RU2754839C2 - Air-dried insulation packing - Google Patents

Abstract

FIELD: textile industry.SUBSTANCE: air-dried packing includes non-woven material canvas. The packing contains 75-97.5% by wt. of a fiber mixture and 2.5-25% by wt. of resin containing cross-linked copolymer of butyl acrylate and methyl methacrylate, while resin is present on the first packing surface and on the second packing surface, while the second surface is parallel to the first surface, and resin sticks to fibers of the fiber mixture by means of which a glued structure is formed so that, by means of resin, the air-dried packing has structural integrity, which provides for workability of the packing in the form of a sheet. Products containing the air-dried packing and methods for manufacturing the air-dried packing are also proposed.EFFECT: obtaining air-dried insulation packing.27 cl, 10 dwg

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to US Provisional Patent Application No. 62 / 415,137, filed October 31, 2016, the entire contents of which are hereby incorporated by reference.

TECHNICAL FIELD OF THE INVENTION

[0002] The present invention relates generally to air-dried packing, to articles containing the packing, and to methods for making the packing.

BACKGROUND OF THE INVENTION

[0003] To make a pad (eg, a synthetic pad such as a polyester pad), a binder resin or low melting fiber is used to bond a web of fibers together, thereby providing reinforcement and structure and / or strength to the pad. The resins and binder fibers used require heat to bond the fibers together. In practice, this is done by passing the web through an oven. Typically used ovens are single pass, 3 pass, or 5 pass ovens (i.e., the web is passed through the oven one, three, or five times). The heat from the oven either cures the resin and / or melts the binder fiber, which causes the unbonded fibers to stick together. Both ends of the oven are open to allow the insulation material to pass through the oven. Thus, heat is easily released and there is a need to use excess energy to maintain a given temperature in the oven. Furnaces with more than one level create the possibility of even more heat escaping. Since furnaces are typically heated using oil, coal, electricity or gas, the described packing processes are energy intensive, can cause environmental pollution due to the release of carbon monoxide due to the composition, and can deplete non-renewable resources. In addition to the high energy consumption of these ovens, in particular due to their open ends, ovens can create a hazardous environment, causing risks such as possible burns and painful conditions caused by overheating.

[0004] Thus, there is a need for new packing and packing manufacturing methods that require less energy, less depletion of energy sources (including non-renewable resources) and avoid the hazardous environment risks discussed above.

[0005] While some aspects of conventional techniques have been considered to facilitate disclosure, Applicant in no way disclaims these technical aspects, and it is contemplated that the claimed invention may encompass one or more common technical aspects.

[0006] When mentioning or considering a document, action or information object in this description, this mention or consideration does not constitute an admission that the document, action or information object, or any combination of them, was publicly available, publicly known, was part of publicly available information or otherwise at the priority date. thus constituted the prior art in accordance with applicable statutory provisions, or are known to be related to an attempt to solve any problem to which this description relates.

SUMMARY OF THE INVENTION

[0007] In short, the present invention satisfies the need for improved packing and manufacturing methods that require less energy, less drain on energy sources (eg, non-renewable resources), and / or avoid the hazardous environment risks associated with furnaces. used to make the packing. In addressing these problems, it is believed that the packing embodiments and methods of the invention are preferably environmentally friendly, in particular when compared to documented processes.

[0008] The present invention can provide a solution to one or more of the problems and an elimination of one or more of the disadvantages of the prior art discussed above. However, it is contemplated that the invention may be useful in solving other problems and other disadvantages in a number of technical fields. Therefore, the claimed invention is not necessarily to be construed as limited to solving any of the specific problems or eliminating any of the specific disadvantages discussed herein.

[0009] In a first aspect of the invention, there is provided an air-dried pad comprising a web of nonwoven fabric, said pad comprising:

- 75-97.5% of the mass. blends of fibers; and

- 2.5-25% of the mass. resin containing a crosslinked copolymer of butyl acrylate and methyl methacrylate,

the resin is present on the first surface of the packing and on the second surface of the packing, the second surface being parallel to the first surface, and the resin adheres to the fibers from the mixture of fibers, whereby a bonded structure is formed, so that the air-dried packing by means of the resin has structural integrity that allows the workability of the sheet-like packing.

[0010] In a second aspect of the invention, there is provided an article comprising an air-dried pad according to the first aspect of the invention.

[0011] In a third aspect of the invention, there is provided a method of making an air-dried packing according to the first aspect of the invention, said method comprising:

- forming a web of nonwoven fabric from a mixture of fibers and, if necessary, superimposing two or more layers of webs on top of each other, thereby creating an intermediate structure of an insulating pad having a first surface and a second surface parallel to the first surface;

- applying on the first surface and the second surface of the intermediate structure of the insulating packing of a resin solution containing:

- 15-60% vol. a resin containing a crosslinked copolymer of butyl acrylate and methyl methacrylate;

- 20-80% vol. a fast drying solvent that is soluble in water; and

- 0-70% vol. water,

whereby the structure of the packing with the applied solution is formed; and

- exposing the structure of the packing with the applied solution to the action of air, whereby the evaporation of the solvent in the resin solution and the curing of the resin are ensured, as a result of which an air-dried packing is formed containing 75-97.5% of the mass. a mixture of fibers and 2.5-25% of the mass. resin, whereby the resin adheres to the fibers of the fiber mixture, whereby a bonded structure is formed, so that by means of the resin, the air-dried packing has a structural integrity that allows the workability of the packing as a sheet.

[0012] Certain embodiments of the packings disclosed herein, packing-containing articles and methods of making the packing have a number of features, none of which alone provide the desired properties. More specific features of the packing, articles and methods defined in the following claims will be briefly discussed below without limiting their scope. Upon reading this discussion, and in particular after reading the section of this specification that is entitled "Detailed Description of the Invention," it will be understood how features of the various embodiments disclosed herein provide a number of advantages over the prior art. For example, packing options provide environmentally friendly alternatives to commercially available packing, are manufactured in processes that require less energy, are less energy depleting, and / or avoid the risk of a hazardous environment. Stuffing options can be used to make a variety of products, including clothing, outerwear, footwear, etc.

[0013] These and other features and advantages of the present invention will become apparent from the following detailed description of various aspects of the invention, taken in conjunction with the appended claims and accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

[0014] The present invention will be further described in conjunction with the following drawings, which are not necessarily drawn to scale, and in which like reference numbers indicate like elements, and:

[0015] Fig. 1A is a top view of embodiment 10 of the packing according to the invention.

[0016] FIG. 1B is a line drawing corresponding to a top view of embodiment 10 of the packing of the invention shown in FIG. 1A.

[0017] Fig. 2A is a side view of embodiment 10 of the packing of the invention.

[0018] FIG. 2B is a line drawing corresponding to a side view of embodiment 10 of the inventive packing shown in FIG. 2A.

[0019] FIG. 3A is a photograph of embodiment 10 of the packing of the invention draped over a structural member.

[0020] FIG. 3B is a line drawing corresponding to the photograph of FIG. 3A of embodiment 10 of the padding of the invention draped over a structural member.

[0021] Fig. 4A is a photograph showing a profile of embodiment 10 of the packing according to the invention.

[0022] FIG. 4B is a line drawing corresponding to the photograph of FIG. 4A showing the profile of embodiment 10 of the packing according to the invention.

[0023] FIG. 5 is a simplified side view of an embodiment 10 of a packing according to the invention.

[0024] FIG. 6 is a simplified side view of an embodiment 20 of a packing according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0025] Aspects of the present invention and certain features, advantages and details thereof are explained more fully below with reference to non-limiting embodiments illustrated in the accompanying drawings. Descriptions of well-known materials, fabrication tools, manufacturing techniques, etc. are excluded so as not to obscure the invention in unnecessary detail. However, it should be understood that the detailed description and specific example (s), which indicate embodiments of the invention, are given by way of illustration only and not as limitation. Various substitutions, modifications, additions and / or configurations that fall within the spirit and / or scope of the underlying ideas of the invention will be apparent to those skilled in the art from this disclosure.

[0026] In a first aspect of the invention, there is provided an air-dried pad comprising a web of nonwoven fabric, said pad comprising:

- 75-97.5% of the mass. blends of fibers; and

- 2.5-25% of the mass. resin containing a crosslinked copolymer of butyl acrylate and methyl methacrylate,

the resin is present on the first surface of the packing and on the second surface of the packing, the second surface being parallel to the first surface, and the resin adheres to the fibers from the mixture of fibers, whereby a bonded structure is formed, so that the air-dried packing by means of the resin has structural integrity that allows the workability of the sheet-like packing.

[0027] Certain embodiments of the padding of the invention are made by a method of making an air-dried pad according to a third aspect of the invention (described in more detail below), which typically includes forming a nonwoven web from a blend of fibers (and optionally overlapping two or more layers of scrims), whereby an intermediate insulating pad structure is created having a first surface and a second surface parallel to the first surface; applying a predetermined resin solution to the first and second surfaces, whereby the solution-applied packing structure is formed, and exposing the solution-applied packing structure to air (air drying), whereby the solvent in the resin solution is evaporated and the resin cured, whereby an air-dried pad is formed in which the resin and fiber blend form an adhered structure such that the air-dried pad has a structural integrity that allows the sheet-like packing to be workable.

[0028] Briefly, it can be pointed out that the invention provides “workability” packing embodiments in which the fibers in the packing fiber mixture are sufficiently adhered to each other by means of a resin solution to form a separate packing structure that has a structural integrity and can be handled and used in its original form ("as is") without disintegrating or otherwise degrading the structural integrity of the packing that would render it unusable for end use (eg, as an insulating material in an article). As discussed above, binder fibers are optionally included in certain embodiments of the packing of the invention, and heat treatment is optionally used in packing manufacturing processes. However, tests carried out by the Applicant have shown that even embodiments of the packing according to the invention, which are completely free of binder fiber and which were obtained without any heat treatment, surprisingly, had good structural integrity and workability and could be easily used by themselves. without in non-thermally bonded form instead of traditional (for example, thermally bonded) packing.

[0029] As discussed below, in some embodiments, the air-dried packing of the invention is formed by applying a resin solution to a first packing surface and a second packing surface, and then exposing the solution-applied packing to air, thereby allowing the resin solution to evaporate and hence form an embodiment of the packing according to the invention. In some methods, the solution contains 15-60% vol. resin containing crosslinked acrylic polymer, 20-80% vol. fast-drying solvent, which is soluble in water, and 0-70% vol. water. These embodiments typically involve spraying a semi-finished product (for example, a web of nonwoven fabric or a multi-layer structure of a pad formed from two or more superimposed webs of nonwoven fabric) (or otherwise applying to the semi-finished product) with a solution that dries to air, it dries quickly (for example, in some embodiments, it dries in 5-20 minutes), and the resin adheres to the fiber in the fiber mixture, while the crosslinked polymer remains on the surfaces, which together with the fiber mixture forms a glued pad. In other words, by means of the crosslinked polymer, the fibers in the pad that would not otherwise be held together are held together, resulting in an environmentally friendly pad that does not require the cumbersome energy costs associated with the heat treatment used to melt the binder fibers or cure and bond together. packing fibers known in the art.

[0030] Embodiments of the padding of the invention provide a low-density, high-bulk, heat-insulating padding with desirable drape and compressibility characteristics suitable for use in articles including, but not limited to, clothing (e.g., clothing such as cold weather clothing, gloves, etc.) bedding (such as quilts and blankets), pillows, cushions, and sleeping bags.

[0031] In some embodiments, the air-dried wadding of the invention comprises a single web of nonwoven fabric that contains the fiber blend. This is the case shown, for example, in FIG. 5, which is a simplified side view of an embodiment 10 of the packing according to the invention. The shown pad 10 contains one web 12 of nonwoven fabric. The padding 10 has a first surface 2 and a second surface 4 that correspond to the first and second surfaces of the nonwoven web 12.

[0032] In other embodiments, the packing of the invention comprises two or more webs of nonwoven fabric that are superimposed on one another. This is the case shown, for example, in FIG. 6, which is a simplified side view of an embodiment 20 of the packing according to the invention. The shown pad 20 comprises three nonwoven webs 12, 14 and 16 which are superimposed on one another. The packing 20 has a first surface 2 and a second surface 4 '. As can be seen, in the multi-layer pad 20, the second surface 4 'corresponds to the surface of the nonwoven web 16. In the illustrated embodiment 20, the nonwoven webs 12 and 14 are in direct contact with each other, as are the nonwoven webs 14 and 16.

[0033] In some embodiments, the packing of the invention comprises 1, 2, 3, 4, 5, or 6 webs of nonwoven fabric. When used in a single web of nonwoven padding, the padding may be referred to as multi-layer padding. When a plurality of (i.e., 2 or more) webs of nonwoven fabric are used, the packing may be referred to as multi-layer packing. If there is more than one nonwoven web in the packing of the invention, the fiber composition of the nonwoven webs may be the same or different.

[0034] In various embodiments, when the resin solution is applied to the first and second packing surfaces, it penetrates the interior of the packing. Accordingly, in some packing embodiments, resin is present throughout the thickness (eg, as shown in FIG. 2A, is present in packing 10 at a thickness X) of the packing. In some embodiments, the resin penetrates from the surface to which it is applied into the pad in the direction of the thickness by 0.5-30 mm (for example, 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 sub-ranges within the above limits. For example, in some embodiments, resin penetrates the packing from the first surface of the packing towards the second surface of the packing in the direction of the thickness by 0.5-30 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 sub-ranges within the above ranges and / or resin penetrates the packing from the second packing surface towards the first packing surface in the thickness direction by 0.5-30 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 sub-ranges within the above ranges.

[0035] The packing according to the invention contains 75-97.5% of the mass. fiber blends (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% of the mass.), including any and all ranges and subranges in the above ranges, and 2.5-25% of the mass. resin containing a crosslinked copolymer of butyl acrylate and methyl methacrylate, (for example, 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 sub-ranges within the above ranges.

[0036] The resin solution used herein contains an acrylic polymer (eg, a self-crosslinking acrylic polymer). In various embodiments, the self-crosslinking acrylic polymer is a “crosslinked copolymer of butyl acrylate and methyl methacrylate,” which refers to a polymer that contains structural units from butyl acrylate and methyl methacrylate monomers. Typically, crosslinked copolymers of butyl acrylate and methyl methacrylate are obtained by polymerizing a reaction mixture that contains monomers including butyl acrylate and methyl methacrylate.

[0037] In some embodiments, the resin containing the crosslinked copolymer of butyl acrylate and methyl methacrylate contains carboxylic acid groups. In some embodiments, the resin containing the crosslinked copolymer of butyl acrylate and methyl methacrylate does not contain hydroxyl groups.

[0038] In some embodiments, the resin containing the crosslinked copolymer of butyl acrylate and methyl methacrylate does not contain any carbohydrate moieties. In some embodiments, the resin containing the crosslinked copolymer of butyl acrylate and methyl methacrylate does not contain any unpolymerized monomers.

[0039] In some embodiments, the resin is an acrylic polymer according to any embodiment described herein or having properties in common with any embodiment described herein, wherein the resin has one or more of the following properties, including any combination:

- is self-linking;

- contains butyl acrylate and methyl methacrylate as monomers;

- contains a copolymer of butyl acrylate and methyl methacrylate;

- does not contain any carbohydrate fragments;

- does not contain formaldehyde;

- does not contain alkyl phenols (for example, alkyl phenol ethoxylates (APEO));

- has a pH of from about 6.0 to about 10.0 (for example, a 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 within the above ranges (e.g., pH approximately 7.5-8.5);

- contains a nonionic and / or anionic emulsifier;

- does not contain a cationic compound or its residue;

- has a solids content of 45% - 55%, including any and all ranges and subranges in the above ranges, for example, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54 or 55%;

- has a glass transition temperature (Tg) from -30 ° C to + 30 ° C (for example, -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 sub-ranges within the above limits, (e.g. -20 to 10 ° C, -18 to 0 ° C, etc.);

- has a relative density of 0.90-1.20, including any and all ranges and sub-ranges within the above limits, for example, 0.90, 0.91, 0.92, 0.93, 0.94, 0.95 , 0.96, 0.97, 0.98, 0.99, 1.0, 1.01, 1.02, 1.03, 1.04, 1.05, 1.06, 1.07, 1 , 08, 1.09, 1.10, 1.11, 1.12, 1.13, 1.14, 1.15, 1.16, 1.17, 1.18, 1.19 or 1.20 ;

- has such a viscosity that the resin is fluid;

- is not completely sewn;

- has such a character that, when applied to the surface of the intermediate structure of the insulating pad, it continues to undergo crosslinking (for example, at indoor temperature) in some embodiments even in the absence of formaldehyde;

- provides the possibility of softness to the touch and good drape;

- has such a character that it is capable, after application to the surface, to continue to be crosslinked for hours, for example up to 48 hours at 25 ° C and ambient conditions;

- can be diluted with water;

- has a boiling point of 205 ° F to 220 ° F (96.11 ° C to 104.44 ° C), including any and all ranges and subranges within the above limits (e.g. 205, 206, 207, 208, 209, 210, 211, 212, 213, 214, 215, 216, 217, 218, 219 or 220 ° F (96.11, 96.67, 97.22, 97.78, 98.33, 98.89, 99, 44, 100, 100.56, 101.11, 101.67, 102.22, 102.78, 103.33, 103.89 or 104.44 ° C));

- has an evaporation rate lower than that of simple ether;

- has a weight of from 8 to 10 pounds per gallon (958.64 to 1198.3 kg / m ³⁾ (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 / gallon (958.64, 970.62, 982.61, 994.59, 1006.54, 1018.52, 1030.51, 1042.49, 1054.47, 1066.46, 1078.44, 1090.42, 1102.40, 1114.39, 1126.37, 1138.35, 1150.33, 1162.32, 1174.30, 1186.28 or 1198.3 kg / m ^3)), including any and all ranges and subranges within the above range (e.g., 8,30-9,20 pounds per gallon (982,61-1114,39 kg / m ^3));

- is stable when stored for at least 7 days at 25 ° C (for example, for at least 6 months or at least 12 months).

[0040] As will be clear to those of ordinary skill in the art, in some embodiments of the packing of the invention that comprise a single web of nonwoven fabric, all of the fiber blend and all of the resin may be contained in a single web of nonwoven fabric (including its first and second surfaces) ... On the other hand, in embodiments containing a plurality of webs of nonwoven fabric, the entire mixture of fibers and resin may be contained in a plurality of webs of nonwoven fabric (including the first and second surfaces of the multi-layer wadding formed by the plurality of webs), although the distribution of resin may vary across the layers. Indeed, in some embodiments of the proposed multi-layer padding, the nonwoven web that forms the first or second padding surface will have a higher resin concentration than the nonwoven web that is not adjacent to the first or second padding surface (e.g., in FIG. 6 , the nonwoven web 12 forms the first surface 2 of the pad 20, and the nonwoven web 16 forms the second surface 4 'of the pad 20; in some embodiments, the nonwoven webs 12 and 16 have higher resin concentrations than the inner nonwoven web 14).

[0041] In some embodiments, the fiber blend comprises synthetic fibers. Those of ordinary skill in the art are familiar with many synthetic fibers, and it is largely within their competence to select an appropriate synthetic fiber for use in embodiments of the packing of the invention, depending on the desired properties of the packing and / or article in which it is intended to be used. Embodiments of the padding of the invention may comprise any synthetic fiber known in the art to aid in the manufacture of textiles. In some embodiments, non-exclusive synthetic fibers that can be used in the invention are selected from nylon, polyester, polypropylene, polylactic acid (PLA) fibers, polybutyl acrylate (PBA), polyamide, acrylic, acetate, polyolefin, nylon, cellulose hydrate, lyocell , aramid, spandex, rayon and modified rayon fibers and combinations thereof. In certain embodiments, the synthetic fibers comprise polyester fibers. For example, in some embodiments, the polyester is selected from polyethylene terephthalate, poly (hexahydro-p-xylylene terephthalate), polybutylene terephthalate, poly-1,4-cyclohexylenedimethylene (PCDT), polytrimethylene terephthalate (PTT), and terephthalate copolymers, in which at least esters , 85 mole percent of the ester units are ethylene terephthalate or hexahydro-p-xylylene terephthalate units. In a specific embodiment, the polyester is polyethylene terephthalate. In some embodiments, synthetic fibers comprise virgin fibers. In some embodiments, the synthetic fibers comprise recycled fibers (eg, recycled polyester fibers).

[0042] The mixture of fibers contains 0-100% of the mass. 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, 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 in the above ranges (for example, 10-100 wt%, 30-100 wt%, 51-100 wt%, 40-90 wt%. , 20-80% by weight, etc.). In some embodiments, the blend of fibers contains more than 50, 55, 60, 65, 70, or 75 wt%. synthetic fiber.

[0043] In general, fibers can be crimped or non-crimped. Various crimped fibers with helical and standard (eg, planar) crimps are known in the art.

[0044] In some embodiments, the synthetic fibers are staple fibers (ie, standardized length fibers). For example, in some embodiments, synthetic fibers have a staple length of 12 mm to 70 mm, such as 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 sub-ranges above limits.

[0045] While the fibers may be linear, optionally with crimp, in some embodiments, the packing of the invention comprises fibers that have a desired shape that is not linear or linear with crimp. While those of ordinary skill in the art are aware of the various desirable shapes selected for fibers that are contemplated to be useful in embodiments of the invention, some non-limiting examples include Y-shaped fibers, butterfly-shaped (looped) fibers, etc.

[0046] Denier is a unit of measure defined as the weight in grams of 9000 meters of fiber or filament. This is a common way to indicate the weight (or size) of a fiber or thread. For example, polyester fibers that are 1.0 denier typically have a diameter of about 10 microns. Micro-denier fibers are fibers having a weight number of 1.0 denier or less, while macro-denier fibers have a weight number greater than 1.0.

[0047] In some embodiments, synthetic fibers have a weight number of 0.7 denier to 8.0 denier, including any and all ranges and sub-ranges within the above ranges. For example, in some embodiments, synthetic fibers have a weight number 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, 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 sub-ranges within the above ranges.

[0048] In some embodiments, synthetic fibers comprise microdenier fibers (eg, fibers having a weight number of 0.7 to 1.0 denier). In some embodiments, synthetic fibers comprise macro-denier fibers (eg, fibers having a grammage of 1.1 to 8.0 denier). In some embodiments, synthetic fibers comprise micro-denier fibers and macro-denier fibers.

[0049] In some embodiments, synthetic fibers comprise siliconized fibers. The term "siliconized" means that the fiber is coated with a silicon-containing composition (eg, silicone). Siliconization techniques are well known in the art and are described, for example, in US Pat. No. 3,454,422. The silicon-containing composition can be applied using any method known in the art, such as spraying, mixing, dipping, padding, etc. A silicon-containing (eg, silicone) composition, which may include an organosiloxane or polysiloxane, adheres to the outside of the fiber. In some embodiments, the silicone coating is a polysiloxane, such as methyl polysiloxane, modified methyl polysiloxane, polydimethylsiloxane, or amine modified dimethyl polysiloxane. As is known in the art, the silicon-containing composition can be applied directly to the fiber or can be diluted with a solvent in the form of a solution or emulsion, such as an aqueous polysiloxane emulsion, prior to application. After processing, the coating can be dried and / or cured. As is known in the art, the catalyst can be used to accelerate the cure of a silicon-containing composition (e.g., polysiloxane containing Si-H bonds) and conveniently added to an emulsion of a silicon-containing composition, with the resulting combination being used to treat the synthetic fiber. Suitable catalysts include salts of iron, cobalt, manganese, lead, zinc and tin and carboxylic acids such as acetates, octanoates, naphthenates and oleates. In some embodiments, after siliconization, the fiber can be dried to remove residual solvent and then optionally heated to temperatures between 65 ° C and 200 ° C for curing.

[0050] In a mixture of fibers 0-100% of the mass. fibers are siliconized 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, 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 within the above ranges (e.g. 20-95 wt%, 25-90 wt%, 30-90 wt%, 40-85 % wt., 51-90% wt., etc.). In some embodiments, the siliconized fibers are polyethylene fibers.

[0051] Treatment with durable water repellents (DWR) is well known in the art and imparts water repellency to treated components. Those of ordinary skill in the art are aware of various permanent water repellent treatments, any of which may be used on fiber aggregates as needed in connection with the present invention. In some embodiments, the fibers used in the padding of the invention (which may be referred to as fibers treated with permanent water repellents or water repellents) have been treated with a polymer solution of zirconium acetate that can impart permanent water repellency while minimizing and / or avoiding adverse effects on characteristics of fibers. In some embodiments, fibers treated with a permanent water repellant are treated with a water repellent, bacterial resistant, low friction cured zirconium acetate finish such that the fibers have improved wash dryability and improved tactile and lump resistance. ... An example of a zirconium acetate solution that can be used for a permanent water repellent treatment in connection with the present invention is disclosed in US Pat. No. 4,537,594. In some embodiments, the fiber treated with the permanent water repellant is bath or dry spray treated. In some embodiments, the treatment includes surface energy modification technology, which, as is known in the art, may include, for example, plasma treatment. Such treatments or processes are explained in US Pat. No. 4,869,922, US Pat. No. 5,262,208, US Pat. No. 5,895,558, US Pat. No. 6,416,633, US Pat. No. 7,510,632, US Pat. No. 8,309,033, and US Pat. No. 8,298,627.

[0052] In some embodiments, synthetic fibers contain up to 15% of the mass. particles or material that is (are) different from the synthetic material of which the synthetic fiber is mainly composed. For example, in some embodiments, 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, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5 , 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4 , 8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0 , 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7 , 3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5 , 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9 , 8, 9.9, 10.0, 10.1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 11.0 , 11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, 12.0, 12.1, 12.2, 12 , 3, 12.4, 12.5, 12.6, 12.7, 12.8, 12.9, 13.0, 13.1, 13.2, 13.3, 13.4, 13.5 , 13.6, 13.7, 13.8, 13.9, 14.0, 14.1, 14.2, 14.3, 14.4, 14.5, 14.6, 14.7, 14 , 8, 14.9 or 15.0% of the mass. particles or material other than the synthetic material of which the synthetic fibers are primarily composed, including any and all ranges and sub-ranges within the above ranges. In some embodiments, the particles or material are contained (eg, encapsulated) in a polymer matrix, which is a synthetic material that predominantly consists of synthetic fibers. In some embodiments, the synthetic fibers in the fiber blend comprise an airgel fiber like that described in WO 2017/087511.

[0053] In some embodiments, the fiber blend of the padding comprises natural fibers. For example, in some embodiments, the fiber blend comprises one or more elements selected from wool, cotton, tencel, kapok (cotton-like fluff derived from cottonseed / kapok seeds that can be further processed prior to use if necessary), flax, hair animal coverings, silk and down (for example, duck or goose down).

[0054] The mixture of fibers contains 0-100% of the mass. natural 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, 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 in the above ranges (for example, 0-50 wt%, 1-40 wt%, 5-25 wt%, 30-60 wt%. etc.). In some embodiments, the blend of fibers contains less than 50, 40, 30, 20, or 10 wt%. natural fiber.

[0055] In some embodiments, the fiber blend comprises synthetic fibers and natural fibers.

[0056] In some embodiments, the fiber blend comprises:

- 50-90% of the mass. siliconized synthetic fibers (e.g. polyester fibers) (e.g. 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89 or 90% by weight, including any and all ranges and subranges within the above ranges) having a staple fiber length of 40-60 mm and a weight number of 0.6-1.0 denier (e.g. 0.6, 0.7, 0.8, 0, 9 or 1.0 denier, including any and all ranges and sub-ranges within the above ranges);

- 10-50% of the mass. non-siliconized fibers (e.g. natural and / or synthetic fibers such as polyester) (e.g. 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 or 50 wt%, including any and all ranges and subranges within the above ranges) having a staple fiber length of 40-60 mm and a weight number of 2.5-5.0 denier (e.g. 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, or 5.0 denier, including any and all ranges and sub-ranges within the above limits); and

- 0-40% of the mass. (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 or 40 wt%, including any and all ranges and subranges within the above limits) siliconized synthetic macro-denier fibers (eg polyester fibers) having a staple fiber length of 40-70 mm and a weight number greater than 1.0. In some embodiments, the siliconized macrodenier fibers have a weight number greater than or equal to 3.0.

[0057] In some embodiments, the fiber blend comprises:

- 35-80% of the mass. microdenier 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% of the mass.) , including any and all ranges and sub-ranges within the above limits; and

- 20-65% of the mass. macrodene 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% of the mass.) , including any and all ranges and sub-ranges within the above limits.

Microdenier and macrodenier fibers can be individually siliconized or non-siliconized. For example, from microdenier fibers 0-100% of the mass. 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, 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 in the above ranges) are siliconized, and from macrodedener fibers 0-100 wt%. 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, 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 sub-ranges within the above ranges) are siliconized.

[0058] As discussed above, the invention provides packing embodiments in which, even in the absence of heat treatment (for example, in the absence of any fibers fused and bonded to other fibers in the packing), the fibers in the packing are sufficiently adhesively bonded to each other to form a discrete packing structure that has structural integrity and can be processed and used as is ("as is") without degrading or otherwise degrading the structural integrity of the packing that would render it unusable for end use. Accordingly, in some embodiments, the fiber blend is free of binder fiber. In some embodiments, the nonwoven web is free of binder fiber. In some embodiments, the packing is free of binder fiber.

[0059] In some embodiments, the packing does not contain any molten fibers.

[0060] In some embodiments, none of the fibers in the pad (or in the nonwoven web of the pad) are bonded to each other by melting the fiber in the fiber blend. This is in contrast to the case in which the fiber mixture contains, for example, a binder fiber and the web is heat treated to melt the binder fiber and allow it to bond with other fibers in the fiber mixture contained in the nonwoven web. In some embodiments, none of the fibers in the packing are adhered to each other unless it is adhered by a resin containing a crosslinked copolymer of butyl acrylate and methyl methacrylate. In some embodiments, 90% of the mass. or more fibers present in the packing (for example, fibers in an amount greater than or equal to 90, 91, 92, 93, 94, 95, 96, 97, 98 or 99 wt%) are adhered to each other only by means of a resin containing crosslinked copolymer of butyl acrylate and methyl methacrylate.

[0061] While a number of the embodiments discussed above are free of binder fibers or other thermally bonded fibers, other embodiments of the invention comprise binder fibers. For example, sometimes one skilled in the art may want to use the inventive concept of using a crosslinked polymer to form an air-dried pad at ambient temperature in which the fibers are bonded with resin so that the air-dried pad has structural integrity that provides workability of packing in the form of a sheet, but also use a binder fiber. Indeed, although the use of an air-cured resin to impart structural integrity avoids binder fiber and heat treatment to form a pad, in some embodiments it may be desirable to simply reduce the amount of binder fiber used or the amount of heat treatment used, or add binder fiber and / or heat treatment. Accordingly, in some embodiments, the fiber blend comprises a binder fiber.

[0062] In some embodiments, the blend of fibers contains 1-25% of the mass. synthetic binder fibers, wherein said binder fibers have a bonding temperature that is lower than the softening temperature of the synthetic polymer fibers present in the mixture.

[0063] In some embodiments, synthetic binder fibers are, for example, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24 or 25% of the mass. from a blend of fibers, including any and all ranges and sub-ranges within the above ranges.

[0064] In some embodiments, the synthetic binder fibers have a weight number of 1.5-4.0 denier, for example, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3, 3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, or 4.0 denier, including any and all ranges and sub-ranges within the above ranges (e.g. 2.0-2, 2 denier).

[0065] In some embodiments, the binder fibers have staple cut lengths of 38-105 mm, including any and all ranges and sub-ranges within the above ranges. For example, in some embodiments, 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 105mm including any and all ranges / sub-ranges within the above limits (for example, 38-51 mm).

[0066] As indicated above, the binder fibers have a bonding temperature that is lower than the softening temperature of the synthetic fibers. In some embodiments, the binder fibers have a bonding temperature that is less than or equal to 200 ° C. In some embodiments, the binder fibers have a bonding temperature of 50-200 ° C, including any and all ranges and sub-ranges within the above ranges. 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.

[0067] In some embodiments, the binder fibers comprise low melting point polyester fibers.

[0068] In some embodiments, 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.

[0069] The packing of the invention, in some embodiments, has been heat-treated to melt all or part of the binder fibers, thereby forming a heat-bonded web type packing. Those of ordinary skill in the art will appreciate that in such embodiments, although "binder fibers" are referred to in the wadding fiber blend, said fibers may be wholly or partially melted fibers as opposed to the binder fibers in their original form prior to heat treatment.

[0070] As discussed above, the packing of the invention comprises at least one web of nonwoven fabric. In some embodiments, the fibers contained in the nonwoven web (s) are comprised of a mixture of fibers.

[0071] In general, by adding layers of webs of nonwoven fabric to a pad, the thickness and insulating capacity of the pad can be increased. In some embodiments, the packing is 4-30 mm thick (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 sub-ranges within the above ranges (e.g. 10-20 mm).

[0072] In some embodiments, the gasket has a density of 0,9-8 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 sub-ranges within the above limits (for example, 1-4 kg / m ³ , 1.5-7 kg / m ³ , 2-6 kg / m ³ , 2.5-5 kg / m ³ , etc.).

[0073] In some embodiments, the packing has a Thermal Insulation Index of at least 0.70 clo / oz / sq. yard (2.1 clo / 100 g / m ² ) ( clo is a unit of thermal insulation ) when tested according to ISO 11092. For example, in some embodiments, the packing has a thermal insulation value of 0.70 clo / oz / sq. yard - 0.95 clo / ounce / sq. yard (2,1 clo / 100 g / m ^2- 2,85 clo / 100 g / m 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 / yd2 (2.10, 2.13, 2.16, 2.19, 2.22, 2.25, 2.28, 2.31, 2.34, 2.37, 2.40, 2.43, 2.46, 2.49, 2.52, 2, 55, 2.58, 2.61, 2.64, 2.67, 2.70, 2.73, 2.76, 2.79, 2.82 or 2.85 clo / 100 g / m ² )) including any and all ranges and sub-ranges within the above limits.

[0074] In some embodiments of the packing of the invention, the fiber blend elements are uniformly blended, which means that the fiber blend has a substantially uniform (ie, 90-100% uniform) composition.

[0075] FIG. 1A is a top view of one embodiment 10 of a packing of the invention in accordance with a first aspect of the invention. The shown pad 10 is a single web of nonwoven material that contains a first surface 2 and a second surface 4 (which is not shown, but which is parallel to the first surface 2 and which, in the embodiment shown, faces the surface on which the pad 10 is placed). In some embodiments, when the padding 10 is contained in an article (for example, as an insulating material), the first surface 2 will face the outside (for example, fabric or other material or lining) of the article, for example, a jacket, and the second surface 4 will face to the interior (for example, fabric or other material or lining) of the product. In other embodiments, the first surface 2 faces the inside of the product and the second surface 4 faces the outside of the product.

[0076] FIG. 1B is a line drawing corresponding to a top view of embodiment 10 of the packing of the invention shown in FIG. 1A.

[0077] FIG. 2A is a side view of embodiment 10 of the packing of the invention, with X being the thickness of the packing.

[0078] Fig. 2B is a line drawing corresponding to a side view of embodiment 10 of the packing of the invention shown in Fig. 2A.

[0079] FIG. 3A is a photograph of embodiment 10 of the packing of the invention draped over a structural member. As can be seen, the padding 10 shown has good drapeability (ie, the padding hangs down under its own weight). The drapeability of the padding is essential for such qualities as the comfort and aesthetics of the product in which the padding is used.

[0080] FIG. 3B is a line drawing corresponding to the photograph of FIG. 3A of embodiment 10 of the padding of the invention draped over a structural member.

[0081] In some embodiments, the padding 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 cm or 3.5 cm), including any and all ranges and sub-ranges within the above limits, determined according to ASTM D1388.

[0082] Fig. 4A is a photograph showing the profile of embodiment 10 of the packing according to the invention, with X being the thickness of the packing.

[0083] FIG. 4B is a line drawing corresponding to the photograph of FIG. 4A showing the profile of embodiment 10 of the packing according to the invention.

[0084] In some embodiments, the packing has a weight of 25-200 g / m ² (eg, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, 180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190, 191, 192, 193, 194, 195, 196, 197, 198, 199 or 200 g / m ^2), including any and all ranges and subranges within the above range (e.g., 25-10 0 g / m ^2, 40-100 g / m ^2, etc.).

[0085] In some embodiments, the packing is in the form of a sheet (suitable for use as a rolled product) and has not been cut.

[0086] In some embodiments, the packing is pigment free. In some embodiments where the packing contains pigment, the pigment is not present in the resin (ie, the pigment, if present in the packing, is not added to the resin).

[0087] In accordance with a second aspect of the invention, there is provided an article comprising a packing according to the invention. Non-limiting examples of such products include, for example, outerwear (for example, outerwear such as jackets, etc.), clothing, pillows, liners, sleeping bags, bedding (for example, quilts, blankets), etc. ...

[0088] According to a third aspect of the invention, there is provided a method of making an air-dried packing, said method comprising:

- forming a web of nonwoven fabric from a mixture of fibers and, if necessary, superimposing two or more layers of webs on top of each other, thereby creating an intermediate structure of an insulating pad having a first surface and a second surface parallel to the first surface;

- applying on the first surface and the second surface of the intermediate structure of the insulating packing of a resin solution containing:

- 15-60% vol. a resin containing a crosslinked copolymer of butyl acrylate and methyl methacrylate;

- 20-80% vol. a fast drying solvent that is soluble in water; and

- 0-70% vol. water,

whereby the structure of the packing with the applied solution is formed; and

- exposing the structure of the packing with the applied solution to the action of air, whereby the evaporation of the solvent in the resin solution and the curing of the resin are ensured, as a result of which an air-dried packing is formed containing 75-97.5% of the mass. a mixture of fibers and 2.5-25% of the mass. resin, whereby the resin adheres to the fibers of the fiber mixture, whereby a bonded structure is formed, so that by means of the resin, the air-dried packing has a structural integrity that allows the workability of the packing as a sheet.

[0089] The blend of fibers can be any of the embodiments described above in the first aspect of the invention.

[0090] In some embodiments (eg, when the binder fiber is present in the fiber blend), the method of the invention includes heating the pad to a bonding temperature or above the bonding temperature of the binder fibers. In other embodiments, the method of the invention according to the third aspect of the invention does not include heating the packing to a bonding temperature or to a temperature higher than the bonding temperature of the binder fibers used in the fiber blend. As will be apparent to those skilled in the art, embodiments of the inventive method of making an air-dried pad that do not include this heating step are applicable to the finished air-dried pad as well as any intermediate pad structure containing a web of nonwoven fabric.

[0091] In some embodiments, the inventive method of making an air-dried packing does not include a processing step performed at a temperature greater than 48 ° C. In some embodiments, the inventive method of making an air-dried packing does not include a process step performed at a temperature greater than 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.

[0092] In some embodiments, the method of the invention does not include a bonding step that results in bonding or adhesion of the fibers in the fiber blend at temperatures 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.

[0093] In some embodiments, a nonwoven web is formed using a carding or airlaying process. Both technologies are well known to those of ordinary skill in the art.

[0094] As mentioned above, the resin solution contains:

- 15-60% vol. resin containing a crosslinked copolymer of butyl acrylate and methyl methacrylate. For example, in some embodiments, the solution contains 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% about. resins, including any and all ranges and sub-ranges within the above ranges (eg, 20-50 vol.%, 25-35 vol.%, etc.);

- 20-80% vol. a fast drying solvent that is soluble in water. For example, in some embodiments, the solution contains 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. a fast drying solvent, including any and all ranges and subranges within the above ranges (eg, 30-75% by volume, 50-70% by volume, etc.); and

- 0-70% vol. water. For example, in some embodiments, the solution contains 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% about. water, including any and all ranges and subranges in the above ranges (for example, 0-50% vol., 1-30% vol., 2-20% vol., 5-15% vol., etc.).

[0095] In the context of this document, a fast drying solvent refers to a solvent that has an evaporation rate that is greater than or equal to 1.3. The evaporation rate is the rate at which the material will evaporate (vaporize, change from liquid to vapor) and is determined by the ASTM D3539-11 method in relation to the evaporation rate of n-butyl acetate, measured under the same conditions. This quantity is a ratio and therefore it is dimensionless. In some embodiments, the fast drying solvent has an evaporation rate greater than 1.3 (e.g., greater than 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 or 5.0). For example, in some embodiments, the fast drying solvent has an evaporation rate greater than 3.0.

[0096] 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 (that is, at least 8 ml of solvent will dissolve in 100 ml of water at 20 ° C). In some embodiments, the solvent has a solubility that is greater than or equal to 10 grams per 100 ml of 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 of solvent per 100 ml of water at 20 ° C).

[0097] In some embodiments, the fast drying solvent is selected from isopropyl alcohol, ethanol, methanol, glyme ( ethylene glycol dimethyl ether ), acetone, tetrahydrofuran, methyl ethyl ketone (MEK), methyl acetate, and ethyl acetate, and combinations thereof. In certain embodiments, the fast drying solvent is isopropyl alcohol.

[0098] In some embodiments, the resin solution contains no pigment.

[0099] In some embodiments, applying the resin solution to the first and second surfaces of the intermediate structure of the insulating pad includes spraying the solution onto the first and / or second surfaces. In some embodiments, during spraying, the resin solution spray droplets have an average median diameter of 150-250 μm (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, 217, 218, 219, 220, 221, 222, 223, 224, 225, 226, 227, 228, 229, 230, 231, 232, 233, 234, 235, 236, 237, 238, 239, 240, 241, 242, 243, 244, 245, 246, 247, 248, 249 or 250 μm), including any and all ranges and sub-ranges within the above ranges.

[00100] In some embodiments, during said application, the spray nozzles move over the first and second surfaces of the packing structure and across the width of these surfaces.

[00101] In some embodiments, applying the resin solution to the first and second surfaces of the intermediate structure of the insulating pad includes applying the solution to the first and / or second surfaces by bath or padding, both techniques known in the art.

[00102] In some embodiments, exposing the solution-applied packing structure to air comprises exposing the solution-applied packing to forced air or circulated air. In some embodiments, said exposure includes subjecting the solution-applied packing to forced air or circulating air having an air velocity during contact with the solution-applied packing of at least 2.5 m / s, at least 3 , 0 m / s or at least 3.5 m / s. In some embodiments, said exposure includes subjecting the solution-applied packing to forced air or circulating air having an air velocity of 2.5-15 m / s during contact with the solution-applied packing (e.g., 2.5, 2, 6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5, 1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7, 6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, 10.0, 10, 1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 11.0, 11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, 12.0, 12.1, 12.2, 12.3, 12.4, 12.5, 12, 6, 12.7, 12.8, 12.9, 13.0, 13.1, 13.2, 13.3, 13.4, 13.5, 13.6, 13.7, 13.8, 13.9, 14.0, 14.1, 14.2, 14.3, 14.4, 14.5, 14.6, 14.7, 14.8, 14.9 or 15.0 m / s ), including any and in All ranges and sub-ranges are within the above limits (for example, 2.5-12 m / s, 2.5-10 m / s, etc.).

[00103] In some embodiments, when exposed to forced air or circulating air having an air velocity of 2.5-15 m / s during contact with the sprayed packing (eg, 2.5, 2.6, 2, 7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5, 2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7, 7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, 10.0, 10.1, 10, 2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 11.0, 11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, 12.0, 12.1, 12.2, 12.3, 12.4, 12.5, 12.6, 12, 7, 12.8, 12.9, 13.0, 13.1, 13.2, 13.3, 13.4, 13.5, 13.6, 13.7, 13.8, 13.9, 14.0, 14.1, 14.2, 14.3, 14.4, 14.5, 14.6, 14.7, 14.8, 14.9 or 15.0 m / s), including any and all ranges and sub-ranges within the above limits (for example , 2.5-12 m / s, 2.5-10 m / s, etc.), the structure of the packing with the applied solution dries within 3-60 minutes (for example, 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 or 60 minutes), including any and all bands and sub-bands within the above ranges (e.g., 5-30 minutes, 6-25 minutes, 7-15 minutes, etc.).

[00104] In some embodiments, the method of the invention comprises, after forming the air-dried packing, winding the packing as a roll as a commodity. Such embodiments are suitable for, for example, easy handling of the packing. In some embodiments, the air-dried pad is wound with the nonwoven mesh layer and transported as a roll as a commodity.

ITEMS

[00105] In some embodiments, the invention provides a packing, article, or method according to an embodiment of one of the following:

Item 1. Air-dried padding comprising a web of nonwoven fabric, said padding comprising:

- 75-97.5% of the mass. blends of fibers; and

- 2.5-25% of the mass. resin containing a crosslinked copolymer of butyl acrylate and methyl methacrylate,

the resin is present on the first surface of the packing and on the second surface of the packing, the second surface being parallel to the first surface, and the resin adheres to the fibers of the fiber mixture, whereby a bonded structure is formed so that the air-dried packing has structural integrity by means of the resin which ensures the workability of the sheet-like packing.

Item 2. Air-dried packing according to item 1, the packing being in the form of a sheet.

Item 3. Air-dried packing according to any of the preceding claims, wherein the fiber blend contains natural fibers.

Item 4. An air-dried wadding according to any of the preceding claims, wherein the fiber blend contains synthetic fibers.

Item 5. Air-dried packing according to item 4, in which the synthetic fibers contain polyester fibers.

Item 6. Air-dried packing according to item 4 or item 5, in which the synthetic fibers contain siliconized fibers.

Clause 7. Air-dried packing according to clause 6, wherein the fiber blend contains:

- 25-90% of the mass. siliconized synthetic fibers.

Clause 8. Air-dried packing according to any one of the preceding claims, wherein the fiber mixture comprises:

- 35-80% of the mass. microdenier fibers; and

- 20-65% of the mass. fibers macrodene.

Clause 9. Air-dried packing according to clause 8, wherein the fiber blend contains:

- 50-75% of the mass. microdenier fibers; and

- 25-50% of the mass. fibers macrodene.

Item 10. Air-dried packing according to item 8 or item 9, in which the microdenier fibers contain siliconized fibers.

Item 11. Air-dried packing according to any one of items 8-10, wherein the macrodedener fibers comprise siliconized fibers.

Item 12. Air-dried packing according to item 11, wherein the macrodedener fibers further comprise non-siliconized fibers.

Item 13. Air-dried packing according to any of the preceding paragraphs, in which the fiber mixture contains more than 95% of the mass. polyester fibers.

Item 14. The air-dried packing according to any one of the preceding claims, wherein the air-dried packing does not contain synthetic binder fibers.

Item 15. The air-dried packing according to any one of the preceding claims, wherein the air-dried packing does not contain molten fibers.

Item 16. Air-dried packing according to any one of the preceding claims, wherein more than 95% of the fibers in the fiber blend are staple fibers.

Item 17. Air-dried packing according to item 16, wherein the staple fibers have a staple fiber length between 12 mm and 70 mm.

Item 18. An air-dried packing according to any of the preceding claims, further comprising a mesh layer in contact with at least one of the first surface and the second surface.

Item 19. An air-dried packing according to any one of the preceding claims, wherein said packing comprises a plurality of webs of nonwoven fabric.

Item 20. The air-dried wadding according to item 19, wherein a plurality of webs of nonwoven fabric are transversely superimposed on one another.

Item 21. An air-dried packing according to any of the preceding claims, having a density of 1-8 kg / m ³ .

Clause 22. An article comprising an air-dried pad according to any one of the preceding claims.

Clause 23. A product according to clause 22, wherein said product is selected from the group consisting of an article of outerwear, clothing, a sleeping bag and bedding.

Item 24. A method for making an air-dried packing according to any one of items 1-21, said method comprising:

- forming a web of nonwoven fabric from a mixture of fibers and, if necessary, superimposing two or more layers of webs on top of each other, thereby creating an intermediate structure of an insulating pad having a first surface and a second surface parallel to the first surface;

- applying on the first surface and the second surface of the intermediate structure of the insulating packing of a resin solution containing:

- 15-60% vol. a resin containing a crosslinked copolymer of butyl acrylate and methyl methacrylate;

- 20-80% vol. a fast drying solvent that is soluble in water; and

- 0-70% vol. water,

whereby the structure of the packing with the applied solution is formed; and

- exposing the structure of the packing with the applied solution to the action of air, whereby the evaporation of the solvent in the resin solution and the curing of the resin are ensured, as a result of which an air-dried packing is formed containing 75-97.5% of the mass. a mixture of fibers and 2.5-25% of the mass. resin, whereby the resin adheres to the fibers of the fiber mixture, whereby a bonded structure is formed, so that the air-dried packing by means of the resin has a structural integrity that allows the workability of the sheet-like packing.

Item 25. The method according to item 24, wherein the quick-drying solvent is isopropyl alcohol.

Item 26. A method according to any one of items 24-25, wherein said formation of a nonwoven web from a fiber blend is performed using a card or airlaid process.

Item 27. A method according to any one of items 24-26, wherein said application comprises spraying a resin solution onto a first surface and a second surface of the intermediate structure of the insulating pad.

Item 28. A method according to any one of items 24-27, wherein the method does not include heating the web of nonwoven fabric.

Item 29. A method according to any one of items 24-27, the method comprising heating a web of nonwoven fabric.

Item 30. A method according to any one of items 24-29, wherein said subjecting the solution-applied packing to air comprises exposing the solution-applied packing to forced air or circulating air.

EXAMPLES

[00106] The invention will be further illustrated with reference to, but not limited to, the specific embodiment described in the example below.

[00107] Example 1

[00108] The mixture of fibers is prepared by mixing the following:

50% Siliconized Polyester Staple Fiber, PCR (Recycled and Recycled), 0.9 denier, 51 mm;

25% Non-Siliconized Polyester Staple Fiber, PCR, 3.0 Denier, 51mm;

- 25% Siliconized Polyester Staple Fiber, PCR, 6.6 Denier, 64mm.

After mixing / kneading, the fiber blend is then formed into a web on a conventional card to form a nonwoven web. Thereafter, the web is guided through the liner to obtain the target weight and thickness. Thereafter, a resin solution (30% by volume of a resin containing a crosslinked copolymer of butyl acrylate and methyl methacrylate, 60% by volume of isopropyl alcohol, 10% by volume of water) is sprayed onto the web subjected to webs / web conversion, and the web is directed through an oven having indoor temperature and designed for 3 passes, with convection fans operating to help speed up the drying process. The resin in resin solution is a milky white fluid liquid that contains a self-crosslinkable crosslinkable copolymer of butyl acrylate and methyl methacrylate that is free of formaldehyde and APEO, has a pH of ~ 8.0, a relative density of 1.04, a solids content of 49% ± 1 , 00%, Tg component -15 °, comprising nonionic and / or anionic emulsifier, a water soluble, has a weight of the product constituting 8,34-9,17 pounds per gallon (999,38-1098,84 kg / m ³ ), and has a boiling point of ~ 212 ° F (100 ° C). As the packing passes through the oven (or an alternative system that allows injection air to be blown into the packing), the resin solution is sprayed on both sides of the insulating material. The resin solution dries in 10-15 minutes, leaving a dry, air-dried pack in which the resin adheres to the fibers of the fiber blend to form a bonded structure so that the air-dried pack has structural integrity that allows the pack to be workable. in the form of a sheet.

[00109] An exemplary packing has a weight of 61 g / m ² (grams per square meter), a density of 1.34 g / m ^3, and a thickness of 5.99 mm.

[00110] The terminology used herein is intended only to describe specific embodiments and is not intended to limit the invention. In this context, the singular is intended to encompass the plural as well, unless the context clearly dictates otherwise. In addition, it should be understood that the terms “contain” (and any form of the verb “contain” such as “contains” and “containing”), “have” (and any form of the verb “have” such as “has” and “ having ")," include "(and any form of the verb" include "such as" includes "and" including ")," include "(and any form of the verb" include " , such as "contains" and "includes") and any other grammatical variant thereof are non-limiting linking verbs. As a result, a method or product that (s) "contains", "has", "includes" or "encloses" one or more steps or elements, has these one or more steps or elements, but is not limited to the presence of only these one or more stages or elements. Likewise, a method step or product element that “contains,” “has,” “includes,” or “contains” one or more elements / features, has, but is not limited to, one or more feature elements. one or more elements / features.

[00111] In the context of this document, the terms "comprising", "has", "including", "comprising" and their other grammatical variants encompass the terms "consisting of" and "consisting essentially of".

[00112] The expression "consisting essentially of" or its grammatical variants when used in this document should be considered as indicating the given features, whole objects, steps or components, but not excluding the addition of one or more additional features, whole objects, steps, components or their groups, but only if additional features, whole objects, stages, components or their groups do not cause significant changes in the main and new features of the claimed compositions or methods.

[00113] All publications cited in this description are incorporated into this document by reference, as if each individual publication were specifically and separately indicated as to be included in this document by reference, as if it were cited in its entirety.

[00114] The subject matter incorporated by reference is not considered as an alternative to any limitations of the claims, unless explicitly stated otherwise.

[00115] Where one or more ranges are indicated throughout this specification, each range is intended to be an abbreviated format for representing information, and it should be understood that the range encompasses each individual value within the range as if it were are shown in full in this document.

[00116] Although a number of aspects and embodiments have been described and shown herein, alternative aspects and embodiments may be modified by those skilled in the art to achieve the same objectives. Accordingly, it is intended that this disclosure and the appended claims cover all such additional and alternative aspects and embodiments that fall within the true spirit and scope of the invention.

Claims (49)

1. Air-dried packing comprising a web of nonwoven fabric, said packing comprising: - 75-97.5% of the mass. blends of fibers and - 2.5-25% of the mass. resin containing a crosslinked copolymer of butyl acrylate and methyl methacrylate, the resin is present on the first surface of the packing and on the second surface of the packing, the second surface is parallel to the first surface and the resin adheres to the fibers of the mixture of fibers, whereby a bonded structure is formed, so that by means of the resin, the air-dried packing has a structural integrity that allows the workability of the packing in the form of a sheet, and The air-dried packing is formed by: - applying a resin solution to the first surface of the intermediate packing structure and the second surface of the intermediate packing structure, comprising: - 15-60% vol. a resin containing a crosslinked copolymer of butyl acrylate and methyl methacrylate; - 20-80% vol. a fast drying solvent having an evaporation rate greater than or equal to 1.3, which is soluble in water; and - 0-70% vol. water, exposing the solution-applied packing structure to air, whereby the solvent in the resin solution is evaporated and the resin cured, whereby an air-dried packing is formed, wherein the resin is such that, under ambient conditions, it is crosslinked for 48 hours at 25 ° C, and / or when the solution-applied packing structure is exposed to forced air or circulating air having an air velocity during contact with the packing with the applied solution, constituting 2.5-15 m / s, the structure of the packing with the applied solution dries up within 3-60 minutes. 2. The air-dried packing of claim 1, wherein the packing is in the form of a sheet. 3. The air-dried packing of claim 1, wherein the fiber blend comprises natural fibers. 4. The air-dried packing of claim 1, wherein the fiber blend comprises synthetic fibers. 5. Air-dried packing according to claim 4, wherein the synthetic fibers comprise polyester fibers. 6. The air-dried packing of claim 4, wherein the synthetic fibers comprise siliconized fibers. 7. The air-dried packing of claim 6, wherein the fiber blend comprises - 25-90% of the mass. siliconized synthetic fibers. 8. The air-dried packing of claim 1, wherein the fiber blend comprises: - 35-80% of the mass. microdenier fibers and - 20-65% of the mass. fibers macrodene. 9. Air-dried packing according to claim 8, wherein the fiber blend comprises: - 50-75% of the mass. microdenier fibers and - 25-50% of the mass. fibers macrodene. 10. The air-dried packing of claim 8, wherein the microdenier fibers comprise siliconized fibers. 11. The air-dried packing of claim 8, wherein the macroddener fibers comprise siliconized fibers. 12. The air-dried packing of claim 11, wherein the macroddener fibers further comprise non-siliconized fibers. 13. Subjected to air drying packing according to claim 1, in which the mixture of fibers contains more than 95% of the mass. polyester fibers. 14. The air-dried packing of claim 1, wherein more than 95% of the fibers in the fiber blend are staple fibers. 15. Air-dried packing according to claim 14, wherein the staple fibers have a staple fiber length of 12-70 mm. 16. The air-dried packing of claim 1 further comprising a mesh layer in contact with the first surface and / or the second surface. 17. The air-dried packing of claim 1, wherein said packing comprises a plurality of layers of nonwoven webs. 18. The air-dried packing of claim 17, wherein a plurality of web nonwoven layers are stacked across one another. 19. Air-dried packing according to claim 1 having a density of 1-8 kg / m ³ . 20. An article comprising an air-dried pad according to any one of claims 1-19. 21. An article according to claim 20, wherein said article is selected from the group consisting of an article of outerwear, clothing, a sleeping bag and bedding. 22. A method for making an air-dried packing according to any one of claims 1-19, said method comprising: - forming a web of nonwoven fabric from a mixture of fibers and, optionally, superimposing two or more layers of webs on top of each other, thereby creating an intermediate structure of an insulating pad having a first surface and a second surface parallel to the first surface; - applying on the first surface and the second surface of the intermediate structure of the insulating packing of a resin solution containing: - 15-60% vol. a resin containing a crosslinked copolymer of butyl acrylate and methyl methacrylate; - 20-80% vol. a fast drying solvent having an evaporation rate greater than or equal to 1.3, which is soluble in water; and - 0-70% vol. water, whereby the structure of the packing with the applied solution is formed; and - exposing the structure of the packing with the applied solution to the action of air, whereby the evaporation of the solvent in the resin solution and the curing of the resin are ensured, as a result of which an air-dried packing is formed containing 75-97.5% of the mass. a mixture of fibers and 2.5-25% of the mass. resin, whereby the resin adheres to the fibers of the fiber mixture, whereby a bonded structure is formed, so that the air-dried packing by means of the resin has a structural integrity that allows the workability of the sheet-like packing. 23. The method of claim 22, wherein the fast drying solvent is isopropyl alcohol. 24. The method of claim 22, wherein said forming the web of nonwoven fabric from the blend of fibers is performed using a carding or airlaying process. 25. The method of claim 22, wherein said application comprises spraying the resin solution onto a first surface and a second surface of the intermediate structure of the insulating pad. 26. The method of claim 22, the method comprising heating a web of nonwoven fabric. 27. The method of claim 22, wherein said exposing the solution-applied packing to air comprises exposing the solution-applied packing to forced air or circulated air.

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