Durable, anti-pilling nonwoven insulation

Abstract

A batt is provided that includes a bonded nonwoven web made from a fiber mixture that contains: (a) 20 to 55 weight percent of siliconized fibers having a denier of 1.5 to 10.0 and a length of 51 mm to 84 mm; (b) 10 to 45 weight percent of hollow composite fibers, the hollow composite fibers having a spiral crimp and having a denier of 1.5 to 10.0 and a length of 51 to 84 mm; (c) 10 to 45 weight percent of a first group of binder fibers, the first group of binder fibers being elastomeric copolyester binder fibers having a denier of 1.5 to 8.0, a length of 51 mm to 84 mm, and a bonding temperature of 110°C to 180°C; and (d) 1 to 20 weight percent of a second group of binder fibers, the second group of binder fibers having a denier of 1.5 to 6.0, a length of 51 mm to 84 mm, and a bonding temperature of 80°C to 135°C.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 150,311, filed on February 17, 2021, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This invention generally relates to durable, pilling / fiber migration-resistant nonwoven barrier materials, methods for preparing the barrier materials, and articles comprising the barrier materials. Barrier materials are particularly useful in the textile industry. Background Technology

[0004] Fibers and filling materials, including synthetic fibers and natural filling materials (such as down), have long been used as insulating materials in the textile industry. For example, the outdoor industry has used fibers and down for many years in clothing, cold-weather jackets, sleeping bags, and so on. However, a disadvantage of using such fibers is that this type of insulating material is very prone to pilling or exhibits significant fiber migration through the fabric surface, even when combined with low-air-permeability down-proof fabrics and / or protected by nonwoven loose materials.

[0005] Loose fabric is a type of lining that is typically used as a protective layer between the outer shell and the inner lining fabric of an article. Fiber migration is the penetration of fibers through the surface of a fabric, resulting in fibers remaining on the front side of the article, which is usually the exterior of the article exposed to the external environment. Pilling refers to the tendency of fibers to loosely act from the fabric surface and form fibrous particles that remain attached to the fabric surface, forming balls or napped surfaces.

[0006] Down-proof fabrics are generally defined as tightly woven fabrics with a yarn count greater than 250 and an air permeability rating of less than 1 cubic foot per minute (CFM) according to ASTM D737. Sometimes, the fabric has a coating applied to it or is calendered to seal its surface as a means of reducing fiber migration and / or achieving down-proof properties. These treatments further reduce the fabric's air permeability, which has a direct impact on the overall comfort of the finished product. The lower the air permeability of a fabric, the worse its breathability and comfort. The higher the air permeability of a fabric, the better its breathability and comfort.

[0007] Certain types of anti-migration insulators used in the textile industry are known in the art. These insulators typically consist primarily of high-denier fibers exceeding 1.0 denier and contain no hydrophobic finishing agents. An anti-migration surface is created on these types of commonly produced general-purpose insulators using commercially available chemical resins as adhesives on the insulator surface. However, various disadvantages are associated with this type of treatment, including the fact that the treatment makes the insulator feel stiff and brittle, reduces stretch, and is uncomfortable to wear. Furthermore, most commercially available chemical resins used to create anti-migration surfaces rapidly absorb water, which is a significant drawback for textiles requiring both performance and comfort, such as outdoor products.

[0008] Therefore, there is a need for an improved barrier that has the required properties and also improves resistance to fiber migration or prevents fiber migration (including pilling).

[0009] Although certain aspects of conventional techniques have been discussed in order to disclose the invention, the applicant does not waive these aspects and anticipates that the claimed invention may include one or more of the conventional techniques discussed herein.

[0010] In this specification, any reference to or discussion of a document, act, or knowledge item is not an admission that the document, act, or knowledge item, or any combination thereof, was publicly available, publicly known, part of common general knowledge, or constituted prior art under applicable law as of the priority date; or that it was known to be related to any attempt to solve any problem covered in this specification. Invention Overview

[0012] In short, the present invention addresses the need for an improved barrier that resists fiber migration and pilling, and also provides excellent properties, including barrier properties and absorbency. The present invention can solve one or more problems and deficiencies in the art discussed above. However, it is contemplated that the present invention can prove useful in solving other problems and deficiencies in many other technical fields. Therefore, the claimed invention should not be construed as limited to solving any particular problem or deficiency discussed herein.

[0013] The applicant was surprised to find that certain embodiments of the insulating body of the present invention, which comprises a fiber mixture, discussed herein possess the desired properties, including good thermal properties, good water absorption properties (i.e., the embodiment does not absorb unacceptable amounts of water), rapid drying time, and resistance to or prevention of fiber migration and / or pilling.

[0014] In a first aspect, the present invention provides a flocculent comprising an adhesive nonwoven web, the flocculent having a first surface parallel to a second surface, and the adhesive nonwoven web comprising a fiber mixture, the fiber mixture containing, based on the total weight of the fiber mixture:

[0015] (a) 20 to 55% by weight of siliconized fibers having a denier of 1.5 to 10.0 and a length of 51 to 84 mm;

[0016] (b) 10 to 45% by weight of hollow composite fibers having a helical crimp and a denier of 1.5 to 10.0 and a length of 51 to 84 mm;

[0017] (c) 10 to 45% by weight of a first group of bonding fibers, wherein the first group of bonding fibers are elastomeric copolyester bonding fibers having a denier of 1.5 to 8.0, a length of 51 mm to 84 mm, and a bonding temperature of 110°C to 180°C; and

[0018] (d) 1 to 20% by weight of a second group of adhesive fibers that are different from the first group of adhesive fibers, the second group of adhesive fibers having a denier of 1.5 to 6.0, a length of 51 mm to 84 mm, and an adhesive temperature of 80°C to 135°C;

[0019] The fibers in the fiber mixture are uniformly mixed.

[0020] In a second aspect, the present invention provides an article comprising a flocculent material according to the first aspect of the invention.

[0021] In a third aspect, the present invention provides a method for manufacturing a flocculent substance according to the first aspect of the invention or an article according to the second aspect of the invention. The method includes:

[0022] -The fiber mixture of the present invention is prepared by mixing the following substances:

[0023] (a) 20 to 55% by weight of siliconized fibers having a denier of 1.5 to 10.0 and a length of 51 mm to 84 mm;

[0024] (b) 10 to 45% by weight of hollow composite fibers, said hollow composite fibers having a helical crimp and having a denier of 1.5 to 10.0 and a length of 51 to 84 mm;

[0025] (c) 10 to 45% by weight of a first group of bonding fibers, wherein the first group of bonding fibers are elastomeric copolyester bonding fibers having a denier of 1.5 to 8.0, a length of 51 mm to 84 mm, and a bonding temperature of 110°C to 180°C; and

[0026] (d) 1 to 20% by weight of a second group of adhesive fibers that are different from the first group of adhesive fibers, wherein the second group of adhesive fibers has a denier of 1.5 to 6.0, a length of 51 mm to 84 mm, and an adhesive temperature of 80°C to 135°C;

[0027] - (e.g., via combing) forming a nonwoven web from a fiber blend;

[0028] - Provide a nonwoven web, or optionally laminate a nonwoven web formed of a fiber mixture with one or more (e.g., 1, 2, 3, 4 or 5) other nonwoven webs (e.g., cross-laying);

[0029] - Heating a nonwoven web to or above the maximum bonding temperature of the bonding fibers to form a flocculent or flocculent intermediate comprising one or more nonwoven webs, which at least includes a bonded nonwoven web comprising a fiber mixture, the flocculent or flocculent intermediate having a first surface parallel to the second surface;

[0030] - Optionally, the resin solution is applied to the first and second surfaces of the flocculent intermediate;

[0031] - Optionally, the flocculent intermediate is heated to a temperature exceeding the glass transition temperature of the resin in the resin solution; and

[0032] -Optional one or more surfaces of the calendered flocculent intermediate.

[0033] This results in the formation of flocculent matter.

[0034] Certain embodiments of the flocculent material, articles comprising the flocculent material, and methods for manufacturing the flocculent material disclosed in this invention have several features, none of which alone is responsible for their desired properties. Without limiting the scope of the flocculent material, articles, and methods as defined by the appended claims, their more prominent features will now be briefly discussed. After considering this discussion, and especially after reading the section entitled “Detailed Description of the Invention” in this specification, it will be understood how the features of the various embodiments disclosed herein provide numerous advantages over the prior art. For example, embodiments of the invention provide improved barrier materials (flocculent materials) that significantly reduce and / or prevent pilling and / or fiber migration. Such barrier materials are particularly useful in the textile field, such as clothing, outerwear, home furnishings, bedding, etc.

[0035] These and other features and advantages of the invention will become apparent from the following detailed description of various aspects of the invention, taken in conjunction with the appended claims and drawings. Attached Figure Description

[0036] The invention will be described below with reference to the following figures, which are not necessarily drawn to scale:

[0037] Figure 1 A side cross-sectional view of one embodiment of the flocculent material of the present invention is shown.

[0038] Figure 2A side cross-sectional view of one embodiment of the flocculent material of the present invention is shown.

[0039] Figure 3A -F describes a non-limiting example of the cross-section that the bicomponent adhesive fibers used in certain embodiments of the present invention may have. Invention Details

[0041] The invention, including its various aspects, features, advantages, and details, is explained more fully below with reference to the non-limiting embodiments shown in the accompanying drawings. Descriptions of well-known materials, manufacturing tools, processing techniques, etc., are omitted to avoid unnecessarily obscuring the details of the invention. However, it should be understood that while the detailed specification and specific embodiments indicate embodiments of the invention, they are given by way of illustration only and not by way of limitation. Various substitutions, modifications, additions, and / or arrangements within the spirit and / or scope of the basic inventive concept will be apparent to those skilled in the art based on this disclosure.

[0042] In a first aspect, the invention provides a flocculent comprising an adhesive nonwoven web having a first surface parallel to a second surface, and the adhesive nonwoven web comprising a fiber mixture, the fiber mixture containing, based on the total weight of the fiber mixture:

[0043] (a) 20 to 55% by weight of siliconized fibers having a denier of 1.5 to 10.0 and a length of 51 mm to 84 mm;

[0044] (b) 10 to 45% by weight of hollow composite fibers, said hollow composite fibers having a helical crimp and having a denier of 1.5 to 10.0 and a length of 51 to 84 mm;

[0045] (c) 10 to 45% by weight of a first group of bonding fibers, wherein the first group of bonding fibers are elastomeric copolyester bonding fibers having a denier of 1.5 to 8.0, a length of 51 mm to 84 mm, and a bonding temperature of 110°C to 180°C; and

[0046] (d) 1 to 20% by weight of a second group of adhesive fibers different from the first group of adhesive fibers, wherein the second group of adhesive fibers has a denier of 1.5 to 6.0, a length of 51 mm to 84 mm, and an adhesive temperature of 80°C to 135°C;

[0047] The fibers in the fiber mixture are uniformly mixed.

[0048] Figure 1A side cross-sectional view of one embodiment of the flocculent 10 of the present invention is shown. The flocculent 10 includes a first surface 2 parallel to the second surface 4. The embodiment of the flocculent 10 comprises a single bonded nonwoven web 6 containing a fiber mixture (which may be referred to herein as "the fiber mixture of the present invention"), which, based on the total weight of the fiber mixture, contains: (a) 20 to 55% by weight of siliconized fibers having a denier of 1.5 to 10.0 and a length of 51 mm to 84 mm; and (b) 10 to 45% by weight of hollow composite fibers having a helical crimp and having a denier of 1.5 to 10.0 and a length of 51 mm to 84 mm. (c) 10 to 45% by weight of a first group of bonding fibers, the first group of bonding fibers being elastomeric copolyester bonding fibers having a denier of 1.5 to 8.0, a length of 51 to 84 mm, and a bonding temperature of 110°C to 180°C; and (d) 1 to 20% by weight of a second group of bonding fibers different from the first group of bonding fibers, the second group of bonding fibers having a denier of 1.5 to 6.0, a length of 51 to 84 mm, and a bonding temperature of 80°C to 135°C.

[0049] Embodiments of the flocculent material of the present invention include one or more bonded nonwoven fiber webs (e.g., 1, 2, 3, 4, 5, 6, etc.). Figure 1 In this depiction, the flocculent 10 comprises a single bonded nonwoven web 6. In the depicted flocculent, the first surface 2 and the second surface 4 of the flocculent 10 are also opposing parallel surfaces of the bonded nonwoven web 6. On the other hand, Figure 2 A side cross-sectional view of one embodiment of the flocculent 10′ of the present invention is shown, comprising two bonded nonwoven webs 6 and 8 interlaced with each other. In embodiments comprising more than one nonwoven web, at least one nonwoven web comprises the fiber mixture of the present invention. In some embodiments, a majority of the nonwoven webs contained in the flocculent comprise the fiber mixture of the present invention. In some embodiments, all the nonwoven webs contained in the flocculent comprise the fiber mixture of the present invention.

[0050] Denier is a unit of measurement defined as the weight (in grams) of 9000 meters of fiber or yarn. It is a common way to specify the weight (or size) of a fiber or yarn. For example, a 1.0 denier polyester fiber typically has a diameter of about 10 micrometers.

[0051] (a) Siliconized fibers having a denier of 1.5 to 10.0 and a length of 51 mm to 84 mm

[0052] The fiber blend of the present invention comprises 20 to 55% by weight of siliconized fibers (sometimes referred to herein as "silicified fibers (a)") having a denier of 1.5-10.0 and a length of 51 mm-84 mm. For example, in some embodiments, the fiber blend of the present invention comprises 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, or 55% by weight of siliconized fibers (a), including any and all of these ranges and subranges (e.g., 20-45% by weight, 20-40% by weight, 25-35% by weight, etc.).

[0053] As used herein, the term "silicification" refers to coating fibers with a silicon-containing composition (e.g., silicone). Siliconization techniques are well known in the art and are described, for example, in U.S. Patent No. 3,454,422. Any method known in the art, such as spraying, mixing, impregnation, padding, etc., can be used to apply the silicon-containing composition. Silicon-containing (e.g., silicone) compositions, including organosiloxanes or polysiloxanes, can be bonded to the exterior of the fibers. In some embodiments, the silicone coating is a polysiloxane, such as methylhydropolysiloxane, modified methylhydropolysiloxane, polydimethylsiloxane, or amino-modified dimethylpolysiloxane. As known in the art, the silicon-containing composition can be applied directly to the fibers, or it can be diluted with a solvent to form a solution or emulsion, such as an aqueous emulsion of a polysiloxane, prior to application. After treatment, the coating can be dried and / or cured. As known in the art, catalysts can be used to accelerate the curing of the silicon-containing composition (e.g., a polysiloxane containing Si-H bonds) and, for convenience, can be added to the silicon-containing composition emulsion, wherein the resulting combination is used to treat synthetic fibers. Suitable catalysts include iron, cobalt, manganese, lead, zinc, and tin salts of carboxylic acids, such as acetates, octanoates, naphthenates, and oleates. In some embodiments, after siliconization, the fibers can be dried to remove residual solvent, and then optionally heated to 65°C to 200°C for curing.

[0054] The denier of the siliconized fiber (a) is 1.5 to 10.0, for example 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6. 6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, or 10.0 denier, including any and all of these ranges and subranges (e.g., 2 to 10 denier, 3 to 10 denier, 4 to 10 denier, 5 to 10 denier, 6 to 10 denier, 5 to 9 denier, 6 to 8 denier, 6.5 to 7.5 denier, etc.).

[0055] The length of the siliconized fiber (a) is 51 to 84 mm, such as 51, 52, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, or 84 mm, including any and all of these ranges and subranges (e.g., 60 to 84 mm, 65 to 84 mm, 70 to 80 mm, etc.).

[0056] In some embodiments, the siliconized fiber (a) is a hollow fiber. In some embodiments, the siliconized fiber (a) is a solid (non-hollow) fiber.

[0057] In some embodiments, the siliconized fiber (a) is a polymer fiber. In a particular embodiment, the siliconized fiber (a) is a polyester fiber. In some embodiments, the siliconized fiber (a) comprises recycled polyester (e.g., post-consumer recycled (PCR) polyester).

[0058] (b) Hollow composite fibers having a helical crimp and a denier of 1.5 to 10.0 and a diameter of 51 to 84 mm. length

[0059] The fiber blend of the present invention comprises 10 to 45% by weight of hollow composite fibers having a helical crimp and a denier of 1.5 to 10.0 and a length of 51 to 84 mm (sometimes referred to herein as "hollow composite fiber (b)"). For example, in some embodiments, the fiber blend of the present invention comprises 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44 or 45% by weight of hollow composite fibers (b), including any and all of these ranges and subranges (e.g., 15-45% by weight, 20-40% by weight, 25-35% by weight, etc.).

[0060] Hollow composite fiber (b) has a spiral (helical) crimp.

[0061] The denier of the hollow composite fiber (b) is 1.5 to 10.0, for example 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, or 10.0 denier, including any and all ranges and their subranges (e.g., 2 to 10 denier, 3 to 10 denier, 4 to 10 denier, 5 to 10 denier, 6 to 10 denier, 5 to 9 denier, 6 to 8 denier, 6.5 to 7.5 denier, etc.).

[0062] The length of the hollow composite fiber (b) is 51 to 84 mm, for example 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83 or 84 mm, including any and all of these ranges and subranges (e.g. 51-75 mm, 55-75 mm, 60-70 mm, etc.).

[0063] The hollow composite fibers (b) can be siliconized or dried (i.e., unsiliconized). In some embodiments, the hollow composite fibers (b) are dried and have not undergone any surface chemical treatment. In some embodiments, the hollow composite fibers (b) have been surface chemically treated (e.g., they are siliconized).

[0064] In some embodiments, the composite fiber (b) is a polymer fiber. In a particular embodiment, the composite fiber (b) is a polyester fiber. In some embodiments, the composite fiber (b) comprises recycled polyester (e.g., PCR polyester).

[0065] First group of adhesive fibers

[0066] The fiber blend of the present invention comprises 10 to 45% by weight of a first group of bonding fibers, wherein the first group of bonding fibers are elastomeric copolyester bonding fibers having a denier of 1.5 to 8.0, a length of 51-84 mm and a bonding temperature of 110-180°C (sometimes referred to herein as "bonding fiber (c)").

[0067] In some embodiments, the fiber mixture of the present invention comprises 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, or 45 wt% of adhesive fibers (c), including any and all of these ranges and subranges (e.g., 15-40 wt%, 20-40 wt%, 25-35 wt%, etc.).

[0068] In some embodiments, the bonding fiber (c) has a high elongation at break (e.g., 200%-800%, such as 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420, 430, 440, 450, 460, 470). 480, 490, 500, 510, 520, 530, 540, 550, 560, 570, 580, 590, 600, 610, 620, 630, 640, 650, 660, 670, 680, 690, 700, 710, 720, 730, 740, 750, 760, 770, 780, 790, or 800%, including any and all of these ranges and subranges. Elongation at break refers to the percentage increase in fiber length when the fiber is stretched to its breaking point.

[0069] In some embodiments, the elongation at break of the bonding fiber (c) is, for example, at least 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420, 430, 440, 450, 460, 4 70, 480, 490, 500, 510, 520, 530, 540, 550, 560, 570, 580, 590, 600, 610, 620, 630, 640, 650, 660, 670, 680, 690, 700, 710, 720, 730, 740, 750, 760, 770, 780, 790, or 800%. In some embodiments, the bonding fiber (c) is stretched to 200-800% of its initial length (e.g., 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420, 430, 440, 450, 460, 4...). Complete recovery within 5 minutes (70, 480, 490, 500, 510, 520, 530, 540, 550, 560, 570, 580, 590, 600, 610, 620, 630, 640, 650, 660, 670, 680, 690, 700, 710, 720, 730, 740, 750, 760, 770, 780, 790 or 800%).

[0070] The denier of the bonding fiber (c) is 1.5 to 8.0, for example 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1. 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, or 8.0 denier, including all ranges and subranges therein (e.g., 2-8 denier, 3-8 denier, 4-7.5 denier, 5-7 denier, etc.).

[0071] The length of the adhesive fiber (c) is from 51 mm to 84 mm, for example 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, or 84 mm, including any and all of these ranges and subranges (e.g., 51-75 mm, 55-75 mm, 60-70 mm, etc.).

[0072] The bonding temperature of the adhesive fiber (c) is 110-180℃, for example, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 1 47, 148, 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, or 180°C, including any and all of these ranges and subranges (e.g., 120°C-170°C, 125°C-160°C, etc.).

[0073] Adhesive fiber (c) is a copolyester fiber containing two different polyester components.

[0074] In some embodiments, the adhesive fiber (c) comprises an inner polyester component and an outer polyester elastomer component. In such embodiments and some other embodiments, the adhesive fiber (c) is considered to be 100% polyester fiber.

[0075] In some embodiments, the adhesive fiber (c) comprises an inner polyester component and an outer polyester elastomer component with a melting point lower than that of the inner polyester component.

[0076] Figure 3A -F describes non-limiting examples of the cross-sections that a bicomponent adhesive fiber (e.g., used as adhesive fiber (c) or adhesive fiber (d)) may have in certain embodiments of the invention. Figure 3A In this configuration, the core 42 and sheath 44 are arranged in a 50:50 ratio and side-by-side. As used herein, the term "core" refers to the fundamental portion of the bicomponent fiber distinct from the sheath portion. In various embodiments, the core may be located at the innermost center of the bicomponent fiber. However, in other embodiments, the core may be eccentric or present at at least a portion of the outer peripheral surface of the bicomponent fiber. Figure 3B In this configuration, the core 42 and sheath 44 may exist in unequal proportions and be arranged side-by-side. Furthermore, the interface between the core 42 and sheath 44 is not planar. Figure 3C-3F In this structure, the core 42 and sheath 44 are arranged concentrically, with the core 42 forming the inner portion of the bicomponent fiber 20′ and being surrounded by the sheath 44. Figures 3A to 3E In the non-limiting embodiment shown, the core 42 is arranged asymmetrically relative to the sheath 44 (i.e., the core 42 is symmetrically offset within the bicomponent fiber 20′). Figure 3C-3F In the middle, the core 42 is eccentric (i.e., displaced from the center point or axis of the fiber), but is still completely surrounded by the sheath 44. Figure 3E The trilobal fiber 20′ is shown. Figure 3C-3F The arrangement shown is also referred to as an "island" or "island in the sea" configuration. Those skilled in the art will understand that these are unrestricted arrangements and may include additional components or additional "islands".

[0077] Second group of adhesive fibers

[0078] The fiber mixture of the present invention comprises 1 to 20% by weight of a second group of bonding fibers, which are different from the first group of bonding fibers, having a denier of 1.5-6.0, a length of 51-84 mm, and a bonding temperature of 80-135°C (sometimes referred to herein as "bonding fiber (d)").

[0079] The fiber mixture of the present invention comprises 1 to 20% by weight of adhesive fiber (d), for example 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20% by weight of adhesive fiber (d), including any and all ranges and subranges thereof (e.g., 2-18% by weight, 3-17% by weight, 4-16% by weight, 5-15% by weight, etc.).

[0080] The denier of the adhesive fiber (d) is 1.5 to 6.0, such as 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, or 6.0 denier, including any and all of these ranges and subranges (e.g., 1.5-5 denier, 1.5-4 denier, 1.5-3 denier, etc.).

[0081] The length of the adhesive fiber (d) is 51 mm to 84 mm, such as 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, or 84 mm, including any and all of these ranges and subranges (e.g., 51-75 mm, 51-70 mm, 51-65 mm, 51-60 mm, etc.).

[0082] The bonding temperature of the bonding fiber (d) is 80-135℃, for example, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 11 2, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134 or 135°C, including any and all of these ranges and subranges (e.g., 90-125°C, 95-115°C, etc.).

[0083] In some embodiments, the adhesive fiber (d) is a polymer fiber. In a particular embodiment, the adhesive fiber (d) comprises polyester. In some embodiments, the adhesive fiber (d) comprises recycled polyester (e.g., PCR polyester).

[0084] Bonding fibers are well known in the art, and a range of bonding fibers are commercially available. The bonding fiber (d) used in this invention can be a conventional bonding fiber (e.g., a low-melting-point polyester bonding fiber) or other bonding fibers, provided that, regardless of the bonding fiber used, its bonding temperature is lower than the softening temperature of the siliconized fiber (A) and the hollow composite fiber (b). Bonding fibers are discussed, for example, in U.S. Patent No. 4,794,038, and general embodiments of certain embodiments of bonding fibers are described in U.S. Patent Nos. 4,281,042 and 4,304,817. In some embodiments, the bonding fiber (d) is a monocomponent fiber. In some embodiments, the bonding fiber (d) is a multicomponent fiber (e.g., a bicomponent fiber, such as a sheath-core fiber, wherein the core contains a component with a higher melting point than the sheath). In some embodiments, the bonding fiber (d) is a... Figure 3A -F is a bicomponent fiber with one of the non-restrictive configurations shown in the figure.

[0085] In some embodiments, the flocculent of the present invention is heat-treated to melt all or part of the bonding fibers therein, thereby forming a bonded nonwoven web-type flocculent. Those skilled in the art will understand that although "bonding fibers" are listed in the fiber mixture of the flocculent, the bonding fibers can be completely or partially molten fibers, as opposed to the original preheat-treated form of the bonding fibers.

[0086] In embodiments of the flocculent of the present invention, the siliconized fiber (a), hollow composite fiber (b), adhesive fiber (c), and adhesive fiber (d) are each separate and different, mutually exclusive fiber groups.

[0087] In the fiber mixture of the present invention, fiber components comprising siliconized fibers (a), hollow composite fibers (b), adhesive fibers (c), and bonding fibers (d) are mixed (e.g., uniformly mixed). As will be understood by those skilled in the art, the mixed fibers typically produce a homogeneous mixture.

[0088] In some embodiments, the fiber blend of the present invention is a substantially homogeneous (i.e., 90-100% homogeneous) composition.

[0089] In some embodiments, the fiber mixture of the present invention comprises siliconized fibers (a), hollow composite fibers (b), adhesive fibers (c), and adhesive fibers (d).

[0090] In some embodiments, at least 90% by weight (e.g., at least 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 99.5% by weight) of the fiber mixture of the present invention comprises the total weight percentage of siliconized fibers (a), hollow composite fibers (b), adhesive fibers (c), and adhesive fibers (d). For example, when the total weight percentage of siliconized fibers (a), hollow composite fibers (b), adhesive fibers (c), and adhesive fibers (d) is 90% by weight of the fiber mixture, then 10% by weight of the fiber mixture may consist of other fiber components.

[0091] Unless otherwise stated, the fibers used in the flocculent material of this invention may be crimped or uncrimped. Various types of crimping, including spiral crimps and standard crimps, are known in the art.

[0092] Unless otherwise stated, the fibers used in the flocculents of this invention may have any desired cross-sectional shape (e.g., circular or other).

[0093] In some embodiments, the fiber blend of the present invention comprises, based on the weight of the fiber blend:

[0094] -20 to 40% by weight of siliconized fiber(a) (e.g., 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39 or 40% by weight, including any and all of these ranges and subranges); and / or:

[0095] -20 to 40% by weight of hollow composite fibers (b) (e.g., 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39 or 40% by weight, including any and all of these ranges and subranges); and / or

[0096] -20 to 40% by weight of the first group of adhesive fibers (c) (e.g., 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39 or 40% by weight, including any and all of these ranges and subranges); and / or

[0097] -5 to 15% by weight of the second group of adhesive fibers (d) (e.g., 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 or 15% by weight, including any and all of these ranges and subranges);

[0098] In some embodiments of the fiber blend of the present invention:

[0099] - The denier of the siliconized fiber (a) is 3.0 to 10.0 (e.g., 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6... 5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9 or 10.0 denier, including any and all of these ranges and subranges);

[0100] - The denier of the hollow composite fiber (b) is 3.0 to 10.0 (e.g., 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6...). 5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9 or 10.0 denier (including any and all of these ranges and subranges); and / or

[0101] - The denier of the first group of adhesive fibers (c) is 3.0 to 8.0 (e.g., 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0 denier, including any and all of these ranges and subranges); and / or

[0102] - The denier of the second group of adhesive fibers (d) is 1.5 to 4.0 (e.g., 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9 or 4.0 denier, including any and all of these ranges and subranges).

[0103] In some embodiments, the fiber blend of the present invention may comprise synthetic fibers and optionally natural fibers.

[0104] In some embodiments, the fiber mixture of the present invention in the form of flocculent material comprises natural fibers. For example, in some embodiments, the fiber mixture comprises one or more members selected from wool, cotton, Tencel, kapok (cotton-like down obtained from the seeds of the kapok tree, which may optionally be further processed before use), flax, animal hair, silk, and down (e.g., duck down or goose down).

[0105] In some embodiments, the fiber blends of the present invention comprise natural and / or synthetic polymer fibers.

[0106] Many synthetic fibers are known in the art, and any desired synthetic fiber acceptable to the art is contemplated for use in this invention. Indeed, different fibers possess different properties and contribute to advantageous uses in various applications. This information is entirely within the capabilities of those skilled in the art. While a wide variety of synthetic fibers can be used in this invention, in some embodiments, the synthetic fibers are selected from polyamides (e.g., nylon / polyamide 6.6, polyamide 6, polyamide 4, polyamide 11, and polyamide 6.10, etc.), polyesters, polybutylene terephthalate (PBT), polypropylene, polylactic acid (also known as polylactide) (PLA), poly(butyl acrylate) (PBA), acrylics, acrylates, acetates, polyolefins, nylon, rayon, lyocell, aramids, spandex, viscose and modal, biopolymer fibers (e.g., polyhydroxyalkanoates (PHA), poly-(hydroxybutyrate-covalerate) (PHBV)) and combinations thereof.

[0107] In specific embodiments, the fiber blends of the present invention comprise polyester synthetic fibers. In some embodiments, such polyester fibers comprise one or more of polyethylene terephthalate (PET), poly(hexahydro-p-xylene terephthalate), polybutylene terephthalate (PBT), poly-1,4-cyclohexyldimethyl terephthalate (PCDT), and terephthalate copolyesters, wherein at least 85 mol% of the ester units are polyethylene terephthalate or hexahydro-p-xylene terephthalate units. In one specific embodiment, the synthetic fiber is polyethylene terephthalate fiber.

[0108] In some embodiments, the flocculants of the present invention comprise 4 to 15 wt% resin, based on the total weight of the flocculants. For example, in some embodiments, the flocculants comprise 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 wt% resin, including any and all of these ranges and subranges (e.g., 6-10 wt%).

[0109] In some embodiments, the first and / or second surfaces of the flocs contain 2 to 8% by weight of resin, based on the total weight of the flocs, such as 2, 3, 4, 5, 6, 7 or 8% by weight, including any and all of these ranges and subranges (e.g., 2-5% by weight).

[0110] In some embodiments, the areal weight of the flocculent material of the present invention is 25 to 60 g / m². 2 For example, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59 or 60g / m 2 This includes any and all of its ranges and subranges (e.g., 30-40 g / m³). 2 ).

[0111] In some embodiments, the density of the flocculent material of the present invention is 5-15 kg / m³. 3 For example, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 or 15 kg / m 3 This includes any and all of its ranges and subranges (e.g., 5-14 kg / m²). 3 13-14 kg / m 3 wait).

[0112] In some embodiments, the thickness of the flocculent material is from 3 mm to 100 mm (e.g., 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, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51). 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99 or 100 mm), including any and all of these ranges and subranges.

[0113] Clo (clo / oz / yd2) is a unit used to measure the heat resistance of clothing or other insulating materials. A value of 1.0 clo is defined as the amount of insulation that allows a person at rest to maintain thermal equilibrium in a normally ventilated room (air movement of 0.1 m / s) at 21°C (70°F). Generally, above this temperature, a person wearing such clothing will sweat, while below this temperature, a person will feel cold. Articles such as clothing and / or its components (e.g., insulating materials, such as linoleum) can be assigned clo values. A higher clo indicates that the article is warmer than another article with a relatively lower clo.

[0114] In some embodiments, according to ISO 11092, the flocculent material of the present invention has a content greater than 0.012 clots / g / m³. 2 Thermal insulation performance per unit weight (e.g., greater than 0.012, 0.013, 0.014, 0.015, 0.016, 0.017, 0.018, 0.019, 0.02, 0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0.09, 0.10, 0.11, 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18, 0.19, 0. 20, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28, 0.29, 0.30, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.40, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49 or 0.50 clo / g / m 2 ), including any and all of its ranges and subranges.

[0115] In some embodiments, the water absorption rate of the flocculent of the present invention is less than or equal to 150 wt% (e.g., less than or equal to 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 1...). 13, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149 or 150 wt%), based on the weight of the flocculent when dried.

[0116] In some embodiments, the water absorption rate of the flocculent of the present invention is 50 to 150 wt% (e.g., 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 97, 98, 99, 100, 101, 102, 103, 104, 105, 1...). 06, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149 or 150 wt%, including any and all of these ranges and subranges, based on the weight of the flocculent when dried.

[0117] The embodiments of the flocculents of the present invention surprisingly exhibit excellent anti-pilling and anti-fiber migration properties.

[0118] To prevent fiber migration from the barrier structure (including the fibrous material), excessive amounts of resin and / or down-proof fabric were used in the past. True down-proof fabrics typically have an air permeability of less than 1 cubic foot per square meter (CFM). Unfortunately, the weight and low air permeability of the fabric in down-proof structures sacrifice breathability and comfort to prevent fiber migration.

[0119] The applicant was surprised to find that, in resisting or preventing fiber migration / pilling, the embodiments of the flocculation of the present invention were comparable to comparative embodiments prepared using excessive resin and / or down-proof fabrics, but were more comfortable and breathable, resulting in highly improved textiles. This feature stems from the unique composition of the fiber mixture of the present invention used in the nonwoven web for manufacturing the flocculation of the present invention.

[0120] Those skilled in the art would not typically consider performing fiber migration testing on bonded nonwoven flocs containing short fibers (fibers of defined length, as opposed to filaments of variable length). In fact, according to conventional wisdom, nonwoven insulators should not withstand the Martindale test. The Martindale test procedure, performed before and after 10 washes of the sample, is used to determine the fiber migration that will occur when the insulator is exposed under pressure to friction against different materials (such as high-CFM fabrics, seat belts, backpacks, suspenders, etc.). Normal flocs containing bonded nonwoven webs would be severely damaged by this test and would result in excessive fiber migration. However, surprisingly, embodiments of the flocs of the present invention described herein did not exhibit surface pilling or fiber migration when subjected to the fiber migration test. This is a new benchmark for insulator durability. Insulators (e.g., flocs) capable of withstanding the fiber migration test described herein can be combined with highly breathable fabrics (high CFM, e.g., 1-500 CFM, including fabrics with textured surfaces) to produce exceptionally comfortable and breathable textiles. The performance of the flocculent of the present invention is even more surprising, because those skilled in the art would expect the presence of the siliconized fibers (a) to impair durability (this is because using a higher amount of siliconized fibers would expect fewer bonding points, since bonding fibers typically do not bond well to siliconized fibers). Surprisingly, the presence of these siliconized fibers does not impair the fiber migration properties of the barrier, but contributes to the beneficial waterproof properties of embodiments of the flocculent of the present invention, thereby forming a highly advantageous barrier that is breathable, waterproof, migration-resistant, and has good drape (properties are generally considered mutually exclusive – at least one property must be compromised to achieve a beneficial result for the other properties).

[0121] The test method used to determine the fiber migration resistance of an insulator is the IDFL (International Down and Feather Testing Laboratory) DownProofness-International Rotation Box standard test method. According to this method, a 45.5 cm plastic box with a door on one side is used to construct a rotating drum. The drum is rotated by a motor at a speed of 48 + / - 2 revolutions per minute. Twenty-four 6.5# solid silicone stoppers are used in the drum. A clean sample article is placed in the drum, and the drum is rotated for 30 minutes. All fibers and clumps are collected from the surface of the article, the rotating drum, and the silicone stoppers. The collected material is evaluated and counted, and as shown in Table I, a numerical grade from 1 (significant fiber migration) to 5 (little or no fiber migration) is assigned based on the amount of fibers escaping or protruding from the fabric of the article after the 30-minute tumbling period (only fibers >4 mm are counted).

[0122] Table I: Fiber Migration Grades

[0123] grade Fibers (>4mm) 5 <5 4 6-10 3 11-20 2 21-30 1 >31

[0124] In some embodiments, the flocs of the present invention have a fiber migration rating of 4 or 5 according to the IDFL DownProofness-International Rotation Box standard test method. Good fiber migration resistance also indicates good pilling resistance; therefore, fiber migration resistance discussed herein includes pilling resistance.

[0125] The “INS-17 Fiber Migration Test” is a fiber migration resistance test standard developed by the applicant, which is more intense and rigorous than the IDFL DownProofness-International Rotation Box standard test method.

[0126] In some embodiments, when tested according to the INS-17 fiber migration test, the flocculent of the present invention has fiber migration resistance of fewer than 20 fibers.

[0127] The INS-17 fiber migration test determines the likelihood of fiber migration through various types of fabrics. The test is described below.

[0128] Prepare the sample as follows: Select a fabric and fold it in half to form a pillow with three openings (approximately 12″ × 12″). Sew both sides of the pillow together, leaving the side opposite the fold unsewn. Cut a piece of insulator (e.g., in this case, the fibrous material of the present invention) into approximately 12″ × 12″ pieces to fit snugly within the fabric pillow. Place the insulator inside the pillow and sew the last side of the pillow together. Seal the entire outer edge of the pillow separately approximately 0.25 inches from the edge to prevent the insulator from shifting. The A and / or B sides of the pillow are thus marked.

[0129] The testing procedure for pillow samples requires:

[0130] Loop 1: The pillow was placed in a household dryer (without heating) with 21 rubber plugs (e.g., HERCO black rubber single-hole plugs sold by Hecht Rubber Corporation, part number ST1H-04-BK, used in the embodiments described herein) for 45 minutes in a cycle. After completing cycle 1, both sides of the pillow were closely observed to detect any fibers that had migrated through the fabric. For the embodiments described herein, the pillow was observed against a dark background with appropriate lighting, and the fibers on the pillow surface were thoroughly scanned using the packing straps.

[0131] Cycle 2: Place the pillow in a household washing machine and perform a wash cycle with the following settings: regular wash cycle, cold water rinse, small wash load, and two tablespoons of laundry detergent (e.g., Tide). After the wash cycle is complete, remove the pillow from the washing machine, place it in the dryer, and perform a dryer cycle with 21 rubber stoppers at low heat until completely dry. After completing cycle 2, closely observe both sides of the pillow to detect any fibers that have migrated through the fabric. Count the fibers that have migrated through the fabric and record the count on both sides of the pillow. For the embodiment described herein, observe the pillow against a dark background with appropriate lighting, and thoroughly scan the fibers on the pillow surface using a packing strap.

[0132] Cycle 3: Repeat cycle 2, but without laundry detergent.

[0133] Cycle 4: Repeat cycle 2, but without laundry detergent.

[0134] After completing cycles 1-4, the fabric is graded as follows:

[0135]

[0136]

[0137] In some embodiments, the flocs of the present invention have “anti-migration” (i.e., count of 0 fibers) or “acceptable migration” (i.e., count of less than 3 fibers) anti-migration properties according to the INS-17 fiber migration test.

[0138] In some embodiments, when tested according to ASTM D 3107, the flocculents exhibit tensile or multidirectional tensile properties of 5% to 30% in one or more of the longitudinal (MD), transverse (CD), and diagonal directions, including any range and subrange thereof, under a load of 0.65 lb. For example, in some embodiments, the flocculents have tensile properties of 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, or 30% in the MD, CD, and / or diagonal directions.

[0139] In some embodiments, the flocculent of the present invention has good drape (the insulator hangs under its own weight). The drape of the insulator can have a significant impact on the quality (such as comfort and aesthetics) of articles in which the insulator can be used. In some embodiments, the insulator has a drape of 1.0 cm to 3.0 cm (e.g., 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, or 3.0 cm), including any and all of these ranges and their sub-ranges (e.g., 1.5 to 2.5 cm, etc.).

[0140] In some embodiments, the flocculent material of the present invention, as measured according to ISO 3385, has a compression recovery rate of greater than 50%, for example greater than 50, 51, 52, 53, 54, 55, 56, 57, 58, 59 or 60%.

[0141] In some embodiments, according to ISO 3385, the flocculents of the present invention have a compression recovery of 50.5% to 70%, such as 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69 or 70%, including any and all ranges and subranges (e.g. 50.5-68%, 55-67%, 60-65%, etc.).

[0142] In a second aspect, the present invention provides an article comprising a flocculent material according to the first aspect of the invention.

[0143] In some non-limiting embodiments, the articles are footwear (e.g., shoes, socks, slippers, boots), outerwear (e.g., outer garments such as jackets, coats, vests, shoes, boots, trousers (e.g., snow pants, ski pants, etc.), gloves, mittens, scarves, headwear, hats, etc.), clothing / apparel (e.g., shirts, trousers, underwear (e.g., underwear, thermal underwear, socks, stockings, etc.), sleepwear (e.g., pajamas, robes, gowns, etc.)), sportswear (e.g., clothing for sports or physical activity, including footwear), sleeping bags, bedding (e.g., blankets or quilts), pillows, cushions, pet beds, home furnishings (e.g., upholstered chairs), etc.

[0144] In some embodiments, the fibers of the present invention are contained within at least a portion of one of the articles of manufacture.

[0145] In some embodiments, the air permeability of the article is from 1 CFM to 500 CFM, for example, 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, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75 76, 56, 56, 57, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 1 35, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164, 165, 1 66, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, 180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190, 191, 192, 193, 194, 195, 196, 19 7, 198, 199, 200, 201, 202, 203, 204, 205, 206, 207, 208, 209, 210, 211, 212, 213, 214, 215, 216, 217, 218, 219, 220, 221, 222, 223, 224, 225, 226, 227, 228 229, 230, 231, 232, 233, 234, 235, 236, 237, 238, 239, 240, 241, 242, 243, 244, 245, 246, 247, 248, 249, 250, 251, 252, 253, 254, 255, 256, 257, 258, 259260, 261, 262, 263, 271, 272, 273, 274, 275, 276, 277, 278, 279, 280, 281, 282, 283, 284, 285, 286, 287, 288, 289, 290, 291, 292, 293, 294, 295, 296, 297, 298, 299, 300, 301, 302, 303, 304, 305, 306, 307, 308, 309, 310, 311, 312, 313, 314, 315, 316, 317, 318, 319, 320, 321, 322 323, 324, 325, 326, 327, 328, 329, 330, 331, 332, 333, 334, 335, 336, 337, 338, 339, 340, 341, 342, 343, 344, 345, 346, 347, 348, 349, 350, 351, 352, 353, 370, 371, 372, 373, 374, 375, 376, 377, 378, 379, 380, 381, 382, ​​383, 384, 385, 386, 387, 388, 389, 390, 391, 392, 393, 394 395, 396, 397, 398, 399, 400, 401, 402, 403, 404, 405, 406, 407, 408, 409, 410, 411, 412, 413, 414, 415, 416, 417, 418, 419, 420, 421, 422, 423, 424, 425, 426, 427, 428, 429, 430, 431, 432, 433, 434, 435, 436, 437, 438, 439, 440, 441, 442, 443, 444, 445, 446, 447, 448, 449, 4 50, 451, 452, 453, 454, 455, 456, 457, 458, 459, 460, 461, 462, 463, 464, 465, 466, 467, 468, 469, 470, 471, 472, 473, 474, 475, 476, 477, 478, 479, 480, 481, 482, 483, 484, 485, 486, 487, 488, 489, 490, 491, 492, 493, 494, 495, 496, 497, 498, 499, or 500CFM, including any and all of these ranges and subranges.

[0146] In a third aspect, the present invention provides a method for preparing a flocculent material according to the first aspect of the invention or an article according to the second aspect of the invention, the method comprising:

[0147] -The fiber mixture of the present invention is prepared by mixing the following substances:

[0148] (a) 20 to 55% by weight of siliconized fibers having a denier of 1.5 to 10.0 and a length of 51 mm to 84 mm;

[0149] (b) 10 to 45% by weight of hollow composite fibers, said hollow composite fibers having a helical crimp and having a denier of 1.5 to 10.0 and a length of 51 to 84 mm;

[0150] (c) 10 to 45% by weight of a first group of bonding fibers, wherein the first group of bonding fibers are elastomeric copolyester bonding fibers having a denier of 1.5 to 8.0, a length of 51 mm to 84 mm, and a bonding temperature of 110°C to 180°C; and

[0151] (d) 1 to 20% by weight of a second group of adhesive fibers different from the first group of adhesive fibers, wherein the second group of adhesive fibers has a denier of 1.5 to 6.0, a length of 51 mm to 84 mm, and an adhesive temperature of 80°C to 135°C;

[0152] - (e.g., via combing) forming a nonwoven web from a fiber blend;

[0153] - Provide a nonwoven web, or optionally laminate a nonwoven web formed of a fiber mixture with one or more (e.g., 1, 2, 3, 4 or 5) other nonwoven webs (e.g., cross-laying);

[0154] - Heating a nonwoven web to or above the maximum bonding temperature of the bonding fibers to form a flocculent or flocculent intermediate comprising one or more nonwoven webs, which at least includes a bonded nonwoven web comprising a fiber mixture, the flocculent or flocculent intermediate having a first surface parallel to the second surface;

[0155] - Optionally, the resin solution is applied to the first and / or second surface of the flocculent intermediate;

[0156] - Optionally, the flocculent intermediate is heated to a temperature exceeding the glass transition temperature of the resin in the resin solution; and

[0157] -Optionally press one or more surfaces of the flocculent intermediate.

[0158] This results in the formation of flocculent matter.

[0159] In some embodiments, after providing a nonwoven web and optionally laminating (e.g., cross-laying) the web, the resulting flocculent intermediate is needle-punched. Needling is typically performed on a knitting machine, a machine used to bond the nonwoven web by mechanically orienting fibers through it. During needle punching (also known as needle piercing), barbed needles arranged in a plate (“needle plate”) pierce the fibers into the flocculent intermediate and withdraw them, thereby mechanically entangled the fibers. While needle punching is commonly used on nonwoven webs to produce dense products (typical needle-punched fabrics include pads, paper felt, linings, and so on), the applicant has found that ideal embodiments of the invention can be produced using a needle punching process. For example, in some embodiments, the flocculent intermediate is slightly looped by needle punching, wherein the needle plate is modified to be less dense (i.e., containing fewer needles than typically used for needle punching) and / or the needle punching is restricted so that the needles only partially penetrate the flocculent intermediate. The applicant has found that this “partial needle punching” results in a less dense implementation than typical needle punched products, but still has fiber migration properties that are even further improved.

[0160] In some embodiments, the needle-punching process is performed on the flocculent intermediate before any of the above steps following the step of “providing a nonwoven web, or optionally laminating a nonwoven web formed of a fiber blend with one or more (e.g., 1, 2, 3, 4, or 5) additional nonwoven webs (e.g., cross-laying)”. Example

[0161] The invention will now be described with reference to specific embodiments in the following examples, but without limiting the scope of the invention.

[0162] One embodiment of the flocculent of the present invention is prepared by mixing a fiber mixture, the fiber mixture comprising:

[0163] -30% by weight of siliconized fiber(a), which contains recycled polyethylene and has a denier of 7 and a length of 76 mm;

[0164] -30% by weight of dry hollow composite fiber (b), which contains recycled polyethylene and has a denier of 7 and a length of 64 mm;

[0165] -30% by weight of polymer adhesive fiber (c), which has a denier of 6 and a length of 64 mm; and

[0166] -10% by weight of adhesive fiber (d), which contains recycled polyethylene and has a denier of 2 and a length of 51 mm;

[0167] The fiber mixture is formed into a nonwoven web on a carding machine, and then heated to bond the bonding fibers (c) and (d), thereby forming a bonded nonwoven web. A 70 / 30 water / resin solution is applied to both surfaces (A and B) of the bonded nonwoven web, and then it is heated to a temperature exceeding the glass transition temperature of the resin in the resin solution. The flocculent intermediate is calendered at 185°C to form a flocculent embodiment.

[0168] Fiber migration tests were conducted on the flocculent formulation according to the INS-17 fiber migration test. The migration test results for pillows 1-3 are as follows:

[0169]

[0170]

[0171] It is evident that, despite the rigorous fiber migration testing procedures, the flocculent embodiments of the present invention exhibit excellent resistance to fiber migration. The ability to achieve this level of reduction / prevention of fiber migration in bonded nonwoven flocculents containing short fibers is particularly advantageous.

[0172] The 40 g sm flocculent sample prepared as described above was subjected to the applicant's standard operating procedure corresponding to ASTM D 3107. The results are as follows:

[0173]

[0174] Another embodiment of the flocculent of the present invention is prepared by mixing a fiber mixture, said fiber mixture comprising:

[0175] -20% by weight of siliconized fiber (a), which contains recycled polyethylene terephthalate and has a denier of 6 and a length of 64 mm;

[0176] -50% by weight of dry hollow composite fiber (b), which contains recycled polyethylene terephthalate and has a denier of 3 and a length of 51 mm;

[0177] -15% by weight of polymer adhesive fiber (c), which has a denier of 6 and a length of 64 mm; and

[0178] -15wt% adhesive fiber (d), which contains recycled polyethylene and has a denier of 2 and a length of 51mm.

[0179] The fiber mixture is formed into a nonwoven web on a carding machine, and then slightly entangled (i.e., subjected to a partial needle-punching process) to further entangle the fibers, thereby providing more protection against fiber migration. A 70 / 30 water / resin solution is applied to both surfaces (surfaces A and B) of the bonded, entangled nonwoven web, and then it is heated to a temperature exceeding the glass transition temperature of the resin in the resin solution. This heating is also used to bond the bonding fibers (c) and (d), thereby forming a bonded and slightly entangled nonwoven web. The flocculent intermediate is calendered at 170°C to form the flocculent embodiment.

[0180] Fiber migration tests were conducted on the flocculent formulation according to the INS-17 fiber migration test. The results of the migration tests are as follows:

[0181]

[0182] Martindale testing was also performed on the flocculent implementation. Specifically, unwashed samples of the flocculent intermediates were covered with fabric and tested on a Martindale machine. Individual tests were conducted using samples rubbed with fabric, seatbelt material, and backpack material, with the following results:

[0183]

[0184] It is evident that, despite the rigorous Martindale tests (which are typically not performed on flocculent insulators), the flocculent implementation exhibits superior performance. The ability to achieve this level of reduced / prevented fiber migration in bonded nonwoven flocculents containing short fibers is particularly advantageous.

[0185] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprise” (and any form of “comprises” and “comprising”), “have” (and any form of “has” and “having”), “include” (and any form of “include” and “including”), “include” (and any form of “includes” and “including”), and any other grammatical variations thereof are open-ended connecting verbs. Thus, a method or article of article that “comprises,” “has,” “includes,” or “includes” one or more steps or elements has, but is not limited to, those one or more steps or elements. Similarly, the elements of a method or article of article that “comprises,” “has,” “includes,” or “contains” one or more features have, but are not limited to, those one or more features.

[0186] As used herein, the terms “contains,” “has,” “includes,” “comprising,” and other grammatical variations encompass the terms “composed of” and “substantially composed of.”

[0187] When used herein, the phrase “consistently of…” or its grammatical variations shall be regarded as specifying the said feature, integer, step or component, but without excluding the addition of one or more additional features, integers, steps, components or groups thereof, only if the additional features, integers, steps, components or groups thereof do not substantially alter the essential and novel features of the claimed composition or method.

[0188] All publications cited in this specification are incorporated herein by reference as if each individual publication were specifically and individually indicated as incorporated herein by reference, as if fully explained.

[0189] Unless otherwise expressly stated, the subject matter incorporated by reference is not considered a substitute for any claim limitation.

[0190] Where one or more ranges are mentioned throughout the specification, each range is intended to be a simplified format for presenting information, wherein the range is understood to cover each discrete point within that range, as fully explained herein.

[0191] While several aspects and embodiments of the invention have been described and depicted herein, those skilled in the art can influence alternative aspects and embodiments to achieve the same purpose. Therefore, the embodiments disclosed in this disclosure and specification include all such additional and alternative aspects and embodiments falling within the true spirit and scope of the invention, as the appended claims are intended to cover.

Claims

1. A flocculent comprising a bonded nonwoven web, the flocculent having a first surface parallel to a second surface, and the bonded nonwoven web comprising a fiber mixture, the fiber mixture containing, based on the total weight of the fiber mixture: (a) 20 to 55% by weight of siliconized fibers having a denier of 1.5 to 10.0 and a length of 51 to 84 mm; (b) 10 to 45% by weight of hollow composite fibers having a helical crimp and a denier of 1.5 to 10.0 and a length of 51 to 84 mm; (c) 10 to 45% by weight of a first group of bonding fibers, wherein the first group of bonding fibers are elastomeric copolyester bonding fibers having a denier of 1.5 to 8.0, a length of 51 mm to 84 mm, and a bonding temperature of 110°C to 180°C; and (d) 1 to 20% by weight of a second group of adhesive fibers different from the first group of adhesive fibers, the second group of adhesive fibers having a denier of 1.5 to 6.0, a length of 51 mm to 84 mm and an adhesive temperature of 80°C to 135°C; The fibers in the fiber mixture are uniformly mixed.

2. The flocculent according to claim 1, wherein the first surface and the second surface comprise resin.

3. The flocculent according to claim 2, comprising 4 to 15% by weight of resin, based on the total weight of the flocculent.

4. The flocculent according to claim 3, comprising 6-10% by weight of resin, based on the total weight of the flocculent.

5. The flocculent according to any one of the preceding claims, wherein, based on the total weight of the fiber mixture, the fiber mixture comprises: (a) 20 to 40% by weight of siliconized fibers; and / or (b) 20 to 40% by weight of hollow composite fibers; and / or (c) 20 to 40% by weight of the first group of adhesive fibers; and / or (d) 5 to 15% by weight of the second group of adhesive fibers.

6. The flocculent body according to any one of the preceding claims, wherein: (a) The siliconized fiber has a denier of 3.0 to 10.0; and / or (b) The hollow composite fiber has a denier of 3.0 to 10.0; and / or (c) The first set of adhesive fibers has a denier of 3.0 to 8.0; and / or (d) The second group of adhesive fibers has a denier of 1.5 to 4.

0.

7. The flocculent body according to any one of the preceding claims, wherein: (a) The siliconized fiber is hollow.

8. The flocculent body according to any one of the preceding claims, wherein: (b) The hollow composite fiber is a dry fiber.

9. The flocculent body according to any one of the preceding claims, wherein: (a) The siliconized fiber is a polyester fiber.

10. The flocculent material according to claim 9, wherein: (a) The siliconized fiber is a polyester fiber containing recycled polyester.

11. The flocculent body according to any one of the preceding claims, wherein: (b) The hollow composite fiber is polyester fiber.

12. The flocculent material according to claim 11, wherein: (b) The hollow composite fiber is a polyester fiber containing recycled polyester.

13. The flocculent body according to any one of the preceding claims, wherein: (c) The second set of adhesive fibers contains polyester.

14. The flocculent material according to claim 13, wherein: (c) The polyester in the second set of adhesive fibers contains recycled polyester.

15. The flocculent material according to any one of the preceding claims, having a concentration of 25 to 60 g / m³ 2 Area weight and 11 to 15 kg / m 3 The density.

16. The flocculent material according to any one of the preceding claims, having a concentration of 30 to 40 g / m³ 2 Area weight and 13 to 14 kg / m² 3 The density.

17. The flocculent material according to any one of the preceding claims, having a content greater than 0.012 clots / g / m³ according to ISO 11092. 2 Thermal properties of heat retention per unit weight.

18. The flocculent according to any one of the preceding claims, having a water absorption capacity of less than 150% by weight.

19. The flocculent according to claim 18, having a water absorption capacity of less than 100% by weight.

20. The flocculent according to any one of the preceding claims, when tested according to the INS-17 fiber migration test, has a migration resistance of less than 20 fibers.

21. An article comprising flocculent material according to any one of the preceding claims.

22. The article of claim 21, wherein the article of claim 21 is selected from clothing, sleeping bags and bedding.

23. A method for preparing flocculent material according to any one of the preceding claims, the method comprising: -This fiber mixture is prepared by mixing the following substances: (a) 20 to 55% by weight of siliconized fibers having a denier of 1.5 to 10.0 and a length of 51 to 84 mm; (b) 10 to 45% by weight of hollow composite fibers having a helical crimp and a denier of 1.5 to 10.0 and a length of 51 to 84 mm; (c) 10 to 45% by weight of a first group of bonding fibers, wherein the first group of bonding fibers are elastomeric copolyester bonding fibers having a denier of 1.5 to 8.0, a length of 51 mm to 84 mm, and a bonding temperature of 110°C to 180°C; and (d) 1 to 20% by weight of a second group of adhesive fibers different from the first group of adhesive fibers, the second group of adhesive fibers having a denier of 1.5 to 6.0, a length of 51 mm to 84 mm and an adhesive temperature of 80°C to 135°C; -A nonwoven fiber web is formed from this fiber mixture; - Provide a nonwoven web, or laminate a nonwoven web formed of a fiber mixture with one or more other nonwoven webs; and - Heating a nonwoven web to or above the maximum bonding temperature of the bonding fibers to form a flocculent or flocculent intermediate comprising one or more nonwoven webs, which at least includes a bonding nonwoven web comprising a fiber mixture, the flocculent or flocculent intermediate having a first surface parallel to a second surface. This results in the formation of flocculent matter.

24. The method of claim 23, wherein the provision of the nonwoven web, or the lamination of a nonwoven web formed of a fiber mixture with one or more other nonwoven webs to form a flocculent intermediate, and wherein the method includes subjecting the flocculent intermediate to a needle-punching process.

25. The method of claim 23, further comprising: - Apply the resin solution to the first and second surfaces of the flocculent intermediate; - Heating the flocculent intermediate to a temperature exceeding the glass transition temperature of the resin in the resin solution; and - One or more surfaces of the calendered flocculent intermediate.

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