ThermArk THERMAL INSULATION FOR HOMELESS AND DISASTER RELIEF

KINSEY CANOVA, TYLER RICE, JARAD HEIMER, & ERIN FLYNN

INTRODUCTION

INTRODUCTION

• In the state of Georgia, on any given night, approximately 6,000 people are sleeping unsheltered

• About 700 people die from hypothermia due to homelessness in the US annually• For comparison, on average

400 people die from police shootings annually.

CURRENTLY AVAILABLE OPTIONS

CURRENT TECHNOLOGIES

• Bivy retails for about $60 on the low end

• Emergency shelters can be expensive and too noticeable for use in urban areas

Product Description Low-cost, high-efficiency thermal insulator that protects the user from wet, wind, and cold environments commonly faced by the homeless and/or victims of a disaster.

MISSION STATEMENT

Benefit Proposition• Can be rapidly distributed• Waterproofing and heat-reflective

capability• High efficiency: able to keep a person

warm while lightweight and cheapKey Business Goals• Cheap to produce and transport to relief

site• Environmentally friendly• Give consumers peace of mind for

emergency preparation

Assumptions and Constraints• Can be used for rough sleeping and in

shelters• Waterproof• Breathable• Non-Toxic components• ReusablePotential Markets• Homeless and Disaster Relief(PRIMARY)• Disaster Kits• Doomsday preppers• Camping

USER NEEDS

Functionality• Thermally insulating• No risk of suffocation• Thermal protection

against ground• Waterproof• Wind breaker

Affordability• Low-cost

Portability• Simple packing• Lightweight• Packs to small volume• Easy to carry• Acceptable to mass

transit systems

Safety• Discrete• Can see surroundings

from inside• Antimicrobial • Condensation escapes• Meets local

restrictions• Locking mechanism

Reliability• Survives opening and

closing

Usability• Condensation can

escape• Spatially efficient• Expandable• Comfortable

Durability• Endures one month of

use• Can be cleaned• Retains function when

punctured/abraded• Gouge resistant

SUPER GROUP DEFINITION

Functionality- protects against temperatures and weather

Affordability- price range affordable for charities and shelters

Durability- lasts for extended period of time of multiple uses

Safety- does not contribute to increased safety risk

Portability- can be easily packed and moved from place to place

Reliability- works when it needs to work

Usability- nice-to-haves; more about comfort than necessity

SUPER GROUPS MATRIX

ITY Functionality Usability Durability Safety Portability Affordability Reliability Sum Normalized (%)

Functionality 10 5 1 5 1 5 27 23.94%

Usability 0.1 0.1 0.1 0.2 0.1 0.2 0.8 0.71%

Durability 0.2 10 1 1 0.2 5 17.4 15.43%

Safety 1 10 1 0.2 0.2 5 17.4 15.43%

Portability 0.2 5 1 5 1 5 17.2 15.25%

Affordability 1 10 5 5 1 5 27 23.94%

Reliability 0.2 5 0.2 0.2 0.2 0.2 6 5.32%

Totals 112.8 100.0%

NEEDS-METRICS MATRIX

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Need Metric

Thermally Insulating

Internal Temperature

Breathable

Water-Resistance

Wind-breaking

Consumer Cost

Cost to Manufacture

Cost of Distribution

Percent Recycled Materials Used

Chemical resistance

Lifetime of product

Use Cycles until failure

Yield Strength

Glass Transition Temperature

Load required to open

Visibility of user

Internal Humidity

User Visibility

Microbial Growth

Legality

Steps to breakdown

Time to breakdown

No unused material on product

Volume when packed

Weight

Follows rules for MARTA, bus, etc.

Conducive to Sleep

Length

Width

Height

Sound Dampening

1 Thermally insulating et. al. x x 2 No risk of suffocation x 3 Thermal protection against ground x x 4 Waterproof x 5 Windbreaker/Wind-proof/resistant x 6 Low-cost x x x x 7 Endures one month of use x x x x x 8 Can be cleaned x 9 Functions when abraded etc. x x

10 Gouge resistant x x 11 Discrete x 12 Able to see surroundings from inside x 13 Antimicrobial x 14 Breathable x x 15 Meets restrictions set by locality x 16 Locking mechanism 17 Simple packing x x 18 Lightweight x x 19 Packable to fit in small volume x x 20 Convenient to carry x x x x 21 Carry in mass transit systems x x x x 22 Survives opening and closing x x x x 23 Breathable x x x 24 Spatially efficient x x x x x 25 Expandable x x x 26 Comfortable x x x x x x

NEEDS-METRICS MATRIX BREAKDOWN

Part 1

Thermally Insulating

Internal Temperature

Breathable

Water-Resistance

Wind-breaking

Consumer Cost

Cost to Manufacture

Cost of Distribution

Percent Recycled Materials Used

Chemical resistance

Lifetime of product

Use Cycles until failure

Yield Strength

Glass Transition Temperature

Load required to open

Visibility of user

User Visibility

Microbial Growth

Thermally insulating et. al. x x No risk of suffocation x Thermal protection against ground x x

Waterproof x Windbreaker/Wind-proof/resistant x

Low-cost x x x x Endures one month of use x x x x x Can be cleaned x

Functions when abraded etc. x x

Gouge resistant x x Discrete x Able to see surroundings x Antimicrobial x

NEEDS-METRICS MATRIX BREAKDOWN

Part 2

Breathable

Lifetime of product

Use Cycles until failure

Yield Strength

Load required to open

Internal Humidity

Legality

Steps to pack

Time to pack

No unused material on product

Volume when packed

Weight

Allowed on public transportation

Conducive to Sleep

Length

Width

Height

Sound Dampening

Breathable x x

Meets local restrictions x

Locking mechanism

Simple packing x x

Lightweight x x

Packable to fit in small volume x x

Convenient to carry x x x x

Carry in mass transit systems x x x x

Survives opening and closing x x x x

Breathable x x x

Spatially efficient x x x x x

Expandable x x x

Comfortable x x x x x x

INITIAL CONCEPTS

Structure• Livable Laundry Basket• Bivy-style• Accordion Sleeper• Garage Door Concept• Intense Sleeping Bag

Insulation• Alternating Rings of

Vacuum and Foam• Water-Resistant Liner• Emergency Blanket Liner• Heat Reflective Layer• Multi-Layer Closing Mechanisms• Button snaps• Zippers• Ties

CONCEPT SCORING MATRIX: STRUCTURE

Structure Concepts Spring Tube Sleeping Bag Bivy-Style Garage Door Accordion Style

Functionality 3 3 3 3 3

Affordability 3 4 2 3 2

Durability 2 3 3 3 2

Safety 1 1 3 3 3

Portability 3 3 3 1 3

Reliability 2 3 3 2 2

Usability 3 4 2 2 3

Weighted Score 248.39 293.79 275.29 263.43 255.25

Final Selection: Intense Sleeping Bag• Simple design reduces cost and improves usability

CONCEPT SCORING MATRIX: INSULATION

Insulation Concepts Vacuum-Foam Rings

Emergency Blanket Liner

Multi-Layer Sandwich

Heat Reflective Liner

Waterproof Liner

Functionality 4 3 4 3 3

Affordability 1 4 3 3 1

Durability 1 2 3 4 3

Safety 2 2 2 4 3

Portability 1 4 1 2 3

Reliability 1 2 3 4 3

Usability 2 2 3 3 3

Weighted Scores 187.91 302.26 278 320.85 252.06

Final Selection: Multi-Layer• Each layer can serve a purpose to make best overall product• Waterproof outside, Heat-reflective inside, and Insulation between

CONCEPT SCORING MATRIX: CLOSING MECHANISM

Closing Mechanism Concepts Snap Zipper Tie

Functionality 3 3 2

Affordability 3 3 4

Durability 3 2 3

Safety 3 4 3

Portability 3 2 3

Reliability 3 3 3

Usability 4 4 2

Weighted Scores 300.65 285.38 299.23

Final Selection: Snaps• Low cost, low weight, and easy to use

FINAL CONCEPT

• Intense Sleeping Bag structure

• Using multi-layer insulation • Waterproof outside layer

• Insulating material between

• Heat-reflective inside layer

• Snaps for closing mechanism

MATERIALS SELECTION: CANDIDATES

• Bottom Layer• PET• LDPE• Cork• Neoprene

• Outer Layer• PVC• Polyester• LDPE• PET

• Insulation• PET Foam• LDPE Foam• Polyimide Foam• Polyurethane Foam

• Inner Layer• PET• Aluminum-LDPE sandwich• Alumina Foam

• Snaps• PVC• Brass• ABS• Polypropylene

MATERIALS SELECTION: FINAL RESULTS

• LDPE Foam sandwiched between layers of LDPE• Single material increases

recyclability

• Aluminized inner layer of LDPE• Adds manufacturing cost but

improves functionality

• Snaps made of PVC• Readily available and low cost

MANUFACTURING STEPS

1. Extrude LDPE sheets and foam

2. Use physical vapor deposition to aluminize one LDPE layer

3. Align and cut layers into units

4. Hot bar weld LDPE layers together

5. Fasten snaps on edges

DESIGN FOR SUSTAINABILITY

Sustainability Measure Product Score ThermArk

Inherent Rather Than Circumstantial

Designers need to strive to ensure that all materials and energy inputs and outputs are as inherently nonhazardous as possible.

YesNo hazardous waste produced in manufacture, and product materials are chosen to minimize health risk

Prevention Instead of Treatment

It is better to prevent waste than to treat or clean up waste after it is formed. Yes Process does not produce any harmful

emissions to be scrubbed

Design for SeparationSeparation and purification operations should be designed to minimize energy consumption and materials use.

Yes Easily separated materials used.

Maximize Efficiency Products, processes, and systems should be designed to maximize mass, energy, space, and time efficiency. Yes Product and process designed to maximize

efficiency

Output-Pulled Versus Input-Pushed

Products, processes, and systems should be "output pulled" rather than "input pushed" through the use of energy and materials. Demand-Driven Production

No Market demand and production are based on emergency preparation.

Conserve ComplexityEmbedded entropy and complexity must be viewed as an investment when making design choices on recycle, reuse, or beneficial disposition.

Yes Fabricated from one material so it can be recycled without separation

DESIGN FOR SUSTAINABILITY

Sustainability Measure Product Score ThermArk

Durability Rather Than Immortality

Targeted durability, not immortality, should be a design goal. No Not biodegradeable but recyclable

Meet Need, Minimize Excess

Design for unnecessary capacity or capability solutions should be considered a design flaw. Yes No extra "bells and whistles" and is a "one-

size fits all" configuration

Minimize Material Diversity

Material diversity in multi-component products should be minimized to promote disassembly and value retention.

Yes Three materials are used: LDPE, PVC, and aluminum

Integrate Material and Energy Flows

Design of products, processes, and systems must include integration and interconnectivity with available energy and materials flows.

Yes Product and energy move linearly through assembly

Design for Commercial "Afterlife"

Products, processes, and systems should be designed for performance in a commercial "afterlife." Yes May be recycled

Renewable Rather Than Depleting

Material and energy inputs should be renewable rather than depleting. Yes Material can be made of recycled material

INDUSTRIAL DESIGN EVALUATION

Quality of User Interface

Emotional Appeal

Ability to Maintain the Product

Appropriate Use of Resources

Product Differentiation

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Series2

Percent importance

FINAL DESIGN

• Sleeping bag style design

• Insulation of LDPE foam between LDPE sheets• Outside layer is gray

• Inside layer is aluminized

• Adjustable snapping geometry

• Made from recycled materials and be recycled

BILL OF MATERIALS

Per item Per factory

Purchased

materials (Average USD/item

)

Processing

(Machine+Labor

)

Assembly

(labor)

Total Unit

variable cost

Tooling and

NREs

Tooling lifetime (yr)

Total unit fixed cost (per year)

Total cost

PVC Snaps 0.0429 0.0167 0.0444 0.1040 3770 5 754

6.05x + 2104 (USD/yr)Outer/Inner LDPE shells 0.7087 0.0167 0.0056 0.7309 3000 3 1000LDPE foam 4.7695 0.0167 0.0056 4.7917

Aluminum heat reflector 0.2555 0.1667 0.0056 0.4277 1000 3 350

Total Labor: $20 per hour 6.0543 2104 x = # units per year

FINAL PRODUCT SPECIFICATIONS

Metric Description Unit Final ProductThermally insulating BTU/hr 1315.8-1258.9Breathable mL/hr 0.00027Water-Resistance % Water absorption @ 24 hours 0.01%Wind-breaking mph 50Consumer Cost $ $12 Cost to Manufacture $ per unit $10 Cost of Distribution $ per unit $2 Percent Recycled Materials Used % 0-100%Lifetime of product Days 25-40Use Cycles until failure Discrete 90(-20)Material Strength Yield strength, ksi 1.3-2.1Load required to open Load, kg 0-10Chemical Resistance Acceptability Acceptable. Visibility subjective Outside dull gray colorUser Visibility Binary Yes Microbial Growth CFU's/ml Can be washed to remove bacteriaSteps to set-up/breakdown steps 2-5Time to set-up/breakdown minutes 1.5-8No unused material on product Unitless, binary MeetsVolume when packed ft^3 3.672Weight lb 4.94-4.71Follows rules for MARTA, bus, etc. Unitless, binary MeetsConducive to Sleep subjective Provides some cushioningLength ft 7Width ft 6Sound Dampening Db 30-50

IS IT FEASIBLE?

• The market exists

• It can save lives

• It is designed to fit the unique needs of the homeless

• It has a sustainable lifecycle

Yes!

LESSONS LEARNED

• Attempting to design concepts without materials influencing ideas is difficult.

• Look into patents from the beginning, for both ideas and to see what is done.

• Iteration is the heart of design.

REFERENCES

[1] J. Tanner (January 29, 2014), Atlanta ‘Snowpocalypse’ Mocked After2 Inches of Snow Strands Thousands, Atlanta, Ga: Wordpress.com. Retrieved from: http://pix11.com/2014/01/29/atlanta-snowpocalypse-mocked-on-twitter-after-2-inches-of-snow-strands-thousands/.

[2] No Author (September 2015), 2015 Report on Homelessness; Georgia’s 14,000, Atlanta, Ga: Georgia Department of Community Affairs. Retrieved from: http://www.dca.state.ga.us/housing/specialneeds/programs/documents/HomelessnessReport2015.pdf.

[3] R. Sturgis, A. Sirgany, M. Stoops, and N. Donovan (January 2010), Winter Homeless Services: Bringing Our Neighbors in from the Cold, Tallahassee, Fl: National Coalition for the Homeless. Retrieved from: http://www.nationalhomeless.org/publications/winter_weather/report.html.

[4] Clare (May 21, 2015), Global Camping Equipment Market Trend Forecast and Opportunity Analysis, New York, NY: PR Newswire. Retrieved from: http://www.prnewswire.com/news-releases/global-camping-equipment-market-trend-forecast-and-opportunity-analysis-300087306.html.

[5] D. Ronca (November 24, 2009), How Space Blankets Work, HowStuffWorks.com. Retrieved from: http://adventure.howstuffworks.com/survival/gear/space-blanket.htm.

[6] CES Edupack 2016 (Granta Design Limited, 2016)

[7] No Author (2016), Sleeping Bags, Bivi Bags and Bed Rolls, Worcestershire, England, United Kingdom: SurplusAndOutdoors.com. Retrieved from: https://www.surplusandoutdoors.com/shop/camping-equipment/sleeping-bags.html.

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[9] No Author (2016), Physical Vapor Deposition (PVD), Sigma-Aldrich Co. Retrieved from: http://www.sigmaaldrich.com/materials-science/material-science-products.html?TablePage=108832720.

[10] H. L. Willis and C.T. Martin (March 28, 2012), ‘An Ordinance to Amend Atlanta Code of Ordinances Chapter 106, Article 1, Section 106-12, Entitled Urban Camping and Improper use of Public Places; and for Other Purposes’. Atlanta, Ga: City of Atlanta Government. Retrieved from: http://citycouncil.atlantaga.gov/2012/images/adopted/0319/12O0360.pdf.

[11] E. J. Kuncir, R. W. Wirta, and F. L. Golbranson (November 3, 1990), Load-Bearing Characteristics of Polyethylene foam: An Examination of Structural and Compression Properties, San Diego, Ca: Department of Veterans Affairs. Retrieved from: http://www.rehab.research.va.gov/jour/90/27/3/pdf/kuncir.pdf.

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[13] G. Ogin (2016), How Much Heat Per Hour do Humans Dissipate?, St. Paul, Mn: University of St. Thomas. Retrieved from: http://www.physlink.com/education/askexperts/ae420.cfm.

[14] C. Adams (January 14, 2011), Do You Really Sweat One Liter Each Night?, Washington City Paper. Retrieved from: http://www.washingtoncitypaper.com/news/city-desk.

AP File Photo. Available: http://www.nola.com/news/index.ssf/2009/07/katrinas_displaced_worry_about.html

Décor Linen. Available: http://decorlinen.com/images/blankets/blankets-21.jpg

Amazon. Available: https://images-na.ssl-images-amazon.com/images/I/41mKYGT8UeL.jpg

REI. Available: https://www.rei.com/media/e87e205d-46f2-4030-9192-efb04ea819f1

Tyler Rice

Jarad Heimer

Kinsey Canova

Erin Flynn(& Bill Nye the Science Guy)