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
  • D04H1/42—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
  • D04H1/4374—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 using different kinds of webs, e.g. by layering webs
• • 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
  • D04H1/04—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres
  • D04H1/06—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres 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
  • D04H1/42—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
• • 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
  • D04H1/58—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/587—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
• • 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
  • D04H1/58—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/593—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives to layered webs
• • 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
  • D04H1/58—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/64—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
• • 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
  • D04H1/58—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/64—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
  • D04H1/641—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions characterised by the chemical composition of the bonding agent
• • 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
  • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
  • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
  • D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
• • 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
  • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
  • D04H1/74—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel (anisotropic fleeces)
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
  • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
  • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • D06M15/263—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated carboxylic acids; Salts or esters thereof
• • 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
  • D04H1/43912—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 fibres with noncircular cross-sections
• • 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
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2101/00—Inorganic fibres
  • D10B2101/10—Inorganic fibres based on non-oxides other than metals
• • 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
  • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
  • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
• • 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

Definitions

• the present invention generally relates to air-cured batting, to articles comprising the batting, and to methods of making the batting.
• a binder resin or a low melt fiber is used in order to bond a web of fibers together, thereby reinforcing and giving structure and/or strength to the batting.
• the resins and binder fibers that are used require heat in order to bond the fibers together. In practice, this is accomplished by passing the web through an oven. Ovens typically used are single pass, 3-pass, or 5 pass ovens (i.e., the web is passed through the oven once, three, or five times). The heat from the oven either cures the resin, and/or melts the binder fiber causing the loose fibers to be adhered together. To allow the insulation to pass through the oven, both ends of the oven are open.
• ovens having more than one level allow even more heat to escape.
• processes of record for making batting are high in energy consumption, can pollute the environment by releasing carbon monoxide due to composition, and can be draining on nonrenewable resources.
• ovens can create a hazardous environment, posing risks of, for example, potential burning and heat exhaustion.
• the present invention satisfies the need for improved batting and processes of making the same that require less energy expenditure, are less taxing on energy sources (e.g., nonrenewable resources), and/or avoid hazardous environmental risks associated with ovens used to make batting.
• embodiments of the inventive batting and processes are considered to advantageously be eco-friendly, particularly as compared to processes of record.
• 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 air-cured batting comprising a nonwoven web, said batting comprising:
• the invention provides an article comprising the air-cured batting according to the first aspect of the invention.
• the invention provides a method of making the air-cured batting according to the first aspect of the invention, said method comprising: forming a nonwoven web from a fiber mixture and, optionally, layering two or more web layers, thereby creating an intermediate batting insulation structure having a first surface and a second surface parallel to the first surface; applying to the first surface and the second surface of the intermediate batting insulation structure a resin solution comprising:
• the air-cured batting comprising 75 to 97.5 wt % of fiber mixture and 2.5 to 25 wt % of the resin, wherein the resin is adhered to fibers of the fiber mixture, thereby forming a bonded structure, such that, by virtue of the resin, the air-cured batting has structural integrity that imparts handleability of the batting in sheet form.
• Certain embodiments of the presently-disclosed batting, articles comprising the batting, and methods of making the batting have several features, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of the batting, 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 batting offer eco-friendly alternatives to commercially-available batting, are produced by methods that require less energy expenditure, are less taxing on energy sources, and/or avoid hazardous environmental risks. Embodiments of the batting can be used to make various articles, including clothing, outerwear, footwear, etc.
• FIG. 1 A is a top-view photograph of an embodiment 10 of the inventive batting.
• FIG. IB is a line drawing of the top-view photograph of the embodiment 10 of inventive batting depicted in FIG. 1 A.
• FIG. 2A is a side-view photograph of an embodiment 10 of the inventive batting.
• FIG. 2B is a line drawing of the side-view photograph of the embodiment 10 of inventive batting depicted in FIG. 2A.
• FIG. 3 A is a photograph of an embodiment 10 of the inventive batting draped over a structure.
• FIG. 3B is a line drawing of the photograph in FIG. 3 A of embodiment 10 of inventive batting draped over a structure.
• FIG. 4A is a profile-view photograph of an embodiment 10 of the inventive batting.
• FIG. 4B is a line drawing of the photograph in FIG. 4A of a profile-view of embodiment 10 of inventive batting.
• FIG. 5 is a simplified profile view of an embodiment 10 of the inventive batting.
• FIG. 6 is a simplified profile view of an embodiment 20 of the inventive batting.
• the invention provides air-cured batting comprising a nonwoven web, said batting comprising:
• Some embodiments of the inventive batting are made by the method of making air- cured batting according to the third aspect of the invention (described below in greater detail), which generally comprises forming a nonwoven web from a fiber mixture (and optionally layering two or more web layers), thereby creating an intermediate batting insulation structure having a first surface and a second surface parallel to the first surface; applying a specified resin solution to the first and second surfaces, thereby forming a solution-applied batting structure, and exposing the solution-applied batting structure to air (air-curing it), thereby causing solvent in the resin solution to evaporate and the resin to cure, thus forming the air- cured batting wherein the resin and the fiber mixture form a bonded structure, such that the air- cured batting has structural integrity that imparts handleability of the batting in sheet form.
• the invention provides batting embodiments having "handleability", wherein fibers within the fiber mixture of the batting are sufficiently adhered to one another via the resin from the resin solution so as to form a discrete batting structure that has structural integrity and is capable of being handled and used as-is, without falling apart or otherwise compromising the structural integrity of the batting so as to make it unfit for end use (e.g., as insulation in an article).
• binder fibers are optionally included in certain embodiments of the inventive batting, and heat treatment is optionally used in processes of preparing the batting.
• the inventive air-cured batting is formed by applying a resin solution to a first batting surface and a second batting surface, then subjecting the solution-applied batting to air, thereby causing the resin solution to evaporate and thus forming the inventive batting embodiment.
• the solution contains 15 to 60 vol. % of a resin comprising a cross-linked acrylic polymer, 20 to 80 vol. % of a fast- drying solvent that is soluble in water; and 0 to 70 vol. % water.
• These embodiments typically involve spraying an intermediate to the batting (e.g., a nonwoven web or a layered batting structure made up of two or more layered nonwoven webs) with (or otherwise applying to the intermediate) a solution that air-cures - it quickly dries (e.g., in some embodiments it dries within 5 to 20 minutes) and the resin adheres to fiber in the fiber mixture, leaving on the surfaces a cross-linked polymer that, together with the fiber mixture, forms a bonded batting.
• an intermediate to the batting e.g., a nonwoven web or a layered batting structure made up of two or more layered nonwoven webs
• a solution that air-cures - it quickly dries (e.g., in some embodiments it dries within 5 to 20 minutes) and the resin adheres to fiber in the fiber mixture, leaving on the surfaces a cross-linked polymer that, together with the fiber mixture, forms a bonded batting.
• Embodiments of the inventive batting offer a low density, high loft, thermally insulative batting with desirable drape and compressibility characteristics suitable for use in articles including, inter alia, apparel (e.g., clothing such as cold weather clothing apparel, gloves, etc.), bedding (e.g., quilts and comforters), pillows, pads, and sleeping bags.
• apparel e.g., clothing such as cold weather clothing apparel, gloves, etc.
• bedding e.g., quilts and comforters
• pillows e.g., pads, and sleeping bags.
• the inventive air-cured batting comprises a single non-woven web that contains the fiber mixture.
• FIG. 5 is a simplified profile view of an embodiment 10 of the inventive batting.
• the depicted batting 10 comprises a single nonwoven web 12.
• Batting 10 has a first surface 2 and second surface 4, which correspond to first and second surfaces of nonwoven web 12.
• the inventive batting comprises two or more non-woven webs, which are layered.
• FIG. 6, which is a simplified profile view of an embodiment 20 of the inventive batting.
• the depicted batting 20 comprises three nonwoven webs, 12, 14, and 16, which are layered.
• Batting 20 has a first surface 2 and a second surface 4' .
• second surface 4' corresponds to a surface of nonwoven web 16.
• nonwoven webs 12 and 14 are in direct contact with one another, as are nonwoven webs 14 and 16.
• the inventive batting comprises 1, 2, 3, 4, 5, or 6 nonwoven webs. Where a single nonwoven web is used in the batting, the batting may be referred to as a non-layered batting. Where a plurality (i.e., 2 or more) of nonwoven webs are used, the batting may be referred to as a layered batting. Where more than one nonwoven webs are present in the inventive batting, the fiber composition of the nonwoven webs may be the same or different.
• the resin solution when the resin solution is applied to the first and second surfaces of the batting, it permeates into an inner portion of batting. Accordingly, in some batting embodiments, resin is present throughout an entire thickness (e.g., with reference to FIG. 2A, is present in the batting 10 throughout thickness X) of the batting. In some embodiments, the resin penetrates from a surface on which it is applied into the batting in a thickness direction of 0.5 to 30 mm (e.g., 0.5, 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, or 30 mm), including any and all ranges and subranges therein.
• 0.5 to 30 mm e.g., 0.5, 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, or 30 mm
• the resin penetrates into the batting in a thickness direction of 0.5 to 30 mm (e.g., 0.5, 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, or 30 mm) from the first surface of the batting toward the second surface of the batting, including any and all ranges and subranges therein, and/or the resin penetrates into the batting in a thickness direction of 0.5 to 30 mm (e.g., 0.5, 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, or 30 mm) from the second surface of the batting toward the first surface of the batting, including any and all ranges and subranges therein.
• 0.5 to 30 mm e.g., 0.5, 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, or 30 mm
• the inventive batting comprises: 75 to 97.5 wt % (e.g., 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, or 97.5 wt %), including any and all ranges and subranges therein, of a fiber mixture; and 2.5 to 25 wt % (e.g., 2.5, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, or 25 wt %), including any and all ranges and subranges therein, of a resin comprising a cross-linked copolymer of butyl acrylate and methyl methacrylate.
• 75 to 97.5 wt % e.g., 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86,
• the resin solution comprises an acrylic polymer (e.g., a self- crosslinking acrylic polymer).
• the self-crosslinking acrylic polymer is a "cross-linked copolymer of butyl acrylate and methyl methacrylate," which refers to a polymer that comprises structural units from the monomers butyl acrylate and methyl methacrylate.
• cross-linked copolymers of butyl acrylate and methyl methacrylate result from polymerization of a reaction mixture that comprises monomers including butyl acrylate and methyl methacrylate.
• the resin comprising the cross-linked copolymer of butyl acrylate and methyl methacrylate contains carboxylic acid groups. In some embodiments, the resin comprising the cross-linked copolymer of butyl acrylate and methyl methacrylate does not contain hydroxyl groups.
• the resin comprising the cross-linked copolymer of butyl acrylate and methyl methacrylate does not contain any carbohydrate moieties. In some embodiments, the resin comprising the cross-linked copolymer of butyl acrylate and methyl methacrylate does not contain any non-polymerized monomers.
• the resin is an acrylic polymer according to, or sharing properties with any embodiment described herein, wherein the resin has one or more of the following attributes, including any combination thereof:
• alkylphenols e.g., alkylphenol ethoxylates (APEOs)
• - Has a pH of about 6.0 to about 10.0 (e.g., pH of 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, or 10.0), including any and all ranges and subranges therein (e.g., a pH of about 7.5-8.5); Comprises a nonionic and/or anionic emulsifier;
• Tg glass transition temperature
• -30 °C to +30 °C e.g., -30, -29, -28, - 27, -26, -25, -24, -23, -22, -21, -20, -19, -18, -17, -16, -15, -14, -13, -12, -11, - 10, -9, -8, -7, -6, -5, -4, -3, -2, -1, 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, or 30 °C), including any and all ranges and subranges therein (e.g., -20 to 10 °C, -18 to 0 °C, etc.);
• - Has a weight of 8 to 10 lb. /gal (e.g., 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, or 10.0 lb./gal), including any and all ranges and subranges therein (e.g., 8.30 - 9.20 lb./gal);
• the entirety of the fiber mixture and the resin may be comprised within the single nonwoven web (including on the first and second surfaces thereof).
• the entirety of the fiber mixture and the resin may be comprised within the plurality of nonwoven webs (including on the first and second surfaces of the layered batting formed by the plurality of webs), although the distribution of resin may vary by layer.
• a nonwoven web that contributes the first or second surface of the batting will comprise a higher concentration of resin than a nonwoven web that is not adjacent to a first or second surface of the batting (e.g., in FIG. 6, nonwoven web 12 contributes first surface 2 of batting 20, and nonwoven web 16 contributes second surface 4' of the batting 20; in some embodiments, nonwoven webs 12 and 16 comprise higher concentrations of resin than interior nonwoven web 14).
• the fiber mixture comprises synthetic fibers.
• synthetic fibers Persons having ordinary skill in the art are readily familiar with many synthetic fibers, and it is well within their purview to select an appropriate synthetic fiber for use in inventive batting embodiments depending on desired properties of the batting and/or article within which it is intended to be employed.
• Embodiments of the inventive batting 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- 1,4-cyclohexelyne dimethylene (PCDT), polytrimethylene terephthalate (PTT), 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 fiber mixture comprises 0 to 100 wt% synthetic fibers, 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., 10 to 100 wt
• fibers may be crimped or uncrimped.
• Various crimps including spiral and standard (e.g., planar) crimp, are known in the art.
• the synthetic fibers are staple fibers (i.e., fibers of
• the synthetic fibers have a staple length of 12 mm to 70 mm, for example, 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 mm, including any and all ranges and subranges therein.
• the fibers may be linear, optionally with crimp
• the inventive batting comprises fibers that have a desirable shape that is not linear or linear with crimp. While persons having ordinary skill in the art are familiar with various desirable shapes to choose for the fiber, which are contemplated as being used in embodiments of the invention, some non-limiting examples include Y-shaped fibers, bow-tie shaped fibers, etc.
• 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.
• Microdenier fibers are those having a denier of 1.0 or less, while macrodenier fibers have a denier greater than 1.0.
• the synthetic fibers have a denier of 0.7 denier to 8.0 denier, including any and all ranges and subranges therein.
• the synthetic fibers have a denier of 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,
• the synthetic fibers comprise microdenier fibers (e.g., fibers having a denier of 0.7 to 1.0 denier). In some embodiments, the synthetic fibers comprise macro-denier fibers (e.g., fibers having a denier of 1.1 to 8.0 denier). In some embodiments, the synthetic fibers comprise micro-denier fibers and macro-denier fibers.
• the synthetic fibers comprise 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.
• 0 to 100 wt% of the fibers are siliconized fibers, 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.,
• DWR durable water repellant
• inventive batting which may be referred to as DWR-treated fibers or water repellant fibers
• 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.
• synthetic fibers 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, 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,
• 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 Publication No. WO 2017/087511.
• the fiber mixture of the batting comprises 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 fiber mixture comprises 0 to 100 wt% natural fibers, 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., 0 to 50 wt
• the fiber mixture comprises synthetic fibers and natural fibers.
• the fiber mixture comprises:
• 50 to 90 wt % siliconized synthetic fibers e.g., polyester fibers
• siliconized macrodenier synthetic fibers e.g., polyester fibers having a staple length of 40 to 70 mm and a denier of greater than 1.0.
• the siliconized macrodenier fibers have a denier of greater than or equal to 3.0.
• the fiber mixture comprises:
• micro-denier fibers e.g., 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 wt %), including any and all ranges and subranges therein; and
• macro-denier fibers 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, or 65 wt %), including any and all ranges and subranges therein.
• the microdenier and macrodenier fibers can individually be siliconized or nonsiliconized.
• 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, or 100 wt%, including any
• the invention provides batting embodiments wherein, even in the absence of heat treatment (e.g., in the absence of any fibers melting and bonding to other fibers in the batting), fibers within the batting are sufficiently adhered to one another so as to form a discrete batting structure that has structural integrity and is capable of being handled and used as-is, without falling apart or otherwise compromising the structural integrity of the batting so as to make it unfit for end use.
• the fiber mixture is free of binder fiber.
• the nonwoven web is free of binder fiber.
• the batting is free of binder fiber.
• the batting does not comprise any melted fibers.
• no fibers within the batting are bonded to one another via the melting of a fiber in the fiber mixture.
• the fiber mixture comprises, e.g., a binder fiber
• the web is heat treated so as to melt the binder fiber and cause it to bond to other fibers in the fiber mixture comprised within the nonwoven web.
• no fibers within the batting are adhered to one another unless it is via the resin comprising the cross-linked copolymer of butyl acrylate and methyl methacrylate.
• 90 wt% or more of fibers present in the batting are only adhered to one another via the resin comprising the cross-linked copolymer of butyl acrylate and methyl methacrylate.
• inventive embodiments comprise binder fibers.
• a skilled artisan may wish to use the inventive concept of using the cross-linked polymer to form an ambient temperature air-cured batting wherein fibers are adhered via the resin, such that the air-cured batting has structural integrity that imparts handleability of the batting in sheet form, but to also use binder fiber.
• the fiber mixture comprises binder fiber.
• the fiber mixture comprises 1 to 25 wt % synthetic binder fibers, said binder fibers having a bonding temperature lower than the softening temperature of synthetic polymeric fibers present in the mixture.
• the synthetic binder fibers make up, e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, or 25 wt % of the fiber mixture, including any and all ranges and subranges therein.
• the synthetic 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 (e.g., 2.0-2.2 denier).
• the binder fibers have a staple cut length of 38 to 105 mm, including any and all ranges and subranges therein.
• the length is 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/subranges therein (e.g., 38-51 mm).
• the binder fibers have a bonding temperature lower than the softening temperature of the synthetic fibers.
• the binder fibers have a bonding temperature of less than or equal to 200 °C.
• the binder fibers have a bonding temperature of 50 to 200 °C, including any and all ranges and subranges therein.
• the binder fibers have a bonding temperature of 80 °C to 150 °C.
• 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 a sheath and a core, wherein the sheath comprises a material having a lower melting point than the core.
• the inventive batting in some embodiments, has been heat treated so as to melt all or a portion of the binder fibers, thereby forming a thermally bonded web-type batting.
• binder fibers are recited in the fiber mixture of the batting, said fibers may be wholly or partially melted fibers, as opposed to binder fibers in their original, pre-heat treatment form.
• the inventive batting comprises at least one nonwoven web.
• the fiber content of the nonwoven web(s) consists of the fiber mixture.
• the thickness and insulative properties of the batting can be increased.
• the batting has a thickness of 4 to 30 mm (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, or 30 mm), including any and all ranges and subranges therein (e.g., 10 to 20 mm).
• the batting has a density of 0.9 to 8 kg/m 3 (e.g., 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 kg/m 3 ), including any and all ranges and subranges
• the batting has a thermal performance rating of at least 0.70 clo/oz/yd 2 when tested according to ISO 11092.
• the batting has a thermal performance rating of 0.70 clo/oz/yd 2 to 0.95 clo/oz/yd 2 (e.g., 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, 0.92, 0.93, 0.94, or 0.95 clo/oz/yd 2 ), including any and all ranges and subranges therein.
• the members of the fiber mixture are homogenously mixed, meaning, the fiber mixture has a substantially uniform (i.e., 90 - 100% uniform) composition.
• FIG. 1 A is a top-view photograph of one embodiment 10 of the inventive batting according to the first aspect of the invention.
• the depicted batting 10 is a single non-woven web that comprises first surface 2 and second surface 4 (not pictured, but which is parallel to first surface 2, and which, in the depicted embodiment, faces the surface on which batting 10 is placed).
• first surface 2 when batting 10 is contained within an article (e.g., as insulation), first surface 2 will face toward an outer portion (e.g., fabric or other material or liner) of the article, e.g., a jacket, and second surface 4 will face toward an inner portion (e.g., fabric or other material or liner) of the article.
• first surface 2 faces toward an inner portion of an article and second surface 4 faces toward an outer portion of an article.
• FIG. IB is a line drawing of the top-view photograph of the embodiment 10 of inventive batting depicted in FIG. 1 A.
• FIG. 2A is a side-view photograph of an embodiment 10 of the inventive batting, wherein X is the thickness of the batting.
• FIG. 2B is a line drawing of the side-view photograph of the embodiment 10 of inventive batting depicted in FIG. 2A.
• FIG. 3 A is a photograph of an embodiment 10 of the inventive batting draped over a structure.
• the depicted batting 10 has good drape (i.e., the batting hangs under its own weight).
• a batting's drape has bearing on qualities such as comfort and aesthetics of an article within which batting is used.
• FIG. 3B is a line drawing of the photograph in FIG. 3 A of embodiment 10 of inventive batting draped over a structure.
• the batting has a drape of 1.5 cm to 3.5 cm (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, or 3.5 cm) including any and all ranges and subranges therein, as measured in accordance with Method ASTM D1388.
• FIG. 4A is a profile-view photograph of an embodiment 10 of the inventive batting, wherein X is the thickness of the batting.
• FIG. 4B is a line drawing of the photograph in FIG. 4A of a profile-view of embodiment 10 of inventive batting.
• the batting 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 batting is in sheet form (suitable for use as a rolled good) and has not been shredded.
• the batting does not comprise pigment.
• the pigment is not present in the resin (i.e., the pigment, if present in the batting, is not contributed by the resin).
• the invention provides an article comprising the inventive batting.
• articles include, for example, outerwear (e.g.
• outerwear garments such as jackets, etc.
• clothing pillows, pads, sleeping bags, bedding (e.g., quilts, comforters), etc.
• the invention provides a method of making air-cured batting, said method comprising: forming a nonwoven web from a fiber mixture and, optionally, layering two or more web layers, thereby creating an intermediate batting insulation structure having a first surface and a second surface parallel to the first surface; applying to the first surface and the second surface of the intermediate batting insulation structure a resin solution comprising:
• the air-cured batting comprising 75 to 97.5 wt % of fiber mixture and 2.5 to 25 wt % of the resin, wherein the resin is adhered to fibers of the fiber mixture, thereby forming a bonded structure, such that, by virtue of the resin, the air-cured batting has structural integrity that imparts handleability of the batting in sheet form.
• the fiber mixture can be any embodiment as described above in the first aspect of the invention.
• the inventive method comprises heating the batting to or in excess of the bonding temperature of the binder fibers.
• the inventive method of the third aspect of the invention does not comprise heating the batting to or in excess of the bonding temperature of binder fibers employed in the fiber mixture.
• embodiments of the inventive method of making air-cured batting that do not comprise a specified heating step apply to the final air-cured batting and also any intermediate batting structure thereof comprising the nonwoven web.
• the inventive method of making air-cured batting does not comprise a process step performed in excess of 48 °C. In some embodiments, the inventive method of making air-cured batting does not comprise a process step performed in excess of 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 °C.
• the inventive method does not comprise a bonding step that results in bonding or adhesion of fibers within the fiber mixture at a temperature in excess of 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 °C.
• the nonwoven web is formed using a carding machine or air- lay process. Both techniques are well known by persons having ordinary skill in the art.
• the resin solution comprises:
• the solution comprises 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, or 60 vol. % of the resin, including any and all ranges and subranges therein (e.g., 20 to 50 vol.%, 25 to 35 vol.%, etc.);
• the solution comprises 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 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 vol. % of the fast-drying solvent, including any and all ranges and subranges therein (e.g., 30 to 75 vol.%, 50 to 70 vol.%, etc.); and
• the solution comprises 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, or 70 vol. % water, including any and all ranges and subranges therein (e.g., 0 to 50 vol.%, 1 to 30 vol.%, 2 to 20 vol.%. 5 to 15 vol.%, etc.).
• the fast-drying solvent refers to a solvent having an evaporation rate of greater than or equal to 1.3.
• the evaporation rate is the rate at which a material will vaporize (evaporate, change from liquid to vapor), measured by ASTM D3539-11 method, compared to the rate of vaporization of n-butyl acetate measured in the same conditions. This quantity is a ratio, therefore it is unitless.
• the fast-drying solvent has an evaporation rate of greater than 1.3 (e.g., greater than 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0,
• the fast- drying solvent has an evaporation rate of greater than 3.0.
• the fast-drying solvent is soluble in water, which, for the purposes of this application, means that the solvent has a solubility of at least 8 grams per 100 mL of water at 20 °C (i.e., at least 8 mL of the solvent will dissolve in 100 mL water at 20 °C).
• the solvent has a solubility of greater than or equal to 10 grams per 100 mL water at 20 °C (e.g., greater than or equal to 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, or 99 grams solvent per 100 mL water at 20 °C).
• the fast-drying solvent is selected from isopropyl alcohol, ethanol, methanol, glyme, acetone, tetrahydrofuran, methyl ethyl ketone (MEK), methyl acetate, and ethyl acetate, and combinations thereof.
• the fast- drying solvent is isopropyl alcohol.
• the resin solution does not comprise pigment.
• applying the resin solution to the first and second surfaces of the intermediate batting insulation structure comprises spraying the solution onto the first and/or second surfaces.
• spray drops of the resin solution have an average median diameter of 150 to 250 ⁇ (e.g., 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
• spray nozzles traverse over the top and across the width of the first and second surfaces of the batting structure.
• applying the resin solution to the first and second surfaces of the intermediate batting insulation structure comprises applying via a bath or padding, both techniques being known in the art, the solution onto the first and/or second surfaces.
• exposing the solution-applied batting structure to air comprises subjecting the solution-applied batting to forced air or circulated air.
• said exposing comprises subjecting the solution-applied batting to forced air or circulated air having an air speed, at time of contact with the solution-applied batting, of at least 2.5 m/s, at least 3.0 m/s, or at least 3.5 m/s.
• said exposing comprises subjecting the solution-applied batting to forced air or circulated air having an air speed, at time of contact with the solution-applied batting, of 2.5 to 15 m/s (e.g., 2.5, 2.6, 2.7,
• the inventive method comprises, after forming the air-cured batting, winding the batting into roll good form.
• Such embodiments lend themselves toward, e.g., easy shipping of the batting.
• the air-cured batting is wound up along with a nonwoven scrim layer and shipped in roll good form.
• the invention provides a batting, article or method according to an embodiment of one of the following clauses:
• Air-cured batting comprising a nonwoven web, said batting comprising:
• the resin is present on a first surface of the batting, and on a second surface of the batting, the second surface being parallel to the first surface, and wherein the resin is adhered to fibers of the fiber mixture, thereby forming a bonded structure, such that, by virtue of the resin, the air-cured batting has structural integrity that imparts handleability of the batting in sheet form.
• nonwoven web layers are crosslapped with one another.
• Clause 23 The article according to clause 22, wherein said article is selected from the group consisting of an outerwear product, clothing, a sleeping bag, and bedding.
• said method comprising:
• the air-cured batting comprising 75 to 97.5 wt % of fiber mixture and 2.5 to 25 wt % of the resin, wherein the resin is adhered to fibers of the fiber mixture, thereby forming a bonded structure, such that, by virtue of the resin, the air-cured batting has structural integrity that imparts handleability of the batting in sheet form.
• Clause 27 The method according to any one of clauses 24-26, wherein said applying comprises spraying the resin solution on the first surface and the second surface of the intermediate batting insulation structure.
• Clause 28 The method according to any one of clauses 24-27, wherein the method does not comprise heating the nonwoven web.
• Clause 29 The method according to any one of clauses 24-27, wherein the method comprises heating the nonwoven web.
• Clause 30 The method according to any one of clauses 24-29, wherein said exposing the solution-applied batting to air comprises subjecting the solution-applied batting to forced air or circulated air.
• a fiber mixture is prepared by mixing the following:
• 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 get the desired weight and thickness.
• the cross-lapped webbing is then sprayed with a resin solution (30 vol. % resin comprising a cross-linked copolymer of butyl acrylate and methyl methacrylate; 60 vol. % isopropyl alcohol; 10 vol. % water), and sent through a room temperature 3 pass oven with the convection fans running to help expedite the drying process.
• the resin in the resin solution is a milky white pourable liquid that comprises a self- crosslinking crosslinked copolymer of butyl acrylate and methyl methacrylate that is formaldehyde and APEO free, has a pH of -8.0, a specific gravity of 1.04, a solids content of 49% +/- 1.00%, a Tg of -15 °, comprises a nonionic and/or anionic emulsifier, is dilutable in water, has a product weight of 8.34 - 9.17 lb. /gal, and has a boiling point of -212 °F.
• the resin solution is sprayed on both sides of the insulation.
• the resin solution cures within 10-15 minutes, leaving a dry, air-cured batting wherein the resin adheres to fibers of the fiber mixture forming a bonded structure, such that the air-cured batting has structural integrity that imparts handleability of the batting in sheet form.
• the example batting has a weight of 61 gsm (grams per square meter), a density of 1.34 g/m 3 , and a thickness of 5.99 mm.
• 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)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Dispersion Chemistry (AREA)
• Nonwoven Fabrics (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
• Bedding Items (AREA)
• Treatment Of Fiber Materials (AREA)

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• 2017
  • 2017-10-31 JP JP2019522460A patent/JP7184767B2/ja active Active
  • 2017-10-31 WO PCT/US2017/059188 patent/WO2018081771A1/en unknown
  • 2017-10-31 KR KR1020197015624A patent/KR102476962B1/ko active IP Right Grant
  • 2017-10-31 TW TW106137631A patent/TWI788308B/zh active
  • 2017-10-31 RU RU2019116789A patent/RU2754839C2/ru active
  • 2017-10-31 EP EP17865837.3A patent/EP3532666B1/de active Active
  • 2017-10-31 US US16/342,109 patent/US20190249345A1/en not_active Abandoned
  • 2017-10-31 CN CN201780067618.1A patent/CN109996913B/zh active Active

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