Baffle constructs for insulative fill materials

Abstract

The inventive subject matter is directed to an assembly of a plurality of baffle constructs which each include: a primary baffle, comprising a pliable textile, and a secondary baffle. The baffle constructs are configured to be alignable along a vertical axis relative to the ground. Each primary baffle defines a bounded, volumetric space for enclosing a first volume of insulative fill material and a secondary baffle. Each secondary baffle defines a bounded, volumetric space for enclosing a second volume of fill material. One or more of the secondary baffle are disposed in the primary baffle so that most of the second volume of insulative fill material is contained above most of the first insulative material when the primary baffle is maintained in an intended vertical orientation. The secondary baffles are mainly responsible for filling the primary baffle to its intended shape in an upper portion of the primary baffle.

1 . An assembly of a plurality of baffle constructs, each baffle construct comprising:
 a primary baffle, comprising a pliable textile, and one or more secondary baffles, the baffle constructs configured to be alignable along a vertical axis relative to the ground;   each primary baffle defining a bounded, volumetric space for enclosing a first volume of insulative fill material in a first part of the space and a secondary baffle in a second part of the space; and   each secondary baffle defining a bounded, volumetric space for enclosing a second volume of fill material, the secondary baffle being disposed in the primary baffle so that most of the second volume of insulative fill material is contained above most of the insulative material in the first part of the space when the main baffle is maintained in an intended vertical orientation.   
     
     
         2 . The assembly of  claim 1  wherein the primary baffle has a bottom and the secondary baffle has a bottom, the bottom of the secondary baffle being spaced a predetermined height above the bottom of the primary baffle. 
     
     
         3 . The assembly of  claim 1  wherein the primary baffle has a predetermined profile in a desired expanded condition and the secondary baffle has a predetermined desired profile in the expanded condition, and wherein the primary baffle's profile in the expanded condition is supported and not disrupted by the secondary baffle when the secondary baffle's profile in the expanded condition. 
     
     
         4 . The assembly of  claim 1  wherein the primary baffle has a height H and the secondary baffle has a height H′ and the ratio H/H′ is at least 1.25. 
     
     
         5 . The assembly of  claim 1  wherein the primary baffle has a height H and a secondary baffle has a height H′ and the ratio H/H′ is between 1.25 and 10. 
     
     
         6 . The assembly of  claim 5  wherein a single secondary baffle is enclosed in the primary baffle and an upper end of the secondary baffle is pendulously appended to an upper end of the primary baffle. 
     
     
         7 . The assembly of  claim 1  wherein the secondary baffle has an oblong shaped configuration. 
     
     
         8 . The assembly of  claim 1  wherein the secondary baffle has a pendulous configuration. 
     
     
         9 . The assembly of  claim 8  wherein the secondary baffle has a generally teardrop or piriform shape. 
     
     
         10 . The assembly of  claim 1  wherein the assembly has face layer and a back layer and the primary baffles are defined in part by horizontal seam or joints connecting the face layer and back layer and which define a top and the bottom for a given baffle. 
     
     
         11 . The assembly of  claim 10  wherein the secondary baffle(s) is/are disposed on an inner surface of the back layer and are not connected to the back layer so that the face layer is free of any seams or joints for the secondary baffle(s). 
     
     
         12 . The assembly of  claim 10  wherein each secondary baffle has a pendulous profile. 
     
     
         13 . The assembly of  claim 1  wherein the primary baffle in an expanded condition has sides that converge at upper and lower ends when moving from an intermediate section. 
     
     
         14 . The assembly of  claim 1  wherein an upper-most secondary baffle(s) has a first edge of the secondary baffle merges into the upper end of a primary baffle, and a second edge is downwardly spaced apart from the upper edge and merges into a vertical wall of the primary baffle, such that the secondary baffle's bounded space is defined in part by a wall of the primary baffle. 
     
     
         15 . The assembly of  claim 14  further comprising a second secondary baffle spaced at least in part below the upper-most secondary baffle, a first edge of the secondary baffle merges into the vertical wall of the primary baffle, and a second edge is downwardly spaced apart from the second secondary baffle's upper edge and merges into the vertical wall of the primary baffle, such that the second secondary baffle's bounded space is defined in part by a wall of the primary baffle. 
     
     
         16 . The assembly of  claim 7  wherein the secondary baffle(s) has/have a pendulous profile. 
     
     
         17 . The assembly of  claim 7  wherein the secondary baffle(s) is/are disposed on an inner surface of the back layer and are not connected to the back layer so that the face layer does not show any seams or joints for the secondary baffles, the wall with which the second edge of the secondary baffle merges with being the back layer. 
     
     
         18 . The assembly of  claim 1  wherein when the secondary baffle(s) and is/are in an expanded condition, the primary baffle in an expanded profile can receive fill material below the bottom of the secondary baffle(s) and along at least one vertical side of the secondary baffle(s). 
     
     
         19 . The assembly of  claim 10  wherein at least two secondary baffles are disposed in the primary baffle and are arranged at different heights in the primary baffle. 
     
     
         20 . The assembly of  claim 1  wherein at least three secondary baffles are disposed in the primary baffle and are arranged at different heights in the primary baffle. 
     
     
         21 . The assembly of  claim 19  wherein the secondary baffles are each disposed on an inner surface of the back layer and are not connected to the back layer so that the face layer is free of any seams or joints for the secondary baffles. 
     
     
         22 . The assembly of  claim 19  wherein one of the secondary baffles stacks in partial overlap with the lower one of the secondary baffles. 
     
     
         23 . A garment comprising, a panel configured to cover a torso area of a wearer, the panel comprising:
 an assembly of a plurality of baffle constructs, each baffle construct comprising:   a primary baffle, comprising a pliable textile, and one or more secondary baffles, the baffle constructs configured to be alignable along a vertical axis relative to the ground;   each primary baffle defining a bounded, volumetric space for enclosing a first volume of insulative fill material in a first part of the space and a secondary baffle in a second part of the space; and   each secondary baffle defining a bounded, volumetric space for enclosing a second volume of fill material, the secondary baffle being disposed in the primary baffle so that most of the second volume of insulative fill material is contained above most of the insulative material in the first part of the space when the main baffle is maintained in an intended vertical orientation.   
     
     
         24 . The garment of  claim 23  further comprising an insulative fill material disposed in each primary baffle and secondary baffle, the insulative fill material filling the primary baffle and secondary baffles to a desired profile. 
     
     
         25 . A method of producing an insulative panel, comprising:
 providing an assembly of a plurality of baffle constructs, each baffle construct comprising:   a primary baffle, comprising a pliable textile, and one or more secondary baffles, the baffle constructs configured to be alignable along a vertical axis relative to the ground;   each primary baffle defining a bounded, volumetric space for enclosing a first volume of insulative fill material in a first part of the space and a secondary baffle in a second part of the space; and each secondary baffle defining a bounded, volumetric space for enclosing a second volume of fill material, the secondary baffle being disposed in the primary baffle so that most of the second volume of insulative fill material is contained above most of the insulative material in the first part of the space when the main baffle is maintained in an intended vertical orientation; and   filling each primary baffle and secondary baffle with an insulative fill material to a desired profile.