a face of the first layer. The fourth wall may be secured to the first wall. The fifth wall may be secured to the third wall. One or more of the first wall, the second wall and the third wall may be secured to the first layer (for example, a face of the first layer) by a connector. One or more of the first wall, the second wall and the third wall may be secured to the first layer (for example, a face of the first layer) by stitching.

The fourth wall may be secured to the first wall by a connector. The fourth wall may be secured to the first wall by stitching. The fifth wall may be secured to the third wall by a connector. The fifth wall may be secured to the third wall by stitching.

The panel, following three laundering cycles, may lose less than or equal to <NUM> particles from the insulating particle layer per square meter of the panel. The panel, following three laundering cycles may lose less than or equal to five particles from the insulating particle layer per square meter of the panel.

Another aspect of the present disclosure relates to a method for forming a baffled insulating garment/blanket panel, the method comprising:.

The method may comprise securing the trough bottom of one or more of the first wall, the second wall and the third wall to the first liner. The method may comprise securing the fourth wall to the trough bottom of the first wall. The method may comprise securing the fifth wall to the trough bottom of the third wall.

The method may comprise stitching the trough bottom of one or more of the first wall, the second wall and the third wall to the first liner. The method may comprise stitching the fourth wall to the trough bottom of the first wall. The method may comprise stitching the fifth wall to the trough bottom of the third wall.

The method may comprise securing the trough top of the second wall into a closed state. The method may comprise securing a trough top of the fourth wall into a closed state. The method may comprise securing a trough top of the fifth wall into a closed state.

The method may comprise stitching the trough top of the second wall into a closed state. The method may comprise stitching a trough top of the fourth wall into a closed state. The method may comprise stitching a trough top of the fifth wall into a closed state.

The method may comprise forming a second insulating particle layer between the fourth wall and the fifth wall. The method may comprise forming a second insulating particle layer sandwiched between the inner liner and the layer, for example such that the second insulating particle layer spans across the trough top of the second wall.

It should be understood that the features defined in relation to one aspect may be provided in combination with any other aspect.

These and other aspects of the present disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying drawings described herein below, and wherein like reference numerals refer to like parts.

Disclosed are example baffled insulating garment/blanket panels and example baffled insulating garment/blanket panel forming methods that may provide a more aesthetically pleasing outer appearance and that may reduce the extent to which insulating particles protrude following laundering of a blanket or garment. The disclosed example insulating panels and panel forming methods may be used to reduce the total number of stitches in the panel while maintaining securement of an insulating particle layer. In some implementations, the example panels may include multiple insulating particle layers including a first insulating particle layer captured between a pair of consecutive walls (sometimes referred to as "baffles") and a second insulating particle layer that extends over and spans across a top of at least one of the consecutive walls. The second insulating particle layer assists in concealing the underlying wall and associated stitching.

<FIG> is a plan view illustrating portions of an example baffled insulating garment/blanket panel <NUM>. Panel <NUM> may be employed as part of a larger insulating blanket or garment. Examples of such a garment may include, but not limited to, a coat, jacket, vest, ski bib, pants or the like. Panel <NUM> is baffled, meaning that panel <NUM> comprises baffles or walls that form multiple internal compartments. The compartments contain insulating particles. Example of insulating particles include, but are not limited to, various forms of down and/or various forms of natural and/or synthetic fibers. As will be described hereafter, panel <NUM> has a construction or architecture that maintains the aesthetic attractiveness of the panel while reducing the likelihood of such insulating particles escaping or protruding through an exterior of the panel following laundering of the blanket or garment.

<FIG> illustrate an example garment <NUM>, in the form of a jacket, which comprises panel <NUM>. As shown by <FIG>, panel <NUM> comprises double walled baffles <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM> (collectively referred to as double walled baffles <NUM>) and single walled baffles <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> (collectively referred to as single walled baffles <NUM>). For purposes of this disclosure, a "baffle" refers to a structure that is configured to restrain the flow or movement of a loose material, such as insulating particles. Double walled baffles <NUM>-<NUM> and <NUM>-<NUM> and single walled baffles <NUM>-<NUM> form baffled region <NUM>. Double walled baffles <NUM>-<NUM>, <NUM>-<NUM> and single walled baffles <NUM>-<NUM>, <NUM>-<NUM> form baffled region <NUM>. Baffled regions <NUM> and <NUM> may differ in the density of baffle walls and/or the size of the baffled compartments.

<FIG> is a sectional view of baffled region <NUM> taken along line <NUM>-<NUM> of <FIG>. As shown by <FIG>, baffled region <NUM> comprises a first layer <NUM>, second layer <NUM>, insulating layer <NUM> and third layer <NUM>. First layer <NUM>, sometimes referred to as a liner, comprises a single continuous uninterrupted layer of fabric or other flexible material. First layer <NUM> cooperates with second layer <NUM> to form baffled compartments <NUM>-<NUM> and <NUM>-<NUM> (collectively referred to as compartments <NUM>). Each of compartments <NUM> contains a portion of insulating layer <NUM>. First layer <NUM> forms a floor (as seen in <FIG>) of both of compartments <NUM>. In some implementations, first layer <NUM> may serve as an innermost layer of a garment, such as garment <NUM> (shown in <FIG>) or an exterior layer of a blanket or other insulating structure. In some implementations, additional layers may be secured to layer <NUM> beneath layer <NUM> (as seen in <FIG>).

Second layer <NUM> comprise a single continuous uninterrupted layer of fabric or other flexible material. Second layer <NUM> extends on top of (as seen in <FIG>) and between compartments <NUM>. Second layer <NUM>, sometimes referred to as an inner liner, comprises folds <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM> (collectively referred to as inner liner folds <NUM>) which form trough-shaped walls <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM> (collectively referred to as trough walls <NUM>), respectively. Each of trough shaped walls <NUM> has a top <NUM> and a bottom <NUM>. Top <NUM> forms a mouth or opening of the trough-shaped wall <NUM> while bottom <NUM> forms the interior floor of the trough formed by the wall <NUM>. Although walls <NUM> are illustrated having generally flat or rectangular bottoms <NUM>, it should be appreciated that the folds may alternatively be figured such that walls <NUM> have rounded or V-shaped bottoms <NUM>.

Insulating layer <NUM> is sandwiched or captured between layers <NUM> and <NUM>. In some implementations, insulating layer <NUM> has a thickness of at least <NUM> and no greater than <NUM>, and nominally <NUM>. Insulating layer <NUM> is composed of multiple individual insulating particles <NUM> that capture air therebetween to form a layer of particles and air that inhibits the conduction of heat. Insulating layer <NUM> may be formed from a variety of different insulating particles <NUM> such as down and/or synthetic and/or natural fibers. Down refers to soft, fine fluffy feathers which may form a first covering the young bird or the insulating layer below the contour feathers of an adult bird. Down may also refer to other short hairs on plants or animals. Such down may be used alone or in combination with synthetic or natural fibers to form insulating layer <NUM>. Due to the size of down and/or fibers, panel <NUM> is vulnerable to such insulating particles <NUM> protruding through layer <NUM> or escaping from compartments <NUM>.

In some implementations, insulating layer <NUM> (each of its portions) comprises an <NUM> down fill power with an application of <NUM>/m<NUM>. In other implementations, insulating layer <NUM> may have other qualities or fill power and may have other grams per meter squared, such as down fills within the range of <NUM> to <NUM>/m2.

Insulating layer <NUM> comprises portions <NUM>-<NUM> and <NUM>-<NUM> (collectively referred to as portions <NUM>) which are captured and retained within compartments <NUM>-<NUM> and <NUM>-<NUM>, respectively. Portions <NUM> are spaced or separated from one another and from other portions of layer <NUM> by walls <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM>. Wall <NUM>-<NUM> extends between portion <NUM>-<NUM> and <NUM>-<NUM> and forms single wall baffle <NUM>-<NUM>. Single wall baffle <NUM>-<NUM> inhibits the flow of the insulating particles forming portions <NUM>-<NUM> and <NUM>-<NUM> between compartments <NUM>-<NUM> and <NUM>-<NUM>. In some implementations, the trough-shaped wall <NUM>-<NUM> and the single walled baffle <NUM>-<NUM> formed therefrom, extends in a generally horizontal plane when garment <NUM> is being worn to inhibit the vertical movement of the insulating particles of portion <NUM>-<NUM> in compartment <NUM>-<NUM> into the compartment <NUM>-<NUM> underlying compartment <NUM>-<NUM>.

Third layer <NUM> comprises a single continuous uninterrupted layer of fabric or other flexible material extending over second layer <NUM> (as seen in <FIG>). Third layer <NUM>, sometimes referred to as a self, comprises folds <NUM>-<NUM> and <NUM>-<NUM> which form consecutive trough-shaped walls <NUM>-<NUM> and <NUM>-<NUM> (collectively referred to as walls <NUM>), respectively. Walls <NUM>-<NUM> and <NUM>-<NUM> project into and are secured within walls <NUM>-<NUM> and <NUM>-<NUM>, respectively. Walls <NUM>-<NUM> and <NUM>-<NUM> overlap one another to form double walled baffle <NUM>-<NUM>. Walls <NUM>-<NUM> and <NUM>-<NUM> overlap one another to form double walled baffle <NUM>-<NUM>. Due to the multiple wall construction, double walled baffles <NUM>-<NUM> and <NUM>-<NUM> may have an increased thickness, an increased rigidity and an increased strength as compared to single walled baffle <NUM>-<NUM>.

As further shown by <FIG>, second layer <NUM> further comprises a bridge region <NUM> that is part of a single integral unitary body with walls <NUM>-<NUM> and <NUM>-<NUM>, wherein bridge region <NUM> continuously extends between walls <NUM>-<NUM> and <NUM>-<NUM>, spanning over and across a top (as seen in <FIG>) of the single walled baffle <NUM>-<NUM> formed by wall <NUM>-<NUM>. Bridge region <NUM> conceals the top <NUM> of the trough shaped wall <NUM>-<NUM>. As a result, even though the illustrated portion of panel <NUM> comprises three baffles, <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM>, third wall <NUM> presents an upper surface (as seen in <FIG>) in which just two tops or mouths of folds or trough-shaped walls (sometimes referred to as outer seams) are exposed. The overlapping architecture of panel <NUM> provides baffles of different thickness and strength along the various insulating particle containing compartments <NUM>, provides a ratio of the number of baffles to the number of outer seams of greater than one and provides an additional outer covering layer which is securely retained in place against movement and which may inhibit the escape of insulating particles from panel <NUM>.

<FIG> is a fragmentary sectional view illustrating baffled region <NUM> which may be used in place of baffled region <NUM>. Baffled region <NUM> illustrates an example of how additional insulating layers may be provided in the multilayered overlapping architecture of panel <NUM> or garment <NUM>. Baffled region <NUM> is similar to baffled region <NUM> described above except that baffled region <NUM> additionally comprises insulating layer <NUM>. The remaining components of baffled region <NUM> which correspond to components of baffled region <NUM> are numbered similarly.

Insulating layer <NUM> comprises a layer of insulating particles such as down and/or synthetic or natural fibers. Insulating layer <NUM> is sandwiched and captured between second layer <NUM> and third layer <NUM>. Insulating layer <NUM> is captured and retained within a baffle compartment <NUM> having a floor formed by the top of second layer <NUM> and a ceiling formed by the underside of third layer <NUM>.

Insulating layer <NUM> comprises portions <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM> (collectively referred to as portions <NUM>). Portion <NUM>-<NUM> extends directly over compartments <NUM>-<NUM> and <NUM>-<NUM> and continuously spans across and over the top <NUM> of trough wall <NUM>-<NUM> forming the single walled baffle <NUM>-<NUM>. As a result, portion <NUM>-<NUM> further provides a layer of cushioning over the juncture of portions <NUM>-<NUM> and <NUM>-<NUM> as well as single walled baffle <NUM>-<NUM>. Portions <NUM>-<NUM> and <NUM>-<NUM> are similar to portion <NUM>-<NUM> in that they continuously span across and over the top <NUM> of their respective underlying trough walls that form single walled baffles.

In some implementations, insulating layer <NUM> has a first thickness while insulating layer <NUM> has a second thickness less than the first thickness. In some implementations, insulating layer <NUM> has a thickness of no greater than <NUM>. In other implementations, insulating layer <NUM> has a thickness of no greater than <NUM>. In some implementations, insulating layer <NUM> has a thickness of at least <NUM>. In some implementations, insulating layer <NUM> has a nominal thickness of at least <NUM> and no greater than <NUM>. In some implementations, insulating layer <NUM> is formed from insulating particles having the same composition as the insulating particles of insulating layer <NUM>. In some implementations, insulating layer <NUM> comprises <NUM> down fill power with an application of <NUM>/m<NUM>. In other implementations, insulating layer <NUM> may have a different composition of insulating particles. For example, insulating layer <NUM> may be formed from a different mixture of down and/or synthetic/natural fibers. The reduced thickness of most embodiments of insulating layer <NUM> enables baffle compartments <NUM> to be longer than other thicker baffle compartments. The reduced thickness of most embodiments of the insulating layer <NUM> retains the insulating particles in place due to the proximity to the inner surface of the third layer <NUM> and the outer surface of the second layer <NUM>. The insulating material <NUM> inhibits the build-up of static between the second and third layers <NUM> and <NUM>, and prevents the top <NUM> of the trough shaped walls <NUM> from being visible outside of the third layer <NUM>.

<FIG> is a sectional view illustrating an example baffled region <NUM> of panel <NUM>. Baffled region <NUM> is similar to baffled region <NUM> except that second layer <NUM> comprises an additional fold to form an additional trough wall and that insulating layer <NUM> comprises an additional portion of insulating particles. In some implementations, baffled region <NUM> may be employed to form portions of a garment, such as garment <NUM>, where the garment may undergo more substantial bending, flexing or stress. The additional trough walls and additional baffles may serve to better retain the insulating particles in the respective baffle compartments. In some implementations, the construction of baffled region <NUM> is employed in those portions of a garment or blanket where the exterior stitch lines or seams (the top of folds <NUM>/trough walls <NUM>) are spaced less than or equal to <NUM>, whereas the construction of baffled region <NUM> is employed in those portions of a garment or blanket where the exterior stitch lines or seams (the top of folds <NUM>/trough walls <NUM>) are spaced by spacing (similar to spacing S1 in <FIG>) that is greater than <NUM>. As the spacing between the stitch lines or seams increases, the number of additional single walled baffles <NUM> formed by second layer <NUM> between the consecutive double walled baffles <NUM> may be increased.

Baffled region <NUM> comprises the above-described trough walls <NUM>-<NUM> and <NUM>-<NUM> which form double walled baffle <NUM>-<NUM>. Second layer <NUM> comprises folds which additionally form trough walls <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM>. Third layer <NUM> comprises an additional fold which additionally forms trough wall <NUM>-<NUM>. Trough wall <NUM>-<NUM> and <NUM>-<NUM> form single walled baffles <NUM>-<NUM> and <NUM>-<NUM>. Trough wall <NUM>-<NUM> projects into and is secured within trough wall <NUM>-<NUM>. Walls <NUM>-<NUM> and <NUM>-<NUM> overlap one another to form double walled baffle <NUM>-<NUM>. Due to the two overlapping trough walls, double walled baffle <NUM>-<NUM> may have an increased thickness, an increased rigidity and an increased strength as compared to single walled baffles <NUM>.

First layer <NUM> and second layer <NUM> form the bottom and top of baffle compartments <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM>, respectively. Trough walls <NUM>-<NUM> and <NUM>-<NUM> form the lateral sides of compartment <NUM>-<NUM>. Trough walls <NUM>-<NUM> and <NUM>-<NUM> form the lateral sides of compartment <NUM>-<NUM>. Trough walls <NUM>-<NUM> and <NUM>-<NUM> form the lateral sides of compartment <NUM>-<NUM>. In the example illustrated, compartments <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM> have different sizes, different widths. Compartments <NUM>-<NUM> and <NUM>-<NUM>, which are adjacent to double walled baffles <NUM>-<NUM> and <NUM>-<NUM>, respectively, have wider widths, whereas compartment <NUM>-<NUM>, which is bordered on both sides by single walled baffles <NUM>-<NUM> and <NUM>-<NUM> has a smaller width. The smaller width of compartment <NUM>-<NUM> may better retain the received portion of insulating layer <NUM> given that both sides are bordered by a single walled baffle. In other implementations, compartments <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM> can all be formed with the same width, or substantially the same widths. In other implementations, trough walls <NUM>-<NUM> and <NUM>-<NUM> may have a spacing that is equal to the spacing of trough walls <NUM>-<NUM> and trough wall <NUM>-<NUM> and the spacing between trough wall <NUM>-<NUM> and trough wall <NUM>-<NUM>. Although baffled region <NUM> is illustrated as having a pair of single walled baffles <NUM>-<NUM> and <NUM>-<NUM> between double walled baffles <NUM>-<NUM> and <NUM>-<NUM>, in other implementations, second layer <NUM> may include additional folds and additional trough walls <NUM> between double walled baffles <NUM>-<NUM> and <NUM>-<NUM> to provide additional single walled baffles <NUM> between double walled baffles <NUM>-<NUM> and <NUM>-<NUM>.

Insulating layer <NUM> comprises portions <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM> (collectively referred to as portions <NUM>). Portions <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM> fill compartment <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM>, respectively. Portion <NUM>-<NUM> is sandwiched between and captured within compartment <NUM>-<NUM>. Portion <NUM>-<NUM> is sandwiched between and captured within compartment <NUM>-<NUM>. Portion <NUM>-<NUM> is sandwiched between and captured within compartment <NUM>-<NUM>. Each of portions <NUM> is composed of insulating particles <NUM>. Such insulating particles may be in the form of down, synthetic fibers, natural fibers or combinations thereof. In the example illustrated, portion <NUM>-<NUM> has a smaller volume (a smaller width) as compared to portions <NUM>-<NUM> and <NUM>-<NUM> due to the smaller volume and width of compartment <NUM>-<NUM>. In another implementation, portions <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM> can all have the same volume to match the compartments <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM> having the same width.

Similar to the portion of third layer <NUM> forming baffled region <NUM>, the third layer <NUM> forming baffled region <NUM> further comprises a bridge region <NUM> that continuously extends between walls <NUM>-<NUM> and <NUM>-<NUM>, spanning over and across a top (as seen in <FIG>) of the single walled baffles <NUM>-<NUM> and <NUM>-<NUM> formed by walls <NUM>-<NUM> and <NUM>-<NUM>, respectively. Bridge region <NUM> conceals the top <NUM> of the trough shaped walls <NUM>-<NUM> and <NUM>-<NUM>. As a result, even though the illustrated portion of panel <NUM> comprises four baffles <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM>, third wall <NUM> presents an upper surface (as seen in <FIG>) in which just two tops or mouths of folds or trough-shaped walls (sometimes referred to as outer seams) are exposed. The overlapping architecture of panel <NUM> provides baffles of different thickness and strength along the various insulating particle containing compartments <NUM>, provides a ratio of the number of baffles to the number of outer seams of greater than one and provides an additional outer covering layer which is securely retained in place against movement and which may inhibit the escape of insulating particles from compartments <NUM>.

<FIG> is a fragmentary sectional view illustrating baffled region <NUM> which may be used in place of baffled region <NUM>. Baffled region <NUM> illustrates an example of how additional insulating layers may be provided in the multilayered overlapping architecture of panel <NUM>. Baffled region <NUM> is similar to baffled region <NUM> described above except that baffled region <NUM> additionally comprises insulating layer <NUM>. The remaining components of baffled region <NUM> which correspond to components of baffled region <NUM> are numbered similarly.

Insulating layer <NUM> comprises a layer of insulating particles such as down and/or synthetic or natural fibers. Insulating layer <NUM> is sandwiched in captured between second layer <NUM> and third layer <NUM>. Insulating layer <NUM> is captured and retained within a baffle compartment <NUM> having a floor formed by the top of second layer <NUM> and a ceiling formed by the underside of third layer <NUM>.

Insulating layer <NUM> comprises portions <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM> (collectively referred to as portions <NUM>). Portion <NUM>-<NUM> extends directly over compartments <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM> and continuously spans across and over the top <NUM> of trough walls <NUM>-<NUM> and <NUM>-<NUM> forming the single walled baffles <NUM>-<NUM> and <NUM>-<NUM>. As a result, portion <NUM>-<NUM> further provides a layer of cushioning over the juncture of portions <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM> as well as single walled baffles <NUM>-<NUM> and <NUM>-<NUM>. Portions <NUM>- and <NUM>-<NUM> are similar to portion <NUM>-<NUM> in that they continuously span across and over the top <NUM> of their respective underlying trough walls that form single walled baffles.

In some implementations, insulating layer <NUM> has a first thickness while insulating layer <NUM> has a second thickness less than the first thickness. In some implementations, insulating layer <NUM> has a thickness of no greater than <NUM>. In other implementations, insulating layer <NUM> has a thickness of no greater than <NUM>. In some implementations, insulating <NUM> has a thickness of at least <NUM> in some implementations, insulating layer <NUM> is formed from insulating particles having the same composition as the insulating particles of insulating layer <NUM>. In other implementations, insulating layer <NUM> may have a different composition of insulating particles. For example, insulating layer <NUM> may be formed from a different mixture of down and/or synthetic/natural fibers. The reduced thickness of most embodiments of insulating layer <NUM> enables baffle compartments <NUM> to be longer than other thicker baffle compartments. The reduced thickness of most embodiments of the insulating layer <NUM> retains the insulating particles in place due to the proximity to the inner surface of the third layer <NUM> and the outer surface of the second layer <NUM>. The insulating material <NUM> inhibits the build-up of static between the second and third layers <NUM> and <NUM>, and prevents the top <NUM> of the trough shaped walls <NUM> from being visible outside of the third layer <NUM>.

<FIG> illustrate baffled regions <NUM>, <NUM>, <NUM> and <NUM>, respectively, but with the addition of connectors that secure the above-described trough walls to themselves, to other trough walls and/or to adjacent layers. As shown by <FIG>, baffled regions <NUM> and <NUM> comprise connectors <NUM>-<NUM>, <NUM>-<NUM> (collectively referred to as connectors <NUM>), connectors <NUM>, connectors <NUM>-<NUM>, <NUM>-<NUM> (collectively referred to as connectors <NUM>), connectors <NUM>-<NUM>, <NUM>-<NUM> (collectively referred to as connectors <NUM>) and connector <NUM>.

Connectors <NUM> connect portions of third layer <NUM>, adjacent to tops <NUM> of trough walls <NUM>-<NUM> and <NUM>-<NUM>, closing the mouth or top openings of such trough walls <NUM>-<NUM> and <NUM>-<NUM>. In some implementations, connectors <NUM> may each comprise stitching. In other implementations, connectors <NUM> may comprise adhesive, welds or other connection structures. Connector <NUM> connects portions of second layer <NUM>, adjacent to tops <NUM> of trough wall <NUM>-<NUM>, closing the mouth or top openings of trough wall <NUM>-<NUM>. In some implementations, connector <NUM> may comprise stitching. In other implementations, connector <NUM> may comprise adhesive, welds or other connection structures.

Connectors <NUM> secure portions of trough wall <NUM>-<NUM> and <NUM>-<NUM> within trough walls <NUM>-<NUM> and <NUM>-<NUM>, respectively. In the example illustrated, connectors <NUM> connect the floors <NUM> of trough walls <NUM>-<NUM> and <NUM>-<NUM> directly to the floors of trough walls <NUM>-<NUM> and <NUM>-<NUM>, respectively. In other implementations, connectors <NUM> may connect lower interior sides of trough walls <NUM>-<NUM> and <NUM>-<NUM> to lower interior sides of trough walls <NUM>-<NUM> and <NUM>-<NUM>, respectively. In some implementations, connectors <NUM> may each comprise stitching. In other implementations, connectors <NUM> may comprise adhesive, welds or other connection structures.

Connectors <NUM> secure portions of trough walls <NUM>-<NUM> and <NUM>-<NUM> directly to first layer <NUM>. In the example illustrated, connectors <NUM> connect the floors <NUM> of trough walls <NUM>-<NUM> and <NUM>-<NUM> directly to first layer <NUM>. In other implementations, connectors <NUM> may connect lower sides of trough walls <NUM>-<NUM> and <NUM>-<NUM> to first layer <NUM>. In some implementations, connectors <NUM> may each comprise stitching. In other implementations, connectors <NUM> may comprise adhesive, welds or other connection structures.

Connector <NUM> connects trough wall <NUM>-<NUM> to first wall <NUM>. In the example illustrated, connector <NUM> directly connects a floor of trough wall <NUM>-<NUM> to first wall <NUM>. In other implementations, connector <NUM> may directly connect a side or sides of trough wall <NUM>-<NUM> to first wall <NUM>. In some implementations, connector <NUM> may comprise stitching. In other implementations, connector <NUM> may comprise adhesive, welds or other connection structures.

When connectors <NUM>, <NUM>, <NUM>, <NUM> and <NUM> are stitchings, the stitching may be aligned in a generally horizontal direction, a generally vertical direction, or in other angled positions, with respect to the orientation of panel <NUM> in <FIG>.

As shown by <FIG>, baffled regions <NUM> and <NUM> comprise connectors <NUM>-<NUM>, <NUM> -<NUM> (collectively referred to as connectors <NUM>), connectors <NUM>-<NUM>, <NUM>-<NUM> (collectively referred to as connectors <NUM>), connectors <NUM>-<NUM>, <NUM>-<NUM> (collectively referred to as connectors <NUM>), connectors <NUM>-<NUM>, <NUM>-<NUM> (collectively referred to as connectors <NUM>) and connectors <NUM>-<NUM> and <NUM>-<NUM> (collectively referred to as connectors <NUM>).

Connectors <NUM> connect portions of third layer <NUM>, adjacent to tops <NUM> of trough walls <NUM>-<NUM> and <NUM>-<NUM>, closing the mouth or top openings of such trough walls <NUM>-<NUM> and <NUM>-<NUM>. In some implementations, connectors <NUM> may each comprise stitching. In other implementations, connectors <NUM> may comprise adhesive, welds or other connection structures. Connectors <NUM> connect portions of second layer <NUM>, adjacent to tops <NUM> of trough walls <NUM>-<NUM> and <NUM>-<NUM>, closing the mouth or top openings of such trough walls <NUM>-<NUM> and <NUM>-<NUM>. In some implementations, connectors <NUM> may each comprise stitching. In other implementations, connectors <NUM> may comprise adhesive, welds or other connection structures.

Connectors <NUM> secure portions of trough walls <NUM>-<NUM> and <NUM>-<NUM> within trough walls <NUM>-<NUM> and <NUM>-<NUM>, respectively. In the example illustrated, connectors <NUM> connect the floors <NUM> of trough wall <NUM>-<NUM> and <NUM>-<NUM> directly to the floors of trough walls <NUM>-<NUM> and <NUM>-<NUM>, respectively. In other implementations, connector <NUM> may connect lower interior sides of trough walls <NUM>-<NUM> and <NUM>-<NUM> to lower interior sides of trough walls <NUM>-<NUM> and <NUM>-<NUM>, respectively. In some implementations, connectors <NUM> may each comprise stitching. In other implementations, connectors <NUM> may comprise adhesive, welds or other connection structures.

Connectors <NUM> connects trough walls <NUM>-<NUM> and <NUM>-<NUM> to first wall <NUM>. In the example illustrated, connectors <NUM> directly connect a floor of trough walls <NUM>-<NUM> and <NUM>-<NUM> to first wall <NUM>. In other implementations, connectors <NUM> may directly connect a side or sides of each of trough walls <NUM>-<NUM> and <NUM>-<NUM> to first wall <NUM>. In some implementations, connectors <NUM> may comprise stitching. In other implementations, connectors <NUM> may comprise adhesive, welds or other connection structures.

In the example illustrated in <FIG>, the trough walls of the second layer <NUM> have a height H of at least <NUM> and no greater than <NUM>. The trough walls <NUM>-<NUM> and <NUM>-<NUM> are spaced by spacing S1 of at least <NUM> and no greater than <NUM>. In some implementations, trough walls <NUM>-<NUM> and <NUM>-<NUM> are spaced by spacing S1 of at least <NUM> and no greater than <NUM>. Trough walls <NUM>-<NUM> and <NUM>-<NUM> are spaced by spacing S2 of at least <NUM> and no greater than <NUM>. Trough walls <NUM>-<NUM> and <NUM>-<NUM> are spaced by a spacing S3 of at least <NUM> and no greater than <NUM>. Such spacings and heights may facilitate sufficient insulation as well as retention of the various portions of insulation layer <NUM>. In other implementations, the various spacings and heights may be altered.

<FIG> illustrate one example method for forming the example baffled region <NUM> showing <FIG>. As shown by <FIG>, third wall <NUM> is folded to form folds <NUM>-<NUM> and <NUM>-<NUM> which form consecutive trough-shaped walls <NUM>-<NUM> and <NUM>-<NUM>. Each of the trough shaped walls <NUM> has a top <NUM> forming an opening or mouth and a bottom <NUM>. In the example illustrated, the shape of each of the folds <NUM> is maintained by applying or forming connectors <NUM>-<NUM> and <NUM>-<NUM>. As discussed above, some implementations, connectors <NUM> may comprise stitching. In <FIG>, in one implementation, when connectors <NUM>-<NUM> and <NUM>-<NUM> are stitchings, the stitchings can be aligned in a generally horizontal direction with respect to the orientation of panel <NUM> in <FIG>. In other implementations, the stitchings can be aligned in a generally vertical direction, or in other angled positions.

As shown by <FIG>, second layer <NUM> is folded or shaped to form folds <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM> which form trough walls <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM>, respectively. As with trough walls <NUM>, trough walls <NUM> each include a top <NUM> having an open mouth and a bottom <NUM>. In the example illustrated, the top <NUM> of trough walls <NUM>-<NUM> and <NUM>-<NUM> are closed by connectors <NUM>-<NUM> and <NUM>-<NUM>. As discussed above, in some implementations, connectors <NUM> may be formed by stitching across the opposite side walls of the trough walls <NUM>. The tops <NUM> of trough walls <NUM>-<NUM> and <NUM>-<NUM> are left open for the subsequent reception of trough walls <NUM>-<NUM> and <NUM>-<NUM>, respectively. In <FIG>, in one implementation, when connectors <NUM>-<NUM> and <NUM>-<NUM> are stitchings, the stitchings can be aligned in a generally horizontal direction with respect to the orientation of panel <NUM> in <FIG>. In other implementations, the stitchings can be aligned in a generally vertical direction, or in other angled positions.

As shown by <FIG>, insulating layer <NUM> is located on top of second wall <NUM>. In particular, portion <NUM>-<NUM> is located between trough walls <NUM>-<NUM> and <NUM>-<NUM>, extending directly on top of and over connectors <NUM> and trough walls <NUM>-<NUM> and <NUM>-<NUM>. Portions of insulating layer <NUM> are separated from one another directly above trough walls <NUM>-<NUM> and <NUM>-<NUM> for the subsequent insertion of trough walls <NUM>-<NUM> and <NUM>-<NUM> into trough walls <NUM>-<NUM> and <NUM>-<NUM>, respectively.

As shown by <FIG>, the third layer <NUM> prepared in <FIG> is overlaid upon the intermediate assembly of <FIG> with trough layers <NUM>-<NUM> and <NUM>-<NUM> being inserted into trough layers <NUM>-<NUM> and <NUM>-<NUM>, respectively. Thereafter, trough walls <NUM>-<NUM> and <NUM>-<NUM> are connected or secured within trough layers <NUM>-<NUM> and <NUM>-<NUM>, respectively, by connectors <NUM>-<NUM> and <NUM>-<NUM>. As discussed above, in some implementations, connectors <NUM>-<NUM> and <NUM>-<NUM> are formed by stitching through the material of trough wall <NUM>-<NUM> into trough wall <NUM>-<NUM> and through wall <NUM>-<NUM> and into trough wall <NUM>-<NUM>. In <FIG>, in one implementation, when connectors <NUM>-<NUM> and <NUM>-<NUM> are stitchings, the stitchings can be aligned in a generally vertical direction with respect to the orientation of panel <NUM> in <FIG>. In other implementations, the stitchings can be aligned in a generally horizontal direction, or in other angled positions. In other implementations, a mass of adhesive may be provided to form connectors <NUM>. In some implementations, an adhesive may be applied along interior sides and/or the floor of each of trough walls <NUM>-<NUM> and <NUM>-<NUM>.

As shown by <FIG>, the various portions of insulating layer <NUM> are located within the partially formed compartments <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM>. Thereafter, the intermediate assembly of <FIG> is secured to first wall <NUM>, in some implementations, the liner of the garment. In particular, connectors <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM> are formed to connect and secure trough walls <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM> to first wall <NUM>. As discussed above, in some implementations, connectors <NUM> and <NUM> may be formed by stitching. In some implementations, connectors <NUM>-<NUM> and <NUM>-<NUM> and connectors <NUM>-<NUM> and <NUM>-<NUM> may be provided by single stitching operation, wherein the stitching extends through first wall <NUM>, through trough wall <NUM>-<NUM> and <NUM>-<NUM> and into or through trough walls <NUM>-<NUM> and <NUM>-<NUM>. In one implementation, when connectors <NUM>-<NUM> and <NUM>-<NUM> and connectors <NUM>-<NUM> and <NUM>-<NUM> are stitchings, the stitchings can be aligned in a generally vertical direction with respect to the orientation of panel <NUM> in <FIG>. In other implementations, the stitchings can be aligned in a generally horizontal direction, or in other angled positions.

In some implementations, the order of the various processes shown in <FIG> may be varied. For example, the fabrication steps shown in <FIG> may be carried out in any order. In some implementations, the second layer <NUM> may be connected to first layer <NUM>, with the inserted portions of insulation layer <NUM>, prior to the positioning of the insulation layer <NUM> and the joining of third layer <NUM>.

<FIG> is a sectional view of an example baffled insulating panel <NUM> which may be utilized as part of a blanket or a garment, such as garment <NUM>. Insulating panel <NUM> comprises multiple consecutive individual regions, each of which is similar to region <NUM> described above. Insulating panel <NUM> comprises additional trough walls, additional insulating layers and additional layers for enhanced insulation and an even lower density of outer or exposed stitches/connectors/folds per surface area of the blanket or garment. <FIG> illustrates three consecutive baffled regions <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM> (collectively referred to as baffled regions <NUM>) which include a third layer <NUM> having folds so as to form trough walls <NUM>-<NUM>, <NUM>-<NUM> (described above with respect to the baffled region <NUM> shown in <FIG>) as well as trough walls <NUM>-<NUM> and <NUM>-<NUM> which form baffled region <NUM>-<NUM> and baffled region <NUM>-<NUM>, respectively.

As shown by <FIG>, in addition to the structures described above with respect to each of the baffled regions <NUM> (and numbered similarly in <FIG>), panel <NUM> comprises fourth layer <NUM>, insulating layer <NUM>, fifth layer <NUM> and sixth layer <NUM>. Fourth layer <NUM> comprises a continuous layer of flexible material, such as a fabric, a perforate, breathable material or an imperforate material. Fourth layer <NUM> comprises folds <NUM>-<NUM> and <NUM>-<NUM> which form trough-shaped trough walls <NUM>-<NUM>, <NUM>-<NUM> (collectively referred to as walls <NUM>). Trough walls <NUM>-<NUM> and <NUM>-<NUM> are closed by connectors <NUM>-<NUM> and <NUM>-<NUM>, respectively. Connectors <NUM>-<NUM> and <NUM>-<NUM> may comprise stitching, adhesive, welds and the like.

Similar to trough walls <NUM>-<NUM> and <NUM>-<NUM>, trough walls <NUM>-<NUM> and <NUM>-<NUM> project into and are secured within an underlying trough wall over and underlying layer. In the example illustrated, trough walls <NUM>-<NUM> and <NUM>-<NUM> project into corresponding trough walls <NUM>-<NUM> and <NUM>-<NUM>. Trough walls <NUM>-<NUM> and <NUM>-<NUM> cooperate with the underlying trough walls to form triple walled baffles <NUM>-<NUM>, <NUM>-<NUM> which may have a larger stiffness as compared to the double walled baffles <NUM>-<NUM>, <NUM>-<NUM> and the single walled baffles <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM> and <NUM>-<NUM>.

Trough walls <NUM>-<NUM> and <NUM>-<NUM> are secured and connected to trough walls <NUM>-<NUM> and <NUM>-<NUM> by connectors <NUM>-<NUM> and <NUM>-<NUM> (collectively referred to as connectors <NUM>. Connectors <NUM> may be formed by stitching, adhesive, welding or other connection structures.

Trough walls <NUM>-<NUM> and <NUM>-<NUM> cooperate with third layer <NUM> to form baffle compartment <NUM>. Baffle compartment <NUM> spans across and over double walled baffles <NUM>-<NUM>, <NUM>-<NUM> between triple walled baffles <NUM>-<NUM> and <NUM>-<NUM>. Baffle compartment <NUM> receives portion <NUM> of insulating layer <NUM>. Portion <NUM> is composed of insulating particles <NUM> which may comprise down, natural fibers, synthetic fibers or combinations thereof. In some implementations, portion <NUM> may be composed of insulating particles similar to that of insulating layer <NUM> and/or insulating layer <NUM>. In some implementations, insulating layer <NUM> may have a thickness less than the thickness of insulating layer <NUM>.

As shown by <FIG>, portion <NUM> of insulating layer <NUM> is captured within compartment <NUM> and spans or extends over double walled baffles <NUM>-<NUM> and <NUM>-<NUM>. As a result, portion <NUM> further provides a layer of cushioning over the juncture of portions <NUM> as well as single and double walled baffles. In addition, fourth layer <NUM> further provides panel <NUM> with a lower density of folds/seams along the surface of fourth layer <NUM>. In the example illustrated, for each of the lowermost <NUM> baffles secured to first layer <NUM>, the exterior of layer <NUM> has two exposed folder seams, <NUM>-<NUM> and <NUM>-<NUM>. In some implementations, insulating layer <NUM> may be omitted.

As further shown by <FIG>, panel <NUM> may comprise additional inner and outermost liners or layers. In the example illustrated, panel <NUM> comprises an additional innermost liner or layer <NUM> secured to layer <NUM> by connectors <NUM>. Connectors <NUM> may be in the form of stitching, adhesives, welds or the like. Panel <NUM> additionally comprise an outermost self or layer <NUM> connected to layer <NUM> by connectors <NUM>. Connectors <NUM> may be in the form of stitching, adhesive, welds or the like. In some implementations, one or both of layers <NUM> and <NUM> may be imperforate to block moisture or wind. In some implementations, one or both of layer <NUM> and <NUM> may be perforate or breathable. Layers <NUM> and <NUM> may protect layers <NUM> and <NUM> or may provide different outer surface finish for the garment or blanket employing panel <NUM>. In some implementations, layer <NUM> and/or layer <NUM> may be omitted.

The above example baffled insulating garment/blanket panels can reduce the number of insulating particles that protrude or escape from the panels during laundering. An evaluation or rating of the downproofness of a down panel or garment made from down panels may be made using the following particle loss test. In one example testing, a specimen garment in the form of a vest or a jacket having baffled sections <NUM> described above on both its front and back panels and having a surface area of <NUM><NUM> underwent the following particle loss test. The insulating layers <NUM> were composed of <NUM> down fill applied at <NUM>/m<NUM>. Layer <NUM> was formed from #<NUM> Toray while layers <NUM> and <NUM> were formed from #<NUM> Toray. The insulating layer <NUM> was composed of <NUM> down fill applied at <NUM>/m<NUM>. Layer <NUM> had a thickness of <NUM> while layer <NUM> had a thickness of between two and <NUM>. The connectors were in the form of stitching. Prior to laundering, inspection of the vest revealed three individual pieces are particles of down on its exterior, wherein such pieces were removed prior to laundering.

During laundering, the sample vest was placed in a polyester mesh bag having a porosity so as to prevent the escape of any down pieces as particles. During laundering, the vest, within the polyester bag drying, the bag with the vest was placed in a large box having an interior of at least <NUM>+/-<NUM> x <NUM>+-<NUM> x <NUM>+-<NUM> at a rotating speed of <NUM> revolutions per minute in a forward direction for <NUM> revolutions (a large box test). The selection of the large box test was based upon the garment having a length of greater than <NUM>. For garments less than <NUM>, a small box test may be used, wherein the small box has an interior of <NUM>+/-<NUM> x <NUM>+/-<NUM> x <NUM>+/-<NUM> with <NUM> rubber or silicone stoppers. When a large box test is used, <NUM> rubber or silicone stoppers are used within the bag during testing.

The washing machine complies with the description of ISO Standard, ISO <NUM>-<NUM> (Annex A). The machine is rotated at a speed of <NUM> revolutions per minute at a forward speed for <NUM> revolutions. The vest was washed pursuant to recommendations provided on the vest. In the particular example, the vest was washed at a cold temperature of <NUM> and dried at a low temperature of between <NUM> and <NUM>. Each wash cycle lasted <NUM> minutes while the dry cycle lasted until the vest was completely dry. The water cycle was a "normal" water cycle in accordance with ISO <NUM>-<NUM> (Annex A) while the dry cycle was a tumble dry cycle in accordance with ISO Standard, ISO <NUM>-<NUM> (Annex G). During such testing, <NUM> individual stoppers are deposited into the polyester bag along with the vest. As should be appreciated, the number of individual rubber stoppers and their individual size may vary as they are simply used to attract released particles. The rubber stoppers attract any released particles. To facilitate turning of the vest during drying, three standard tennis balls were placed in the dryer, outside of the polyester bag during drying. Three complete laundering cycles were performed prior to any inspection.

Following three wash/dry times, the garment and rubber stoppers were inspected. No insulating particles were found on the specimen vest. Two insulating particles were found on the rubber stoppers. No insulating particles were found on the surface of the box. A total of two insulating particles were found, indicating a loss of <NUM> particles per square meter of the garment. In another test of a garment, wherein the garment was a jacket having a garment surface area of <NUM> m2, the jacket was placed into a large box and tested (washed) in accordance with ISO <NUM>-<NUM> (Annex A) while the dry cycle was a tumble dry cycle in accordance with ISO Standard, ISO <NUM>-<NUM> (Annex G), in the manner described above. Following three wash/dry times, the jacket and rubber stoppers were inspected. Two insulating particles were found on the specimen jacket. No insulating particles were found on the rubber stoppers. No insulating particles were found on the surface of the box. A total of two insulating particles were found, indicating a loss of <NUM> particles per square meter of the garment.

Down proofness of a down garment may be generally evaluated in terms of lost pieces or particles protruding or escaping from a garment per square meter of the garment. A "lost" particle is a particle that is protruding from or that is completely separated from the garment. A "Superior" quality rating is achieved when a specimen garment experiences a loss of less than or equal to <NUM> particles per square meter. A "First-Class" quality rating for garment is achieved when a garment experiences a particle loss of less than or equal to <NUM> insulating particles or down particles per square meter. A "Qualified" rating is achieved when a garment experiences a particle loss of less than or equal <NUM> particles per square meter. The baffled insulating garment/blanket panel described above, following three laundering cycles, lost less than or equal to <NUM> particles per square meter of the panel. The baffled insulating garment/blanket panel described above, following three laundering cycles, lost less than or equal to five particles per square meter of the panel. The above test demonstrated that a garment formed with the baffled insulating garment/blanket panel construction may achieve a "Superior" down garment downproofness rating. Accordingly, in the two example downproofness tests described above, the vest and the jacket, both produced in accordance with implementations of the present invention, resulted in downproofness values (pieces / m2) of less than <NUM>, well within the Superior Quality downproofness rating of less than or equal to <NUM> pieces / m2.

Garments produced in accordance with above-described implementations can have Superior Quality downproofness ratings, when tested in downproofness tests as described above, of less than or equal to <NUM> pieces / m2. Garments produced in accordance with above-described implementations can have Superior Quality downproofness ratings of less than or equal to <NUM> pieces / m2. Garments produced in accordance with above-described implementations can have Superior Quality downproofness ratings of less than or equal to <NUM> pieces / m2.

Claim 1:
A baffled insulating garment/blanket panel (<NUM>, <NUM>) comprising:
a first layer (<NUM>);
a second layer (<NUM>) having folds (<NUM>) forming trough-shaped walls comprising a first wall (<NUM>-<NUM>), a second wall (<NUM>-<NUM>, <NUM>-<NUM>) and a third wall (<NUM>-<NUM>, <NUM>-<NUM>), wherein each of the first wall (<NUM>-<NUM>), second wall (<NUM>-<NUM>, <NUM>-<NUM>) and the third wall (<NUM>-<NUM>, <NUM>-<NUM>) has a trough bottom (<NUM>) and a trough top (<NUM>) and wherein the trough bottom (<NUM>) is secured adjacent to the first layer (<NUM>);
an insulating particle layer (<NUM>) comprising:
a first portion (<NUM>-<NUM>, <NUM>-<NUM>) between the first wall (<NUM>-<NUM>) and the second wall (<NUM>-<NUM>, <NUM>-<NUM>) and sandwiched between the first layer (<NUM>) and the second layer (<NUM>); and
a second portion (<NUM>-<NUM>, <NUM>-<NUM>) between the second wall (<NUM>-<NUM>, <NUM>-<NUM>) and the third wall (<NUM>-<NUM>, <NUM>-<NUM>) and sandwiched between the first layer (<NUM>) and the second layer (<NUM>); and
a third layer (<NUM>) having folds (<NUM>) forming consecutive trough-shaped walls comprising a fourth wall (<NUM>-<NUM>) secured within the first wall (<NUM>-<NUM>) and a fifth wall (<NUM>-<NUM>, <NUM>-<NUM>) secured within the third wall (<NUM>-<NUM>, <NUM>-<NUM>), characterised in that portions of the third layer (<NUM>) between the fourth wall (<NUM>-<NUM>) and the fifth wall (<NUM>-<NUM>, <NUM>-<NUM>) span across the trough top (<NUM>) of the second wall (<NUM>-<NUM>, <NUM>-<NUM>).