Thermal blankets

Abstract

Among other things, the disclosure features a thermal blanket including a unitary fabric element having predetermined discrete regions of contrasting insulative capacities arranged based on insulative needs of corresponding regions of a user's body. At least two of the predetermined, discrete regions of contrasting insulative capacities, in one or more first discrete regions of the unitary fabric element, consisting of loop yarn having a first pile height, and in one or more other discrete regions of the unitary fabric element, consist of loop yarn having another pile height different from and relatively greater than the first pile height.

1 . A thermal blanket comprising:
 a unitary fabric element,
 the unitary fabric element having a multiplicity of predetermined discrete regions of contrasting insulative capacities, the discrete regions being arranged based on insulative needs of corresponding regions of a user's body, 
 at least two of the predetermined, discrete regions of contrasting insulative capacities comprising
 in one or more first discrete regions of the unitary fabric element, loop yarn having a first pile height, the one or more first discrete regions corresponding to one or more regions of the user's body having first insulative needs, and, 
 in one or more other discrete regions of the unitary fabric element, loop yarn having another pile height different from and relatively greater than the first pile height, the one or more other discrete regions corresponding to one or more regions of the user's body having other insulative needs different from and relatively greater than the first insulative needs. 
 
   
     
     
         2 . The thermal blanket of  claim 1 , wherein the thermal blanket consists essentially of the unitary fabric element. 
     
     
         3 . The thermal blanket of  claim 1 , further comprising additional unitary fabric elements. 
     
     
         4 . The thermal blanket of  claim 1 , wherein each of the multiplicity of predetermined discrete regions extends generally across a width of the thermal blanket in a band form. 
     
     
         5 . The thermal blanket of  claim 1 , wherein the one or more first discrete regions corresponds to one or more of an upper torso, head, and hip of the user's body. 
     
     
         6 . The thermal blanket of  claim 1 , wherein the one or more other discrete regions corresponds to one or more of lower legs and feet, arms, and shoulders of the user's body. 
     
     
         7 . The thermal blanket of  claim 1 , wherein the unitary fabric element comprises a single face raised fabric. 
     
     
         8 . The thermal blanket of  claim 1 , wherein the unitary fabric element comprises a double face raised fabric. 
     
     
         9 . The thermal blanket of  claim 1 , wherein the unitary fabric element comprises warp knit yams and/or fibers, circular knit yams and/or fibers, regular plaited yarns and/or fiber, reverse plaited yams and/or fibers, or woven yarns and/or fibers. 
     
     
         10 . The thermal blanket of  claim 1 , wherein the unitary fabric element comprises a surface containing a chemical resin or a chemical binder for improved pill resistance and/or abrasion resistance. 
     
     
         11 . The thermal blanket of  claim 1 , further comprising an air permeability control element laminated with the unitary fabric element to form a unitary fabric laminate. 
     
     
         12 . The thermal blanket of  claim 11 , wherein the air permeability control element is selected from the group consisting of: perforated membrane, crushed adhesive as a layer, foam adhesive as a layer, discontinuous breatheable membrane, porous hydrophobic breatheable film, and non-porous hydrophilic breatheable film. 
     
     
         13 . The thermal blanket of  claim 1 , further comprising an air and liquid water impermeable element laminated with the unitary fabric element to form a unitary fabric laminate. 
     
     
         14 . The thermal blanket of  claim 1 , wherein the air and liquid water impermeable element is in the form of a breatheable film select from the group consisting of: porous hydrophobic film and non-porous hydrophilic film. 
     
     
         15 . The thermal blanket of  claim 1 , wherein the unitary fabric element comprises yarns and/or fibers of one or more materials selected from the group consisting of: synthetic yarn and/or fibers, natural yarn and/or fibers, regenerate yarn and/or fibers, and specialty yarn and/or fibers. 
     
     
         16 . The thermal blanket of  claim 15 , wherein the synthetic yarn and/or fibers is selected from the group consisting of: polyester yarn and/or fibers, nylon yarn and/or fibers, acrylic yarn and/or fibers, polypropylene yarn and/or fibers, and continuous filament flat or textured or spun yarn made of synthetic staple fibers. 
     
     
         17 . The thermal blanket of  claim 15 , wherein the natural yarn and/or fibers are selected from the group consisting of: cotton yarn and/or fibers and wool yarn and/or fibers. 
     
     
         18 . The thermal blanket of  claim 15 , wherein the regenerate yarn and/or fibers are selected from the group consisting of: rayon yarn and/or fibers. 
     
     
         19 . The thermal blanket of  claim 15 , wherein the specialty yarn and/or fibers are selected from the group consisting of flame retardant yarn and/or fibers. 
     
     
         20 . The thermal blanket of  claim 19 , wherein the flame retardant yarn and/or fibers are selected from the group consisting of: flame retardant aramid yarn and/or fibers, flame retardant polyester yarn and/or fibers, and modacrylic yarn and/or fibers blended with cellulosic with or without other flame retardant fibers. 
     
     
         21 . The thermal blanket of  claim 1 , wherein the one or more first discrete regions having a first pile height comprise loop yarn formed to a relatively lower pile using low sinker and/or shrinkable yarn. 
     
     
         22 . The thermal blanket of  claim 1 , wherein the one or more first discrete regions having a first pile height comprise loop yarn formed to a relatively lower pile height of up to about 1 mm. 
     
     
         23 . The thermal blanket of  claim 1 , wherein the one or more other discrete regions having another pile height different from and relatively greater than the first pile height comprise loop yarn formed to a relatively higher pile height in the range of greater than about 1 mm up to about 20 mm in a single face fabric. 
     
     
         24 . The thermal blanket of  claim 1 , wherein the one or more other discrete regions having another pile height different from and relatively greater than the first pile height comprise loop yarn formed to a relatively higher pile height in the range of greater than about 2 mm up to about 40 mm in a double face fabric. 
     
     
         25 . A thermal blanket comprising:
 an inner fabric layer;   an outer fabric layer; and   an insulating fabric layer attached to the outer fabric layer, wherein the insulating fabric layer is a textile fabric having a raised surface facing towards the outer fabric layer, and   wherein the raised surface includes a plurality of first discrete regions having a first pile height interspersed among a plurality of other discrete regions having contrasting pile height relatively greater than the first pile height.   
     
     
         26 . The thermal blanket of  claim 25 , wherein the insulating-filler fabric layer has a terry sinker loop surface including a plurality of discrete regions of no terry sinker loop interspersed among regions of terry sinker loop. 
     
     
         27 . The thermal blanket of  claim 25 , wherein the insulating fabric layer has a weight of about 1 ounce per square yard to about 12 ounces per square yard. 
     
     
         28 . The thermal blanket of  claim 25 , wherein the insulating-filler fabric layer is quilted to one or both of the inner fabric layer and the outer fabric layer. 
     
     
         29 . The thermal blanket of  claim 25 , wherein the insulating-filler fabric layer is stitched to one or both of the inner fabric layer and the outer fabric layer along a periphery of the thermal blanket. 
     
     
         30 . The thermal blanket of  claim 25 , wherein the insulating-filler fabric layer is laminated to one or both of the inner fabric layer and the outer fabric layer. 
     
     
         31 . The thermal blanket of  claim 25 , wherein the insulating-filler fabric layer is constructed to include face yarn that is positioned generally perpendicular to stitching or backing yarn. 
     
     
         32 . The thermal blanket of  claim 25 , wherein the insulating-filler fabric layer has a thickness (bulk) of about 0.1 inch to about 4.0 inches. 
     
     
         33 . The thermal blanket of  claim 25 , wherein the first pile height in the first discrete regions is zero. 
     
     
         34 . The thermal blanket of  claim 25 , wherein yarns forming the first discrete regions have a denier per filament (dpf) of about 0.3 to about 5.0. 
     
     
         35 . The thermal blanket of  claim 25 , wherein the insulating-filler fabric layer provides insulation of about 0.2 clo/oz 2  to about 1.6 clo/oz 2 . 
     
     
         36 . The thermal blanket of  claim 25 , wherein the inner fabric layer comprises a woven fabric or a knit fabric. 
     
     
         37 . The thermal blanket of  claim 36 , wherein the knit fabric has single jersey construction, double knit construction, warp knit construction, or mesh construction. 
     
     
         38 . The thermal blanket of  claim 25 , wherein the inner fabric layer has air permeability of about 5 ft 3 /ft 2 /min to about 300 ft 3 /ft 2 /min, tested according to ASTM D-737 under a pressure difference of ½ inch of water across the inner fabric layer. 
     
     
         39 . The thermal blanket of  claim 25 , wherein the outer fabric layer has air permeability of about 1 ft 3 /ft 2 /min to about 100 ft 3 /ft 2 /min, tested according to ASTM D-737 under a pressure difference of ½ inch of water across the outer fabric layer. 
     
     
         40 . The thermal blanket of  claim 25 , wherein the outer fabric layer is treated with durable water repellent, an abrasion resistant coating, camouflage, or infrared radiation reduction. 
     
     
         41 . The thermal blanket of  claim 25 , wherein at least one of the inner fabric layer, the outer fabric layer, and the insulating-filler fabric layer includes flame-retardant material and/or is treated to provide flame-retardance. 
     
     
         42 . The thermal blanket of  claim 25 , further comprising a waterproof membrane laminated to an inner surface of the outer fabric layer, and disposed between the outer fabric layer and the insulating-filler fabric layer. 
     
     
         43 . The thermal blanket of  claim 42 , wherein the waterproof membrane is a vapor permeable membrane or is selected from a porous hydrophobic membrane, a hydrophilic non-porous membrane, and an electrospun membrane. 
     
     
         44 . A thermal blanket comprising:
 an inner fabric layer;   an outer fabric layer; and   a unitary fabric element between the inner fabric layer and the outer fabric layer,
 the unitary fabric element having a multiplicity of predetermined discrete regions of contrasting insulative capacities, the discrete regions being arranged based on insulative needs of corresponding regions of a user's body. 
   
     
     
         45 . The thermal blanket of  claim 44  wherein
 at least two of the predetermined, discrete regions of contrasting insulative capacities comprise
 in one or more first discrete regions of the unitary fabric element, loop yarn having a first pile height and/or a first pile density, the one or more first discrete regions corresponding to one or more regions of the user's body having first insulative needs, and, 
 in one or more other discrete regions of the unitary fabric element, loop yarn having a second pile height and/or a second pile density, 
 the second pile height being different from and relatively greater than the first pile height and/or the second pile density being different from and relatively greater than the first pile density, the one or more other discrete regions corresponding to one or more regions of the user's body having other insulative needs different from and relatively greater than the first insulative needs. 
 
 
     
     
         46 . The thermal blanket of  claim 45 , wherein the outer fabric layer comprises a jacquard pattern to be exposed as an exterior surface of the thermal blanket. 
     
     
         47 . The thermal blanket of  claim 45 , wherein the inner fabric layer and/or the outer fabric layer comprise a light weight woven or knit having a density of about 2 oz/yard 2  to about 6 oz/yard 2 . 
     
     
         48 . The thermal blanket of  claim 45 , wherein the inner fabric layer and/or the outer fabric layer comprise a knit having a density of about 1.0 oz/yard 2  to about 10.0 oz/yard 2 . 
     
     
         49 . The thermal blanket of  claim 45 , wherein the unitary fabric element is connected to the outer fabric layer and the inner fabric layer by stitching, quilting, or inserting the unitary fabric layer between the outer and inner fabric layers. 
     
     
         50 . The thermal blanket of  claim 45 , wherein the inner layer comprises a multiplicity of predetermined discrete regions of contrasting insulative capacities corresponding to the multiplicity of predetermined discrete regions of contrasting insulative capacities of the unitary fabric element. 
     
     
         51 . The thermal blanket of  claim 50 , wherein the multiplicity of predetermined discrete regions of the inner fabric comprise:
 in one or more in one or more first discrete regions of the inner fabric corresponding to the one or more first discrete regions of the unitary fabric element, loop yarn having a third pile height and/or a third pile density, and,   in one or more other discrete regions of the inner fabric corresponding to the one or more other discrete regions of the unitary fabric element, loop yarn having a fourth pile height and/or a fourth pile density, the fourth pile height being different from and relatively greater than the third pile height and/or the fourth pile density being different from and relatively greater than the third pile density.   
     
     
         52 . The thermal blanket of  claim 45 , wherein the outer layer comprises a multiplicity of predetermined discrete regions of contrasting insulative capacities corresponding to the multiplicity of predetermined discrete regions of contrasting insulative capacities of the unitary fabric element. 
     
     
         53 . The thermal blanket of  claim 52 , wherein the multiplicity of predetermined discrete regions of the outer fabric comprise:
 in one or more in one or more first discrete regions of the outer fabric corresponding to the one or more first discrete regions of the unitary fabric element, loop yarn having a third pile height and/or a third pile density, and,   in one or more other discrete regions of the outer fabric corresponding to the one or more other discrete regions of the unitary fabric element, loop yarn having a fourth pile height and/or a fourth pile density, the fourth pile height being different from and relatively greater than the third pile height, and/or the fourth pile density being different from and relatively greater than the third pile density.   
     
     
         54 . The thermal blanket of  claim 52 , wherein the unitary fabric element has an air permeability of about 80 CMF to about 200 CMF in the one or more first discrete regions, and an air permeability of about 200 CMF to about 350 CMF in the one or more other discrete regions. 
     
     
         55 . The thermal blanket of  claim 54 , wherein different regions of the thermal blanket have substantially the same permeability as the respective regions of the unitary fabric element. 
     
     
         56 . The thermal blanket of  claim 45 , wherein the loop yam in different regions of the one or more second discrete regions of the unitary fabric element have different pile densities. 
     
     
         57 . The thermal blanket of  claim 45 , wherein the first pile height is the same as the second pile height and the second pile density is greater than the first pile density. 
     
     
         58 . The thermal blanket of  claim 1 , wherein the loop yarn in different regions of the one or more second discrete regions of the unitary fabric element have different pile densities. 
     
     
         59 . The thermal blanket of  claim 25 , wherein different regions of the plurality of other discrete regions have different pile densities.