Van Rysel
Connected cycling vest with smart inflatable insulation
A vest that adapts to the cyclist and their environment
Developed for the Van Rysel brand (Decathlon) in partnership with Jonathan & Fletcher, this innovative cycling vest embeds a smart inflatable thermal insulation technology: it automatically adjusts its volume and insulation level depending on the temperature and the rider's effort.
The technical challenge: combine thermal comfort, lightness and freedom of movement by integrating technical textile, sensors and a miniaturised inflation system into a flexible, breathable, washable garment.
Our technical approach
From inflatable textile to embedded electronics: a mastered integration for a reliable, durable garment.
On-demand thermal insulation
An inflatable envelope trapping an insulating layer of dry air.
We developed an inflatable envelope made of TPU-coated textile, assembled by high-frequency (HF) welding, whose trapped layer of dry air provides thermal insulation on demand. This development included defining the thermal protection zones as well as fine-tuning the inflation shapes and volumes.
A smart inflation system
A custom pump unit that controls the insulation fully autonomously.
The vest embeds a custom-built smart pump unit that continuously monitors inside and outside temperatures and pressures. It autonomously drives the inflation level, delivering optimised thermal insulation on demand, without any input from the rider.
Integration without compromise
Co-designed with the client and their design / apparel team.
Working hand in hand with the client and their design / apparel team, we pursued the perfect integration of the system into the garment. The result: a comfortable, lightweight and breathable product, with no compromise on robustness or design.
Prototyping, testing & validation
A complete journey, from the idea to the final field-tested prototype.
Thanks to our engineering team and our in-house prototyping workshop, we developed, manufactured, tested and optimised the electronics, the mechanics and the textile of this product, through fast iterations validated in the field.
Results & impact
Regulating a garment's insulation through an electronically controlled layer of air: an unprecedented technical challenge at the crossroads of technical textiles, miniaturised pneumatics and embedded electronics. Air-tightness, battery life, washability, comfort — every constraint was solved without degrading the sporting experience.
The Van Rysel vest illustrates the level of innovation that integrated multidisciplinary engineering makes possible: a garment that continuously adapts its thermal insulation to the environment and the rider's effort — a rarity in sports apparel.
Status: functional prototype — in pre-industrialisation phase
Complementary expertise
An integrated textile, electronic and inflatable design
This project illustrates the synergy between our Smart Textile, Inflatable Systems and Electronics teams for next-generation technical garments.
Inflatable Systems
Development of flexible membranes, overmoulding and integrated pneumatic control.
Do you have a smart textile project?
AQ-Tech designs and integrates electronic and inflatable technologies into technical textiles. Let's discuss your future connected products together.
