Fibre filler clusters and methods for making same

Abstract

The present invention provides a discrete fibrous filler cluster comprised of a plurality of randomly entangled fibers. Among the plurality of fibers, there are between 25 and 3600 fibers having a denier of between 0.2 and 12.0 and a length of between 8 and 160 mm. The plurality of fibers are randomly and non-uniformly oriented relative to one another. Among the discrete fibrous filler cluster, there are: one or more regions of relatively dense fibers having a first degree of entanglement; and one or more regions of relatively sparse fibers adjacent at least one of the one or more relatively dense regions having a second degree of entanglement less than the first degree of entanglement.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application Publication No. 63 / 211,792, filed June 17, 2021, U.S. Provisional Patent Application Publication No. 63 / 264,426, filed November 22, 2021, and U.S. Provisional Patent Application Publication No. 63 / 362,484, filed April 5, 2022, the entire contents of each of which are hereby incorporated by reference into this application. [Technical field]

[0002] FIELD OF THEINVENTION This invention relates generally to fiberfill clusters, articles comprising such clusters, and methods of making such clusters. Fiberfill clusters are particularly useful in the textile field. [Background technology]

[0003] Attempts have been made to achieve insulating and / or filling materials with down-like qualities for use in textile products.

[0004] For example, US Patent No. 5,851,665 relates to a filling material comprising clusters of bonded crimped thermoplastic fibers, the fibers being bonded at different positions in different clusters of the filling material. US Patent No. 5,851,665 emphasizes the importance of the fibers in the clusters being fully opened without constraints (e.g. entanglement) to fully bulk the fibers and obtain the resulting properties. The filling material is made from a large web of carded fibers or from continuous filaments in a tow that are cut and separated (after bonding) into clusters. A tow refers to a large bundle of continuous man-made fiber filaments with no apparent twist, usually held together by crimping in a loose rope-like configuration. A tow typically contains thousands of filaments. For example, the tow used in US Pat. No. 5,851,665 had approximately 122,000 filaments and a total denier of 48.9 ktex (440,100 denier), which resulted in clusters with a high fiber density.

[0005] Generally speaking, previous efforts to develop insulating and / or filling materials with down-like qualities have in most cases resulted in insulating and / or filling materials that, in the applicant's judgment, are too heavy and dense to be considered down-like and / or cannot be properly utilized with conventional blowing equipment. For example, these materials may tend to clog and / or be difficult to feed or load into conventional blowing equipment. Or, even if blowable, the materials are often entirely inadequate to mimic the desired down-like properties.

[0006] An exception is US Patent No. 10,633,244, which relates to a blowable insulation or filler material having a longitudinal length of about 2-4.5 cm and consisting of a plurality of separate longitudinally elongated floccules formed from a plurality of fibers, the floccules having a relatively open, expanded central section and only a pair of relatively compact, twisted tail sections extending from either longitudinal end of the central section. The insulation / filler material of US Patent No. 10,633,244 can be utilized in typical current garment filler blowing machines and has down-like qualities such as the hand, washability, loft and blowing efficiency of down insulation.

[0007] Nevertheless, there remains a need for additional and improved fibrous filler materials that are blownable with conventional blowing equipment and that have desirable down-like properties.

[0008] Although certain aspects of the prior art have been discussed to facilitate disclosure of the present invention, the applicants do not in any way deny these technical aspects, and it is believed that the present invention as claimed may include one or more of the prior art aspects discussed herein.

[0009] 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 any applicable statutory provision, 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

[0010] Briefly, the present invention fills the need for a blowable fibrous filler material that has desirable down-like properties.

[0011] The present invention may address one or more of the problems and deficiencies of the art discussed above. However, it is believed that the present invention may prove useful in addressing other problems and deficiencies in many areas of technology. Thus, the invention as set forth in the claims should not necessarily be construed as being limited to addressing any of the specific problems or deficiencies discussed herein.

[0012] Applicants have surprisingly found that embodiments of the fibrous filler clusters of the present invention match both the structure and performance of natural down.

[0013] In a first aspect, the present invention provides a method of making at least one fibrous filler cluster, the method comprising obtaining a plurality of bundles (e.g. individual bundles) of 25-3600 fibers having a denier of 0.2-12.0 dpf (denier per fiber / filament) and a length of 8-160 mm, the plurality of fibers being longitudinally aligned together, the method further comprising disrupting the longitudinal alignment of at least some of the plurality of fibers of the bundle such that the fibers are randomly elongated in three dimensions and intermingled to form the fibrous filler cluster (e.g. individual fibrous filler cluster).

[0014] In some embodiments, the individual bundles consist essentially of a plurality of 25 to 3600 fibers. In some embodiments, the individual bundles consist of a plurality of 25 to 3600 fibers.

[0015] In some embodiments, the step of randomizing the longitudinal alignment of at least a portion of the plurality of fibers of the bundle comprises randomizing the longitudinal alignment of only a portion of the plurality of fibers of the bundle such that a bundle remainder of the plurality of fibers of the bundle remain longitudinally aligned together and are intertwined with the random three-dimensionally extending fibers. In some such embodiments, the random three-dimensionally extending fibers form an outer region extending outwardly from the bundle remainder. In some such embodiments, the bundle remainder comprises a higher density of fibers than the outer region.

[0016] In some embodiments, randomizing the longitudinal alignment of at least a portion of the fibers of the bundle includes randomizing the longitudinal alignment of all of the fibers of the bundle such that none of the fibers remain longitudinally aligned together. In some such embodiments, randomizing the longitudinal alignment of all of the fibers of the bundle forms at least one inner, three-dimensional region of relatively densely packed fibers and an outer, relatively less densely packed region of fibers extending three-dimensionally outward from the at least one inner, relatively densely packed region.

[0017] In some embodiments, the step of randomizing the longitudinal alignment of at least a portion of the plurality of fibers of the bundle includes entangling only a portion of the randomized fibers, such that some of the randomized fibers form fibrous filler clusters and some of the randomized fibers do not form fibrous filler clusters.

[0018] In some embodiments, the step of randomizing the longitudinal alignment of at least a portion of the fibers of the bundle includes placing the bundle between engagement surfaces of at least one pair of randomizing members such that the randomizing surfaces contact the bundle, and translating the at least one first randomizing member relative to the at least one second randomizing member along a path that extends both longitudinally along the longitudinal length of the fibers of the bundle and laterally along a lateral direction oriented perpendicular to the longitudinal direction. In some such embodiments, the distance between the randomizing surfaces is maintained substantially constant during the randomizing step. In some such embodiments, the at least one first randomizing member translates along an arcuate path for at least an initial short time. In some such embodiments, the at least one first randomizing member translates along an elliptical path for at least an initial short time. In some such embodiments, the at least one first randomizing member translates along a random trajectory pattern for at least an initial short time. In some such embodiments, at least one of the engagement surfaces comprises a substantially flat and smooth surface. In some such embodiments, at least one of the engagement surfaces comprises a multiplicity of particles or protrusions arranged in a generally planar manner. In some such embodiments, perturbing the longitudinal alignment of at least a portion of the plurality of fibers of the bundle comprises subjecting the bundle to at least one of a gas flow and / or a liquid flow.

[0019] In some embodiments, the method further comprises, prior to the randomizing step, bonding at least a portion of the plurality of fibers of the bundle together at least one point along a longitudinal length of the bundle to form at least one junction. In some such embodiments, the junction is formed by heating at least a portion of the plurality of fibers at at least one point to attach the fibers to one another at the at least one junction. In some such embodiments, heating at least a portion of the plurality of fibers at at least one point comprises contacting the plurality of fibers at the at least one point with a material at a temperature above the melting temperature of the fibers.

[0020] In some embodiments, the step of randomizing the longitudinal alignment of at least a portion of the fibers of the bundle includes entangling some of the randomized fibers with one another. In some such embodiments, less than about 50% of the randomized fibers are entangled with at least one other fiber. In some such embodiments, less than about 25% of the randomized fibers are entangled with at least one other fiber.

[0021] In some embodiments, the step of randomizing the longitudinal alignment of at least a portion of the fibers of the bundle includes twisting some of the randomized fibers. In some such embodiments, less than about 50% of the randomized fibers are twisted with at least one other fiber. In some such embodiments, less than about 25% of the randomized fibers are twisted with at least one other fiber.

[0022] In some embodiments, the method includes obtaining a plurality of bundles, each bundle having a denier of 0.2-12.0 dpf and a length of 8-160 mm, with the plurality of fibers in each bundle being longitudinally aligned together; and randomizing the longitudinal alignment of at least a portion of the plurality of fibers in each bundle such that the fibers are irregularly elongated and entangled in three dimensions to form a plurality of individual fibrous filler clusters.

[0023] In some embodiments, the fibers in the bundle extend substantially linearly along their longitudinal length. In some embodiments, the fibers in the bundle extend substantially parallel to one another along their longitudinal length. In some embodiments, the fibers in the bundle are straight, non-textured fibers.

[0024] In some embodiments, the plurality of fibers in the bundle extend non-linearly along their longitudinal length. In some embodiments, the plurality of fibers in the bundle extend irregularly along their longitudinal length. In some embodiments, the plurality of fibers in the bundle are textured fibers. In some embodiments, the plurality of fibers in the bundle includes from about 50 to about 500 fibers. In some embodiments, the plurality of fibers includes from about 80 to about 300 fibers.

[0025] In some embodiments, the bundle contains more fibers than the fibrous filler cluster. In some embodiments, the fibrous filler cluster contains at least one minor fiber that was not part of the bundle. In some such embodiments, the at least one minor fiber is entangled with the fibers of the fibrous filler cluster during the randomization step.

[0026] In some embodiments, the plurality of fibers has a denier of about 0.7 to about 1.7 dpf. In some embodiments, the plurality of fibers has about the same denier. In some embodiments, the plurality of fibers in the bundle has a longitudinal length of about 20 to about 50 mm. In some embodiments, the plurality of fibers in the bundle has about the same longitudinal length. In some embodiments, the plurality of fibers has about the same length.

[0027] In some embodiments, the plurality of fibers are synthetic polymer fibers. In some embodiments, the plurality of fibers are fibers selected from polyamide, polyester, polypropylene, polylactic acid (also known as polylactide) (PLA), polybutylacrylate (PBA), acrylic, acrylate, acetate, polyolefin, nylon, rayon, lyocell, aramid, spandex, viscose, and modal fibers, or combinations thereof. In some embodiments, the plurality of fibers are polyester fibers. In some such embodiments, the polyester fibers are selected from polyethylene terephthalate (PET), poly(hexahydro-p-xylylene terephthalate), polybutylene terephthalate (PBT) fibers, polytrimethylene terephthalate (PTT) fibers, copolyester fibers (e.g., copolyester fibers including structural units of PET), or combinations thereof. In some such embodiments, the polyester fibers are PET fibers.

[0028] In some embodiments, the fibers comprise recycled polymeric material. In some embodiments, the plurality of fibers comprises siliconized fibers. In some embodiments, the plurality of fibers comprises non-silicone-treated fibers. In some embodiments, the plurality of fibers comprises solid fibers. In some embodiments, the plurality of fibers comprises hollow fibers.

[0029] In some embodiments, the fiber filler clusters define a length, a width and a thickness, and the length and width are greater than the thickness. In some such embodiments, the length is greater than the width.

[0030] In some embodiments, the fiber filler cluster defines a length, a width, and a thickness, and the length is within the range of about 0.5 to about 6.5 cm (e.g., about 0.90 to about 4 cm). In some embodiments, the fiber filler cluster defines a length, a width, and a thickness, and the width is within the range of about 0.5 to about 6.5 cm (e.g., about 0.70 to about 3 cm). In some embodiments, the fiber filler cluster defines a length, a width, and a thickness, and the width is within the range of about 0.08 to about 0.70 mg / cm. 3(For example, about 0.10 to about 0.50 mg / cm 3 ) In some embodiments, the fiber filler clusters define a generally oval shape. In some embodiments, the fiber filler clusters define a generally spherical shape.

[0031] In some embodiments, the bundles are sections of filament yarn. In some such embodiments, obtaining the bundles includes cutting the sections from the filament yarn. In some embodiments, the filament yarn is a textured filament yarn. In some such embodiments, the filament yarn is a flat filament yarn.

[0032] In some embodiments, the bundles are sections of entangled filament yarns. In some such embodiments, obtaining the bundles includes cutting out sections from the entangled filament yarns.

[0033] In a second aspect, the present invention provides a fibrous filler cluster (e.g., an individual fibrous filler cluster) producible according to the first aspect of the present invention. The individual fibrous filler cluster comprises a plurality of intertwined fibers, the plurality of fibers comprising 25-3600 fibers having a denier of 0.2-12.0 dpf and a length of 8-160 mm. The plurality of fibers form: a bundle remainder portion comprising some or all of the plurality of fibers aligned together in the longitudinal direction; and an outer region of fibers extending three-dimensionally outward from the bundle remainder portion comprising some of the plurality of fibers randomly and non-uniformly oriented relative to one another. The bundle remainder portion comprises a higher density of fibers than the outer region.

[0034] In some embodiments, the individual fiber filler clusters consist essentially of a plurality of fibers. In some embodiments, the individual fiber filler clusters consist essentially of a plurality of fibers. In some embodiments, the individual fiber filler clusters consist essentially of the bundle remainder and the outer region. In some embodiments, the individual fiber filler clusters consist of the bundle remainder and the outer region.

[0035] In some embodiments, the bundle remainder portion contains fewer fibers than the outer region. In some such embodiments, the bundle remainder portion contains at least 25% fewer fibers than the outer region. In some such embodiments, the bundle remainder portion contains at least 50% fewer fibers than the outer region. In some such embodiments, the bundle remainder portion contains at least 75% fewer fibers than the outer region.

[0036] In some embodiments, the bundle remainder portion extends non-linearly along its length. In some embodiments, the bundle remainder portion is a portion of a segment of a filament yarn. In some such embodiments, the bundle remainder portion is a portion of a segment of a textured filament yarn. In some other such embodiments, the bundle remainder portion is a portion of a segment of a flat filament yarn.

[0037] In some embodiments, the fibers of the bundle remainder portion extend substantially parallel to one another along their longitudinal length. In some embodiments, the fibers are straight, non-textured fibers. In some embodiments, the fibers are straight, textured fibers. In some embodiments, the fibers extend non-linearly along their longitudinal length. In some embodiments, the fibers extend irregularly along their longitudinal length.

[0038] In some embodiments, some of the fibers in the outer region are entangled with each other or with at least one fiber in the bundle remainder. In some such embodiments, less than about 50% of the fibers in the outer region are entangled with each other or with at least one fiber in the bundle remainder. In some such embodiments, less than about 25% of the fibers in the outer region are entangled with each other or with at least one fiber in the bundle remainder.

[0039] In some embodiments, the fibers in the outer region are twisted with each other or with at least one fiber in the bundle remainder. In some such embodiments, less than about 50% of the fibers in the outer region are twisted with each other or with at least one fiber in the bundle remainder. In some such embodiments, less than about 25% of the fibers in the outer region are twisted with each other or with at least one fiber in the bundle remainder.

[0040] In some embodiments, the individual fiber filler clusters comprise at least one junction where at least a portion of the fibers are bonded to one another. In some such embodiments, the at least one junction includes some of the fibers in the remaining portion and some of the fibers in the outer region. In some such embodiments, the at least one junction includes only some of the fibers in the remaining portion and only some of the fibers in the outer region.

[0041] In some embodiments, the fiber filler cluster defines a length, a width, and a thickness, and the length and width are greater than the thickness. In some such embodiments, the length is greater than the width. In some embodiments, the fiber filler cluster defines a length, a width, and a thickness, and the length is within the range of about 0.5 to about 6.5 cm (e.g., about 0.90 to about 4 cm). In some embodiments, the fiber filler cluster defines a length, a width, and a thickness, and the width is within the range of about 0.5 to about 6.5 cm (e.g., about 0.70 to about 3 cm).

[0042] In some embodiments, the fiber-filler cluster defines a generally oval shape. In some embodiments, the fiber-filler cluster defines a generally spherical shape. In some embodiments, the plurality of fibers has a denier of about 0.7 to about 1.7 dpf. In some embodiments, the plurality of fibers has about the same denier. In some embodiments, the plurality of fibers in the bundle has a longitudinal length of about 20 to about 50 mm. In some embodiments, the plurality of fibers in the remainder of the bundle has about the same longitudinal length. In some embodiments, the plurality of fibers has about the same length. In some embodiments, the fiber-filler cluster has a density of about 0.08 to 0.70 mg / cm 3 (For example, about 0.10 to about 0.50 mg / cm 3 In some embodiments, the plurality of fibers comprises about 50 to about 500 fibers. In some embodiments, the plurality of fibers comprises about 80 to about 300 fibers.

[0043] In some embodiments, the plurality of fibers are synthetic polymer fibers. In some embodiments, the plurality of fibers are fibers selected from polyamide, polyester, polypropylene, polylactic acid (also known as polylactide) (PLA), polybutylacrylate (PBA), acrylic, acrylate, acetate, polyolefin, nylon, rayon, lyocell, aramid, spandex, viscose, and modal fibers, or combinations thereof. In some embodiments, the plurality of fibers are polyester fibers. In some such embodiments, the polyester fibers are selected from polyethylene terephthalate (PET), poly(hexahydro-p-xylylene terephthalate), polybutylene terephthalate (PBT) fibers, polytrimethylene terephthalate (PTT) fibers, copolyester fibers (e.g., copolyester fibers including structural units of PET), or combinations thereof. In some such embodiments, the polyester fibers are PET fibers. In some embodiments, the fibers comprise recycled polymeric materials.

[0044] In some embodiments, the plurality of fibers comprises siliconized fibers. In some embodiments, the plurality of fibers comprises non-siliconized fibers. In some embodiments, the plurality of fibers comprises solid fibers. In some embodiments, the plurality of fibers comprises hollow fibers.

[0045] In some embodiments, the plurality of fibers are sections of entangled filament yarns, the sections having at least one mingle nip section where the plurality of fibers are entangled with one another, which may be referred to as a mingle nip section or alternatively as a bundle remainder section, in keeping with the shuffling to form the fibrous filler clusters.

[0046] In a third aspect, the present invention provides another fiber-filler cluster (e.g., an individual fiber-filler cluster) producible according to the first aspect of the present invention. The individual fiber-filler cluster comprises a plurality of fibers randomly entangled with one another, the plurality of fibers comprising 25-3600 fibers having a denier of 0.2-12.0 dpf and a length of 8-160 mm. The plurality of fibers are randomly and non-uniformly oriented with respect to one another. The plurality of fibers form at least one inner relatively dense region of fibers; and an outer relatively less dense region of fibers extending three-dimensionally outward from the at least one inner relatively dense region. The individual fiber-filler cluster has a length of about 0.5-6.5 cm (e.g., about 0.90-4 cm), a width of about 0.5-6.5 cm (e.g., about 0.70-3 cm), and a density of about 0.08-0.70 mg / cm. 3 (For example, about 0.10 to 0.50 mg / cm 3 ).

[0047] In some embodiments, the fiber filler cluster consists essentially of a plurality of fibers. In some embodiments, the individual fiber filler clusters consist essentially of a plurality of fibers. In some embodiments, the fiber filler cluster consists essentially of the bundle remainder and the outer region. In some embodiments, the individual fiber filler clusters consist essentially of the bundle remainder and the outer region.

[0048] In some embodiments, the inner region comprises fewer fibers than the outer region. In some such embodiments, the inner region comprises at least 25% fewer fibers than the outer region. In some such embodiments, the inner region comprises at least 50% fewer fibers than the outer region.

[0049] In some embodiments, the outer region comprises fewer fibers than the inner region. In some such embodiments, the outer region comprises at least 25% fewer fibers than the inner region. In some such embodiments, the outer region comprises at least 50% fewer fibers than the inner region.

[0050] In some embodiments, the plurality of fibers extend non-linearly along their length. In some embodiments, the plurality of fibers are non-textured fibers. In some embodiments, the plurality of fibers are textured fibers.

[0051] In some embodiments, some of the fibers of the plurality are entangled with one another. In some such embodiments, less than about 50% of the fibers of the plurality are entangled with one another. In some such embodiments, less than about 25% of the fibers of the plurality are entangled with one another.

[0052] In some embodiments of the fibrous filler cluster of the present invention, less than 70% (e.g., less than 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, or 70%) of the plurality of fibers in at least one outer region are entangled with one another.

[0053] In some embodiments, some of the fibers of the plurality are twisted together. In some such embodiments, less than about 50% of the fibers of the plurality are twisted together. In some such embodiments, less than about 25% of the fibers of the plurality are twisted together.

[0054] In some embodiments, the fiber-filler cluster comprises at least one junction where at least a portion of the fibers are bonded to one another. In some such embodiments, the at least one junction includes some of the fibers in the inner region and some of the fibers in the outer region. In some such embodiments, the at least one junction includes only some of the fibers in the inner region and only some of the fibers in the outer region.

[0055] In some embodiments, the fiber filler cluster defines a length, a width, and a thickness, and the length and width are greater than the thickness. In some such embodiments, the length is greater than the width. In some embodiments, the fiber filler cluster defines a length, a width, and a thickness, and the length is within the range of about 0.5-6.5 cm (e.g., about 0.90-about 4 cm). In some embodiments, the fiber filler cluster defines a length, a width, and a thickness, and the width is within the range of about 0.5-6.5 cm (e.g., about 0.70-about 3 cm).

[0056] In some embodiments, the fiber filler clusters define a generally oval shape. In some embodiments, the fiber filler clusters define a generally spherical shape.

[0057] In some embodiments, the plurality of fibers has a denier of about 0.7 to about 1.7, hi some embodiments, the plurality of fibers has about the same denier.

[0058] In some embodiments, the fibers in the bundle have a longitudinal length of about 20 to about 50 mm. In some embodiments, the fibers have approximately the same longitudinal length. In some embodiments, the fiber filler cluster has a longitudinal length of about 0.10 to about 0.50 mg / cm. 3In some embodiments, the plurality of fibers comprises from about 50 to about 500 fibers. In some such embodiments, the plurality of fibers comprises from about 80 to about 300 fibers.

[0059] In some embodiments, the plurality of fibers are synthetic polymer fibers. In some embodiments, the plurality of fibers are fibers selected from polyamide, polyester, polypropylene, polylactic acid (also known as polylactide) (PLA), polybutylacrylate (PBA), acrylic, acrylate, acetate, polyolefin, nylon, rayon, lyocell, aramid, spandex, viscose, and modal fibers, or combinations thereof. In some embodiments, the plurality of fibers are polyester fibers. In some such embodiments, the polyester fibers are selected from polyethylene terephthalate (PET), poly(hexahydro-p-xylylene terephthalate), polybutylene terephthalate (PBT) fibers, polytrimethylene terephthalate (PTT) fibers, copolyester fibers (e.g., copolyester fibers containing structural units of PET), or combinations thereof. In some embodiments, copolyester fibers containing structural units of PET refer to fibers composed of polymer chains containing structural units of PET, as shown below, together with structural units of one or more (e.g., one) other non-PET polyesters. [ka]

[0060] In some such embodiments, the polyester fibers are PET fibers. In some embodiments, the fibers comprise recycled polymeric materials.

[0061] In some embodiments, the plurality of fibers comprises siliconized fibers. In some embodiments, the plurality of fibers comprises non-siliconized fibers. In some embodiments, the plurality of fibers comprises solid fibers. In some embodiments, the plurality of fibers comprises hollow fibers.

[0062] In some embodiments, the plurality of fibers is a section of entangled filament yarn, the section having at least one gathering nip portion where the plurality of fibers are entangled with one another, In such embodiments, the gathering nip portion corresponds to at least one inner relatively densely packed region of fibers.

[0063] In a fourth aspect, the present invention provides an insulation or filling material comprising a plurality of fibre filler clusters according to the second and / or third aspects of the invention (which may be made according to the first aspect of the invention).

[0064] In some embodiments, the insulation or filling material consists essentially of fibrous filler clusters according to the second and / or third aspect of the invention. In some embodiments, the insulation or filling material consists essentially of fibrous filler clusters according to the second aspect of the invention. In some embodiments, the insulation or filling material consists essentially of fibrous filler clusters according to the third aspect of the invention. In some embodiments, the insulation or filling material consists essentially of fibrous filler clusters according to the second and / or third aspect of the invention. In some embodiments, the insulation or filling material consists of fibrous filler clusters according to the second aspect of the invention. In some embodiments, the insulation or filling material consists of fibrous filler clusters according to the third aspect of the invention.

[0065] In some embodiments, the insulation or filler material comprises a plurality of first individual fibrous filler clusters according to the second aspect of the invention and a plurality of second individual fibrous filler clusters according to the third aspect of the invention.

[0066] In some embodiments, the plurality of fiber filler clusters includes a first fiber filler cluster made of fibers of a first length and a second fiber filler cluster made of fibers of a second length different from the first length. In some embodiments, the plurality of fiber clusters includes a first cluster made of a first total number of fibers and a second cluster made of a second total number of fibers different from the first total number of fibers. In some embodiments, the plurality of fiber filler clusters includes a first fiber filler cluster made of fibers of a first synthetic material and a second fiber filler cluster made of fibers of a second synthetic material different from the first synthetic material. In some embodiments, the plurality of fiber filler clusters includes a first fiber filler cluster made of fibers of a first denier number and a second fiber filler cluster made of fibers of a second denier number different from the first denier number.

[0067] In some embodiments, the plurality of fiber filler clusters includes fiber filler clusters of a first size and fiber filler clusters of a second size different from the first size. In some embodiments, the plurality of fiber filler clusters includes fiber filler clusters of a first three-dimensional shape and fiber filler clusters of a second three-dimensional shape different from the first three-dimensional shape. In some embodiments, the plurality of fiber filler clusters includes fiber filler clusters of a first density range and fiber filler clusters of a second density range that is different and non-overlapping from the first density range.

[0068] In a fifth aspect, the present invention provides an article comprising a plurality of insulation or filler materials according to the fourth aspect of the invention. In some embodiments, the article is selected from footwear, outerwear, clothing, sleeping bags, and bedding.

[0069] Certain embodiments of the disclosed fiber-filler clusters, articles containing the clusters, and methods for making the clusters have several features, no single one of which is solely responsible for the desirable attributes of the embodiments. Without limiting the scope of the fiber-filler clusters, 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 particularly 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 fiber-filler clusters of the present invention can be blown with conventional blowing equipment and mimic the properties of down. By incorporating embodiments of the fiber-filler clusters of the present invention into an article, the resulting article is provided with increased softness felt in the hand and on the skin compared to other past attempts at synthetic down products. Articles including embodiments of the disclosed fiber-filler clusters can have improved loft, improved blowing efficiency, and improved washability resulting in improved thermal performance compared to other past attempts at synthetic down products. Embodiments of the fibrous filler clusters are further configurable to be utilized with conventional blowing equipment without clogging or other loading issues typically encountered with other synthetic down materials.

[0070] 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. [Brief description of the drawings]

[0071] The present invention is described below in conjunction with the following drawings, which are not necessarily to scale and in which like numerals refer to like elements, and in which:

[0072] [Figure 1] 1 illustrates a fiber bundle for forming individual fiber clusters according to an embodiment of the present invention.

[0073] [Diagram 2] FIG. 2 is an enlarged view of a portion of a textured fiber bundle according to an embodiment of the present invention.

[0074] [Diagram 3] FIG. 2 is an enlarged view of a portion of a straight fiber bundle according to an embodiment of the present invention.

[0075] [Figure 4A] FIG. 13 illustrates unbonded fiber bundles for forming individual fiber clusters according to an embodiment of the present invention.

[0076] [Figure 4B] FIG. 13 illustrates splicing fiber bundles to form individual fiber clusters according to an embodiment of the present invention.

[0077] [Figure 5A] 1 illustrates a cluttering member for a method of producing individual fiber clusters according to an embodiment of the present invention. [Figure 5B] 1 illustrates a cluttering member for a method of producing individual fiber clusters according to an embodiment of the present invention.

[0078] [Figure 6] 1A and 1B are top views of exemplary embodiments of individual fiber clusters with fiber bundle remainders according to the present invention;

[0079] [Figure 7] 13A and 13B are top views of another exemplary embodiment of individual fiber clusters with fiber bundle remainders according to the present invention;

[0080] [Figure 8] 13A and 13B are top views of another exemplary embodiment of individual fiber clusters with fiber bundle remainders according to the present invention;

[0081] [Figure 9] 4 is a top view of another exemplary embodiment of an individual fiber cluster with a fiber bundle remainder according to the present invention; FIG.

[0082] [Figure 10] FIG. 2 shows a top view of an exemplary embodiment of an individual fiber cluster with an inner intertwined fiber region according to the present invention.

[0083] [Figure 11] FIG. 13 is a top view of another exemplary embodiment of an individual fiber cluster with an inner intertwined fiber region according to the present invention.

[0084] [Figure 12] FIG. 13 is a top view of another exemplary embodiment of an individual fiber cluster with an inner intertwined fiber region according to the present invention.

[0085] [Figure 13] FIG. 13 is a top view of another exemplary embodiment of an individual fiber cluster with an inner intertwined fiber region according to the present invention.

[0086] [Figure 14] Photograph of an example of an individual fiber cluster according to the present invention, viewed from above.

[0087] [Figure 15] Side view of an example of an individual fiber cluster from Figure 12.

[0088] [Figure 16] Photograph of a top view of another example of an individual fiber cluster according to the present invention.

[0089] [Figure 17] Photograph of a top view of another example of an individual fiber cluster according to the present invention.

[0090] [Figure 18] Photograph of a top view of another example of an individual fiber cluster according to the present invention.

[0091] [Figure 19] Photograph of a top view of another example of an individual fiber cluster according to the present invention.

[0092] [Figure 20] 1 is a top-down photograph of several exemplary individual fiber clusters according to the present invention.

[0093] [Figure 21] 21 is a front view of several exemplary individual fiber clusters of FIG. 20.

[0094] [Figure 22] 1 is a top-down photograph of several exemplary individual fiber clusters according to the present invention.

[0095] [Figure 23] 1 is a top-down photograph of several exemplary individual fiber clusters according to the present invention.

[0096] [Figure 24] 3 is a top view of a number of exemplary individual interlocking fiber clusters according to the present invention.

[0097] [Diagram 25] 1 is a top-down photograph of several exemplary individual fiber clusters according to the present invention.

[0098] [Figure 26] 3 is a top view of a number of exemplary individual interlocking fiber clusters according to the present invention.

[0099] [Figure 27] A close-up of a portion of an entangled filament yarn.

[0100] [Figure 28] FIG. 2 is a simplified schematic showing the alignment of filaments before and after forming an entangled filament yarn.

[0101] [Figure 29] A close-up of a cut section or "bundle" of intertwined filament yarn.

[0102] [Diagram 30] 1 is a close-up photograph of an embodiment of a fiber filler cluster of the present invention.

[0103] [Diagram 31] 1 is a close-up photograph of an embodiment of a fiber filler cluster of the present invention.

[0104] [Diagram 32] 1 is a close-up photograph of an embodiment of a fiber filler cluster of the present invention.

[0105] [Figure 33A] A close-up of an entangled filament yarn (left) and multiple fibrous filler clusters formed from the filament yarn according to an embodiment of the present invention. [Figure 33B] Close-up of the fiber filler cluster in Figure 33A. [Figure 33C] Close-up of the fiber filler cluster in Figure 33A.

[0106] [Diagram 34] FIG. 1 illustrates a process in which intertwined filament yarns are cut to form bundles, and the bundles are scrambled to form an embodiment of a fibrous filler cluster of the present invention.

[0107] [Diagram 35] FIG. 1 is a simplified diagram of an embodiment of a fiber filler cluster of the present invention. Detailed Description of the Invention

[0108] 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 by way of illustration only and not for purposes 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.

[0109] In one aspect, the present disclosure provides a method of making or manufacturing one or more fibrous filler clusters that have been surprisingly and / or unexpectedly found to closely mimic down in terms of blowability, size, weight, and / or density, and other properties, while at the same time providing improved washability as compared to down.

[0110] As shown in Figure 1, the method may include obtaining a discrete bundle 10 of a plurality of 25-3600 fibers 12 having a denier of 0.2-12.0 and a length of 8-160 mm, the plurality of fibers 12 being longitudinally aligned together (i.e., along their length). The method may further include disrupting the longitudinal alignment of at least a portion of the plurality of fibers 12 of the bundle 10 such that the fibers are randomly elongated and entangled in three dimensions to form discrete fibrous filler clusters 1 as shown in Figures 6-26.

[0111] In some embodiments, obtaining the bundles includes cutting bundles 10 from a yarn or tow of fiber 12. For example, the yarn or tow may be wound on a spool or otherwise contain multiple continuous bundles, and the bundles may be cut or otherwise separated from the yarn or tow. In this manner, multiple bundles 10 may be formed from the yarn or tow.

[0112] In some embodiments, the step of randomizing the longitudinal alignment of at least a portion of the plurality of fibers 12 of the bundle 10 randomizes the longitudinal alignment of only a portion of the plurality of fibers 12 of the bundle 10 such that a bundle remainder 16 of the plurality of fibers 12 of the bundle 10 remains longitudinally aligned together in the formed fiber cluster 1, as shown, for example, in Figures 6-9, 14, 15, and 20-26. In such embodiments, the randomizing step further randomizes the longitudinal alignment of a portion of the plurality of fibers 12 of the bundle 10 such that the fibers intertwine with the fibers 12 of the remainder 16 and extend outwardly therefrom in a random three-dimensional manner, also as shown in Figures 6-9, 14, 15, and 20-26. The fibers 12 extending outwardly in a random three-dimensional manner from the remainder 16 thus form an outer region 18 extending outwardly from the bundle remainder 16. The remainder of the bundle 16 may include a higher density of fibers 12 (ie, the fibers 12 or portions thereof are more densely packed) than the outer regions.

[0113] In some other embodiments, randomizing the longitudinal alignment of at least some of the plurality of fibers 12 of the bundle 10 includes randomizing the longitudinal alignment of all of the plurality of fibers 12 of the bundle 10 such that essentially none of the plurality of fibers 12 remain longitudinally aligned together in the formed fiber cluster 1, as shown in Figures 10-13 and 16-29. In some such embodiments, randomizing the longitudinal alignment of essentially all of the plurality of fibers 12 of the bundle 10 forms at least one inner three-dimensional region 14 of relatively densely packed fibers and an outer region 18 of relatively less densely packed fibers 16 extending three-dimensionally outward from the at least one inner relatively densely packed region 14.

[0114] 4A, the fibers 12 of the bundle 10 may not be mechanically interlocked or bonded to one another. Rather, the fibers 12 of the bundle 10 may be entangled, and natural forces and / or alignments of the fibers 12 resulting from yarn or tow construction or processing may act to keep the fibers 12 of the bundle 10 aligned together.

[0115] In some other embodiments, as shown in FIG. 4B, at least some of the fibers 12 of the bundle 10 may be bonded to one another at a junction or bond area 22. For example, the method may include, prior to the randomizing step, bonding at least some of the fibers 12 of the bundle 10 to one another at at least one point 22 along the longitudinal length of the bundle / fibers 10 / 12 to form at least one junction 22. In some such embodiments, the junction is formed by heating at least some of the fibers 12 at at least one point such that the fibers attach or bond to one another at the at least one junction. In some such embodiments, heating at least some of the fibers 12 at at least one point includes contacting the fibers 12 at at least one point with a material or member that is at a temperature above the melting temperature of the fibers 12. The junction 22 may be formed by any acceptable means (e.g., with hot metal, ultrasonic bonding, laser processing, soldering iron, heated air jet, etc.). In some other embodiments, the junction 22 may be formed by glue, adhesive, or other material that serves to connect or bond the fibers to one another. It should be noted that although a single junction 22 is shown in the example fiber bundle 10 of Figure 4B, the fiber bundle 10 may include two or more junctions 22. In some embodiments, the size of the junctions 22 is between 0.10 and 0.50 mm (e.g., 0.10, 0.15, 0.20, 0.25, 0.30, 0.35, 0.40, 0.45, or 0.50 mm), or any range or subrange therein.

[0116] As shown in Figures 5A and 5B, in some embodiments, the step of randomizing the longitudinal alignment of at least a portion of the plurality of fibers 12 of the bundle 10 includes placing the bundle 10 between the engagement surfaces 32 of at least one pair of randomizing members 30 such that the randomizing surfaces 32 contact the bundle 10, and translating at least one first randomizing member 30 relative to at least one second randomizing member 30 along a path that extends both longitudinally along the longitudinal length of the fibers 12 of the bundle 10 and laterally along a lateral direction oriented perpendicular to the longitudinal direction. In some such embodiments, the distance between the randomizing surfaces 32 is maintained substantially constant during the randomizing step. However, the randomizing surfaces 32 may move closer together or further apart during the randomizing process. In some such embodiments, at least one of the randomizing members 30 may translate along an arcuate path for at least a short period of time and / or along a linear or straight path for at least a short period of time. In some such embodiments, at least one randomization member 30 may translate along an elliptical path, at least for a short period of time. In some embodiments, at least one randomization member 30 translates along a random trajectory pattern, at least for a short period of time.

[0117] At least one engagement surface 32 of the disturbing member 30 may be a substantially flat and smooth surface. In some embodiments, the engagement surface 32 may comprise a substantially planar array of particles or protrusions that extend outward / inward toward the bundle 10 and serve to poke, grab, or otherwise contact the fibers 12 to disturb the longitudinal alignment of the fibers 12 of the bundle 10. In some other embodiments (not shown), disturbing the longitudinal alignment of at least some of the fibers 12 of the bundle 10 comprises subjecting the bundle 10 to at least one gas and / or liquid flow. The disturbing process of disturbing the longitudinal alignment of at least some of the fibers 12 of the bundle 10 (and thus reorganizing such fibers 12) may include rubbing the bundle 10, sanding the bundle 10, abrading the bundle 10, buffing the bundle 10, or subjecting the bundle to a gas and / or liquid flow, or a combination thereof.

[0118] It should be noted that the randomization process may involve removing one or more of the fibers 12 from the bundle 10 without entangling the fibers 12 into the fibrous filler cluster 1. In other words, one or more of the fibers 12 of the bundle 10 may be randomized but not entangled with other fibers forming the fibrous filler cluster 1. Similarly, one or more fibers 12 separated from another bundle 10 during the randomization process may be incorporated (i.e. entangled) with the fibers 10 of the other bundle 10 and incorporated into the fibrous filler cluster 1 formed thereby. Thus, the randomization process may involve adding at least one additional fiber to the plurality of fibers 12 or removing / removing a fiber from the plurality of fibers 12.

[0119] The randomization step acts to entangle a plurality of fibers 12 with one another to form a fibrous filler cluster. The term "intermingle" and like terms are used herein to refer to fibers that cross or pass each other at least once (i.e., an entangled fiber crosses at least one other fiber at least once). In some embodiments, the randomization step also acts to entangle at least some of the randomized fibers 12 with one another. The term "entangle" and like terms are used herein to refer to fibers that cross or wrap around one another at least once (i.e., an entangled fiber crosses or wraps around at least one other fiber at least once). In some such embodiments, less than about 50% of the randomized fibers are entangled with at least one other fiber. In some such embodiments, less than about 25% of the randomized fibers are entangled with at least one other fiber. In some embodiments, the randomization step further acts to twist at least some of the randomized fibers 12 together. The term "twist" and like terms are used herein to refer to fibers that cross or wrap around each other two or more times (i.e., the twisted fibers cross or wrap around at least one other fiber two or more times). In some such embodiments, less than about 50% of the randomized fibers 12 are twisted with at least one other fiber. In some such embodiments, less than about 25% of the randomized fibers 12 are twisted with at least one other fiber.

[0120] The fibers 12 of the bundle 10 may extend generally linearly along their longitudinal length, as shown in Figure 3. The fibers 12 of the bundle 10 can extend generally parallel to one another along their longitudinal length. In some embodiments, the fibers of the bundle are straight fibers that are not textured, as shown in Figure 3.

[0121] In some other embodiments, the fibers 12 of the bundle 10 may extend non-linearly along their longitudinal length, as shown in FIG. 2. In some embodiments, the fibers of the bundle extend irregularly along their longitudinal length, as shown in FIG. 2. For example, the fibers 12 of the bundle may be textured fibers, as shown in FIG. 2. Texturing techniques are well known in the art and typically disrupt the parallel state of the fibers / filaments. Such techniques can be used, for example, to add bulk without adding weight, such that the resulting fiber feels lighter, has improved hand (softness), has a more opaque appearance, and / or has improved thermal insulation properties. While any technically acceptable texturing process may be used, examples of texturing processes applied to the fibers 12 in the bundles 10 and individual fibrous filler clusters 1 of the present invention include crimping, looping, coiling, crinkling, twisting then untwisting, and knitting then deknitting. In some embodiments, the plurality of fibers 12 of the bundle 10 and / or the individual fibrous filler clusters 1 formed thereby may be in the form of a fiber-filler having a molecular weight of 0-100 wt% (e.g., 0, 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, 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, 109, 1 , 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 wt.%, or any range and subrange therein.

[0122] In some embodiments (e.g., embodiments using filament yarns, such as intertwined filament yarns), the present invention provides a method for producing a fiber optic cable comprising: obtaining from the filament yarn a bundle including 25-3600 fibers having a denier of 0.2-12.0 and a length of 8-51 mm, the fibers being aligned together in a longitudinal direction, the bundle having a gathering nip portion where the fibers are entangled with each other; subjecting the bundle to a treatment to randomize the plurality of fibers adjacent the gathering nip portion to form at least one outer region of fibers extending three-dimensionally outward from the gathering nip portion, thereby forming a fibrous filler cluster; The present invention provides a method for making fiber filler clusters, comprising:

[0123] As used herein, fibers "aligned longitudinally together" refers to fibers that run along the same direction as one another, whether straight, twisted, or otherwise. The term includes textured and non-textured fibers, and also includes fibers of filament yarns (including entangled filament yarns having nipped portions). For example, the entangled filament yarns shown in Figures 27 and 33A, and the bundle shown in Figure 29, all have fibers that are aligned longitudinally together.

[0124] Subjecting the bundle to a treatment to randomize the plurality of fibers includes any method that randomizes the parallelism / alignment of the fibers adjacent the nip portion such that the fibers are no longer aligned longitudinally but extend three-dimensionally outward from the nip. For example, in some embodiments, randomizing the plurality of fibers adjacent the nip includes subjecting the bundle to at least one gas and / or liquid flow. In some embodiments, the randomization process can include rubbing the bundle, sanding the bundle, abrading the bundle, buffing the bundle, or subjecting the bundle to a treatment using a gas and / or liquid (e.g., a flow of a gas (such as air) and / or liquid, or other treatment using a gas and / or liquid), or a combination thereof.

[0125] Those skilled in the art, after reviewing this disclosure, will be able to easily select a device capable of randomizing multiple fibers in a bundle (e.g., filaments), and it is believed that all such devices can be used in the method of the present invention. For example, non-limiting machines that can be used include fiber openers or fine openers (e.g., Masias Maquinaria SL (hereinafter referred to as "Masias") opener AD-160-TP, OCTIR fine opener, Rolando bale opener, Masias recycle opener, TGB opener, Trutzschler bale opener), fiber ball formers (e.g., Bolcard type or CMM type ball fiber formers, both manufactured by Masias), etc.

[0126] In some embodiments, the step of subjecting the bundle to a treatment to randomize the plurality of fibers adjacent the gathering nip portion comprises subjecting the bundle to a treatment to randomize the plurality of fibers adjacent the gathering nip portion. - Processing in a fiber opener; - Processing in a wool-removing machine; or -Air treatment This includes providing

[0127] In some embodiments, subjecting the bundle to air treatment includes subjecting the bundle to air tumbling, which can be done in a variety of ways, such as air tumbling in a drum, in a Lorch machine or modified Lorch machine, or other apparatus, etc. Non-limiting examples of air tumbling include those described in, for example, WO 2017 / 058986 and U.S. Pat. Nos. 6,613,431, 4,618,531, and 4,794,038.

[0128] The plurality of fibers 12 may be crimped or uncrimped. Various crimps, including helical and standard crimps, are known in the art, and it is contemplated that any desired crimp may be present when the fibers are crimped. The plurality of fibers 12 in the bundle 10 and / or the individual fibrous filler clusters 1 formed thereby may be in the range of 0-100 wt% (e.g., 0, 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, 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, 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 wt. % of crimped fibers or any range or subrange therein.

[0129] In some embodiments, the bundle 10 of the plurality of longitudinally aligned fibers 12 is 30 to 500 denier (e.g., 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, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 13 , 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, 12 9, 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, 183, 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, 214, 215, 216, 217, 218, 219, 220, 221, 222, 2 23, 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, 4, 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, 334, 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, 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, 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 denier) or any range and subrange therein. 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 (mm). Microdenier fibers are fibers that are 1.0 denier or less, while macrodenier fibers have a denier number greater than 1.0.

[0130] In some embodiments, the plurality of fibers 12 may be 0.2 to 12.0 denier (e.g., 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 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, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 3.10, 3.11, 3.12, 3.13, 3.14, 3.15, 3.16, 3.17, 3.18, 3.19, 3.20, 3.21, 3.22, 3.23, 3.24, 3.25, 3.26, 3.27, 3.28, 3.29, 3.30, 3.31, 3.32, 3.33, 3.34, 3.35, 3.36, 3.37, 3.38, 3.39, 3.40, 3.41, 3.42, 3.43, 3.44, 3.45, 3.46, 3.47, 3.48, 3.49, 3.50, 3.51, 3.52, 3.53, 3.54, 3.55, 3.56, 3.57, 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, 10.0, 10.1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10 0.2 to 10.0 denier, 0.5 to 8.0 denier, 0.6 to 5.0 denier, 0.7 to 3.0 denier, 0.7 to 1.7 denier, etc.

[0131] In some embodiments, the plurality of fibers 12 may be 0.2 to 12.0 denier (e.g., 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 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, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 3.10, 3.12, 3.14, 3.16, 3.18, 3.19, 3.20, 3.21, 3.22, 3.23, 3.24, 3.25, 3.26, 3.27, 3.28, 3.29, 3.30, 3.31, 3.32, 3.33, 3.34, 3.35, 3.36, 3.37, 3.38, 3.39, 3.40, 3.41, 3.42, 3.43, 3.44, 3.45, 3.46, 3.47, 3.48, 3.49, 3.49, 3.49, 3.41, 3.42, 3.43, 3.44, 3.45, 3.46, 3.47, 3.48, 3.49, 3.49, ,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 ,7.1,7.2,7.3,7.4,7.5,7.6,7.7,7.8,7.9,8.0,8.1,8.2,8.3,8.4,8.5,8.6,8.7,8.8,8.9,9.0,9.1,9.2,9.3,9.4,9.5,9.6,9.7,9.8,9.9,10.0,10.1,10.2,10.3,10.4,10.5,10.6,10.7 , 10.8, 10.9, 11.0, 11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, or 12.0 denier) or any range or subrange therein (e.g., 0.5 to 8.0 denier, 0.6 to 5.0 denier, 0.7 to 3.0 denier, 0.7 to 1.7 denier, etc.).

[0132] In some embodiments, the plurality of fibers 12 in the bundle 10 and / or the individual fibrous filler clusters formed thereby may be in a range of 0 to 100 wt% (e.g., 0, 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, 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, 11 , 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 wt % of polymeric microdenier fibers 12 having a denier of 1.0 denier or less (e.g., 0.4 to 1.0 denier, e.g., 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, or 1.0 denier, etc.); ,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, 7 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 wt % of a denier greater than 1.0 (e.g., 1.1 to 15.0 denier, e.g., 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, 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.and a polymeric macro denier fiber 12 having a denier of 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, 7.5, 8.0, 8.5, 9.0, 9.5, 10.0, 10.5, 11.0, 11.5, 12.0, 12.5, 13.0, 13.5, 14.0, 14.5, or 15.0 denier.

[0133] In some embodiments, the fibers 12 in the bundle 10 are between about 0.7 and about 1.7 denier. In some embodiments, the fibers 12 in the bundle 10 have about the same denier. In other embodiments, the fibers 12 in the bundle 10 have at least two different denier.

[0134] In some embodiments, the bundles 10 and / or individual fiber filler clusters made from the bundles 10 contain between 25 and 3600 individual fibers (e.g., 25, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 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, 50 0, 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, 81 0, 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, 1 100, 1110, 1120, 1130, 1140, 1150, 1160, 1170, 1180, 1190, 1200, 1210, 1220, 1230, 1240, 1250, 1260, 1270, 1280, 1290, 1300, 1310, 1320, 1330, 1340, 1350, 1360, 1370, 1380, 1390, 1400, 1410, 1420, 1430, 1440, 1450, 1460, 1470, 1480, 1490, 1500, 1510, 1520, 1530, 1540, 1550, 1560, 1570, 1580, 1590, 1600, 1610, 1620, 1630, 1640, 1650, 1660, 1670, 1680, 1690, 1700, 1710, 1720, 1730, 1740, 1750, 1760, 1770, 1780, 1790, 1800, 1810, 1820, 1830, 1840, 1850, 1860, 1870, 1880, 1890, 1900, 1910, 1920, 1930, 1940, 1950, 1960, 1970, 1980, 1990, 2000, 2010, 2020, 2030, 2040, 2050, 2060, 2070, 2080, 2090,2100, 2110, 2120, 2130, 2140, 2150, 2160, 2170, 2180, 2190, 2200, 2210, 2220, 2230, 2240, 2250, 2260, 2270, 2280, 2290, 2300, 2310, 2320, 2330, 2340, 2350, 2360, 2370, 2380, 2390, 2400, 2410, 2420, 2430, 2440, 2450, 2460, 2470, 2480, 2490, 2500 , 2510, 2520, 2530, 2540, 2550, 2560, 2570, 2580, 2590, 2600, 2610, 2620, 2630, 2640, 2650, 2660, 2670, 2680, 2690, 2700, 2710, 2720, 2730, 2740, 2750, 2760, 2770, 2780, 2790, 2800, 2810, 2820, 2830, 2840, 2850, 2860, 2870, 2880, 2890, 2900, 291 0, 2920, 2930, 2940, 2950, ​​2960, 2970, 2980, 2990, 3000, 3010, 3020, 3030, 3040, 3050, 3060, 3070, 3080, 3090, 3100, 3110, 3120, 3130, 3140, 3150, 3160, 3170, 3180, 3190, 3200, 3210, 3220, 3230, 3240, 3250, 3260, 3270, 3280, 3290, 3300, 3310, 33 20, 3330, 3340, 3350, 3360, 3370, 3380, 3390, 3400, 3410, 3420, 3430, 3440, 3450, 3460, 3470, 3480, 3490, 3500, 3510, 3520, 3530, 3540, 3550, 3560, 3570, 3580, 3590, or 3600 fibers) or any range or subrange therein (e.g., 50 to 500 fibers, 80 to 300 fibers, etc.).

[0135] In some embodiments, an individual bundle 10 includes between about 25 and about 3600 fibers 12. In some embodiments, an individual bundle 10 includes between about 50 and about 500 fibers. In some embodiments, an individual bundle 10 includes between about 80 and about 300 fibers. As noted above, a fibrous-filler cluster 1 formed from bundles 10 may include somewhat more fibers 12 than the bundles 10 that form that fibrous-filler cluster 1, or somewhat fewer fibers 12 than the bundles 10 that form that fibrous-filler cluster 1, due to the nature or mechanics of the randomization process.

[0136] In some embodiments, the length of the plurality of fibers 12 of the bundles 10 and / or the fiber filler clusters 1 formed by the bundles 10 is between 8 and 160 mm (e.g., 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, 109, 109, 108, 109, 109, 110, 111, 112 , 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, 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, or 160 mm) or any range or subrange therein (e.g., 8 to 75 mm, 15 to 115 mm, 20 to 50 mm, etc.). In some embodiments, the longitudinal length of the plurality of fibers 12 in the bundles 10 and / or clusters 1 formed by the bundles 10 is about 20 to about 50 mm. In some embodiments, the plurality of fibers 12 in the bundles 10 and / or clusters 1 formed by the bundles 10 have approximately the same longitudinal length.

[0137] In some embodiments, the plurality of fibers comprises polymeric fibers.

[0138] In some embodiments, the plurality of fibers comprises synthetic polymer fibers. It is within the skill of the art to select suitable polymeric materials for the polymeric fibers included in the individual fiber filler cluster 1 of the present invention, and it is believed that any such materials can be used in the embodiments of the present invention. However, in certain embodiments, non-exclusive polymers that can be used for the polymeric fibers are selected from nylon, polyester, polypropylene, polylactic acid (PLA), polybutyl acrylate (PBA), polyamide (e.g., nylon / polyamide 6.6, polyamide 6, polyamide 4, polyamide 11, and polyamide 6.10), acrylic, acetate, polyolefin, rayon, lyocell, aramid, spandex, viscose, modal fibers, biopolymer fibers (e.g., polyhydroxyalkanoate (PHA), poly(hydroxybutyrate-covalerate) (PHBV)), protein-based synthetic fibers (e.g., Spiber's plant-based artificial protein fibers), and combinations thereof. In some embodiments, the fibers are made from poly(ethylene terephthalate) (PET), poly(hexahydro-p-xylylene terephthalate), poly(butylene terephthalate) (PBT), poly-1,4-cyclohexylene dimethylene terephthalate (PCDT), polytrimethylene terephthalate (PTT), and copolyesters, such as those having at least 30 mole percent (e.g., at least 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, 109, 108, 109, 108, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 3, 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, or 85 mole percent) are ethylene terephthalate units or hexahydro-p-xylylene terephthalate units.

[0139] In some embodiments, the fibers 12 comprise virgin polymeric material. In some embodiments, the fibers 12 comprise recycled polymeric material, such as post-consumer recycled (PCR) polymeric material.

[0140] Of the fibers in the plurality of fibers 12, 0 to 100 wt% (for example, 0, 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, 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 wt.%, or any range or subrange therein (e.g., 0%, 50%, 100%, etc.).

[0141] Siliconization techniques are well known in the art. 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 can include organosiloxanes or polysiloxanes, is bonded to the outer portion of the fiber. In some embodiments, the silicone coating material is a polysiloxane, such as methylhydrogenpolysiloxane, modified methylhydrogenpolysiloxane, polydimethylsiloxane, or amino-modified dimethylpolysiloxane. As is well known in the art, the silicon-containing composition can be applied directly to the fiber or diluted with a solvent as a solution or emulsion (e.g., an aqueous emulsion of polysiloxane) before application. After treatment, the coating material can be dried and / or cured. As is well known in the art, catalysts can be used to speed up the curing 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 silicone treatment, the fibers are dried to remove residual solvent, and then optionally heated to 65°-200° C. for curing.

[0142] In some embodiments, the plurality of fibers 12 of the bundles 10 and / or the individual fibrous filler clusters 1 formed by the bundles 10 may be in the range of 0 to 100 wt% (e.g., 0, 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, 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 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 wt.%, or any range and subrange therein, of one or more additives (e.g., aerogels as described in U.S. Patent Application Publication No. 2018-0313001, microcapsules as described in U.S. Patent Application Publication No. 2020-0141029, etc.).

[0143] In some embodiments, the plurality of fibers is in a range of 0 to 100 wt% (e.g., 0, 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, 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, 109, 109, 108, 109, 109, 109, 110, 111, 1 The term "doped" includes fibers doped with a desired chemical substance, such as 2, 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 wt %, or any range or subrange therein. As used herein, the term "doped" refers to the presence of one or more desired dopants (which may also be referred to as chemical substances) incorporated within the fiber (e.g., within the polymer matrix of a polymer fiber). In some embodiments, the dopants / chemical substances are homogeneously dispersed within the fiber matrix.

[0144] Desirable fiber surface chemistries are well known in the art. While embodiments of the present invention include fibers having a surface chemistry applied to the surface (e.g., silicone treatment as discussed above), the plurality of fibers may also (and / or alternatively) be formed to include a desired chemistry therein. For example, in some embodiments, the plurality of fibers are doped with durable water repellency (DWR) and / or silicone chemistry. This may be accomplished, for example, by adding a desired chemistry to the liquid polymer before it passes through a spinneret during the melt spinning process to form the fibers, and / or by functionalizing the polymer forming the plurality of fibers.

[0145] In some embodiments, the fibers are doped with a DWR chemistry and, as a result, have certain desirable performance attributes, for example, in some embodiments, the DWR doped fibers have a surface that stays dry and / or a high coefficient of friction that is ideal for fiber clustering, as well as a low water sorption of less than 150 wt % suitable for improved wet thermal performance and / or washability.

[0146] Binder fibers are well known in the art and typically have a bonding temperature that is lower than the softening temperature of one or more other polymeric fibrous elements in the product (e.g., fibrous filler). In some embodiments, the bundles 10 and / or the fibers 12 of the individual fibrous filler clusters 1 formed by the bundles 10 contain no binder fiber (i.e., are devoid of binder fiber) or contain less than 5 wt. % binder fiber (e.g., less than 5, 4, 3, 2, or 1 wt. %).

[0147] The fibers used in the plurality of fibers 12 can have any desired cross-sectional shape (eg, circular, etc.).

[0148] The plurality of fibers 12 may be in the range of 0 to 100 wt % (e.g., 0, 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, 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, 109, 109, 109, 108, 109, 110, 111, 112, 2, 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 wt. % solid fibers or any range or subrange therein. The plurality of fibers 12 may be in the range of 0 to 100 wt % (e.g., 0, 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, 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, 109, 109, 109, 108, 109, 110, 111, 112, 2, 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 wt % hollow fibers, or any range and subrange therein. In some embodiments, the plurality of fibers 23 comprises split fibers.

[0149] The fiber-filled cluster embodiments of the present invention are blowable using conventional equipment, or "blowable" for short. "Blowable" is a term commonly used in the textile industry, and those skilled in the art will readily understand what is meant by "blowable using conventional equipment". The term "blowable" refers to a material that can be easily processed by conventional blowing (or "blow injection") equipment and injected from the same into articles (e.g., pockets, channels, or baffles of clothing, bedding, sleeping bags, etc.) as insulation. For example, down and the fiber-filled cluster embodiments of the present invention are very suitable for blowing using conventional equipment due to their light weight and discrete structure, while many other fiber-filled materials clump, stick together, clog conventional equipment, or present other processing difficulties and are therefore not blowable. It is well within the ability of those skilled in the textile industry to determine whether a material is blowable, and if there is any doubt regarding blowability, the answer can be easily obtained by testing the material with conventional equipment. Conventional blowing equipment is described, for example, in U.S. Pat. No. 6,329,051. Consistent with the disclosure of U.S. Pat. No. 6,329,051, conventional blowing equipment typically includes a blowing system having a means (e.g., a duct) for material intake (e.g., through a metering system where the material can be received from a tank, such as a mixing tank). A blowable material can easily pass through the means for material intake without clogging or causing other problems, such as impeding static resistance. The material is then blown through a nozzle into its intended destination. It is well known in the art that if a material cannot be processed with conventional blowing equipment for use in an article, then the material is not "blowable using conventional equipment" (or "blowable").

[0150] The fibrous-filler clusters 1 may form, at least generally, either regular or irregular shapes. It has been found that the configuration of the process of randomizing the longitudinal alignment (such as randomization time, randomization mechanism, and randomization pattern) and the configuration of the bundles 10 (such as the number of fibers 12, texture / non-texture of the fibers 12, and length of the fibers 12) can affect the shape of the clusters 1 as they form. For example, as shown in Figures 6-26, the fibrous-filler clusters 1 can have an elongated shape, such as an oval or elliptical shape. In some embodiments, the fibrous-filler clusters 1 can have an approximately spherical shape.

[0151] In some embodiments, the fibrous-filler cluster 1 can define a length L1, a width W1 and a thickness T1. Because the fibrous-filler cluster 1 is formed by protruding or extended fibers 12, the dimensions of the fibrous-filler cluster 1 can be defined by the furthest extent of the fibers 12 and the average or approximation of the average extent of the fibers 12. For example, the dimensions of the fibrous-filler cluster 1 can be measured by ignoring 3, 5, 10 or 15 fibers 12 that extend furthest along a particular dimension or direction.

[0152] In some embodiments, the length L1 and width W1 may be greater than the thickness T1, as shown in Figures 14 and 15. In some such embodiments, the length L1 may be greater than the width W1, also as shown in Figures 14 and 15. In some embodiments, the length L1 of the individual fiber-filler clusters 1 is between 0.5 cm and 6.5 cm (e.g., 0.5, 0.6, 0.7, 0.8, 0.9, 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, 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 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, or 6.5 cm) or any range or subrange therein (e.g., 0.90 to 4 cm).

[0153] In some embodiments, the width W1 of the fiber-filler cluster 1 is between 0.5 cm and 6.5 cm (e.g., 0.5, 0.6, 0.7, 0.8, 0.9, 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, 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, or 6.5 cm) or any range or subrange therein (e.g., 0.70 to 3 cm).

[0154] In some embodiments, the thickness (or height) T1 of the fiber-filler cluster may be 0.70 to 4 cm (e.g., 0.7, 0.8, 0.9, 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, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, or 4.0 cm) or any range or subrange therein. In some embodiments, the fiber-filler cluster 1 may define a length L1 in the range of about 0.90 to about 4 cm. In some embodiments, the fiber-filler cluster 1 may define a width L1 in the range of about 0.70 to about 3 cm.

[0155] In some embodiments, the volume of an individual fiber-filler cluster 1 of the present invention is between 0.125 and 12 cm 3 (e.g. 0.125, 0.15, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 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, 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, 10.0, 10.1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 11.0, 11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, or 12.0 cm 3 ) or any range or subrange therein (e.g., 0.80 to 12 cm 3 ) may be.

[0156] In some embodiments, the weight of an individual fiber-filler cluster of the present invention can be 0.2 to 3 mg (e.g., 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 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 mg), or any range or subrange therein.

[0157] In some embodiments, the density of the individual fiber-filler clusters of the present invention is between 0.08 and 0.70 mg / cm 3 (e.g. 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, 0.50, 0.51, 0.52, 0.53, 0.54, 0.55, 0.56, 0.57, 0.58, 0.59, 0.60, 0.61, 0.62, 0.63, 0.64, 0.65, 0.66, 0.67, 0.68, 0.69, 0.70, 0.71, 0.72, 0.73, 0.74, 0.75, 0.76, 0.77, 0.78, 0.79, 0.80, 0.81, 0.82, 0.83, 0.84, 0.85, 0.86, 0.87, 0.88, 0.89, 0.90, 0.91, 0 9, 0.40, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, 0.50, 0.51, 0.52, 0.53, 0.54, 0.55, 0.56, 0.57, 0.58, 0.59, 0.60, 0.61, 0.62, 0.63, 0.64, 0.65, 0.66, 0.67, 0.68, 0.69, or 0.70 mg / cm 3 ) or any range or subrange therein (e.g., 0.10 to 0.50 mg / cm 3 ) may be.

[0158] As shown in Figures 6-9, 14, 15 and 20-26, in one aspect of the disclosure, an inventive individual fiber-filler cluster 1 is provided with a remainder portion 16 and an outer region 18. As explained above, the remainder portion 16 of the cluster 1 is a portion of the bundle 10 of fibers 12 after some of the fibers 12 of the bundle 10 have been randomized (by the randomization process) or removed from the bundle 10. Thus, the remainder portion 16 is a remnant of the bundle 10 itself. However, it is noted that the shape, size and / or configuration of the bundle 10 can be altered by the randomization process to form the remainder portion 16. For example, the randomization process can bend or shape the bundle 10 into a non-linear shape, such as the various non-linear shapes shown in Figures 6-9, 14, 15 and 20-26. However, in some embodiments, the remainder portion 16 can extend in a generally linear manner (along its longitudinal length). As another example, the randomization process can act to spread out bundles 10 such that the fibers 12 of the bundles 10 are less densely packed or less closely positioned / spaced as compared to the bundles 10 prior to randomization. For example, as shown in Figures 7 and 8, the randomization process can act to spread out bundles 10 significantly as compared to other clusters 1 shown in Figures 6 and 9, for example, where the randomization process acts to spread out bundles 10 only slightly.

[0159] As further shown in Figures 6-9, 14, 15 and 20-26 and described above, the randomization process randomizes some of the fibers 12 of the bundle 10 to extend three-dimensionally from the remaining portion 16 to form an outer portion or region 18. The randomized fibers 12 forming the outer region 18 are entangled (and potentially to some extent entangled and intertwined) with each other and / or with the fibers 12 of the remaining portion 16 to form individual fibrous filler clusters 1 and to hold together as single individual units during use (and e.g., washing). As shown in Figures 6-9, 14, 15 and 20-26, the outer region 18 is significantly less densely packed with fibers 12 than the remaining portion 16 of the bundle (i.e., the remaining portion 16 of the bundle is more densely packed with fibers 12 than the outer region 18). The combination of the bundle remainder portions 16 and the outer regions 18 surprisingly and / or unexpectedly forms individual fibrous filler clusters 1 that closely mimic down in terms of blowability, size, weight, and / or density, and other properties, while at the same time offering improved use and washability as compared to down.

[0160] As shown in Figure 6, in some embodiments, the remaining portion 16 may be fairly long, for example at least about 75% of the length of the fiber-filler cluster 1. In other embodiments, as shown in Figure 9, the remaining portion 16 may be fairly short, for example less than about 75% of the length of the fiber-filler cluster 1. In other embodiments, as shown in Figures 7 and 8, the remaining portion 16 may be about 25% to about 75% of the length of the fiber-filler cluster 1.

[0161] As shown in Figures 10-13 and 16-29, in one embodiment of the disclosure, an individual fiber-filler cluster 1 of the present invention does not include a remainder portion 16, but includes at least one inner region 14 of relatively densely packed fibers 16 and an outer region of relatively sparsely packed fibers 12 extending three-dimensionally outward from the at least one inner relatively dense region. The fibers 12 of the inner relatively dense region 14 are randomly / non-uniformly extending and randomly / non-uniformly intertwined with one another, and thus are not aligned together along the longitudinal length of the fibers (i.e. aligned together longitudinally) as in the remainder portion 16. The randomization process eliminates or randomizes any longitudinal alignment of the fibers 12 in the bundle 10 and causes the fibers 12 to become entangled with one another (and potentially entangled and twisted to some degree) and form individual fibrous-filler clusters 1 with inner, relatively dense regions 14 and outer, relatively sparse regions 18, as shown in Figures 10-13 and 16-29. The fibers 12 in the inner, relatively dense regions 14 and the outer, relatively sparse regions 18 become entangled with one another (and potentially entangled and twisted to some degree) so that the fibers form individual fibrous-filler clusters 1 that hold together as single, individual units during use (and washing, for example).

[0162] As shown in Figure 10, in some embodiments, the individual fiber-filler clusters 1 may have a gradual transition between the inner relatively dense region 14 and the outer relatively less dense region 18. Alternatively, as shown in Figures 11-13, in some embodiments, the individual fiber-filler clusters 1 may have a more distinct or discernible difference or boundary between the inner relatively dense region 14 and the outer relatively less dense region 18.

[0163] 11 and 12, in some embodiments, the inner relatively dense region 14 and the outer relatively sparse region 18 may be approximately the same size (e.g., three-dimensional size, e.g., length, width and / or thickness). Conversely, in some embodiments, the inner relatively dense region 14 may be significantly smaller in size (e.g., three-dimensional size, e.g., length, width and / or thickness) than the outer relatively sparse region 18, as shown in FIG. 13.

[0164] In some embodiments, the inner relatively dense region 14 may be slightly more dense (e.g., about 50% less dense) than the outer relatively less dense region 18, as shown in Figure 11. Conversely, in some embodiments, the inner relatively dense region 14 may be significantly more dense (e.g., about 50% more dense) than the outer relatively less dense region 18, as shown in Figure 12.

[0165] In some embodiments, the invention provides a fibrous filler cluster comprising a plurality of fibers, the plurality of fibers being 0.2-12.0 denier and having a length of 8-76 mm, the plurality of fibers being cut from a filament yarn (e.g., an interlaced filament yarn), the plurality of fibers forming a collection nip section in which the plurality of fibers are interlaced with one another; and at least one outer region of fibers extending three-dimensionally outward from the collection nip section, the plurality of fibers being randomly and non-uniformly oriented with respect to one another, the collection nip section having a higher density of fibers than the at least one outer region. Such an embodiment may correspond, for example, to the second or third aspects of the invention, where the collection nip section corresponds to the fiber bundle remainder or at least one inner relatively dense region of fibers, respectively.

[0166] Filaments are continuous textile fibers / strands, such as a single long thread. Unlike staple fibers, which are limited in length, filaments are not limited in length and can span yards or miles (or, for example, when used in yarns, can span the entire length of the yarn). In some embodiments, the length of the filaments ranges from 5 inches to miles, or any range or subrange therein. For example, in some embodiments, the length of the filaments is at least 5 inches (e.g., at least 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 inches in length, or any ranges and subranges therein.In some embodiments, the filament length is at least 1 foot (e.g., at least 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, 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, 120, , 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, 110, 120, 130, 140, 150, 160, 170, 18 0, 190, 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, or 1000 feet in length, or any range and subrange therein).

[0167] A filament yarn is a yarn consisting of multiple continuous filaments gathered together with or without twist.

[0168] In some embodiments, the fibers are cut from an intermingled filament yarn, as described, for example, in Baykal et al., "The effects of intermingling process parameters and number of filaments on intermingled", The Journal of The Textile Institute, (England), 2013.

[0169] Entangled filament yarns are typically formed by subjecting a filament yarn (or its pre-yarn form, e.g., multiple longitudinally aligned filaments) to an air entanglement process using air jets to impart interfilament conjugation by forming interspersed collective nip sections (also referred to herein as "nips" or "nip sections") that are knot-like entangled connection points in the yarn. In another embodiment of an entangled yarn, the nips are formed, for example, by a pulsed laser (as opposed to an air jet), which forms a fused nip with the fibers bonded to each other (from at least partial melting of the fibers in the nip) as opposed to an entangled nip. Such embodiments of entangled yarns can also be used in the present invention. In some such embodiments, the bonded and / or at least partially melted fibers are only present in one or more nip sections of the clusters of the present invention.

[0170] 27 is a close-up photograph of a portion of a textured, entangled filament yarn 100 having a plurality of interspersed nips 42 evenly spaced within the yarn. The illustrated filament yarn 100 has 99 nips per meter, which is approximately one nip for every 10.1 mm of yarn length. The nips are separated from each other by open sections 44.

[0171] In some embodiments of the invention, the filament yarn has uniformly spaced nips, between 13 and 125 nips per meter (e.g., 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, 120, 121, 122, 123, 124, or 125 nip frequencies) or any range or subrange therein.

[0172] FIG. 28 is a simplified diagram showing a loose bundle of flat filament yarns 48 comprised of multiple filaments 12 being subjected to air entanglement to form an entangled filament yarn 100 having evenly spaced interspersed nips 42 separated by open portions 44, the nips and open portions being comprised of multiple filaments 12.

[0173] The nip in the interlaced filament yarn embodiment (and similarly the fiber filler cluster of the present invention) has an entangled structure that imparts interfilament conjugation to the yarn. The structure of some nip embodiments is analyzed and discussed in Miao et al., "Air interlaced yarn structure and properties", Textile Research Journal, (US), 1995, Vol. 65, p. 433-440. Of course, when the interlaced filament yarn is made using, for example, a pulsed laser, the nip has a structure in which multiple filaments are bonded to each other, rather than an entangled structure.

[0174] In some embodiments, the nip size is between 0.1 mm and 8 mm (e.g., 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 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, 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 mm) or any range or subrange therein (e.g., 0.4 to 3 mm, 0.5 to 2.5 mm, etc.).

[0175] 29 is a close-up of an embodiment of a section ("bundle") 140 of entangled filament yarn having one nip 42. Such a section (which may also be referred to as a bundle) is subjected to a treatment to scramble the multiple fibers 12 adjacent the nip portion to form the fibrous filler clusters of the present invention.

[0176] FIG. 30 is a close-up of an embodiment of a fibrous-filler cluster 160 of the present invention having one nip 42. FIG. 31 is a close-up of another embodiment of a fibrous-filler cluster 180 of the present invention having one nip 42. As is apparent, the cluster embodiment of FIG. 4 has a nip in the center of the bundle, while the cluster embodiment of FIG. 5 has a nip on the outer portion of the bundle. The nip can be located anywhere along the length of the bundle. As can be seen, the fibrous-filler clusters of the present invention are individual clusters, meaning that they are separate and distinct clusters.

[0177] In an embodiment of the invention, the filament yarn segments are cut to have 1 or 2 nips per segment, and thus the resulting fibrous filler clusters also have 1 or 2 nips. In a preferred embodiment, the segments are cut to have 1 nip, and thus the resulting fibrous filler clusters have 1 nip.

[0178] FIG. 32 is a close-up of an embodiment of a fiber filler cluster 200 of the present invention having two nips 42.

[0179] FIG. 33A is a close-up of an entangled filament yarn (left) and a plurality of fibrous filler clusters formed from the yarn according to an embodiment of the present invention. FIGS. 33B and 33C are close-ups of the fibrous filler clusters of FIG. 33A. The yarn shown in FIG. 33A is a 300 denier entangled filament yarn (formed by air jet entangling nip sections) made of a plurality of fibers, specifically 288 filaments (each filament having a denier of 1.04). The clusters shown were formed by cutting the yarn into bundles of equal length and subjecting each bundle to a process to scramble the plurality of fibers adjacent the gathering nip section.

[0180] As discussed herein, after cutting the filament yarn into one or more bundles, such as bundle 140 shown in FIG. 29 (such bundles can be considered as an embodiment corresponding to bundle 10), the bundle is subjected to a process to randomize the fibers adjacent the nip to form at least one outer region of fibers extending three-dimensionally outward from the nip. In the at least one outer region of fibers, the fibers are randomly and non-uniformly oriented relative to each other. The nip portion has a higher density of fibers than the at least one outer region. Referring to FIG. 30, two outer regions 46 of fibers extend three-dimensionally outward from the nip 42. FIG. 34 illustrates a process of cutting the intertwined filament yarn into bundles and randomizing the bundles to form a fibrous filler cluster 24 having two outer regions of fibers (shown in dashed lines) extending three-dimensionally outward from the nip.

[0181] FIG. 35 is an illustration of a cluster embodiment of the present invention derived from a bundle cut with a nip at the end.

[0182] As discussed above, in some embodiments of the present invention, the fibrous filler cluster is formed from entangled filament yarns. For example, in some embodiments, the fibrous filler cluster is formed from textured entangled filament yarns, such that the fibers within the cluster are textured. In other embodiments, the fibrous filler cluster is formed from non-textured entangled filament yarns, such that the fibers within the cluster are not textured.

[0183] In some embodiments of the fiber-filler cluster of the present invention, the entanglement of the fibers within the nip results in a plurality of fibers in the collection nip portion extending non-linearly along their longitudinal length. Due to both the entanglement within the nip and the randomization of the fibers after the bundle is cut out, the nip has a higher density of fibers than at least one outer region.

[0184] In some embodiments, the present invention provides a plurality of fibrous filler clusters as described herein.

[0185] In some embodiments of the plurality of fiber-filler clusters, at least 90% (e.g., at least 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 99.5%) of the fiber-filler clusters have the same number of fibers therein or have the same number of fibers within ±10% of the average number of fibers (e.g., ±10, 9, 8, 7, 6, 5, 4, 3, 2, or 1% of the average number of fibers in the plurality of fiber-filler clusters). In some embodiments of the plurality of fiber-filler clusters, 100% of the clusters have the same number of fibers therein or have the same number of fibers within ±10% of the average number of fibers.

[0186] In some embodiments of the plurality of fiber filler clusters, at least 90% (e.g., at least 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 99.5%) of the fiber filler clusters have fibers therein that are the same length. In some embodiments of the plurality of fiber filler clusters, 100% of the clusters have fibers therein that are the same length.

[0187] In some embodiments of the plurality of fiber filler clusters, at least 90% (e.g., at least 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 99.5%) of the fiber filler clusters have only one bundle remaining portion (or nip) therein.

[0188] In another aspect of the present disclosure, an insulation or filling material is provided that includes a plurality of the inventive fibrous-filler clusters. The insulation or filling material can be formed from (e.g., comprises, consists essentially of, or consists of) a plurality of individual fibrous-filler clusters 1 with a remainder portion 16 and an outer region 18, and / or a plurality of individual fibrous-filler clusters 1 with an inner region 14 and an outer region 18.

[0189] In some embodiments, the insulation or filling material is formed from (e.g., comprises, consists essentially of, or consists of) a plurality of individual fibrous-filler clusters 1 with a remainder portion 16 and an outer region 18. In some embodiments, the insulation or filling material is formed from (e.g., comprises, consists essentially of, or consists of) a plurality of individual fibrous-filler clusters 1 with an inner region 14 and an outer region 18.

[0190] In some embodiments, a plurality of fibrous filler clusters 1 of an insulating or filling material can include a first fibrous filler cluster 1 formed from fibers 12 of a first length and a second fibrous filler cluster 1 formed from fibers 12 of a second length different from the first length. In some embodiments, a plurality of fibrous filler clusters 1 of an insulating or filling material can include a first cluster 1 formed from a first total number of fibers 12 and a second cluster formed from a second total number of fibers 12 different from the first total number of fibers.

[0191] In some embodiments, a plurality of fibrous filler clusters 1 of insulation or filling material can include a first fibrous filler cluster 1 formed from fibers 12 of a first synthetic material and a second fibrous filler cluster 1 formed from fibers 12 of a second synthetic material different from the first synthetic material. Similarly, in some embodiments, a plurality of fibrous filler clusters 1 of insulation or filling material can include a first fibrous filler cluster 1 formed from fibers 12 of a first denier and a second fibrous filler cluster 1 formed from fibers 12 of a second denier different from the first denier.

[0192] In some embodiments, the plurality of fiber-filler clusters 1 of the insulation or filling material can include a fiber-filler cluster 1 of a first size and a fiber-filler cluster 1 of a second size different from the first size. Similarly, in some embodiments, the plurality of fiber-filler clusters 1 of the insulation or filling material can include a fiber-filler cluster 1 of a first three-dimensional shape and a fiber-filler cluster 1 of a second three-dimensional shape different from the first three-dimensional shape. In some embodiments, the plurality of fiber-filler clusters 1 of the insulation or filling material can include a fiber-filler cluster 1 in a first density range and a fiber-filler cluster 1 in a second density range that is different from and does not overlap with the first density range.

[0193] In another aspect of the disclosure, an article is provided comprising an insulating or filling material (i.e., a plurality of individual fiber filler clusters 1). In some embodiments, the article is selected from footwear, outerwear, clothing, sleeping bags, and bedding. In some embodiments, the article is home furnishings (e.g., bedding such as comforters and quilts, pillows, cushions, upholstered chairs, etc.).

[0194] [section] Non-limiting embodiments of the present invention are described in the following sections.

[0195] Section 1. Obtaining a plurality of 25-3600 individual bundles of fibers having a denier of 0.2-12.0 and a length of 8-160 mm, the plurality of fibers being aligned longitudinally together; disrupting the longitudinal alignment of at least a portion of the plurality of fibers of the bundle such that the fibers are randomly elongated and entangled in three dimensions to form individual fibrous filler clusters; A method for making at least one individual fiber filler cluster, comprising:

[0196] Clause 2. The method of clause 1, wherein the step of randomizing the longitudinal alignment of at least a portion of the plurality of fibers of the bundle includes randomizing the longitudinal alignment of only a portion of the plurality of fibers of the bundle such that a remaining portion of the plurality of fibers of the bundle remain both longitudinally aligned and entangled with the randomly extending three-dimensional fibers.

[0197] Clause 3. The method of clause 2, wherein the irregularly extending three-dimensional fibers form an outer region extending outwardly from the bundle remainder.

[0198] Clause 4. The method of clause 3, wherein the bundle remainder portion comprises a higher density of fibers than the outer region.

[0199] Clause 5. The method of clause 1, wherein the step of randomizing the longitudinal alignment of at least some of the plurality of fibers of the bundle includes randomizing the longitudinal alignment of all of the plurality of fibers of the bundle such that none of the plurality of fibers remain longitudinally aligned together.

[0200] Clause 6. The method of clause 5, wherein the longitudinal alignment of all of the plurality of fibers of the bundle is randomized to form at least one inner three-dimensional region of relatively densely packed fibers and an outer region of relatively less densely packed fibers extending three-dimensionally outward from the at least one inner relatively densely packed region.

[0201] Clause 7. The method of any one of clauses 1-6, wherein the step of randomizing the longitudinal alignment of at least a portion of the plurality of fibers of the bundle includes entangling only a portion of the randomized fibers, such that some of the randomized fibers form fibrous filler clusters and some of the randomized fibers do not form fibrous filler clusters.

[0202] Clause 8. The method of any one of clauses 1-7, wherein the step of randomizing the longitudinal alignment of at least a portion of the fibers of the bundle comprises: disposing the bundle between engagement surfaces of at least one pair of randomizing members such that the randomizing surfaces contact the bundle; and translating the at least one first randomizing member relative to the at least one second randomizing member along a path that extends both longitudinally along the length of the fibers of the bundle and laterally along a lateral direction oriented perpendicular to the longitudinal direction.

[0203] Clause 9. The method of clause 8, wherein the distance between the randomized surfaces is maintained approximately constant during the randomization step.

[0204] Clause 10. At least one first cluttering member translates along an arcuate path for at least an initial short period of time; and / or at least one first cluttering member translates along an elliptical path for at least an initial short period of time; and / or at least one first cluttering member translates along a random trajectory pattern for at least an initial short period of time; and / or At least one of the engagement surfaces comprises a substantially flat and smooth surface; and / or At least one of the engagement surfaces has a number of particles or protrusions arranged in a substantially planar manner. 10. The method according to clause 8 or 9.

[0205] Clause 11. The method of any one of clauses 8-10, wherein the step of disturbing the longitudinal alignment of at least a portion of the plurality of fibers of the bundle comprises subjecting the bundle to at least one gas flow and / or liquid flow.

[0206] Clause 12. The method of any one of clauses 8-11, wherein the individual bundles are derived from filament yarns and include a plurality of 25-3600 fibers having a denier of 0.2-12.0 and a length of 8-76 mm, the plurality of fibers being aligned longitudinally together, the fibers having a collection nip portion in which the plurality of fibers are entangled with one another; and the step of randomizing the longitudinal alignment includes randomizing the plurality of fibers adjacent the collection nip portion to form at least one outer region of fibers extending three-dimensionally outward from the collection nip portion, and wherein after the randomizing step, the plurality of fibers are randomly and non-uniformly oriented with respect to one another, and the collection nip portion corresponding to the remaining portion of the bundle of the plurality of fibers has a higher density of fibers than the at least one outer region.

[0207] Clause 13. The step of randomizing the longitudinal alignment of the bundle comprises: Processing in fiber opening machines; Processing in a wool-removing machine; or Air Treatment 13. The method of claim 12, comprising subjecting the

[0208] Clause 14. The method of clause 13, wherein subjecting the bundle to air treatment comprises subjecting the bundle to air tumbling.

[0209] Clause 15. The plurality of fibers forming the fibrous filler cluster are derived from fragments of entangled filament yarns, and the collection nip portion of the cluster corresponds to the collection nip portion of the entangled filament yarns; the plurality of fibers in the collection nip portion extend nonlinearly along their longitudinal lengths; and None of the fibers in the cluster are joined to each other. 15. The method according to any one of clauses 12 to 14.

[0210] Clause 16. The method of any one of clauses 1-14, further comprising, prior to the randomizing step, bonding at least a portion of the plurality of fibers of the bundle to one another at at least one point along a longitudinal length of the bundle to form at least one bond point.

[0211] Clause 17. The method of clause 16, wherein the juncture is formed by heating at least some of the plurality of fibers at at least one point to adhere the fibers to one another at the at least one juncture.

[0212] Clause 18. The method of clause 17, wherein heating at least a portion of the plurality of fibers at at least one point comprises contacting the plurality of fibers at at least one point with a material having a temperature above a melting temperature of the fibers.

[0213] Clause 19. The method of any one of clauses 1-18, wherein the step of randomizing the longitudinal alignment of at least a portion of the plurality of fibers of the bundle includes entangling some of the randomized fibers with one another.

[0214] Clause 20. The method of clause 19, wherein less than about 50% (e.g., less than about 25%) of the disordered fibers are entangled with at least one other fiber.

[0215] Clause 21. The method of any one of clauses 1-20, wherein the step of randomizing the longitudinal alignment of at least a portion of the plurality of fibers of the bundle includes intertwining some of the randomized fibers.

[0216] Clause 22. The method of clause 21, wherein less than about 50% (e.g., less than about 25%) of the scrambled fibers are intertwined with at least one other fiber.

[0217] Clause 23. Obtaining a plurality of individual bundles, each bundle being a bundle of 25-3600 fibers having a denier of 0.2-12.0 and a length of 8-160 mm, the fibers of each bundle being aligned longitudinally together; randomizing the longitudinal alignment of at least a portion of the plurality of fibers in each bundle such that the fibers are randomly elongated in three dimensions and entangled to form a plurality of individual fibrous filler clusters; 23. The method of any one of clauses 1 to 22, comprising:

[0218] Clause 24. The method of any one of clauses 1-23, wherein prior to the randomizing step, the plurality of fibers of the bundle extend substantially linearly along their longitudinal length.

[0219] Clause 25. The method of any one of clauses 1-24, wherein the fibers of the bundle extend substantially parallel to one another along their longitudinal lengths.

[0220] Clause 26. The method of any one of clauses 1 to 25, wherein the plurality of fibers in the bundle are non-textured fibers.

[0221] Clause 27. The method of clause 26, wherein the bundle is a non-textured entangled filament yarn.

[0222] Clause 28. The method of any one of clauses 1-23, wherein the fibers of the bundle extend non-linearly along their longitudinal length.

[0223] Clause 29. The method of any one of clauses 1-23 and 28, wherein the fibers of the bundle extend randomly along their longitudinal length.

[0224] Clause 30. The method of any one of clauses 1-25, 28, and 29, wherein a plurality of fibers in the bundle are textured fibers.

[0225] Clause 31. The method of clause 30, wherein the bundle is a textured entangled filament yarn.

[0226] Clause 32. The method of any one of clauses 1-31, wherein the plurality of fibers in the bundle comprises about 50 to about 500 fibers.

[0227] Clause 33. The method of any one of clauses 1-32, wherein the plurality of fibers comprises about 80 to about 300 fibers.

[0228] Clause 34. The method of any one of clauses 1-33, wherein the bundle comprises more fibers than the fibrous filler cluster.

[0229] Clause 35. The method of any one of clauses 1-34, wherein the fiber filler cluster includes at least one minor fiber that was not part of a bundle.

[0230] Clause 36. The method of clause 35, wherein at least one minor fiber is entangled with a plurality of fibers of the fibrous filler cluster during the randomizing step.

[0231] Clause 37. The method of any one of clauses 1-36, wherein the plurality of fibers is about 0.7 to about 1.7 denier.

[0232] Clause 38. The method of any one of clauses 1-37, wherein the plurality of fibers have approximately the same denier.

[0233] Clause 39. The method of any one of clauses 1-38, wherein the plurality of fibers in the bundle have a longitudinal length of about 20 to about 50 mm.

[0234] Clause 40. The method of any one of clauses 1 to 39, wherein a plurality of fibers in the bundle are doped with a durable water repellent or a silicone chemical.

[0235] Clause 41. The method of any one of clauses 1-40, wherein the plurality of fibers have approximately the same length.

[0236] Clause 42. The method of any one of clauses 1 to 41, wherein the plurality of fibers are synthetic polymer fibers.

[0237] Clause 43. The method of any one of clauses 1-42, wherein the plurality of fibers are fibers selected from polyamide, polyester, polypropylene, polylactic acid, polybutylacrylate, acrylic, acrylate, acetate, polyolefin, nylon, rayon, lyocell, aramid, spandex, viscose, and modal fibers, or combinations thereof.

[0238] Clause 44. The method of any one of clauses 1 to 43, wherein the plurality of fibers are polyester fibers.

[0239] Clause 45. The method of clause 44, wherein the polyester fibers are selected from polyethylene terephthalate (PET), poly(hexahydro-p-xylylene terephthalate), polybutylene terephthalate (PBT) fibers, polytrimethylene terephthalate (PTT) fibers, copolyester fibers (e.g., copolyester fibers containing structural units of PET), or combinations thereof.

[0240] Clause 46. The method of clause 44, wherein the polyester fibres are PET fibres.

[0241] Clause 47. The method of any one of clauses 1 to 46, wherein the fiber comprises recycled polymeric material.

[0242] Clause 48. The method of any one of clauses 1-47, wherein the plurality of fibers comprises silicone-treated fibers.

[0243] Clause 49. The method of any one of clauses 1-48, wherein the plurality of fibers includes non-silicone-treated fibers.

[0244] Clause 50. The method of any one of clauses 1-49, wherein the plurality of fibers comprises solid fibers.

[0245] Clause 51. The method of any one of clauses 1 to 50, wherein the plurality of fibers comprises hollow fibers.

[0246] Clause 52. The method of any one of clauses 1-51, wherein the fiber filler cluster defines a length, a width and a thickness, and the length and width are greater than the thickness.

[0247] Clause 53. The method of clause 52, wherein the length is greater than the width.

[0248] Clause 54. The method of any one of clauses 1-53, wherein the fiber filler clusters define a length, a width and a thickness, and the length is within the range of about 0.90 to about 4 cm.

[0249] Clause 55. The method of any one of clauses 1-54, wherein the fiber filler cluster defines a length, a width and a thickness, and the width is within the range of about 0.70 to about 3 cm.

[0250] Clause 56. The method of any one of clauses 1-55, wherein the fiber filler clusters have a density of about 0.08 to about 0.70 mg / cm3 (e.g., about 0.10 to about 0.50 mg / cm3).

[0251] Clause 57. The method of any one of clauses 1-56, wherein the fiber filler clusters define a generally oval shape.

[0252] Clause 58. The method of any one of clauses 1-51 and 54-57, wherein the fiber filler clusters define a generally spherical shape.

[0253] Clause 59. The method of any one of clauses 1-58, wherein the bundle is a section of filament yarn.

[0254] Clause 60. The method of clause 59, wherein the step of obtaining a bundle includes cutting segments from the filament yarn.

[0255] Clause 61. The method of clause 59 or 60, wherein the filament yarn is a textured filament yarn.

[0256] Clause 62. The method of clause 59 or 60, wherein the filament yarn is a flat filament yarn.

[0257] Clause 63. A fabric comprising a plurality of intertwined fibers, the fibers being 0.2 to 12.0 denier and having 25 to 3,600 fibers having a length of 8 to 160 mm; The plurality of fibers are a bundle remainder including a portion of the plurality of fibers that are longitudinally aligned together; an outer region of fibers extending outward in three dimensions from the remainder of the bundle, the outer region including a portion of the plurality of fibers that are randomly and non-uniformly oriented with respect to one another; and the remaining bundle portion comprises a higher density of fibers than the outer regions; Individual fiber filler clusters.

[0258] Clause 64. The individual fiber filler cluster of clause 63, wherein the bundle remainder portion comprises fewer fibers than the outer regions.

[0259] Clause 65. The discrete fibrous filler cluster of clause 63 or 64, wherein the bundle remainder portion contains at least 25% (e.g., at least 50%, or at least 75%) fewer fibers than the outer regions.

[0260] Clause 66. The individual fiber filler cluster of any one of clauses 63-65, wherein the plurality of fibers are derived from fragments of entangled filament yarns, and the bundle remaining portion of the individual fiber filler cluster corresponds to a gathering nip portion derived from the entangled filament yarns.

[0261] Clause 67. The individual fibrous filler cluster of clause 66, wherein a plurality of the fibers of the bundle remainder portion are intertwined with one another.

[0262] Clause 68. The individual fiber filler cluster of any one of clauses 63-67, wherein the bundle remainder portion extends non-linearly along its length.

[0263] Clause 69. The individual fibrous filler cluster of any one of clauses 63-68, wherein the bundle remainder portion is a portion of a segment of a filament yarn.

[0264] Clause 70. The individual fibrous filler cluster of clause 69, wherein the bundle remainder portion is a portion of a segment of textured filament yarn.

[0265] Clause 71. The individual fibrous filler cluster of clause 69, wherein the bundle remainder is a portion of a flattened filament yarn segment.

[0266] Clause 72. The discrete fibrous filler cluster of any one of clauses 63-71, wherein the fibers of the bundle remainder portion extend substantially parallel to one another along their longitudinal lengths.

[0267] Clause 73. The discrete fibrous filler cluster of any one of clauses 63-72, wherein the plurality of fibers are non-textured straight fibers.

[0268] Clause 74. The discrete fibrous filler cluster of any one of clauses 63-72, wherein the plurality of fibers are textured straight fibers.

[0269] Clause 75. The discrete fibrous filler cluster of any one of clauses 63-74, wherein the plurality of fibers extend non-linearly along their longitudinal length.

[0270] Clause 76. The discrete fiber filler cluster of any one of clauses 63-75, wherein the plurality of fibers extend randomly along their longitudinal length.

[0271] Clause 77. The individual fibrous filler cluster of any one of clauses 63-76, wherein a portion of the plurality of fibers in the outer region are entangled with each other or with at least one fiber in the remainder of the bundle.

[0272] Clause 78. The discrete fibrous filler cluster of clause 77, wherein less than about 50% of the plurality of fibers in the outer region are entangled with each other or with at least one fiber in the remainder of the bundle.

[0273] Clause 79. The discrete fibrous filler cluster of clause 77, wherein less than about 25% of the plurality of fibers in the outer region are entangled with each other or with at least one fiber in the remainder of the bundle.

[0274] Clause 80. The discrete fibrous filler cluster of any of clauses 1-79, wherein at least a portion of the plurality of fibers in the outer region are twisted with one another or with at least one fiber in the remainder of the bundle.

[0275] Clause 81. The discrete fibrous filler cluster of clause 80, wherein less than about 50% of the plurality of fibers in the outer region are twisted with each other or with at least one fiber in the remainder of the bundle.

[0276] Clause 82. The discrete fibrous filler cluster of clause 80, wherein less than about 25% of the plurality of fibers in the outer region are twisted with each other or with at least one fiber in the remainder of the bundle.

[0277] Clause 83. The discrete fibrous filler cluster of any one of clauses 63-82, comprising at least one junction at which at least a portion of the plurality of fibers are joined to one another.

[0278] Clause 84. The discrete fiber filler cluster of clause 83, wherein at least one bond point comprises some of the fibers in the remaining portion and some of the fibers in the outer region.

[0279] Clause 85. The discrete fiber filler cluster of clause 83 or 84, wherein at least one bond point includes only a portion of the fibers in the bundle remainder portion and only a portion of the fibers in the outer region.

[0280] Clause 86. The individual fiber filler cluster of any one of clauses 63-85, wherein the fiber filler cluster defines a length, a width and a thickness, and the length and width are greater than the thickness.

[0281] Clause 87. A discrete fiber filler cluster as described in clause 86, the length being greater than the width.

[0282] Clause 88. The discrete fiber-filler cluster of any one of clauses 1-87, wherein the fiber-filler cluster defines a length, a width and a thickness, and the length is within the range of about 0.90 to about 4 cm.

[0283] Clause 89. The discrete fiber-filler cluster of any one of clauses 1-88, wherein the fiber-filler cluster defines a length, a width and a thickness, and the width is within the range of about 0.70 to about 3 cm.

[0284] Clause 90. The individual fiber filler cluster of any one of clauses 1-89, wherein the fiber filler cluster defines a generally oval shape.

[0285] Clause 91. The individual fiber filler cluster of any one of clauses 63-85 and 88-90, wherein the fiber filler cluster defines a generally spherical shape.

[0286] Clause 92. The discrete fibrous filler cluster of any one of clauses 63-91, wherein the plurality of fibers is about 0.7 to about 1.7 denier.

[0287] Clause 93. The discrete fibrous filler cluster of any one of clauses 63-92, wherein the plurality of fibers have approximately the same denier.

[0288] Clause 94. The discrete fibrous filler cluster of any one of clauses 63-93, wherein the plurality of fibers in the bundle have a longitudinal length of about 20 to about 50 mm.

[0289] Clause 95. The individual fibrous filler cluster of any one of clauses 63-94, wherein the fibers of the bundle remainder portion have approximately the same longitudinal length.

[0290] Clause 96. The individual fibrous filler cluster of any one of clauses 63-95, wherein the fibers have approximately the same length.

[0291] Clause 97. The individual fiber filler cluster of any one of clauses 63-96, wherein the fiber filler cluster has a density of about 0.08 to about 0.70 mg / cm3 (e.g., about 0.10 to about 0.50 mg / cm3).

[0292] Clause 98. The discrete fibrous filler cluster of any one of clauses 63-97, wherein the plurality of fibers comprises about 50 to about 500 fibers.

[0293] Clause 99. The discrete fibrous filler cluster of any one of clauses 63-98, wherein the plurality of fibers comprises about 80 to about 300 fibers.

[0294] Clause 100. The discrete fiber filler cluster of any one of clauses 63-99, wherein the plurality of fibers are synthetic polymer fibers.

[0295] Clause 101. The discrete fibrous filler cluster of any one of clauses 63-100, wherein the plurality of fibers are selected from polyamide, polyester, polypropylene, polylactic acid, polybutylacrylate, acrylic, acrylate, acetate, polyolefin, nylon, rayon, lyocell, aramid, spandex, viscose, and modal fibers, or combinations thereof.

[0296] Clause 102. The discrete fibrous filler cluster of any one of clauses 63-101, wherein the plurality of fibers are polyester fibers.

[0297] Clause 103. The discrete fibrous filler cluster of clause 102, wherein the polyester fibers are selected from polyethylene terephthalate (PET), poly(hexahydro-p-xylylene terephthalate), polybutylene terephthalate (PBT) fibers, polytrimethylene terephthalate (PTT) fibers, copolyester fibers (e.g., copolyester fibers containing structural units of PET), or combinations thereof.

[0298] Clause 104. The discrete fiber filler cluster of clause 102, wherein the polyester fibers are PET fibers.

[0299] Clause 105. The individual fiber filler cluster of any one of clauses 63-104, wherein the fibers comprise recycled polymeric material.

[0300] Clause 106. The discrete fiber filler cluster of any one of clauses 63-105, wherein the plurality of fibers comprises siliconized fibers.

[0301] Clause 107. The discrete fibrous filler cluster of any one of clauses 63-106, wherein the plurality of fibers comprises non-silicone-treated fibers.

[0302] Clause 108. The discrete fibrous filler cluster of any one of clauses 63-107, wherein the plurality of fibers comprises solid fibers.

[0303] Clause 109. The discrete fibrous filler cluster of any one of clauses 63-108, wherein the plurality of fibers comprises hollow fibers.

[0304] Clause 110. A method of making a woven fabric comprising the steps of: a) forming a woven fabric comprising: a woven fabric having a denier of 0.2 to 12.0; b) forming a woven fabric having a length of 8 to 160 mm and a number of fibers of 25 to 3,600; c) forming a woven fabric having a denier of 0.2 to 12.0; the fibers are randomly and non-uniformly oriented with respect to one another; The plurality of fibers are with at least one inner area of ​​relatively dense fibers; an outer region of relatively less dense fibers extending three-dimensionally outward from at least one inner region of relatively dense fibers; and The length is 0.5cm~6.5cm, the width is 0.5cm~6.5cm, and the density is 0.08~0.70mg / cm3.mg / cm3. Individual fiber filler clusters.

[0305] Clause 111. The discrete fibrous filler cluster of clause 110, wherein the inner region comprises fewer fibers than the outer region (e.g., at least 25% or at least 50% fewer fibers than the outer region).

[0306] Clause 112. The discrete fibrous filler cluster of clause 110, wherein the outer region includes fewer fibers than the inner region (e.g., at least 25% or at least 50% fewer fibers than the inner region).

[0307] Clause 113. The discrete fiber filler cluster of any one of clauses 111-112, wherein the plurality of fibers extend non-linearly along their length.

[0308] Clause 114. The discrete fibrous filler cluster of any one of clauses 110-113, wherein the plurality of fibers are non-textured fibers.

[0309] Clause 115. The discrete fiber filler cluster of any one of clauses 110-113, wherein the plurality of fibers are textured fibers.

[0310] Clause 116. The discrete fibrous filler cluster of any one of clauses 110-115, wherein the plurality of fibers are derived from pieces of entangled filament yarns, and wherein at least one inner region of relatively dense fibers of the discrete fibrous filler cluster corresponds to a gathering nip portion derived from the entangled filament yarns.

[0311] Clause 117. The discrete fiber filler cluster of clause 116, wherein the fibers of at least one inner relatively densely packed fiber region are intertwined with one another.

[0312] Clause 118. A discrete fibrous filler cluster according to clause 116 or clause 117, wherein none of the fibers within the cluster are bonded to one another.

[0313] Clause 119. The method of any one of clauses 1-118, wherein a plurality of fibers of the bundle are doped with a durable water repellent or silicone chemical.

[0314] Clause 120. The discrete fibrous filler cluster of any one of clauses 110-119, wherein some of the plurality of fibers are entangled with one another.

[0315] Clause 121. The discrete fibrous filler cluster of clause 120, wherein less than about 50% of the plurality of fibers are entangled with one another.

[0316] Clause 122. The discrete fibrous filler cluster of clause 120, wherein less than about 25% of the plurality of fibers are entangled with one another.

[0317] Clause 123. The discrete fibrous filler cluster of any one of clauses 110-122, wherein some of the plurality of fibers are twisted together.

[0318] Clause 124. The discrete fibrous filler cluster of clause 123, wherein less than about 50% of the plurality of fibers are twisted together.

[0319] Clause 125. The discrete fibrous filler cluster of clause 123, wherein less than about 25% of the plurality of fibers are twisted together.

[0320] Clause 126. The discrete fibrous filler cluster of any one of clauses 110-117 or 119-125, comprising at least one junction at which at least a portion of the plurality of fibers are joined to one another.

[0321] Clause 127. The discrete fiber filler cluster of clause 126, wherein at least one junction includes some of the fibers in the inner region and some of the fibers in the outer region.

[0322] Clause 128. The discrete fiber filler cluster of clause 126 or clause 127, wherein at least one bond point includes only a portion of the fibers in the inner portion and only a portion of the fibers in the outer region.

[0323] Clause 129. The individual fiber filler cluster of any one of clauses 110-128, wherein the fiber filler cluster defines a length, a width and a thickness, and the length and width are greater than the thickness.

[0324] Clause 130. A discrete fiber filler cluster as described in clause 129, the length being greater than the width.

[0325] Clause 131. The discrete fiber-filler cluster of any one of clauses 110-130, wherein the fiber-filler cluster defines a length, a width and a thickness, and wherein the length is within the range of about 0.90 to about 4 cm.

[0326] Clause 132. The discrete fiber-filler cluster of any one of clauses 110-131, wherein the fiber-filler cluster defines a length, a width and a thickness, and wherein the width is within the range of about 0.70 to about 3 cm.

[0327] Clause 133. The individual fiber filler cluster of any one of clauses 110-132, wherein the fiber filler cluster defines a generally oval shape.

[0328] Clause 134. The individual fiber filler cluster of any one of clauses 110-128 and 131-132, wherein the fiber filler cluster defines a generally spherical shape.

[0329] Clause 135. The discrete fibrous filler cluster of any one of clauses 110-134, wherein the plurality of fibers is about 0.7 to about 1.7 denier.

[0330] Clause 136. The discrete fibrous filler cluster of any one of clauses 110-135, wherein the plurality of fibers have approximately the same denier.

[0331] Clause 137. The discrete fiber filler cluster of any one of clauses 110-136, wherein the plurality of fibers in the bundle have a longitudinal length of about 20 to about 50 mm.

[0332] Clause 138. The discrete fibrous filler cluster of any one of clauses 110-137, wherein the plurality of fibers have approximately the same longitudinal length.

[0333] Clause 139. The individual fiber filler cluster of any one of clauses 110 to 138, wherein the fiber filler cluster has a density of about 0.10 to about 0.50 mg / cm3.

[0334] Clause 140. The discrete fiber filler cluster of any one of clauses 110-139, wherein the plurality of fibers comprises about 50 to about 500 fibers.

[0335] Clause 141. The discrete fibrous filler cluster of any one of clauses 110-140, wherein the plurality of fibers comprises about 80 to about 300 fibers.

[0336] Clause 142. The discrete fiber filler cluster of any one of clauses 110-141, wherein the plurality of fibers are synthetic polymer fibers.

[0337] Clause 143. The discrete fibrous filler cluster of any one of clauses 110-142, wherein the plurality of fibers are selected from polyamide, polyester, polypropylene, polylactic acid, polybutylacrylate, acrylic, acrylate, acetate, polyolefin, nylon, rayon, lyocell, aramid, spandex, viscose, and modal fibers, or combinations thereof.

[0338] Clause 144. The discrete fibrous filler cluster of any one of clauses 110-143, wherein the plurality of fibers are polyester fibers.

[0339] Clause 145. The discrete fibrous filler cluster of clause 144, wherein the polyester fibers are selected from polyethylene terephthalate (PET), poly(hexahydro-p-xylylene terephthalate), polybutylene terephthalate (PBT) fibers, polytrimethylene terephthalate (PTT) fibers, copolyester fibers (e.g., copolyester fibers containing structural units of PET), or combinations thereof.

[0340] Clause 146. The discrete fiber filler cluster of clause 144, wherein the polyester fiber is a PET fiber.

[0341] Clause 147. The individual fiber filler cluster of any one of clauses 110-146, wherein the fiber comprises recycled polymeric material.

[0342] Clause 148. The discrete fiber filler cluster of any one of clauses 110-147, wherein the plurality of fibers comprises siliconized fibers.

[0343] Clause 149. The discrete fibrous filler cluster of any one of clauses 110-148, wherein the plurality of fibers includes non-silicone-treated fibers.

[0344] Clause 150. The discrete fiber filler cluster of any one of clauses 110-149, wherein the plurality of fibers comprises solid fibers.

[0345] Clause 151. The discrete fibrous filler cluster of any one of clauses 110-150, wherein the plurality of fibers comprises hollow fibers.

[0346] Clause 152. An insulating or filling material comprising a plurality of individual fibrous filler clusters according to any one of clauses 63-151.

[0347] Clause 153. The insulation or filler material of clause 152, comprising a plurality of first discrete fibrous filler clusters of any one of clauses 63-109 and a plurality of second discrete fibrous filler clusters of any one of clauses 110-151.

[0348] Clause 154. An insulation or filler material as described in clause 152, comprising a plurality of individual fibrous filler clusters as described in any one of clauses 63-109.

[0349] Clause 155. An insulation or filler material as described in clause 152, comprising a plurality of individual fibrous filler clusters as described in any one of clauses 110-151.

[0350] Clause 156. The insulation or filler material of any one of clauses 152-155, wherein the plurality of fiber filler clusters includes a first fiber filler cluster formed from fibers of a first length and a second fiber filler cluster formed from fibers of a second length different from the first length.

[0351] Clause 157. The insulation or filler material of any one of clauses 152-156, wherein the plurality of fiber clusters includes a first cluster formed from a first total number of fibers and a second cluster formed from a second total number of fibers different from the first total number of fibers.

[0352] Clause 158. An insulation or filler material according to any one of clauses 152 to 157, wherein the plurality of fibre filler clusters includes a first fibre filler cluster formed from fibres of a first synthetic material and a second fibre filler cluster formed from fibres of a second synthetic material different from the first synthetic material.

[0353] Clause 159. The insulation or filler material of any one of clauses 152-158, wherein the plurality of fibrous filler clusters includes a first fibrous filler cluster formed from fibers of a first denier and a second fibrous filler cluster formed from fibers of a second denier different from the first denier.

[0354] Clause 160. The insulation or filler material of any one of clauses 152 to 159, wherein the plurality of fiber filler clusters includes fiber filler clusters of a first size and fiber filler clusters of a second size different from the first size.

[0355] Clause 161. The insulation or filler material of any one of clauses 152-160, wherein the plurality of fiber filler clusters includes a fiber filler cluster having a first three-dimensional shape and a fiber filler cluster having a second three-dimensional shape different from the first three-dimensional shape.

[0356] Clause 162. An insulation or filler material according to any one of clauses 152 to 161, wherein the plurality of fiber-filler clusters includes fiber-filler clusters in a first density range and fiber-filler clusters in a second density range that is different from and does not overlap with the first density range.

[0357] Clause 163. An article comprising a plurality of individual fibrous filler clusters according to any one of clauses 63-151 or an insulating or filling material according to any one of clauses 152-162.

[0358] Clause 164. The article of clause 163, wherein the article is selected from footwear, outerwear, clothing, sleeping bags, and bedding.

[0359] The invention will now be illustrated, but not limited, by reference to specific embodiments described in the following examples. EXAMPLES

[0360] The invention will now be illustrated, but not limited, by reference to specific embodiments described in the following examples.

[0361] Example 1 Comparative testing was performed on individual embodiments of the individual fiber filler clusters of the present invention and down clusters (1000 fill power (FP) goose down feathers and 550 FP duck down feathers). The individual fiber filler clusters of the present invention were prepared by obtaining a substantially parallel aligned (i.e., longitudinally aligned / side-by-side) drawn polyester yarn or tow with 136 filaments having a denier per filament (dpf) of about 1.10 (so the total denier of the bundle is about 150). The yarn was cut to provide a number of 1", 2", and 4" length longitudinally aligned fiber bundles. Additional individual fiber filler clusters of the present invention were prepared by obtaining a substantially parallel aligned (i.e. longitudinally aligned / side-by-side) drawn polyester yarn or tow having 96 filaments with a denier per filament (dpf) of about 2.08 (thus a total denier of the bundle is about 200). The individual fiber filler clusters of the present invention were then randomized between two randomizers to form a number of individual fiber filler clusters. The 1" 1.1 dpf fiber bundle clusters were tested for length, width, height, and volume, as were the 2" 1.1 dpf fiber bundle clusters, the 4" 1.1 dpf fiber bundle clusters, and the 2" 2.08 dpf fiber bundle clusters. Down clusters were also tested in the same manner. The results for each type of cluster were averaged and are shown below in Table I. [Table 1]

[0362] Example 2 Weight and volume tests were performed on the samples of Example 1 (both for one cluster and for the group of 10 clusters). The results are shown below in Table II. The "single (g)" weight (g) measurements and "density (g / cm 3 ) density measurements are the average of one measurement based on the average of 10 tested. [Table 2]

[0363] As shown in Table II, the 4" 1.1 dpf synthetic cluster was about 27% denser than the 1,000 FP goose down feathers, the 2" 1.1 dpf synthetic cluster was about 17% denser than the 550 FP goose down feathers, and the 2" 2.08 dpf synthetic cluster was about 17% less dense than the 1,000 FP goose down feathers.

[0364] As one of ordinary skill in the art will readily appreciate, the properties tested in the examples may vary widely depending on the fibers that make up the individual fibrous filler clusters, and the foregoing examples are non-limiting.

[0365] The terminology used herein is for the purpose of describing particular embodiments only 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 unless the context clearly indicates otherwise. It is further understood that the terms "comprise" (and any form of such terms, e.g., "comprise" 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.

[0366] As used herein, the terms "comprising," "has," "including," "contains," and other grammatical variations thereof, encompass the terms "consisting of" and "consisting essentially of."

[0367] 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.

[0368] Approximate terms, as used throughout the disclosure herein, can be applied to modify any quantitative expression that may vary within an acceptable range without causing a change in the basic function to which the expression relates. Thus, values ​​modified with terms such as "about" or "substantially" are not limited to the exact value specified. For example, these terms can refer to ±5% or less, such as ±2% or less, such as ±1% or less, such as ±0.5% or less, such as ±0.2% or less, such as ±0.1% or less, such as ±0.05% or less, etc. In some instances, the approximate terms can correspond to the precision of the instrument that measures the value.

[0369] 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.

[0370] Subject matter incorporated by reference is not to be construed as a substitute for any claim limitation, unless expressly indicated otherwise.

[0371] 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.

[0372] 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 step of obtaining a plurality of 25 to 3600 individual bundles of fibers having a denier of 0.2 to 12.0 and a length of 8 to 160 mm, wherein the plurality of fibers are aligned longitudinally together; A step of disrupting at least a part of the longitudinal alignment of the plurality of fibers in the bundle so that the fibers extend irregularly three-dimensionally and are entangled to form individual fiber filler clusters; A method for producing at least one individual fiber filler cluster, comprising: The step of disrupting at least a part of the longitudinal alignment of the plurality of fibers in the bundle includes arranging the bundle between the engaging surfaces of at least one pair of disrupting members so that the disrupting surface contacts the bundle, and at least one first disrupting member is moved relative to at least one second disrupting member along a path extending in both the longitudinal direction along the length of the fibers in the bundle and the transverse direction perpendicular to the longitudinal direction.

2. The method according to claim 1, wherein the step of disrupting at least a part of the longitudinal alignment of the plurality of fibers in the bundle includes disrupting only a part of the longitudinal alignment of the plurality of fibers in the bundle, so that the remaining part of the bundle remains aligned longitudinally together and is entangled with the fibers extending irregularly three-dimensionally.

3. In the method according to claim 2, the fibers extending irregularly three-dimensionally form an outer region extending outward from the remaining part of the bundle, and the remaining part of the bundle contains fibers with a higher density than the outer region.

4. The method according to claim 1, wherein the step of disrupting at least a part of the longitudinal alignment of the plurality of fibers in the bundle includes disrupting the longitudinal alignment of all of the plurality of fibers in the bundle so that there are no fibers that remain aligned longitudinally together.

5. The method according to claim 4, wherein by disrupting the longitudinal alignment of all of the plurality of fibers of the bundle, at least one inner relatively dense three-dimensional region of fibers and at least one outer region of fibers extending three-dimensionally outward from the at least one inner relatively dense region and being less dense are formed.

6. The method according to claim 1, wherein the distance between the disruption surfaces is maintained substantially constant during the disruption step.

7. At least one first disrupting member translates along an arcuate path, at least for an initial short time; and / or At least one first disrupting member translates along an elliptical path, at least for an initial short time; and / or At least one first disrupting member translates along a random orbital pattern, at least for an initial short time; and / or At least one of the engagement surfaces comprises a substantially flat and smooth surface; and / or At least one of the engagement surfaces comprises a plurality of particles or protrusions arranged substantially in a plane. The method according to claim 1.

8. The method according to claim 1, wherein the step of disrupting the longitudinal alignment of at least some of the plurality of fibers of the bundle comprises subjecting the bundle to at least one gas flow and / or liquid flow.

9. Individual bundles are obtained from filament yarns and are bundles comprising 25 to 3600 fibers of 0.2 to 12.0 denier and 8 to 76 mm in length, the plurality of fibers being aligned longitudinally together, said fibers having an aggregate nip portion where the plurality of fibers are intertwined with each other; the step of disrupting the longitudinal alignment forms at least one outer region of fibers extending three-dimensionally outward from the aggregate nip portion by disrupting a plurality of fibers adjacent to the aggregate nip portion, after said disrupting step, the plurality of fibers are oriented in random and non-uniform directions with respect to each other, and the aggregate nip portion corresponding to the remaining portion of the bundle of the plurality of fibers has a higher density of fibers than at least one outer region, the method according to claim 1.

10. The step of disrupting the longitudinal alignment subjects the bundle to - treatment in a fiber opener; - treatment in a garnett machine; or - air treatment The method according to claim 9, comprising.

11. The plurality of fibers forming the fiber filler cluster are derived from fragments of entangled filament yarns, and the aggregate nip portion of the cluster corresponds to the aggregate nip portion of the entangled filament yarns; The plurality of fibers in the aggregate nip portion extend non-linearly along their longitudinal length; and None of the fibers within the cluster are joined to each other, The method according to claim 9.

12. The method according to any one of claims 1 to 8, further comprising the step of joining at least some of the plurality of fibers of the bundle to each other at at least one point along the longitudinal length of the bundle to form at least one joining point before the disrupting step.

13. A fiber filler cluster formed by the method according to claim 1.

14. Comprising from 25 to 3600 fibers that are 0.2 to 12.0 denier and 8 to 160 mm in length, and comprising a plurality of entangled fibers, The plurality of fibers Include a bundle remnant portion that includes a portion of a plurality of fibers that are all aligned longitudinally; And an outer region of fibers that extend three-dimensionally outward from the bundle remnant portion, including a portion of a plurality of fibers that are randomly and non-uniformly oriented with respect to each other Form, and The bundle remnant portion includes fibers at a higher density than the outer region. An individual fiber filler cluster.

15. The bundle remnant portion includes fewer fibers (e.g., at least 25%, at least 50%, or at least 75% fewer fibers than the outer region) and / or The plurality of fibers are derived from a fragment of an entangled filament yarn, and the bundle remnant portion of the individual fiber filler cluster corresponds to an assembly nip portion derived from the entangled filament yarn and / or The bundle remnant portion is a part of a fragment of the filament yarn and / or Less than about 50% (e.g., less than about 25%) of the plurality of fibers in the outer region are intertwined with each other or with at least one fiber of the bundle remnant portion. The individual fiber filler cluster according to claim 14.

16. The individual fiber filler cluster according to claim 14 or 15, wherein at least a portion of the plurality of fibers includes at least one joint point joined to each other.

17. The fiber filler cluster defines a length, a width, and a thickness, and The length and the width are greater than the thickness; and / or The length is greater than the width; and / or The length is in the range of about 0.5 to about 6.5 cm; and / or The width is in the range of about 0.5 to about 6.5 cm; and / or The fiber filling material clusters define a generally oval shape; and / or The fiber filling material clusters define a generally spherical shape. An individual fiber filling material cluster according to any one of claims 14 to 16.

18. The plurality of fibers are from about 0.7 to about 1.7 denier; and / or The plurality of fibers in the bundle have a longitudinal length of from about 20 to about 50 mm; and / or The fiber filling material clusters have a density of from about 0.08 to about 0.70 mg / cm3 (for example, from about 0.10 to about 0.50 mg / cm3); and / or The plurality of fibers include from about 50 to about 500 fibers. An individual fiber filling material cluster according to any one of claims 14 to 17.

19. An individual fiber filling material cluster according to any one of claims 14 to 18, wherein the plurality of fibers are fibers selected from polyamide, polyester, polypropylene, polylactic acid, polybutyl acrylate, acrylic, acrylate, acetate, polyolefin, nylon, rayon, lyocell, aramid, spandex, viscose, and modal fibers, or combinations thereof.

20. A heat insulating material or filling material or article comprising a plurality of individual fiber filling material clusters according to any one of claims 14 to 19.

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