Durable, pilling-resistant nonwoven insulation

Abstract

The present invention provides a batting material comprising a bonded nonwoven web made from a fiber mixture containing: (a) 20-55 wt% of silicone-treated fibers, the fibers being 1.5-10.0 denier and 51 mm-84 mm long; (b) 10-45 wt% of hollow bicomponent fibers having a spiral crimp, the fibers being 1.5-10.0 denier and 51 mm-84 mm long; (c) 10-45 wt% of a first binder fiber group, the first binder fiber group being an elastic copolyester binder fiber having a denier of 1.5-8.0, a length of 51 mm-84 mm, and a bonding temperature of 110°C-180°C; and (d) 1-20 wt% of a second binder fiber group having a denier of 1.5-6.0, a length of 51 mm-84 mm, and a bonding temperature of 80°C-135°C.

Description

Detailed Description of the Invention

[0001] [CROSS REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 150,311, filed February 17, 2021, the entire contents of which are hereby incorporated by reference into this application.

[0002] [Technical field of the present invention] The present invention relates generally to durable, pilling / fiber migration resistant nonwoven insulation, methods of making same, and articles including same, which are particularly useful in the textile field.

[0003] [Background of the invention] Fibers and filler materials, such as synthetic fibers and natural filler materials (e.g., down), have long been used as insulation materials in the textile field. For example, the outdoor industry has utilized fibers and down for many years in clothing, winter clothing, sleeping bags, and the like. However, a disadvantage to the use of such fibers has been that this type of insulation, even when combined with a downproof fabric with low air permeability and / or protected with a nonwoven scrim material, is highly susceptible to pilling and the display of severe fiber migration through the fabric surface.

[0004] A scrim is a core material that is often used as a protective layer between the insulation of an article and the shell or liner fabric. Fiber migration refers to the penetration of fibers through the fabric surface, resulting in the fibers being present on the outer surface side of the article, which is typically the outside of the article that is exposed to the external environment. Pilling refers to the tendency of fibers to detach from the fabric surface and form balled or entangled fiber particles that remain attached to the surface of the fabric.

[0005] Downproof fabrics are typically defined as fabrics that are tightly woven with a thread count greater than 250 and have an air permeability rating of less than 1 cubic foot per minute (CFM) according to ASTM D737. Sometimes, fabrics are coated or calendered to seal the surface of the fabric as a means of reducing fiber migration and / or achieving downproofing. These treatments further reduce the air permeability of the fabric, which has a direct impact on the overall comfort of the article. The lower the air permeability of the fabric, the less breathable and comfortable it is. The higher the air permeability of the fabric, the more breathable and comfortable it is.

[0006] Certain types of migration-resistant insulations used in the field of textile products are known in the art. These insulations are mainly composed of high denier fibers, typically greater than 1.0 denier, and do not contain hydrophobic finishing agents. Migration-resistant surfaces have been created on the above types of commonly produced common insulations using commercial chemical resins as adhesives on the surface of the insulation. However, there are various disadvantages associated with this type of treatment, such as the fact that the treatment makes the insulation feel stiff and flaky, reduces stretchability, and is uncomfortable to wear. Furthermore, most commercially available chemical resins used to create migration-resistant surfaces rapidly adsorb water, which represents a significant disadvantage for textile products such as outdoor equipment that require both performance and comfort. Thus, there is a need for improved insulation materials that have desirable properties and also provide improved resistance to or prevention of fiber migration, including pilling.

[0007] Although certain aspects of the prior art have been discussed to facilitate disclosure of the present invention, applicants are not in any way dismissing these technical aspects, and it is contemplated that the present invention as claimed may encompass one or more of the prior art aspects discussed herein.

[0008] Where a document, act, or item of knowledge is referenced or discussed in this specification, such reference or discussion is not an admission that that document, act, or item of knowledge, or any combination thereof, was publicly available, known, part of the common general knowledge, or otherwise constitutes prior art under applicable statutory provisions, as of the priority date; or was known to be relevant to attempting to solve any problem to which this specification is concerned. Summary of the Invention

[0009] Briefly, the present invention satisfies the need for an improved insulation material that is resistant to fiber migration and pilling, but still exhibits exceptional properties including thermal insulation and water absorption. The present invention may address one or more of the problems and deficiencies of the art discussed above. However, it is contemplated that the present invention will prove useful in addressing other problems and deficiencies in many areas of technology. Thus, the claimed invention should not necessarily be construed as being limited to addressing any of the specific problems or deficiencies discussed herein.

[0010] Applicants have surprisingly found that certain embodiments of the insulation of the present invention comprising the fiber blends discussed herein have desirable properties, such as excellent thermal properties, excellent water absorption properties (i.e., the embodiments do not absorb unacceptable amounts of water), fast drying times, and resistance to or prevention of fiber migration and / or pilling.

[0011] In a first aspect, the present invention provides a batting material comprising a bonded nonwoven web, the batting material having a first surface parallel to a second surface, and the bonded nonwoven web comprising a fibrous blend comprising a fibrous blend having a fibrous blend weight percent of a total fibrous blend. (a) 20-55 wt.% siliconized fiber having a denier of 1.5-10.0 and a length of 51 mm-84 mm; (b) hollow bicomponent fibers having 10-45 wt. % spiral crimp, 1.5-10.0 denier and 51-84 mm in length; (c) 10-45 wt% of a first binder fiber group, the first binder fiber group being an elastic copolyester binder fiber having a denier of 1.5-8.0, a length of 51 mm-84 mm, and a bonding temperature of 110°C-180°C; (d) 1 to 20 wt % of a second binder fiber group different from the first binder fiber group, the second binder fiber group 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.; and the fibers in the fiber mixture are homogeneously mixed.

[0012] In a second aspect, the present invention provides an article comprising a batting material according to the first aspect of the invention.

[0013] In a third aspect, the present invention provides a method of making a batting according to the first aspect of the invention or an article according to the second aspect of the invention, the method comprising: - a fibre mixture according to the invention (a) 20-55 wt.% siliconized fiber having a denier of 1.5-10.0 and a length of 51 mm-84 mm; (b) hollow bicomponent fibers having 10-45 wt. % spiral crimp, 1.5-10.0 denier and 51-84 mm in length; (c) 10-45 wt% of a first binder fiber group, the first binder fiber group being an elastic copolyester binder fiber having a denier of 1.5-8.0, a length of 51 mm-84 mm, and a bonding temperature of 110°C-180°C; (d) 1 to 20 wt % of a second binder fiber group different from the first binder fiber group, the second binder fiber group 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.; preparing the composition by mixing; - forming a nonwoven web from the fiber mixture (e.g. by carding); - providing a nonwoven web or optionally laminating (e.g., cross-lapping) the nonwoven web formed from the fiber mixture with one or more (e.g., 1, 2, 3, 4, or 5) additional nonwoven webs; - forming a batting or batting intermediate comprising one or more nonwoven webs, the batting or batting intermediate having at least a bonded nonwoven web comprising a fiber blend, by heating the nonwoven webs to a temperature at or above a highest binder fiber bonding temperature, the batting or batting intermediate having a first surface parallel to a second surface; - optionally applying a resin solution to the first and second surfaces of the intermediate batting material; - optionally heating the intermediate batting material to a temperature above the glass transition temperature of the resin in the resin solution; and - optionally forming the batting material by calendering one or more surfaces of the intermediate batting material; Includes.

[0014] Certain embodiments of the batting, articles including batting, and methods of making batting disclosed herein have several features, no single feature being solely responsible for the desirable attributes of the embodiments. Without limiting the scope of the batting, articles, and methods as defined by the claims that follow, their more prominent features will now be briefly discussed. In consideration of this discussion, and in particular upon reading the section of this specification entitled "Detailed Description of the Invention," one will understand how the features of the various embodiments disclosed herein provide many advantages over the current state of the art. For example, embodiments of the present invention provide an improved insulation material (batting) that significantly reduces and / or prevents pilling and / or fiber migration. Such insulation materials are used, inter alia, in the textile field, such as clothing, outerwear, furniture, bedding, etc.

[0015] These and other features and advantages of the present invention will become apparent from the following detailed description of the various aspects of the invention taken in conjunction with the appended claims and the accompanying drawings. The present invention is described below in conjunction with the following drawings, which are not necessarily drawn to scale: [Brief description of the drawings]

[0016] [Figure 1] FIG. 2 is a cross-sectional side view of an embodiment of a batting material of the present invention. [Diagram 2] FIG. 2 is a cross-sectional side view of an embodiment of a batting material of the present invention. [Figure 3A-F] FIG. 2 shows non-limiting examples of possible cross-sections of bicomponent binder fibers used in certain embodiments of the present invention.

[0017] [Detailed Description of the Invention] Aspects of the present invention, as well as certain of its features, advantages, and details, are described in more detail below with reference to non-limiting embodiments illustrated in the accompanying drawings. Descriptions of well-known materials, fabrication tools, processing techniques, and the like are omitted so as not to unnecessarily obscure the invention in detail. It should be understood, however, that the detailed description and specific examples, while illustrating embodiments of the present invention, are provided merely by way of illustration and not by way of limitation. Various alternatives, modifications, additions and / or alterations within the spirit and / or scope of the underlying inventive concept will become apparent to those skilled in the art from this disclosure.

[0018] In a first aspect, the present invention provides a batting material comprising a bonded nonwoven web, the batting material having a first surface parallel to a second surface, and the bonded nonwoven web being a fibrous blend comprising a fibrous blend having a fibrous blend weight percent of at least one of the fibrous blend and a fibrous blend weight percent of at least one of the fibrous blend. (a) 20-55 wt.% siliconized fiber having a denier of 1.5-10.0 and a length of 51 mm-84 mm; (b) hollow bicomponent fibers having 10-45 wt. % spiral crimp, 1.5-10.0 denier and 51-84 mm in length; (c) 10-45 wt% of a first binder fiber group, the first binder fiber group being an elastic copolyester binder fiber having a denier of 1.5-8.0, a length of 51 mm-84 mm, and a bonding temperature of 110°C-180°C; (d) 1 to 20 wt % of a second binder fiber group different from the first binder fiber group, the second binder fiber group 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.; and the fibers in the fiber mixture are homogeneously mixed.

[0019] FIG. 1 illustrates a cross-sectional side view of an embodiment of a batting material 10 of the present invention. The batting material 10 has a first surface 2 parallel to a second surface 4. The embodiment of the batting material 10 includes a single bonded nonwoven web 6 that is a fiber blend (sometimes referred to herein as the "fiber blend of the present invention") that is comprised, by total weight of the fiber blend, of: (a) 20-55 wt. % siliconized fibers having a denier of 1.5-10.0 and a length of 51 mm-84 mm; (b) 10-45 wt. % hollow bicomponent fibers having a spiral crimp, a denier of 1.5-10.0 and a length of 51-84 mm; (c) 10-45 wt. % hollow bicomponent fibers having a spiral crimp, a denier of 1.5-10.0 and a length of 51-84 mm; (d) a fiber mixture containing 1 to 20 wt% of a second binder fiber group different from the first binder fiber group, the second binder fiber group being 1.5 to 6.0 denier, 51 to 84 mm in length, and a bonding temperature of 80 to 135°C.

[0020] An embodiment of a batting material of the present invention contains one or more bonded nonwoven webs (e.g., 1, 2, 3, 4, 5, 6, etc.). In FIG. 1, the batting material 10 includes a single bonded nonwoven web 6. In the illustrated batting material, the first surface 2 and the second surface 4 of the batting material 10 are the same parallel surfaces on the front and back of the bonded nonwoven web 6. In contrast, FIG. 2 illustrates a cross-sectional side view of an embodiment of a batting material 10' of the present invention that includes two bonded nonwoven webs 6 and 8 cross-lapped together. In embodiments that include more than one nonwoven web, at least one nonwoven web includes the fiber blend of the present invention. In some embodiments, the majority of the nonwoven webs included in the batting material include the fiber blend of the present invention. In some embodiments, all of the nonwoven webs included in the batting material include the fiber blend of the present invention.

[0021] Denier is a unit of measure defined as the weight (in grams) of 9000 meters of fiber or yarn. Denier is a common way of specifying the weight (or fineness) of a fiber or yarn. For example, a 1.0 denier polyester fiber typically has a diameter of approximately 10 micrometers.

[0022] <(a) Siliconized fiber having a denier of 1.5 to 10.0 and a length of 51 mm to 84 mm> The fiber blend of the present invention comprises 20-55 wt% siliconized fibers (sometimes referred to herein as "siliconized 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 wt%, or any range or subrange therein (e.g., 20-45 wt%, 20-40 wt%, 25-35 wt%, etc.).

[0023] As used herein, the term "siliconized" means that the fiber is coated with a silicon-containing composition (e.g., silicone). Siliconization techniques are well known in the art and are described, for example, in U.S. Pat. No. 3,454,422. The silicon-containing composition can be applied using any method known in the art, such as spraying, mixing, dipping, padding, etc. The silicon-containing (e.g., silicone) composition, which may include organosiloxanes or polysiloxanes, bonds to the outer portion of the fiber. In some embodiments, the silicone coating is a polysiloxane, such as methylhydrogenpolysiloxane, modified methylhydrogenpolysiloxane, polydimethylsiloxane, or amino-modified dimethylpolysiloxane. As is well known in the art, the silicon-containing composition may be applied directly to the fiber or may be diluted with a solvent prior to application as a solution or emulsion (e.g., an aqueous emulsion of polysiloxane). After treatment, the coating may be dried and / or cured. As is well known in the art, catalysts may be used to accelerate the cure of silicon-containing compositions (e.g., polysiloxanes containing Si-H bonds), and for convenience, a catalyst may be added to an emulsion of the silicon-containing composition, and the resulting formulation may be used to treat synthetic fibers. Suitable catalysts include carboxylates of iron, cobalt, manganese, lead, zinc, and tin, such as acetates, octanoates, naphthenates, and oleates. In some embodiments, following siliconization, the fibers are dried to remove residual solvent, and then optionally heated to 65°-200° C. for cure.

[0024] The siliconized fiber (a) may be 1.5 to 10.0 denier, 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, or any range or subrange therein (e.g., 2-10 denier, 3-10 denier, 4-10 denier, 5-10 denier, 6-10 denier, 5-9 denier, 6-8 denier, 6.5-7.5 denier, etc.).

[0025] The length of the siliconized fiber (a) is from 51 mm to 84 mm, e.g., 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, or any range or subrange therein (e.g., 60 to 84 mm, 65 to 84 mm, 70 to 80 mm, etc.).

[0026] In some embodiments, the siliconized fiber (a) is a hollow fiber. In some embodiments, the siliconized fiber (a) is a solid (non-hollow) fiber. In some embodiments, the siliconized fiber (a) is a polymer fiber. In certain embodiments, 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).

[0027] <(b) A hollow composite fiber having a spiral crimp, a denier of 1.5 to 10.0, and a length of 51 to 84 mm> The fiber blends of the present invention include 10-45 wt% hollow bicomponent fibers (sometimes referred to herein as "hollow bicomponent fibers (b)") having a spiral crimp, a denier of 1.5-10.0, and a length of 51-84 mm. For example, in some embodiments, the fiber blends of the present invention include 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%, or any range or subrange therein (e.g., 15-45 wt%, 20-40 wt%, 25-35 wt%, etc.).

[0028] The hollow composite fiber (b) has a spiral (helical) crimp. The hollow composite fiber (b) is 1.5 to 10.0 denier, 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, or any range or subrange therein (e.g., 2-10 denier, 3-10 denier, 4-10 denier, 5-10 denier, 6-10 denier, 5-9 denier, 6-8 denier, 6.5-7.5 denier, etc.).

[0029] The length of the hollow composite fiber (b) is 51 to 84 mm, e.g., 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, or any range or subrange therein (e.g., 51 to 75 mm, 55 to 75 mm, 60 to 70 mm, etc.).

[0030] The hollow composite fibers (b) may be siliconized or dry (i.e., not siliconized). In some embodiments, the hollow composite fibers (b) are dry and have not been treated with any surface chemistry. In some embodiments, the hollow composite fibers (b) are treated with a surface chemistry (e.g., siliconized).

[0031] In some embodiments, the composite fiber (b) is a polymer fiber. In certain embodiments, the composite fiber (b) is a polyester fiber. In some embodiments, the composite fiber (b) comprises recycled polyester (e.g., PCR polyester).

[0032] <First binder fiber group> The fiber mixture of the present invention contains 10 to 45 wt % of a first binder fiber group, and the first binder fiber group is an elastic copolyester binder fiber 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 (sometimes referred to as "binder fiber (c)" in this specification).

[0033] 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 wt% of binder fiber (c), or any range or subrange therein (e.g., 15-40 wt%, 20-40 wt%, 25-35 wt%, etc.).

[0034] In some embodiments, the binder fiber (c) has a high elongation at break (e.g., 200% to 800%, 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, 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, 800, 810, 820, 830, 840, 850, 860, 870, 880, 890, 900, 910, 920, 930, 940, 950, 960, 970, 980, 990, 1000, 1010, 1020, 1030, 1040, 1050, 1060, 1070, 1080, 1090, 1090, 1080 0, 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%, or any range or subrange therein. Elongation at break refers to the percent elongation in length of the fiber when the fiber is stretched to the point where it breaks.

[0035] In some embodiments, the binder fiber (c) may be, 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, 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, 800, 810, 820, 830, 840, 850, 860, 870, 880, 890, 900, 910, 920, 930, 940, 950, 960, 970, 980, 990, 1000, 1010, 1020, 1030, 1040, 1050, 1060, 1070, 1080, 1090, 1010, 1090, 1010, 1020, 1030, 10 having an elongation at break of 80, 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 binder fiber (c) is stretched to a length between 200 and 800% (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, 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%) and fully recovers within 5 minutes.

[0036] The binder fiber (c) is 1.5 to 8.0 denier, 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, or any range or subrange therein (e.g., 2-8 denier, 3-8 denier, 4-7.5 denier, 5-7 denier, etc.).

[0037] The length of the binder fibers (c) is from 51 mm to 84 mm, e.g., 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, or any range or subrange therein (e.g., 51-75 mm, 55-75 mm, 60-70 mm, etc.).

[0038] The binder fiber (c) is heated to 110°C to 180°C, for example, 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, 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., or any range or subrange therein (e.g., 120-170° C., 125-160° C., etc.).

[0039] The binder fiber (c) is a copolyester fiber containing two different polyester components. In some embodiments, the binder fiber (c) comprises an inner polyester component and an outer polyester elastomeric component. In such embodiments and certain other embodiments, the binder fiber (c) is considered to be 100% polyester fiber. In some embodiments, the binder fiber (c) comprises an inner polyester component and an outer polyester elastomeric component having a lower melting point than the inner polyester component.

[0040] 3A-F show non-limiting examples of possible cross-sections of bicomponent binder fibers used in certain embodiments of the present invention (e.g., as binder fiber (c) or binder fiber (d)). In FIG. 3A, the core 42 and sheath 44 are in a 50:50 ratio and are arranged side-by-side. As used herein, the term "core" refers to a fundamental portion of a bicomponent fiber that is distinct from the sheath portion. In various embodiments, the core may be in the center, innermost portion of the bicomponent fiber. However, in other embodiments, the core may be off-center or may be present on at least a portion of the periphery of the bicomponent fiber. In FIG. 3B, the core 42 and sheath 44 are unequal radios and are arranged side-by-side. Additionally, the interface between the core 42 and sheath 44 is not planar. In Figures 3C-3F, the core 42 and sheath 44 are in a concentric arrangement with the core 42 forming a portion of the interior of the bicomponent fiber 20' and surrounded by the sheath 44. In the non-limiting embodiment shown in Figures 3A-3E, the core 42 is asymmetrically positioned with respect to the sheath 44 (i.e., the core 42 is symmetrically offset within the bicomponent fiber 20'). In Figures 3C-3F, the core 42 is off-center (i.e., off-center from the center point or central axis of the fiber) yet is completely surrounded by the sheath 44. Figure 3E shows a trilobal fiber 20'. The arrangements shown in Figures 3C-3F are also known as "sea island" or "island in sea" configurations. As will be appreciated by those skilled in the art, these are non-limiting arrangements that may include additional components or additional "islands."

[0041] <Second group of binder fibers> The fiber mixture of the present invention contains 1-20 wt % of a second binder fiber group different from the first binder fiber group, the second binder fiber group having a denier of 1.5-6.0, a length of 51 mm-84 mm, and a bonding temperature of 80°C-135°C (sometimes referred to in the present specification as "binder fiber (d)").

[0042] The fiber blend of the present invention includes 1 to 20 wt% binder 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 wt%, or any range or subrange therein (e.g., 2 to 18 wt%, 3 to 17 wt%, 4 to 16 wt%, 5 to 15 wt%, etc.).

[0043] The binder fiber (d) is 1.5 to 6.0 denier, 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, 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, or any range or subrange therein (e.g., 1.5 to 5 denier, 1.5 to 4 denier, 1.5 to 3 denier, etc.).

[0044] The length of the binder fibers (d) is from 51 mm to 84 mm, e.g., 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, or any range or subrange therein (e.g., 51-75 mm, 51-70 mm, 51-65 mm, 51-60 mm, etc.).

[0045] The bonding temperature of the binder fiber (d) is 80°C to 135°C, 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, or any range or subrange therein (e.g., 90 to 125°C, 95 to 115°C, etc.).

[0046] In some embodiments, the binder fiber (d) is a polymer fiber. In certain embodiments, the binder fiber (d) comprises polyester. In some embodiments, the binder fiber (d) comprises recycled polyester (e.g., PCR polyester).

[0047] Binder fibers are well known in the art, and many binder fibers are commercially available. The binder fiber (d) used in the present invention can be a conventional binder fiber (e.g., a binder fiber of low melting point polyester) or other binder fiber, provided that whatever binder fiber is used, the binder fiber has a bonding temperature lower than the softening temperature of the siliconized fiber (a) and the hollow composite fiber (b). Binder fibers are discussed, for example, in U.S. Pat. No. 4,794,038, and general protocols for certain embodiments of binder fibers are described in U.S. Pat. Nos. 4,281,042 and 4,304,817. In some embodiments, the binder fiber (d) is a monocomponent fiber. In some embodiments, the binder fiber (d) is a multicomponent fiber (e.g., a bicomponent fiber, for example, a sheath-core fiber in which the core contains a component with a higher melting point than the sheath). In some embodiments, the binder fiber (d) is a bicomponent fiber having one of the non-limiting configurations illustrated in Figures 3A-F.

[0048] The batting material of the present invention, in some embodiments, is heat treated to melt all or a portion of the binder fibers in the batting material to form a bonded nonwoven web type batting material. As will be appreciated by those skilled in the art, although "binder fibers" are referred to in the fiber mixture of the batting material, the binder fibers may be fully or partially melted fibers that are entirely different from the binder fibers in their original pre-heat treatment form.

[0049] In an embodiment of the batting material of the present invention, the siliconized fibers (a), the hollow composite fibers (b), the binder fibers (c), and the binder fibers (d) are each separate and distinct, and are mutually exclusive groups of fibers. In the fiber blend of the present invention, the fiber elements, such as siliconized fiber (a), hollow composite fiber (b), binder fiber (c), and binder fiber (d), are mixed (e.g., homogeneously mixed). As will be appreciated by those skilled in the art, mixing the fibers typically results in a homogeneous mixture.

[0050] In some embodiments, the fiber blends of the present invention are of substantially homogeneous composition (ie, 90-100% homogeneous). In some embodiments, the fiber blend of the present invention comprises siliconized fiber (a), hollow bicomponent fiber (b), binder fiber (c), and binder fiber (d). In some embodiments, at least 90 wt% (e.g., at least 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 99.5 wt%) of the fiber blend of the present invention is comprised of the combined wt% of siliconized fiber (a), hollow composite fiber (b), binder fiber (c), and binder fiber (d). For example, if the combined wt% of siliconized fiber (a), hollow composite fiber (b), binder fiber (c), and binder fiber (d) is 90 wt% of the fiber blend, it is contemplated that 10 wt% of the fiber blend is comprised of other fiber elements.

[0051] Unless otherwise specified, the fibers used in the batting of the present invention may be crimped or uncrimped. A variety of crimps, including spiral crimp and standard crimp, are known in the art. Unless otherwise specified, the cross-section of the fibers used in the batting material of the present invention may be of any desired shape (eg, circular or otherwise).

[0052] In some embodiments, the fiber blend of the present invention comprises, by weight of the fiber blend: - 20 to 40 wt. % siliconized fibers (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 wt. %, or any range or subrange therein); and / or - 20 to 40 wt. % hollow bicomponent 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 wt. %, or any range or subrange therein); and / or - 20 to 40 wt % of a first group of binder 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 wt %, or any range or subrange therein); and / or - 5 to 15 wt. % of a second group of binder fibers (d) (e.g., 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 wt. %, or any range or subrange therein). Includes.

[0053] In some embodiments of the fiber blend of the present invention: Siliconized fiber (a) is 3.0 to 10.0 denier (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, or any range and subrange therein; and / or - Hollow composite fiber (b) is 3.0 to 10.0 denier (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, or any range and subrange therein; and / or - the first group of binder fibers (c) is 3.0 to 8.0 denier (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, or 8.0 denier, or any range or subrange therein); and / or - the second group of binder fibers (d) is 1.5 to 4.0 denier (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, or any range or subrange therein).

[0054] In some embodiments, the fiber blends of the present invention can include synthetic fibers and optionally natural fibers. In some embodiments, the fiber blend of the batting material of the present invention comprises natural fibers, for example, in some embodiments, the fiber blend comprises one or more members selected from wool, cotton, Tencel, kapok (a cotton-like fluff obtained from the seeds of the kapok tree, optionally further processed before use), flax, animal hair, silk, and down (e.g., duck down or goose down). In some embodiments, the fiber blends of the present invention include natural and / or synthetic polymeric fibers.

[0055] Numerous synthetic fibers are known in the art, and any desired art-accepted synthetic fiber is contemplated for use in the present invention. Indeed, different fibers have different properties that lend themselves to advantageous use in different applications. This information is well within the purview of one of ordinary skill in the art. A variety of synthetic fibers can be used in the present invention, and in some embodiments, the synthetic fibers are selected from the group consisting of polyamides (e.g., nylon / polyamide 6.6, polyamide 6, polyamide 4, polyamide 11, and polyamide 6.10), polyesters, polybutylene terephthalates (PBT), polypropylene, polylactic acid (also known as polylactide) (PLA), poly(butyl acrylate) (PBA), acrylic acid, acrylates, acetates, polyolefins, nylons, rayon, lyocell, aramids, spandex, viscose, and modal, biopolymer fibers (e.g., polyhydroxyalkanoates (PHA), poly(hydroxybutyrate-covalerate) (PHBV)), and combinations thereof.

[0056] In certain embodiments, the fiber blends of the present invention include polyester synthetic fibers. In some embodiments, such polyester fibers include one or more of polyethylene terephthalate (PET), poly(hexahydro-p-xylylene terephthalate), polybutylene terephthalate (PBT), poly-1,4-cyclohexylinedimethylene (PCDT), and copolyesters of terephthalate in which at least 85 mole percent of the ester units are ethylene terephthalate or hexahydro-p-xylylene terephthalate units. In certain embodiments, the synthetic fibers are polyethylene terephthalate fibers.

[0057] In some embodiments, the batting of the present invention comprises 4-15 wt% resin based on the total weight of the batting, for example, in some embodiments, the batting comprises 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 wt%, or any range or subrange therein (e.g., 6-10 wt%).

[0058] In some embodiments, the first and / or second surface of the batting comprises 2-8 wt. % resin based on the total weight of the batting, such as 2, 3, 4, 5, 6, 7, or 8 wt. %, or any range or subrange therein (e.g., 2-5 wt. %).

[0059] In some embodiments, the area weight of the batting material of the present invention is between 25 and 60 g / m 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 60 g / m 2 or any range or subrange therein (e.g., 30 to 40 g / m 2 ).

[0060] In some embodiments, the density of the batting material of the present invention is 5 to 15 kg / m 3 , for example 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 kg / m 3 or any range or subrange therein (e.g., 5 to 14 kg / m 3 , 13~14kg / m 3 etc.).

[0061] In some embodiments, the thickness of the batting material is between 3 mm and 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, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 1, 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), or any range or subrange therein.

[0062] Clo (clo / oz / yd2) is a unit used to measure the thermal resistance of clothing or other insulating articles. 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 at 21°C (70°F) temperature. Generally, temperatures above this level will cause a person wearing the garment to sweat, and temperatures below this level will cause the person to feel cold. For articles such as clothing and / or its components (e.g., insulating materials such as batting), a Clo value can be determined. A high Clo value indicates that the article is warmer than another article with a relatively low Clo value.

[0063] In some embodiments, the batting material of the present invention has a hardness of 0.012 claws per g / m according to ISO 11092. 2 higher (e.g., 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 claws per g / m 2 (higher than 100 g), or any range and subrange therein.

[0064] In some embodiments, the batting material of the present invention has a dry weight of 150 wt% or less (e.g., 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, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149, or 150 wt% or less).

[0065] In some embodiments, the batting material of the present invention is a batting material having a dry weight of 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, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 200, 201, 202, 203, 204, 205, 206, 207, 208, 209, 300, 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, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149, or 150 wt %, or any range or subrange therein.

[0066] Batting embodiments of the present invention surprisingly have exceptional resistance to pilling and fiber migration. In the past, excessive resin and / or downproof fabrics have been used in insulating constructions (such as batting) to prevent fiber migration problems. In fact, downproof fabrics are fabrics that 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 downproof constructions sacrifices breathability and comfort to prevent fiber migration.

[0067] Applicants have surprisingly found that embodiments of the inventive batting material are comparable in terms of resistance or prevention of fiber migration / pilling to comparative embodiments prepared using excess resin and / or downproof fabrics, yet are far more comfortable and breathable, resulting in a highly improved textile product. This characteristic is due to the unique composition of the inventive fiber blend used to make the nonwoven web of the inventive batting material.

[0068] Those skilled in the art would not generally consider subjecting a bonded nonwoven batting containing staple fibers (fibers of limited length, as opposed to filaments of unlimited length) to a fiber migration test. Indeed, conventional wisdom would dictate that a nonwoven insulation would not be able to withstand the Martindale test. The Martindale test method, performed before and after washing the sample 10 times, is used to measure fiber migration that occurs when the insulation is exposed to friction under pressure against various materials such as high CFM fabrics, seat belts, backpacks, harnesses, etc. A typical batting containing a bonded nonwoven web would be severely damaged by this test and would experience excessive fiber migration. However, surprisingly, the embodiments of the inventive batting described herein do not exhibit surface pilling or fiber migration when subjected to the fiber migration test. This is an entirely new benchmark for the durability of insulation. Insulation materials (such as batting) that can withstand the fiber migration test described herein can be combined with highly breathable fabrics (high cfm, e.g., 1-500 CFM, e.g., fabrics with textured surfaces) to create exceptionally comfortable and breathable fiber-based articles. The properties of the batting of the present invention are even more surprising because one skilled in the art would expect the presence of siliconized fibers (a) to impair durability (as more siliconized fibers would be expected to provide fewer bond points since binder fibers generally do not bond well to the siliconized fibers). Surprisingly, the presence of these siliconized fibers, without impairing the fiber migration properties of the insulation, contributes to the beneficial water repellency properties of embodiments of the batting of the present invention to create a highly advantageous insulation that is breathable, water repellent, migration resistant, and has excellent drapeability (properties that were previously thought to be mutually exclusive - at least one property would have to be compromised to achieve a beneficial result for the other properties).

[0069] One test method for measuring the fiber migration resistance of insulation is the IDFL (International Down and Feather Testing Laboratory) Downproofness-International Rotation Box Standard Test Method. According to this method, a rolling bin is used, which is a 45.5 cm plastic box with a door on one side. A motor rotates the box at a speed of 48 ± 2 revolutions per minute. Twenty-four No. 6.5 solid silicone plugs are used in the box. A clean sample article is placed in the box and the box is rotated for 30 minutes. All fibers and fiber clumps are collected from the surface of the article, the box and the silicone plugs of the rolling bin. The collection is evaluated and counted and a numeric rating from 1 (significant fiber migration) to 5 (little or no fiber migration) is given based on the amount of fibers escaping or protruding through the fabric of the article after the 30 minute rolling period (only fibers > 4 mm are counted), as shown in Table I.

[0070] [Table 1]

[0071] In some embodiments, the batting material of the present invention has a fiber migration rating according to the IDFL Downproofing - International Rotating Box Standard Test Method of 4 or 5. Excellent resistance to fiber migration also indicates excellent resistance to pilling, and thus fiber migration resistance as discussed herein includes resistance to pilling.

[0072] The "INS-17 Fiber Migration Test" is a fiber migration resistance test standard developed by the applicant, which is more rigorous and stringent than the Downproofing International Rotating Box Standard Test Method. In some embodiments, the batting material of the present invention has a fiber migration resistance of less than 20 fibers when tested according to the INS-17 Fiber Migration Test. The INS-17 Fiber Migration Test measures the likelihood of fibers migrating through various types of fabrics and is described below.

[0073] The sample is prepared as follows: Select a piece of fabric and fold it in half to form a pillow (approximately 12" x 12") that is open on three sides. Sew two sides together and leave the side opposite the fold unsewn. Cut a piece of insulation (e.g., in this case a batting embodiment of the present invention) to approximately 12" x 12" so that it fits snugly inside the fabric pillow without bunching. Place the insulation inside the pillow and sew the last side of the pillow. To prevent the insulation from shifting position, only sew the pillow around the entire outside edge, approximately 0.25 inches from the end. Sides A and / or B of the pillow are marked as such.

[0074] The pillow sample is subjected to a test procedure which includes: Cycle 1: Place the pillow in a home dryer (no heat) for 45 cycles per minute with 21 rubber stoppers (such as Herco Black Rubber One-Hole Stoppers, part number ST1H-04-BK, sold by Hecht Rubber Corporation, used in the examples described herein). After completing cycle 1, closely observe both sides of the pillow to detect any fibers that have threaded through the fabric. For the examples described herein, observe the pillow using a dark background and proper lighting, and thoroughly scrub the surface of the pillow for fibers using packing tape.

[0075] Cycle 2: The pillow is placed in a domestic washing machine and subjected to the following wash cycle settings: normal wash cycle, cold water rinse, small load, 2 tablespoons of laundry detergent (e.g., Tide®). After the wash cycle is completed, the pillow is removed from the washing machine and placed in a dryer and subjected to a low temperature dryer cycle with 21 rubber plugs until completely dry. After completing cycle 2, the pillow is carefully observed on both sides to detect any fibers that have passed through the fabric. The fibers that have passed through the fabric are counted and recorded for both sides of the pillow. For the examples described herein, the pillow is observed using a dark background and appropriate lighting, and the surface of the pillow is thoroughly scrutinized for fibers using packing tape.

[0076] <Cycle 3>: Repeat cycle 2 but do not use laundry detergent. <Cycle 4>: Repeat cycle 2 but do not use laundry detergent.

[0077] After completing cycles 1-4, the dough is graded as follows: [Table 2]

[0078] In some embodiments, the migration resistance of the batting material of the present invention is "migration resistant" (i.e., 0 fibers counted) or "acceptable migration" (i.e., less than 3 fibers counted) according to the INS-17 Fiber Migration Test.

[0079] In some embodiments, the batting material has a stretch or multi-directional stretch in one or more of the machine direction (MD), cross direction (CD), and diagonal of 5-30% (including all ranges and subranges therein) at a wash load of 0.65 lbs when tested per ASTM D3107. For example, in some embodiments, the batting material has a stretch in the MD, CD, and / or diagonal 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%.

[0080] In some embodiments, the batting of the present invention has excellent drapeability (the insulation sags under its own weight). The drapeability of the insulation greatly affects the qualities, such as comfort and aesthetics, of the article in which it is used. In some embodiments, the drapeability of the insulation is between 1.0 cm and 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), or any range or subrange therein (e.g., 1.5 to 2.5 cm), as measured according to test method ASTM D1388.

[0081] In some embodiments, the batting material of the present invention has a compression recovery as measured according to ISO 3385 of greater than 50%, such as greater than 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, or 60%.

[0082] In some embodiments, the batting material of the present invention has a compression recovery according to ISO 3385 of 50.5 to 70%, e.g., 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, or 70%, or any range or subrange therein (e.g., 50.5 to 68%, 55 to 67%, 60 to 65%, etc.).

[0083] In a second aspect, the present invention provides an article comprising a batting material according to the first aspect of the invention.

[0084] In some non-limiting embodiments, the article is an article such as footwear (e.g., shoes, socks, slippers, boots), outerwear (e.g., outdoor apparel such as jackets, coats, vests, shoes, pants (e.g., snow pants, ski pants, etc.), gloves, mittens, scarves, headgear, hats, etc.), clothing / apparel (e.g., shirts, pants, undergarments (e.g., undershirts, thermal undergarments, socks, stockings, etc.), sleepwear (e.g., pajamas, nightgowns, robes, etc.)), activewear (e.g., clothing including footwear worn for sports or exercise), sleeping bags, bedding (e.g., comforters or quilts), pillows, cushions, pet beds, household items (e.g., upholstered chairs), and the like.

[0085] In some embodiments, the fibers of the present invention are included in at least a portion of one of the articles. In some embodiments, the article has an air permeability of 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, 4, 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, 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, 135, 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, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, 180, 181, 182, 1 83, 184, 185, 186, 187, 188, 189, 190, 191, 192, 193, 194, 195, 196, 197, 198, 199, 200, 201, 202, 203, 204, 205, 206, 207, 208, 209, 210, 211, 212, 213, 21 4, 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, 259, 260, 261, 262, 263, 264, 265, 266, 267, 268, 269, 270, 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, 33 4, 335, 336, 337, 338, 339, 340, 341, 342, 343, 344, 345, 346, 347, 348, 349, 350, 351, 352, 353, 354, 355, 356, 357, 358, 359, 360, 361, 362, 363, 364, 365, 366, 367, 368, 369, 370, 371, 372, 373, 374, 375, 376, 377, 378, 379, 380, 381, 382, ​​383, 384, 385, 386, 387, 388, 389, 390, 391, 3 92, 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 , 450, 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 500 CFM, or any range or subrange therein.

[0086] In a third aspect, the present invention provides a method of making a batting according to the first aspect of the invention or an article according to the second aspect of the invention, comprising the steps of: - a fibre mixture according to the invention (a) 20-55 wt.% of a silicone-treated fiber having a denier of 1.5-10.0 and a length of 51 mm-84 mm; (b) hollow bicomponent fibers having 10-45 wt. % spiral crimp, 1.5-10.0 denier and 51-84 mm in length; (c) 10-45 wt% of a first binder fiber group, the first binder fiber group being an elastic copolyester binder fiber having a denier of 1.5-8.0, a length of 51 mm-84 mm, and a bonding temperature of 110°C-180°C; (d) 1 to 20 wt % of a second binder fiber group different from the first binder fiber group, the second binder fiber group 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.; preparing the composition by mixing; - forming a nonwoven web from the fiber mixture (e.g. by carding); - providing a nonwoven web or optionally laminating (e.g. cross-lapping) a nonwoven web formed from the fiber mixture with one or more (e.g. 1, 2, 3, 4, or 5) additional nonwoven webs; - forming a batting or batting intermediate comprising one or more nonwoven webs, the batting or batting intermediate having at least a bonded nonwoven web comprising a fiber blend, by heating the nonwoven webs to a temperature at or above a highest binder fiber bonding temperature, the batting or batting intermediate having a first surface parallel to a second surface; - optionally applying a resin solution to the first and / or second surface of the intermediate batting material; - optionally heating the intermediate batting material to a temperature above the glass transition temperature of the resin in the resin solution; and - optionally forming the batting material by calendering one or more surfaces of the intermediate batting material; The present invention provides a method comprising:

[0087] In some embodiments, after (e.g., immediately after) providing a nonwoven web and optionally laminating (e.g., cross-lapping) the web, the resulting batting intermediate is subjected to a needling process. Needling is typically performed in a needle loom, a machine for bonding nonwoven webs by mechanically orienting the fibers through the web. During needling (also called needle punching), barbed needles attached to a board ("needle board") punch the fibers into the battering intermediate and back, mechanically entangling the fibers. Although needling is typically used on nonwoven webs to produce dense products (typical needling fabrics include pads, paper felts, padding, backing, etc.), the applicant has found that desirable embodiments of the present invention can be produced using a needling process. For example, in some embodiments, the intermediate batting material is lightly stitched by subjecting it to a needling process in which the needle board has been modified to be less dense (i.e., contain fewer needles than typically used in needling) and / or modified to limit needling so that the needles penetrate only partially into the intermediate batting material. Applicants have found that such "partial needling" results in embodiments that are not as dense as typical needling products, but have even further improved fiber transfer characteristics.

[0088] In some embodiments, the needling process is performed on the batting intermediate following the step of "providing a nonwoven web or optionally laminating (e.g., cross-lapping) a nonwoven web formed from a fiber mixture with one or more (e.g., 1, 2, 3, 4, or 5) additional nonwoven webs" above, and prior to performing any of the steps listed above. EXAMPLES

[0089] The invention will now be illustrated, but not limited, by reference to specific embodiments described in the following examples. An embodiment of the batting material of the present invention is - a siliconized fiber (a) containing 30 wt.% recycled polyethylene, having a denier of 7 and a length of 76 mm; - (b) untreated hollow bicomponent fibres containing 30% by weight of recycled polyethylene, having a denier of 7 and a length of 64 mm; - 30 wt. % of polymeric binder fibers (c) having a denier of 6 and a length of 64 mm; - a binder fiber (d) containing 10 wt% recycled polyethylene, having a denier of 2 and a length of 51 mm; A fiber mixture is prepared by mixing the fiber mixture comprising:

[0090] The fiber mixture is formed into a nonwoven web in a carding machine and then heated to bond the binder fibers (c) and (d) to form a bonded nonwoven web. A 70 / 30 water / resin solution is applied to both sides (sides A and B) of the bonded nonwoven web and then heated to a temperature above the glass transition temperature of the resin in the resin solution. This intermediate batting is calendered at 185°C to form an embodiment of the batting.

[0091] Fiber migration testing is performed on the batting embodiments according to the INS-17 fiber migration test. The migration test results for pillows 1-3 are as follows: [Table 3]

[0092] As can be readily seen, despite the rigorous fiber migration testing procedures, embodiments of the batting material of the present invention demonstrate exceptional resistance to fiber migration. The ability to achieve this level of reduction / prevention of fiber migration in a bonded treated nonwoven batting material containing staple fibers is exceptionally advantageous.

[0093] A 40 gsm batting sample prepared as described above is subjected to Applicant's standard operating procedure equivalent to ASTM D3107. The results are as follows: [Table 4]

[0094] Further embodiments of the batting material of the present invention include: - a siliconized fiber (a) containing 20 wt. % recycled polyethylene terephthalate and having a denier of 6 and a length of 64 mm; - untreated hollow bicomponent fibres (b) containing 50% by weight of recycled polyethylene terephthalate, having a denier of 3 and a length of 51 mm; - 15 wt. % of polymeric binder fibers (c) having a denier of 6 and a length of 64 mm; - a binder fiber (d) containing 15 wt% recycled polyethylene, having a denier of 2 and a length of 51 mm; A fiber mixture is prepared by mixing the fiber mixture comprising:

[0095] The fiber mixture is formed into a nonwoven web on a carding machine and then lightly stitched (i.e., subjected to partial needling) to further entangle the fibers and provide greater protection from fiber migration. A 70 / 30 water / resin solution is applied to both sides (sides A and B) of the bonded, stitched nonwoven web, which is then heated to a temperature above the glass transition temperature of the resin in the resin solution. This heating also serves to bond the binder fibers (c) and the binder fibers (d) to form a bonded, lightly stitched nonwoven web. The intermediate batting is calendered at 170°C to form a batting embodiment.

[0096] Fiber migration testing is performed on the batting embodiments according to the INS-17 Fiber Migration Test. The migration test results are as follows: [Table 5]

[0097] Martindale tests are also performed on the batting embodiments. Specifically, unwashed samples of the batting intermediate are covered with fabric and subjected to testing in a Martindale tester. Separate tests are performed rubbing the samples with fabric, seat belt material, and backpack material, with the following results: [Table 6]

[0098] As can be readily seen, the batting embodiments performed exceptionally well despite the rigorous Martindale testing (not typically performed on batting insulation). The ability to achieve this level of fiber migration reduction / prevention in a bonded nonwoven batting containing staple fibers is exceptionally advantageous.

[0099] The terminology used herein is merely for the purpose of describing a particular embodiment and is not intended to limit the present invention. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms unless the context clearly indicates otherwise. It is further understood that the terms "comprise" (and any form of such terms, e.g., "comprises" and "comprising"), "have" (and any form of such terms, e.g., "has" and "having"), "include" (and any form of such terms, e.g., "includes" and "including"), "contain" (and any form of such terms, e.g., "contains" and "containing"), and any other grammatical variants thereof, are open-ended linking verbs. As a result, a method or article that "includes," "has," "comprises," or "contains" one or more steps or elements possesses, but is not limited to possessing only, those one or more steps or elements. Similarly, a method step or article element that "includes," "has," "comprises," or "contains" one or more features possesses, but is not limited to possessing only, those one or more features.

[0100] As used herein, the terms "comprising," "has," "including," "contains," and other grammatical variations thereof, encompass the terms "consisting of" and "consisting essentially of."

[0101] The phrase "consisting essentially of," or grammatical variations thereof, as used herein, is deemed to specify the stated features, integers, steps, or components, but does not exclude the addition of one or more additional features, integers, steps, components, or groups thereof, so long as such additional features, integers, steps, components, or groups thereof do not materially alter the basic and novel characteristics of the claimed composition or method.

[0102] All publications cited in this specification are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference as if it were fully set forth. Subject matter incorporated by reference is not to be construed as a substitute for any claim limitation elements, unless expressly indicated otherwise.

[0103] Where one or more ranges are referred to throughout this specification, each range is intended to be a shorthand format for presenting information, where the range is understood to include each individual point falling within the range as if each point were individually set forth herein.

[0104] While several aspects and embodiments of the present invention have been described and illustrated herein, alternative aspects and embodiments may be selected by those skilled in the art to accomplish the same purposes, and it is therefore intended that this disclosure and the appended claims cover all such additional and alternative aspects and embodiments that fall within the true spirit and scope of the present invention.

Claims

1. A batting material comprising a bonded nonwoven web, the batting material having a first surface parallel to a second surface, the bonded nonwoven web comprising a fiber blend comprising: (a) 20-55 wt % of a silicone treated fiber having a denier of 1.5-10.0 and a length of 51 mm-84 mm; (b) hollow bicomponent fibers having 10-45 wt. % spiral crimp, 1.5-10.0 denier and 51-84 mm in length; (c) 10-45 wt % of a first group of binder fibers, the first group being elastomeric copolyester binder fibers having a denier of 1.5-8.0, a length of 51 mm-84 mm, and a bonding temperature of 110° C.-180° C.; (d) 1 to 20 wt % of a second group of binder fibers different from the first 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.; Contains The fibers in the fiber mixture are homogeneously mixed.

4. A batting material comprising:

2. The batting of claim 1 , wherein the first surface and the second surface comprise a resin.

3. The batting material according to claim 2, comprising 4 to 15 wt % of the resin based on the total weight of the batting material.

4. The batting material according to claim 3, comprising 6 to 10 wt % of the resin based on the total weight of the batting material.

5. The fiber mixture is based on the weight of the fiber mixture. (a) 20-40 wt % siliconized fibers; and / or (b) 20 to 40 wt. % hollow bicomponent fibers; and / or (c) 20 to 40 wt % of a first group of binder fibers; and / or (d) 5 to 15 wt % of a second group of binder fibers. The batting material according to any one of claims 1 to 4, comprising:

6. (a) the siliconized fiber is 3.0 to 10.0 denier; and / or (b) the hollow bicomponent fibers are 3.0 to 10.0 denier; and / or (c) the first group of binder fibers is 3.0 to 8.0 denier; and / or (d) the second group of binder fibers is 1.5 to 4.0 denier; The batting material according to any one of claims 1 to 5.

7. (a) the siliconized fiber is hollow; The batting material according to any one of claims 1 to 6.

8. (b) The hollow bicomponent fibers are untreated fibers; The batting material according to any one of claims 1 to 7.

9. (a) the siliconized fiber is a polyester fiber; The batting material according to any one of claims 1 to 8.

10. (a) the siliconized fiber is a polyester fiber comprising recycled polyester; The batting material according to claim 9.

11. (b) the hollow composite fiber is a polyester fiber; The batting material according to any one of claims 1 to 10.

12. (b) the hollow composite fiber is a polyester fiber containing recycled polyester; The batting material according to claim 11.

13. (c) the second group of binder fibers comprises polyester; The batting material according to any one of claims 1 to 12.

14. (c) the polyester in the second group of binder fibers comprises recycled polyester; The batting material according to claim 13.

15. 25-60g / m ２ and 11-15 kg / m ３ The batting material according to any one of claims 1 to 14, having a density of

16. 30-40g / m ２ and 13-14 kg / m ３ The batting material according to any one of claims 1 to 15, having a density of

17. 0.012 claws per g / m according to ISO 11092 ２ The batting material according to any one of claims 1 to 16, having a heat retention capacity per unit weight higher than

18. The batting material according to any one of claims 1 to 17, having a water absorption capacity of less than 150 wt%.

19. 20. The batting material of claim 18 having a water absorption of less than 100 wt%.

20. 20. The batting material of any one of claims 1 to 19, having a fiber migration resistance of less than 20 fibers when tested according to the INS-17 Fiber Migration Test.

21. An article comprising the batting material according to any one of claims 1 to 20.

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

23. A method of making a batting material according to any one of claims 1 to 22, comprising the steps of: - the fibre mixture, (a) 20-55 wt % of a silicone treated fiber having a denier of 1.5-10.0 and a length of 51 mm-84 mm; (b) hollow bicomponent fibers having 10-45 wt. % spiral crimp, 1.5-10.0 denier and 51-84 mm in length; (c) 10-45 wt % of a first group of binder fibers, the first group being elastic copolyester binder fibers, having a denier of 1.5-8.0, a length of 51 mm-84 mm, and a bonding temperature of 110° C.-180° C.; (d) 1 to 20 wt % of a second group of binder fibers different from the first 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.; preparing the composition by mixing - forming a nonwoven web from the fiber mixture; - providing a nonwoven web or optionally laminating a nonwoven web formed from a fiber mixture with one or more additional nonwoven webs; - forming a batting or batting intermediate comprising one or more nonwoven webs, the batting or batting intermediate having at least a bonded nonwoven web comprising a fiber blend, by heating the nonwoven webs to a temperature at or above a highest binder fiber bonding temperature, the batting or batting intermediate having a first surface parallel to a second surface; - optionally applying a resin solution to the first and second surfaces of the intermediate batting material; - optionally heating the intermediate batting material to a temperature above the glass transition temperature of the resin in the resin solution; and - Optionally, forming the batting material by calendering one or more surfaces of the intermediate batting material. A method comprising:

24. 24. The method of claim 23, wherein a batting intermediate is formed by providing the nonwoven web or optionally laminating the nonwoven web formed from the fiber blend with one or more additional nonwoven webs, and the method includes subjecting the batting intermediate to a needling process.

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