WO2018136629A1 - Isolation avec rabats réactifs - Google Patents

Isolation avec rabats réactifs Download PDF

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Publication number
WO2018136629A1
WO2018136629A1 PCT/US2018/014231 US2018014231W WO2018136629A1 WO 2018136629 A1 WO2018136629 A1 WO 2018136629A1 US 2018014231 W US2018014231 W US 2018014231W WO 2018136629 A1 WO2018136629 A1 WO 2018136629A1
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WO
WIPO (PCT)
Prior art keywords
fibers
insulation
denier
synthetic
population
Prior art date
Application number
PCT/US2018/014231
Other languages
English (en)
Inventor
Vanessa Mason
Original Assignee
Primaloft, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Primaloft, Inc. filed Critical Primaloft, Inc.
Priority to CN201880005924.7A priority Critical patent/CN110168157A/zh
Priority to DE112018000440.6T priority patent/DE112018000440T5/de
Priority to US16/477,666 priority patent/US20190360137A1/en
Publication of WO2018136629A1 publication Critical patent/WO2018136629A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5418—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
    • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
    • A41D31/06—Thermally protective, e.g. insulating
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4391—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece characterised by the shape of the fibres
    • D04H1/43918—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece characterised by the shape of the fibres nonlinear fibres, e.g. crimped or coiled fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/50—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by treatment to produce shrinking, swelling, crimping or curling of fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5414—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres side-by-side
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5416—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sea-island
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/558—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in combination with mechanical or physical treatments other than embossing
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D2500/00—Materials for garments
    • A41D2500/50—Synthetic resins or rubbers
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G9/00—Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows
    • A47G9/02—Bed linen; Blankets; Counterpanes
    • A47G9/0207—Blankets; Duvets
    • A47G9/0223—Blankets
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G9/00—Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows
    • A47G9/08—Sleeping bags
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/04—Heat-responsive characteristics
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2501/00—Wearing apparel
    • D10B2501/04—Outerwear; Protective garments
    • D10B2501/043—Footwear

Definitions

  • the present invention generally relates to insulation, to articles comprising the insulation, and to methods of making the insulation.
  • embodiments of the present invention satisfy the need for insulation and articles that are readily adaptable to an external stimulus such as temperature and/or humidity.
  • the present invention may address one or more of the problems and deficiencies of the art discussed above. However, it is contemplated that the invention may prove useful in addressing other problems and deficiencies in a number of technical areas. Therefore, the claimed invention should not necessarily be construed as limited to addressing any of the particular problems or deficiencies discussed herein.
  • the invention provides insulation having a plurality of slits therein that form a plurality of reactive flaps in the insulation, such that the insulation comprises the flaps and also a non-flap portion, wherein said reactive flaps comprise a flap fiber mixture that comprises:
  • bicomponent fibers having a core and a sheath, said fibers having a denier of 2.0 to 8.0 denier, and a staple cut length of 38 to 105 mm, wherein said bicomponent fibers are reactive to an external stimulus, and have a first configuration in an unactivated state and a second configuration in an activated state, and wherein the
  • bicomponent fibers can reversibly transform between the unactivated and activated states
  • a first population of synthetic fibers being synthetic polymeric fibers having a denier of less than 2.0 denier and a staple cut length of 38 to 105 mm;
  • a second population of synthetic fibers being synthetic polymeric fibers having a denier of 4.0 to 10.0 denier and a staple cut length of 38 to 105 mm.
  • the invention provides an article comprising the inventive insulation according to the first aspect of the invention.
  • the invention provides a method of making the inventive insulation according to the first aspect of the invention, said method comprising:
  • Certain embodiments of the presently-disclosed insulation, articles comprising the insulation, and methods of making the insulation have several features, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of the insulation, articles, and methods as defined by the claims that follow, their more prominent features will now be discussed briefly. After considering this discussion, and particularly after 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 a number of advantages over the current state of the art. For example, embodiments of the insulation provide reactive insulation that quickly adapts in order to maximize user/wearer comfort. Embodiments of the insulation can be used to make various articles, including clothing, outerwear, footwear, bedding, etc.
  • FIG. 1 is a top-view photograph of an embodiment 10 of the inventive insulation.
  • FIG. 2 is a simplified rendering of the top-view photograph FIG. 1, with reactive flaps 4 shown in black shading.
  • FIGS. 3A and 3B depict an embodiment of a bicomponent fiber used in certain embodiments of the inventive insulation in its unactivated state and activated state
  • FIGS 4A-F depict non -limiting examples of cross-sections that bicomponent fibers used in certain embodiments of the invention can have.
  • the invention provides insulation having a plurality of slits therein that form a plurality of reactive flaps in the insulation, such that the insulation comprises the flaps and also a non-flap portion, wherein said reactive flaps comprise a flap fiber mixture that comprises:
  • bicomponent fibers having a core and a sheath, said fibers having a denier of 2.0 to 8.0 denier, and a staple cut length of 38 to 105 mm, wherein said bicomponent fibers are reactive to an external stimulus, and have a first configuration in an unactivated state and a second configuration in an activated state, and wherein the
  • bicomponent fibers can reversibly transform between the unactivated and activated states
  • a first population of synthetic fibers being synthetic polymeric fibers having a denier of less than 2.0 denier and a staple cut length of 38 to 105 mm;
  • a second population of synthetic fibers being synthetic polymeric fibers having a denier of 4.0 to 10.0 denier and a staple cut length of 38 to 105 mm.
  • Denier is a unit of measure defined as the weight in grams of 9000 meters of a fiber or yarn. It is a common way to specify the weight (or size) of the fiber or yarn.
  • polyester fibers that are 1.0 denier typically have a diameter of approximately 10 micrometers.
  • Micro-denier fibers are those having a denier of 1.0 or less, while macro-denier fibers have a denier greater than 1.0.
  • the components of the flap fiber mixture are homogenously mixed, meaning, the mixture has a substantially uniform (i.e., 90 - 100% uniform, e.g., greater than or equal to 90, 91, 92, 93, 94, 95, 96, 97, 98, or 99% uniform) composition.
  • the reactive flaps shrink and expand when exposed to an external stimulus (e.g., humidity).
  • an external stimulus e.g., humidity
  • the flaps shrink when exposed to relatively higher humidity levels, and expand when exposed to relatively lower humidity levels respectively.
  • This reactive functionality essentially results in insulation embodiments' ability to open/close flaps based on changing humidity levels.
  • the flaps when used in, e.g., certain embodiments of an article of clothing or outwear, during periods of general inactivity, the flaps will remain closed (here, the bicomponent fibers are considered to be in an unactivated state), whereas, during periods of activity where moisture is generated leading to a humidity increase, the flaps will shrink (to the bicomponent fibers' activated state), thereby effectively venting the insulation, and providing a more breathable and/or less insulative article.
  • FIG. 1 is a top-view photograph of an embodiment 10 of the inventive insulation.
  • insulation 10 comprises a plurality of slits 2.
  • each slit 2 forms a flap (also referred to herein as a "reactive flap") 4, and the insulation 10 comprises a plurality of flaps 4.
  • insulation 10 additionally comprises at least one non-flap portion 6.
  • non-flap portion 6 is a continuous portion of the insulation 10, having slits 2 therein that form a plurality of reactive flaps 4 in the insulation.
  • reactive flaps 4 comprise a flap fiber mixture as described herein, and non-flap portion 6 comprises the same flap fiber mixture.
  • FIG. 2 is a simplified/marked-up version of the top-view photograph of FIG. 1.
  • slits 2 are shown in white.
  • the reactive flaps 4 defined by slits 2 are shown in black, and the non-flap portion 6 is shown in light grey.
  • the slits 2 in insulation 10 are C-shaped slits forming semicircle-like flaps 4, the insulation can comprise slits of any desired shape.
  • the reactive flaps can take, as the shape of the slits and flaps are generally non-limiting relative to the inventive concept.
  • the flaps are reactive by nature of the composition of the flap fiber mixture, and they will readily be able to ascertain different shapes/configurations that slits and flaps can assume.
  • the flaps are attached to the insulation at one side.
  • the slits are made so as to form flaps that are semi-circular (or otherwise circular in shape, but remain attached to the insulation), oval, square, rectangle, or triangle-shaped.
  • the size and frequency of the flaps can be altered depending on the amount of desired potential reactivity to the external stimulus (e.g., humidity).
  • the flaps have a maximum dimension of 2.5 cm (i.e., when the size of a flap is measured in every two-dimension direction of the shape of the flap formed by the slit, the maximum measurement is 2.5 cm).
  • the flaps have a maximum dimension of 0.5 cm to 2.5 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, or 2.5 cm), including any and all ranges and subranges therein.
  • the flaps have a maximum dimension of 0.5 to 2 cm, including any and all ranges and subranges therein (e.g., 0.75 to 1.25 cm).
  • the flaps make up 5 to 80% of the surface area of the insulation (e.g., 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, or 80%), including any and all ranges and subranges therein.
  • the insulation e.g., 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,
  • the non-flap portion(s) of the insulation makes up 20 to 95% of the surface area of the insulation (e.g., 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, or 95%), including any and all ranges and subranges therein.
  • the area of the entire visible surface of insulation 10 e.g., 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36
  • the flaps constitutes the surface area of said insulation.
  • the flaps are spaced 1.5 to 5 cm from one another, including any and all ranges and subranges therein (e.g., spaced 2 to 3 cm apart).
  • the flaps comprise a flap fiber mixture.
  • the flap fiber mixture comprises:
  • bicomponent fibers having a core and a sheath, said fibers having a denier of 2.0 to 8.0 denier, and a staple cut length of 38 to 105 mm, wherein said bicomponent fibers are reactive to an external stimulus, and have a first configuration in an unactivated state and a second configuration in an activated state, and wherein the
  • bicomponent fibers can reversibly transform between the unactivated and activated states
  • a first population of synthetic fibers being synthetic polymeric fibers having a denier of less than 2.0 denier and a staple cut length of 38 to 105 mm;
  • a second population of synthetic fibers being synthetic polymeric fibers having a denier of 4.0 to 10.0 denier and a staple cut length of 38 to 105 mm.
  • the flap fiber mixture is made up of the reactive bicomponent fibers.
  • the bicomponent fibers are reactive to an external stimulus.
  • the external stimulus is humidity, pH, temperature, light, electrical current, force field, or microbes.
  • the bicomponent fibers have an unactivated state. While in the unactivated state, the bicomponent fibers have a first configuration. When exposed to the intended external stimulus, the bicomponent fibers transform to a second configuration (activated state). When no longer exposed to the external stimulus, the bicomponent fibers transform back to the first
  • the bicomponent fibers go back and forth between activated and unactivated states, depending on whether or not they are exposed to the external stimulus. Therefore, the bicomponent fibers can reversibly transform between the unactivated and activated states. In some embodiments, upon exposure to an intended external stimulus, the bicomponent fibers reversibly transform from unactivated to activated state in less than or equal to 15 minutes (e.g., less than or equal to 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 minutes).
  • the bicomponent fibers upon removal of the intended external stimulus, reversibly transform from activated to unactivated state in less than or equal to 15 minutes (e.g., less than or equal to 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 minutes).
  • FIGS. 3A and 3B depict an embodiment of a bicomponent fiber 20 used in certain embodiments of the inventive insulation in its unactivated state and activated state
  • Bicomponent fiber 20 has a helix (aka helical) shape/crimp.
  • a helix may be described as a three-dimensional curve around an axis.
  • the pitch of a helix is the length of one complete turn measured along the axis of the helix.
  • a circular helix has a constant curvature and constant torsion.
  • fiber embodiment 20 When in a dry environment, fiber embodiment 20 is in the unactivated state shown in FIG. 3 A. When exposed to an intended external stimulus, such as increased humidity, fiber 20 transforms to the activated state shown in FIG. 3B, wherein the crimp of fiber 20 increases, such that the number of bends per length increases and the radius of the bends and/or the pitch decreases, that is, the helix becomes tighter, the radius and pitch of the helix decrease, and the fiber's helical configuration becomes more compact.
  • an intended external stimulus such as increased humidity
  • the bicomponent fibers used herein have a structure that is caused by deliberate selection of the fiber's components.
  • one of the core and sheath of the bicomponent fiber is non-hygroscopic, and the other is hygroscopic.
  • the core comprises a non-hygroscopic material and the sheath comprises a hygroscopic material.
  • the hygroscopic material is selected to have less thermal shrinkage and to be less stiff than the non -hygroscopic material.
  • the hygroscopic material wants to elongate. However, this is restricted by the non-hygroscopic material, thereby resulting in a helix structure.
  • the hygroscopic material wants to further elongate. Again, this action is resisted by the non-hygroscopic material and the stiffer non-hygroscopic component causes the helix angle to tighten. This results in the activated configuration shown in FIG. 3B.
  • FIG. 3B Compared with the fiber 20 in relatively dry conditions (FIG. 3 A), in FIG. 3B, the width a is reduced and the length b is reduced. On removal of the external stimulus (e.g., humidity), fiber 20 returns to its unactivated configuration shown in FIG. 3A.
  • the external stimulus e.g., humidity
  • the length b may be reduced by 5 to 40% (e.g., 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, or 40%), including any and all ranges and subranges therein (e.g., 10 to 20%), and the width a may be reduced by 2 to 30 % (e.g., 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, or 30%), including any and all ranges and subranges therein (e.g., 3 to 15%), in 100% humid conditions as compared with dry conditions.
  • 5 to 40% e.g., 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, or 40%
  • the width a may be reduced by 2 to 30 % (e.g., 2, 3, 4, 5, 6, 7, 8, 9,
  • the non-hygroscopic material comprises non-hygroscopic polyethylene, polypropylene, polystyrene, and/or polyvinyl chloride (PVC).
  • the hygroscopic material comprises nylon, acrylonitrile butadiene styrene (ABS), an acrylic resin, polyurethane, polycarbonate, polyethylene terephthalate (PET), and/or polybutylene terephthalate (PBT).
  • ABS acrylonitrile butadiene styrene
  • acrylic resin polyurethane
  • PET polyethylene terephthalate
  • PBT polybutylene terephthalate
  • the bicomponent fibers comprise nylon and
  • the core comprises polypropylene and the sheath comprises nylon.
  • the bicomponent fibers comprise 20 to 50 weight% (wt%) core material (e.g., 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, or 50 wt%), including any and all ranges and subranges therein (e.g., 20 to 40 wt%, 25 to 35 wt%, etc.).
  • the bicomponent fibers comprise a majority (i.e., > 50 wt%) of sheath material.
  • the bicomponent fibers comprise 50 to 80 wt% sheath material (e.g., 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, or 80 wt%), including any and all ranges and subranges therein (e.g., 60 to 80 wt%, 65 to 75 wt%, etc.).
  • the bicomponent fibers have a helix first configuration and the second configuration is a helix with relatively decreased radius and/or pitch as compared to the first configuration.
  • the bicomponent fibers' second configuration has increased twist as compared to the first configuration. In some embodiments, the bicomponent fiber has twist in both the first and second configurations.
  • twist is imparted upon the shape of the bicomponent fibers by deliberate selection of the different materials that make up the bicomponent fibers.
  • Embodiments of the bicomponent fibers contain two or more components, the components being made of different materials.
  • the components are usually combined during the manufacture of the fibers, and may be combined in any ratio.
  • Known manufacturing processes enable various bicomponent cross-sections to be achieved.
  • FIGS 4A-F depict non-limiting examples of cross-sections that bicomponent fiber 20' used in certain embodiments of the invention can have.
  • the core 42 and sheath 44 are in a 50:50 ratio and are in a side-by-side arrangement.
  • the term "core" refers to a foundational part of the bicomponent fiber that is distinct from the sheath portion.
  • the core may be at the center, innermost part of the bicomponent fiber.
  • the core may be off-centered, or present at at least a portion of a peripheral surface of the bicomponent fiber.
  • the core 42 and sheath 44 are in an unequal radio and are in a side-by-side arrangement. Further, the interface between the core 42 and sheath 44 is not planar.
  • the core 42 and sheath 44 are in a concentric arrangement, where core 42 forms an interior portion of bicomponent fiber 20' and is surrounded by sheath 44.
  • the core 42 is asymmetrically placed relative to the sheath 44 (i.e., the core 42 is symmetrically off-set within the bicomponent fiber 20').
  • FIG. 4E shows a tri-lobal fiber 20' .
  • the arrangements shown in FIGS. 4C-4F are also known as "sea island" configurations. Persons having ordinary skill in the art will understand that these are arrangements that are not limited and may include further components or additional "islands”.
  • the bicomponent fibers are straight or relatively straight in the first configuration, then become crimped or twisted upon exposure to the external stimulus (e.g., humidity).
  • the external stimulus e.g., humidity
  • the bicomponent fibers have a denier of 2.0 to 8.0 denier (e.g., 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, or 8.0 denier), including any and all ranges and subranges therein.
  • the bicomponent fibers have a denier of 2.0 to 7.0 denier, 2.0 to 4.5 denier, 2.0
  • the bicomponent fibers are staple fibers (i.e., fibers having a standardized length) having a length of 38 to 105 mm (e.g., 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, or 105 mm), including any and all ranges and subranges therein.
  • the bicomponent fibers comprise the active fiber as
  • the bicomponent fibers comprise commercially available INOTEK fibers available from MMT Textiles Limited.
  • the flap fiber mixture also comprises 0 to 75 wt % of a first population of synthetic fibers, and 0 to 75 wt % of a second population of synthetic fibers.
  • Embodiments of the inventive insulation can comprise any synthetic fiber known in the art as being conducive to the preparation of textile materials.
  • nonexclusive synthetic fibers that may be used in the invention are selected from nylon, polyester, polypropylene, polylactic acid (PLA), poly(butyl acrylate) (PBA), polyamide, acrylic, acetate, polyolefin, nylon, rayon, lyocell, aramid, spandex, viscose, and modal fibers, and combinations thereof.
  • synthetic fibers comprise polyester fibers.
  • the polyester is selected from poly(ethylene terephthalate), poly(hexahydro-p- xylylene terephthalate), poly(butylene terephthalate), poly-l,4-cyclohexelyne dimethylene (PCDT) and terephthalate copolyesters in which at least 85 mole percent of the ester units are ethylene terephthalate or hexahydro-p-xylylene terephthalate units.
  • the polyester is polyethylene terephthalate.
  • the synthetic fibers comprise virgin fibers.
  • the synthetic fibers comprise recycled fibers (e.g., recycled polyester fibers).
  • the flap fiber mixture of the inventive insulation contains 0 to 75 wt % of the first population of synthetic fibers (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, or 75 wt %), including any and all ranges and subranges therein.
  • the first population of synthetic fibers 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
  • the fibers of the first population have a denier of less than 2.0 denier (for example, 0.4 to 1.9 denier, e.g., 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, or 1.9 denier, including any and all ranges and subranges therein).
  • the fibers of the first population have a staple cut length of 38 to 105 mm (e.g., 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, or 105 mm), including any and all ranges and subranges therein.
  • the flap fiber mixture of the inventive insulation contains 0 to 75 wt % of the second population of synthetic fibers (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, or 75 wt %), including any and all ranges and subranges therein.
  • the fibers of the second population have a denier of 4.0 to 10.0 denier (e.g., 4.0, 4.1,
  • the fibers of the second population have a staple cut length of 38 to 105 mm (e.g., 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, or 105 mm
  • the material of the fibers of the first and second populations are independently selected.
  • the fibers of the first population are the same material as the fibers of the second population.
  • the fibers of the first population are a different material than the fibers of the second population.
  • the fibers of the first and second populations comprise polyethylene.
  • the flap fiber mixture comprises siliconized fibers.
  • the term "siliconized" means that the fiber is coated with a silicon-comprising composition (e.g., a silicone). Siliconization techniques are well known in the art, and are described, e.g., in U.S. Patent No. 3,454,422.
  • the silicon-comprising composition may be applied using any method known in the art, e.g., spraying, mixing, dipping, padding, etc.
  • the silicon-comprising (e.g., silicone) composition which may include an organosiloxane or polysiloxane, bonds to an exterior portion of the fiber.
  • the silicone coating is a polysiloxane such as a methylhydrogenpolysiloxane, modified methylhydrogenpolysiloxane,
  • the silicon-comprising composition may be applied directly to the fiber, or may be diluted with a solvent as a solution or emulsion, e.g. an aqueous emulsion of a polysiloxane, prior to application. Following treatment, the coating may be dried and/or cured.
  • a catalyst may be used to accelerate the curing of the silicon-comprising composition (e.g., polysiloxane containing Si— H bonds) and, for convenience, may be added to a silicon- comprising composition emulsion, with the resultant combination being used to treat the synthetic fiber.
  • Suitable catalysts include iron, cobalt, manganese, lead, zinc, and tin salts of carboxylic acids such as acetates, octanoates, naphthenates and oleates.
  • the fiber may be dried to remove residual solvent and then optionally heated to between 65° and 200° C to cure.
  • the synthetic fibers of the first population are non-siliconized fibers. In some embodiments, the synthetic fibers of the first population are siliconized fibers. In some embodiments, the synthetic fibers of the first population comprise both siliconized and non-siliconized fibers.
  • the synthetic fibers of the second population are non- siliconized fibers. In some embodiments, the synthetic fibers of the second population are siliconized fibers. In some embodiments, the synthetic fibers of the second population comprise both siliconized and non-siliconized fibers.
  • the synthetic fibers of both the first and second populations comprise non-siliconized fibers. In some embodiments, the synthetic fibers of both the first and second populations comprise siliconized fibers. In some embodiments, the synthetic fibers of both the first and second populations comprise both siliconized and non-siliconized fibers.
  • populations are siliconized fibers (with the respective weight percentages of each population being selected independently), 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%, including any and all ranges and subranges therein (e.g., 20 to 95 wt
  • fibers such as those of the first and second populations, may be crimped or uncrimped.
  • Various crimps including spiral and standard (e.g., planar) crimp, are known in the art.
  • fiber lengths are pre-crimp measurements (i.e., the length measurement of a fiber before it is crimped, if said fiber has a crimp).
  • the fibers of the first population of synthetic fibers comprise fibers having a standard or spring-like (e.g., helical) crimp.
  • the fibers of the first population of synthetic fibers comprise fibers having a standard crimp.
  • the fibers of the second population of synthetic fibers comprise fibers having a standard or spring-like (e.g., helical) crimp.
  • a standard or spring-like (e.g., helical) crimp e.g., a standard or spring-like (e.g., helical) crimp.
  • the fibers of the second population of synthetic fibers comprise fibers having a spring-like (e.g., helical) crimp.
  • DWR durable water repellant
  • fibers used in the inventive insulation (which may be referred to as DWR-treated fibers or water repellant fibers) have been treated with a polymer solution of zirconium acetate, which can impart durable water repellant properties while minimizing and/or avoiding negative effects on fiber performance.
  • fibers treated with a durable water repellant are treated with a water-repellant, bacterial -resistant, low friction cured zirconium acetate finish, such that the fibers have improved driability following washing and enhanced handle and resistance to clumping.
  • a zirconium acetate solution that may be used as a DWR treatment in connection with the present invention is disclosed in U.S. Patent No. 4,537,594.
  • the fiber treated with a durable water repellant is treated in a wet bath or dry spraying process.
  • the treatment comprises a surface energy modification technique, which, as is known in the art, may include, e.g., plasma treatment.
  • Such treatments or processes are explained in U.S. Patent No. 4,869,922, U.S. Patent No. 5,262,208, U.S. Patent No.
  • synthetic fibers of the first and/or second populations comprise particles or material that is different from the synthetic material that the synthetic fiber is primarily comprised of.
  • synthetic fibers of the first and/or second populations comprise up to 15 wt % of particles or material that is different from the synthetic material that the synthetic fiber is primarily comprised of.
  • the synthetic fibers comprise 0, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0,
  • said particles or material is comprised within (e.g., encapsulated within) a polymer matrix that represents the synthetic material of which the synthetic fiber is primarily comprised.
  • the synthetic fibers in the fiber mixture comprise aerogel fiber, as described in International Application
  • the synthetic fibers in the fiber mixture comprise microcapsules, as described in U.S. Provisional Application No.
  • the flap fiber mixture also comprises 5 to 40 wt% synthetic binder fibers (e.g., 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, or 40 wt%), including any and all ranges and subranges therein (e.g., 10 to 30 wt%).
  • the binder fibers having a bonding temperature lower than the softening temperature of other synthetic polymeric fibers present in the flap fiber mixture.
  • the binder fibers have a bonding temperature of less than or equal to 200 °C. In some embodiments, the binder fibers have a bonding temperature of 50 to 200 °C, including any and all ranges and subranges therein. In some embodiments, the binder fibers have a bonding temperature of 80 °C to 150 °C. In some embodiments, the binder fibers have a bonding temperature of 100 °C to 125 °C.
  • the binder fibers comprise low-melt polyester fibers.
  • the binder fibers are bicomponent fibers comprising an exterior and interior (commonly known in the art as a sheath and core), wherein the exterior comprises a material having a lower melting point than the interior.
  • the inventive insulation in some embodiments, has been heat treated so as to melt all or a portion of the binder fibers, thereby forming a thermally bonded insulation.
  • binder fibers are recited in the fiber mixture, said fibers may be wholly or partially melted fibers, as opposed to binder fibers in their original, pre-heat treatment form.
  • the binder fibers have a denier of 1.5 to 4.0 denier (e.g., 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, or 4.0 denier), including any and all ranges and subranges therein.
  • 1.5 to 4.0 denier e.g., 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, or 4.0 denier
  • the binder fibers have a staple cut length of 38 to 105 mm (e.g., 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, or 105 mm), including any and all ranges and subranges therein.
  • the composition of the flap fiber mixture makes the flaps of embodiments of the inventive insulation reactive to an external stimulus.
  • the flap fiber mixture is thus the composition of flaps within the insulation (e.g., of flaps 4 depicted in insulation 10 of FIGS. 1 and 2).
  • the non-flap portion(s) of the insulation comprises a different fiber mixture than the flap fiber mixture (e.g., a fiber mixture corresponding to the flap fiber mixture, but excluding the reactive bicomponent fibers discussed above, or even an entirely different fiber mixture).
  • a fiber mixture corresponding to the flap fiber mixture e.g., a fiber mixture corresponding to the flap fiber mixture, but excluding the reactive bicomponent fibers discussed above, or even an entirely different fiber mixture.
  • Such embodiments may be formed, for example, using a pre-determined pattern for laying the fibers making up the insulation.
  • the non-flap portions comprise a non-flap fiber mixture that is the same as the flap fiber mixture.
  • the inventive insulation is non-woven.
  • the inventive insulation comprises a single non-woven web.
  • the inventive insulation comprises two or more (e.g., 2, 3, 4, etc.) non- woven webs, which are layered.
  • the insulation may be referred to as a non-layered insulation.
  • the insulation may be referred to as a layered insulation.
  • Embodiments of the inventive insulation may also be referred to as batting.
  • the flap fiber mixture and/or non-flap portion fiber mixture additionally comprises other synthetic and/or natural fibers.
  • the flap fiber mixture and/or non-flap portion fiber mixture additionally comprises other synthetic and/or natural fibers.
  • the fiber mixture comprises one or more members selected from wool, cotton, tencel, kapok (cotton-like fluff obtained from seeds of a Kapok tree, which may optionally be further processed before use), flax, animal hair, silk, and down (e.g., duck or goose down).
  • the insulation has a thickness of 4 to 30 mm (e.g., 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, or 30 mm), including any and all ranges and subranges therein.
  • the insulation has a density of 3.0 to 12.0 kg/m 3 (e.g., 3.0,
  • Embodiments of the inventive insulation have a first surface parallel to a second surface.
  • the entire top view of insulation 10 depicted in FIGS. 1 and 2 is of the first surface.
  • the second surface of insulation 10 is not visible, as it is parallel to the first surface, and in contact with a table on which insulation 10 is placed.
  • the first surface and/or the second surface of the insulation comprises a cross-linked resin.
  • a cross-linker solution comprising a cross-linker compound has been applied to the first and/or second surface.
  • the resin is a cross-linked (e.g., via heat treatment) version of the cross-linker solution.
  • the cross-linked resin comprises a cross-linker that is a cross-linked acrylate (co)polymer.
  • the cross-linker solution and/or the cross-linker compound display softness and hydrophobicity.
  • the cross-linker compound has a glass transition temperature (Tg) of less than 0 °C.
  • the inventive insulation has a weight of 25 to 200 gsm (e.g., 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, 40, 41, 42, 43,
  • the inventive insulation has good drape (the insulation hangs under its own weight).
  • An insulation's drape can have a significant bearing on qualities such as comfort and aesthetics of an article within which the insulation may be used.
  • the insulation has a drape of 1.5 cm to 5.0 cm (e.g., 1.5, 1.6, 1.7, 1.8, 1.9, 2.0,
  • the insulation is in, or is suitable for providing in sheet form (e.g., suitable for use as a rolled good) and has not been shredded.
  • the invention provides an article comprising the inventive insulation according to the first aspect of the invention.
  • articles include, for example, footwear, outerwear (e.g. outerwear garments such as jackets, pants, etc.), clothing (e.g., socks, under garments, apparel), pillows, pads, sleeping bags, bedding (e.g., quilts, comforters), tents, etc.
  • the invention provides a non-exclusive method of making the inventive insulation according to the first aspect of the invention (or an article according to the second aspect of the invention), said method comprising: forming an intermediate insulation from a fiber mixture, said intermediate insulation comprising a plurality of flap areas that comprise the flap fiber mixture discussed in accordance with the first aspect of the invention;
  • the insulation is nonwoven insulation comprising one or more nonwoven web layers. Where the insulation comprises more than one nonwoven web, the inventive method comprises layering the nonwoven web layers.
  • Said heating can be performed, for example, using one or more heating cycles in a standard textile thermal bonding oven.
  • the one or more nonwoven web layers comprise, in both the flap areas and also non-flap areas, the flap fiber mixture.
  • the method additionally comprises (e.g., after said heating), applying to the first surface and/or the second surface of the intermediate batting insulation structure a resin (e.g., a cross-linked resin as discussed above) Resin-treating one or both of the surfaces of the insulation can help to increase stability and integrity of the intermediate batting so as to improve durability and help make the material durable enough to withstand downstream processing in slit cutting process.
  • a resin e.g., a cross-linked resin as discussed above
  • the flaps are formed by forming slits, e.g., via cutting.
  • cutting comprising manual cutting or laser-cutting using a laser cutting machine.
  • Laser cutting machines conducive toward use in the textile field are well known to persons having ordinary skill in the art.
  • bicomponent fibers having a core and a sheath, said fibers having a denier of 2.0 to 8.0 denier, and a staple cut length of 38 to 105 mm, wherein said bicomponent fibers are reactive to an external stimulus, and have a first configuration in an unactivated state and a second configuration in an activated state, and wherein the bicomponent fibers can reversibly transform between the unactivated and activated states; 5 - 40 wt % synthetic binder fibers having a denier of 1.5 to 4.0 denier and a staple cut length of 38 to 105 mm;
  • a first population of synthetic fibers being synthetic polymeric fibers having a denier of less than 2.0 denier and a staple cut length of 38 to 105 mm;
  • a second population of synthetic fibers being synthetic polymeric fibers having a denier of 4.0 to 10.0 denier and a staple cut length of 38 to 105 mm.
  • Clause 4 The insulation according to any one of clauses 1 to 3, wherein the fibers of the second population of synthetic fibers are siliconized.
  • Clause 7 The insulation according to clause 6, wherein the fibers of the second population of synthetic fibers have a helical crimp.
  • Clause 8 The insulation according to any one of clauses 1 to 7, wherein the non- flap portions of the insulation comprise a non-flap fiber mixture that is the same as the flap fiber mixture (the insulation is made of the same fiber mixture, for both flap and non-flap portions).
  • Clause 10 The insulation according to any one of clauses 1 to 9, wherein the core of the bicomponent fibers comprises a non-hygroscopic core material and the sheath of the bicomponent fibers comprises a hygroscopic sheath material.
  • Clause 11 The insulation according to any one of clauses 1 to 10, wherein the core of the bicomponent fibers comprises polypropylene and the sheath comprises nylon.
  • Clause 13 The insulation according to any one of clauses 1 to 12, wherein the core of the bicomponent fibers is an off-center core. [00106] Clause 14. The insulation according to any one of clauses 1 to 13, wherein the second configuration has increased twist as compared to the first configuration.
  • Clause 15 The insulation according to any one of clauses 1 to 14, wherein the bicomponent fibers have a helical crimp.
  • Clause 16 The insulation according to clause 15, wherein the first configuration is a helix and the second configuration is a helix with relatively decreased radius and pitch as compared to the first configuration.
  • Clause 18 An article comprising the insulation according to any one of clauses 1 to 17.
  • Clause 19 The article according to clause 18, wherein said article is selected from footwear, outerwear, clothing, sleeping bags, tents, and bedding.
  • Example 1 An embodiment of the inventive insulation is made as follows:
  • a fiber mixture is prepared by mixing:
  • the fiber mixture After being mixed/blended, the fiber mixture is then processed into web form on a traditional carding machine to form a nonwoven web.
  • the web is then sent through a cross-lapper in order to obtain the desired weight and thickness.
  • the cross-lapped webbing is then thermally bonded and is subsequently sprayed with a resin solution. C-shaped slits are cut into the material, thereby forming flaps.
  • the final insulation embodiment is depicted in FIG. 1.
  • a method or article that "comprises”, “has”, “includes” or “contains” one or more steps or elements possesses those one or more steps or elements, but is not limited to possessing only those one or more steps or elements.
  • a step of a method or an element of an article that "comprises”, “has”, “includes” or “contains” one or more features possesses those one or more features, but is not limited to possessing only those one or more features.
  • each range is intended to be a shorthand format for presenting information, where the range is understood to encompass each discrete point within the range as if the same were fully set forth herein.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
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  • Thermal Sciences (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

L'invention concerne une isolation comprenant une pluralité de rabats réactifs qui réagissent à un ou plusieurs stimuli externes, par exemple l'humidité. Les rabats sont constitués d'un mélange de fibres qui comprend : 20 – 80 % en poids de fibres réactives à deux composants qui réagissent à un stimulus externe, et qui possèdent une première configuration dans un état non activé et une seconde configuration dans un état activé, et les fibres à deux composants pouvant se transformer de façon réversible entre les états non activé et activé ; 5 – 40 % en poids de fibres de liant synthétique ayant un denier allant de 1,5 à 4,0 deniers ; 0 – 75 % en poids d'une première population de fibres synthétiques, étant des fibres polymères synthétiques ayant un denier inférieur à 2,0 deniers ; et 0 – 75 % en poids d'une seconde population de fibres synthétiques, étant des fibres polymères synthétiques ayant un denier allant de 4,0 à 10,0 deniers. L'invention concerne également des articles et des procédés associés.
PCT/US2018/014231 2017-01-19 2018-01-18 Isolation avec rabats réactifs WO2018136629A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
CN201880005924.7A CN110168157A (zh) 2017-01-19 2018-01-18 具有反应性襟翼的绝缘材料
DE112018000440.6T DE112018000440T5 (de) 2017-01-19 2018-01-18 Isolierung mit reaktiven klappen
US16/477,666 US20190360137A1 (en) 2017-01-19 2018-01-18 Insulation with reactive flaps

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WO2009106785A1 (fr) * 2008-02-28 2009-09-03 University Of Bath Matériau
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