US20170362755A1 - Fiberball batting and articles comprising the same - Google Patents
Fiberball batting and articles comprising the same Download PDFInfo
- Publication number
- US20170362755A1 US20170362755A1 US15/535,645 US201515535645A US2017362755A1 US 20170362755 A1 US20170362755 A1 US 20170362755A1 US 201515535645 A US201515535645 A US 201515535645A US 2017362755 A1 US2017362755 A1 US 2017362755A1
- Authority
- US
- United States
- Prior art keywords
- fibers
- batting
- fiberballs
- nonwoven web
- binder fibers
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000000835 fiber Substances 0.000 claims abstract description 146
- 239000000203 mixture Substances 0.000 claims abstract description 41
- 238000000034 method Methods 0.000 claims abstract description 19
- 239000011230 binding agent Substances 0.000 claims description 70
- 229920002994 synthetic fiber Polymers 0.000 claims description 40
- 239000012209 synthetic fiber Substances 0.000 claims description 40
- 229920000728 polyester Polymers 0.000 claims description 13
- 238000010438 heat treatment Methods 0.000 claims description 9
- 239000000463 material Substances 0.000 claims description 9
- 238000002844 melting Methods 0.000 claims description 9
- 230000008018 melting Effects 0.000 claims description 9
- 238000004519 manufacturing process Methods 0.000 claims description 6
- 238000002156 mixing Methods 0.000 claims description 4
- -1 poly(ethylene terephthalate) Polymers 0.000 description 13
- 239000004971 Cross linker Substances 0.000 description 7
- 229920001296 polysiloxane Polymers 0.000 description 6
- 230000008901 benefit Effects 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 4
- 238000009960 carding Methods 0.000 description 4
- 238000009413 insulation Methods 0.000 description 4
- 150000001875 compounds Chemical class 0.000 description 3
- 230000007812 deficiency Effects 0.000 description 3
- 239000000839 emulsion Substances 0.000 description 3
- 239000011347 resin Substances 0.000 description 3
- 229920005989 resin Polymers 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229920000433 Lyocell Polymers 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 229920000297 Rayon Polymers 0.000 description 2
- 238000007792 addition Methods 0.000 description 2
- 238000007664 blowing Methods 0.000 description 2
- 239000003054 catalyst Substances 0.000 description 2
- 229920001577 copolymer Polymers 0.000 description 2
- 239000004205 dimethyl polysiloxane Substances 0.000 description 2
- 235000013870 dimethyl polysiloxane Nutrition 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 229920000435 poly(dimethylsiloxane) Polymers 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 229920000139 polyethylene terephthalate Polymers 0.000 description 2
- 239000005020 polyethylene terephthalate Substances 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- DNFVWCGSPMSVOO-UHFFFAOYSA-N 3,10-dioxatricyclo[10.2.2.25,8]octadeca-1(15),12(16),13-triene-2,11-dione Chemical group C1OC(=O)C(C=C2)=CC=C2C(=O)OCC2CCC1CC2 DNFVWCGSPMSVOO-UHFFFAOYSA-N 0.000 description 1
- LLLVZDVNHNWSDS-UHFFFAOYSA-N 4-methylidene-3,5-dioxabicyclo[5.2.2]undeca-1(9),7,10-triene-2,6-dione Chemical compound C1(C2=CC=C(C(=O)OC(=C)O1)C=C2)=O LLLVZDVNHNWSDS-UHFFFAOYSA-N 0.000 description 1
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 description 1
- GXGJIOMUZAGVEH-UHFFFAOYSA-N Chamazulene Chemical group CCC1=CC=C(C)C2=CC=C(C)C2=C1 GXGJIOMUZAGVEH-UHFFFAOYSA-N 0.000 description 1
- 229920001634 Copolyester Polymers 0.000 description 1
- 229920000742 Cotton Polymers 0.000 description 1
- 241000208202 Linaceae Species 0.000 description 1
- 235000004431 Linum usitatissimum Nutrition 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 229920002334 Spandex Polymers 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical class [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 150000001242 acetic acid derivatives Chemical class 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 239000004760 aramid Substances 0.000 description 1
- 229920003235 aromatic polyamide Polymers 0.000 description 1
- 150000001735 carboxylic acids Chemical class 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
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- 230000007547 defect Effects 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 150000002148 esters Chemical group 0.000 description 1
- 238000011066 ex-situ storage Methods 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 230000009477 glass transition Effects 0.000 description 1
- 210000004209 hair Anatomy 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000011133 lead Substances 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 230000005012 migration Effects 0.000 description 1
- 238000013508 migration Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 125000005609 naphthenate group Chemical group 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 125000005474 octanoate group Chemical class 0.000 description 1
- 125000005375 organosiloxane group Chemical group 0.000 description 1
- 229920000233 poly(alkylene oxides) Polymers 0.000 description 1
- 229920001281 polyalkylene Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 239000002243 precursor Substances 0.000 description 1
- 125000002924 primary amino group Chemical group [H]N([H])* 0.000 description 1
- 239000002964 rayon Substances 0.000 description 1
- 239000013557 residual solvent Substances 0.000 description 1
- 239000004447 silicone coating Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000004759 spandex Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- KKEYFWRCBNTPAC-UHFFFAOYSA-L terephthalate(2-) Chemical compound [O-]C(=O)C1=CC=C(C([O-])=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-L 0.000 description 1
- 210000002268 wool Anatomy 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
Images
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
- D04H1/5418—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
-
- 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
-
- 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
-
- 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
- D04H1/02—Cotton wool; Wadding
-
- 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
- D04H1/4326—Condensation or reaction polymers
- D04H1/435—Polyesters
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
- D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
Definitions
- the present invention generally relates to fiberball batting comprising synthetic fibers and binder fibers, the batting being useful as, for example, insulation.
- the invention also relates to articles comprising the batting, and to methods of making the batting.
- Fiberballs have been known for some time. While fiberballs have often been seen as undesirable manufacturing defects in, e.g., the carding of various continuous non-woven materials, in other applications, such as for blowable applications, fiberballs have proven useful.
- U.S. Pat. No. 4,618,531 describes one such blowable fiberball invention. Specifically, U.S. Pat. No. 4,618,531 discloses polyester fiberfill having spiral crimp that is randomly arranged and entangled in the form of blowable fiberballs. The fiberballs are said to be easily transported, e.g., by blowing.
- U.S. Pat. No. 4,794,038 discloses fiberballs that are formed of entangled spirally-crimped fiberfill and binder fibers, which are also preferably spirally-crimped.
- the fiberballs are said to be easily transported, e.g., by blowing, and can subsequently be compressed and bonded together.
- binder fiber blends are used on a large scale in furnishings, mattresses, and similar end-uses where strong support is desired.
- U.S. Pat. No. 4,940,502 discloses bonded structures, which are provided in the form of molded fiberball blocks, which are made through a process that involves a compressing stage.
- the resultant molded fiberball blocks are relatively dense (with densities generally ranging from about 20 Kg/m 3 to 80 Kg/m 3 ), have improved resilience, durability, and conformability, and may be used in, e.g., mattresses.
- the present invention satisfies the need for improved fill materials.
- 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.
- Certain embodiments of the presently-disclosed batting, articles comprising the batting, and methods for forming 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.
- the invention provides batting that comprises a nonwoven web comprising a fiber mixture having:
- the invention provides an article comprising the inventive batting.
- articles include, for example, outerwear (e.g. outerwear garments such as jackets, etc.), clothing, sleeping bags, bedding (e.g., comforters), etc.
- the invention provides a method of making the inventive batting, said method comprising:
- FIG. 1 is a top-view photograph of one embodiment of the inventive batting.
- FIG. 2 is a profile-view photograph of one embodiment of the inventive batting.
- the invention provides batting that comprises a nonwoven web comprising a fiber mixture having:
- the plurality of fiberballs and the plurality of portions of the nonwoven web that are adjacent to one or more fiberballs but that do not themselves comprise one or more fiberballs or any portion thereof, also necessarily comprise the fiber mixture of the nonwoven web.
- the inventive batting has typically been heat treated so as melt all or a portion of the binder fibers, thereby forming a bonded web-type batting. Accordingly, persons having ordinary skill in the art will understand that, in such embodiments, although “binder fibers” are recited in the fiber mixture of the nonwoven web, said fibers will be wholly or partially melted fibers, as opposed to binder fibers in their original, pre-heat treatment form. Nevertheless, as used herein, denier and length descriptions of the binder fibers describe characteristics of the binder fibers prior to thermal bonding treatment.
- FIG. 1 is a top-view photograph of one embodiment of the inventive batting 100 .
- the batting includes a plurality of fiberballs 12 , and a plurality of portions of the nonwoven web that are adjacent to one or more fiberballs but that do not themselves comprise one or more fiberballs or any portion thereof, which also necessarily comprise the fiber mixture of the nonwoven web 14 (for the sake of simplicity, these may be referred to as “spaces”).
- the invention is distinguishable from prior art bonded materials formed from blowable fiberballs (for example, as disclosed in U.S. Pat. No.
- FIG. 2 is a profile-view photograph of an embodiment of the inventive batting 200 , which also shows fiberballs 12 and spaces 14 .
- An advantage of the present invention over the state of the art includes the ability of the inventive batting to form rolled goods. While prior art blowable fiberballs have been bonded, bonding typically takes place only after the fiberballs have been introduced into their final destination (e.g., a cushion).
- the inventive batting is made so as to form a non-woven web (generally, in the form of a soft, pliable sheet), which can be subsequently subjected to heat treatment so as to melt the binder fibers and form the inventive batting ex situ (outside of the finished product).
- the inventive batting may then optionally be rolled and shipping to be used as a rolled good. For example, rolls of the batting may be later cut to a desired dimension, depending on intended application, then used as filling and/or insulation in an article.
- the fiber mixture of the batting comprises 40 to 95 wt % of the synthetic fibers, including any and all ranges and subranges therein.
- the batting comprises 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, or 95 wt % of the synthetic fibers, including any and all ranges and subranges therein (e.g., 75 to 90 wt %).
- the synthetic fibers are selected from the group consisting of polyamide, polyester, acrylic, acetate, polyolefin, nylon, rayon, lyocell, aramid, spandex, viscose, and modal fibers, and combinations thereof.
- the synthetic fibers comprise polyester fibers.
- such polyester fibers comprise one or more of ⁇ poly(ethylene terephthalate), poly(hexahydro-p-xylylene terephthalate), poly(butylene terephthalate), poly-1,4-cyclohexelyne dimethylene (PCDT) and terephthalate copolyesters in which at least 85 mole percent of the ester units are ethylene terephthalate or hexahydro-p-xylylene terephthalate units.
- the synthetic fibers are polyethylene terephthalate fibers.
- Denier is a unit of measure defined as the weight in grams of 9000 meters of a fiber or yarn. It is a common way to specify the weight (or size) of the fiber or yarn.
- polyester fibers that are 1.0 denier typically have a diameter of approximately 10 micrometers.
- Micro-denier fibers are those having a denier of 1.0 or less, while macro-denier fibers have a denier greater than 1.0.
- the synthetic fibers have a denier of 0.5 to 7.0, including any and all ranges and subranges therein.
- the denier is 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, or 7.0, including any and all ranges and subranges therein (e.g., 1.0
- the synthetic fibers have a length of 18 mm to 51 mm, including any and all ranges and subranges therein.
- the length is 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, or 51 mm, including all ranges/subranges therein (e.g., 20 to 30 mm).
- the synthetic fibers are siliconized.
- 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, for example, in U.S. Pat. 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, polydimethylsiloxane, or amino modified dimethylpolysiloxane.
- the silicon-comprising composition may be applied directly to the fiber, or may be diluted with a solvent as a solution or emulsion, e.g. an aqueous emulsion of a polysiloxane, prior to application. Following treatment, the coating may be dried and/or cured.
- a catalyst may be used to accelerate the curing of the silicon-comprising composition (e.g., polysiloxane containing Si—H bonds) and, for convenience, may be added to a silicon-comprising composition emulsion, with the resultant combination being used to treat the synthetic fiber.
- Suitable catalysts include iron, cobalt, manganese, lead, zinc, and tin salts of carboxylic acids such as acetates, octanoates, naphthenates and oleates.
- the fiber may be dried to remove residual solvent and then optionally heated to between 65° and 200° C. to cure.
- the synthetic fibers are slickened with another slickening agent, e.g., segmented copolymers of polyalkyleneoxide and other polymers, such as polyester, or polyethylene or polyalkylene polymers as is mentioned in U.S. Pat. No. 6,492,020 B1.
- another slickening agent e.g., segmented copolymers of polyalkyleneoxide and other polymers, such as polyester, or polyethylene or polyalkylene polymers as is mentioned in U.S. Pat. No. 6,492,020 B1.
- Binder fibers are well known in the art, and an array of binder fibers are commercially available.
- the binder fibers used in the present invention may be conventional binder fibers (e.g., low-melt polyester binder fibers), or other binder fibers, provided that whatever binder fiber is used, the binder fiber has a bonding temperature lower than the softening temperature of the synthetic fibers. Binder fibers are discussed, for example, in U.S. Pat. No. 4,794,038, and general protocols for certain embodiments of binder fibers are set forth in U.S. Pat. No. 4,281,042 and in U.S. Pat. No. 4,304,817. In some embodiments, the binder fibers are monocomponent fibers.
- the binder fibers are multicomponent fibers (e.g., bicomponent fibers, for example, sheath-core fibers, where the core comprises a higher melting component than the sheath).
- the binder fibers comprise blends of one or more different types of binder fibers.
- the fiber mixture of the batting comprises 5 to 40 wt % of the binder fibers, including any and all ranges and subranges therein.
- the batting comprises 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 % of the binder fibers, including any and all ranges and subranges therein (e.g., 10 to 25 wt %).
- the binder fibers have a denier of 1.0 to 5.0, including any and all ranges and subranges therein.
- the denier is 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, or 5.0 denier, including any ranges/subranges therein (e.g., 1.5 to 3.5 denier, 1.9 to 2.5 denier, etc.).
- the binder fibers have a length of 18 mm to 71 mm, including any and all ranges and subranges therein.
- the length is 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, or 71 mm, including all ranges/subranges therein (e.g., 18 to 51 mm, 40 to 60 mm, etc.).
- 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, 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 have a melting temperature that is 15 to 170° C. less than the melting temperature of the synthetic fibers.
- the binder fibers have a melting temperature that is 15-170° C. less than the melting temperature of the synthetic fibers (e.g., 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,
- 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 binder fibers are polyethylene/polypropylene bicomponent fibers.
- the synthetic fibers and/or the binder fibers are crimped fibers.
- Various crimps, including spiral and standard crimp, are known in the art.
- the fibers may typically have any crimp.
- the fibers are not spirally or helically crimped fibers.
- synthetic and/or binder fibers are not crimped.
- the fiber mixture additionally comprises one or more types of natural fibers in addition to the synthetic fibers and binder fibers.
- the fiber mixture additionally comprises one or more members selected from wool, cotton, tencel, flax, animal hair, silk, and down.
- the nonwoven web comprises 50 to 90 wt % of fiberballs, including any and all ranges and subranges therein; and 10 to 50 wt % of the spaces, including any and all ranges and subranges therein.
- the batting/nonwoven web comprises 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 wt % fiberballs, including any and all ranges/subranges therein (e.g., 70 to 90 wt %).
- the batting/nonwoven web comprises 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or 50 wt % spaces, including ranges/subranges therein (e.g., 10 to 30 wt %).
- the fiberballs have an average diameter of 3.0 to 8.0 mm (e.g., 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, or 8 mm), including any and all ranges and subranges therein (e.g., 4 to 6 mm, 5 to 6 mm, etc.).
- the batting has a thickness of less than or equal to 40 mm, for example, 5 to 40 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, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, or 40 mm), including all ranges and subranges therein.
- 5 to 40 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, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, or 40 mm
- the batting has a density of 2 to 12 kg/m 3 (e.g., 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 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.
- the density of the batting is thus relatively low compared to prior art that utilizes compacted fiberballs.
- embodiments of the inventive batting unlike prior art, provide a lofty, soft, and pliable insulation.
- inventive batting having a density of 2 to 12 kg/m 3 , may not have sufficient structural integrity to remain intact following handling and use (and thus would not be fit as insulation), would not have sufficient insulating properties, and/or would not be readily producible, Applicant has found that embodiments of the invention surprisingly achieve all of these objectives.
- the inventive batting comprises a first surface and second surface, the second surface being parallel to first surface.
- the first surface and/or the second surface of the batting comprises a cross-linked resin.
- a cross-linker solution comprising a cross-linker compound has been applied to the first and/or second surface.
- the resin is a cross-linked (e.g., via heat treatment) version of the cross-linker solution.
- the cross-linked resin comprises a cross-linker that is a cross-linked acrylate (co)polymer.
- the cross-linker solution and/or the cross-linker compound display softness and hydrophobicity.
- the cross-linker compound has a glass transition temperature (Tg) of less than 0° C.
- At least one of the first surface and second surface comprises a scrim layer.
- Scrim is well known in the art. Use of scrim can help to mitigate fiber migration in the inventive batting (e.g., during handling of the product).
- the inventive batting comprises the nonwoven web, which comprises the fiber mixture.
- the fiber content of the nonwoven web consists of the fiber mixture.
- the batting comprises a single nonwoven web. In other embodiments, the batting comprises a plurality of nonwoven web layers, wherein one or more of said layers is a nonwoven web according to the invention (i.e., containing the fiber mixture and specified weight percentages of fiberballs and spaces). In some embodiments, the batting comprises a plurality of nonwoven webs, all of which are nonwoven webs according to the invention.
- the invention provides an article comprising the inventive batting.
- articles include, for example, outerwear (e.g. outerwear garments such as jackets, etc.), clothing, sleeping bags, bedding (e.g., comforters), etc.
- the invention provides a method of making the inventive batting, said method comprising:
- any known fiberball formation process that is conducive to forming fiberballs from the fiber mixture (knowledge well within the purview of a skilled artisan in the field) may be used.
- methods of forming fiberballs are described, for example in U.S. Pat. Nos. 4,794,038 and 6,613,431.
- the fiberballs are formed by air-tumbling small tufts of the synthetic and binder fibers repeatedly against a wall of a vessel so as to densify the bodies and make them rounder, thereby forming fiberballs.
- a fiber ball machine is used to form fiberballs.
- the fiberballs are formed using a ball card (i.e., a carding machine modified for production of fiberballs).
- the synthetic fibers, and/or the binder fibers are opened prior to fiberball formation.
- opening entails separating the fibers to some extent (e.g., using an opener, such as a bale opening system) prior to further processing.
- the forming a nonwoven web from the fiber mixture may utilize any acceptable web-forming technology (e.g., an airlaid system, or a carding machine).
- the fiber mixture namely, in the form of fiberballs, which have been formed from the mixture
- the spaces may be formed, for example, from “fallout” fiber that has separated from a mixture of fiberballs that are processed through the airlaid system.
- forming the nonwoven web comprises depositing the fiber mixture (e.g., the formed fiberballs and any loose fibers remaining following fiber ball formation) onto a forming wire. In some embodiments, this may be done with vacuum assistance (e.g., the vaccum system being located below the forming wire). In particular embodiments, loose fiberballs are fed into an air lay system. The air lay system meters out the fiberballs via an airflow over a given width and specified thickness.
- the nonwoven web After the nonwoven web is formed, it is heated to or in excess of the bonding temperature of the binder fibers, thereby forming the inventive batting.
- the nonwoven fiberball web After the nonwoven fiberball web is created by the air lay system, it can be carried by an apron into a thermal bonding oven where the binder fibers are activated by heat, thus resulting in a bonded batting.
- the intermediate nonwoven web Prior to thermal bonding (heating the non-woven web to or in excess of the bonding temperature of the binder fibers), the intermediate nonwoven web may optionally be subjected to machining (e.g., rollers) to provide a degree of integrity to the web, if desired (provided, of course, that such machining does not result in a batting that would have a density in excess of 12 kg/m 3 ).
- machining e.g., rollers
- the nonwoven web may serve as the batting, or it may be layered with one or more additional layers (according to the invention or otherwise) to form a layered batting.
- a sample batting is made according to the above method.
- the fiber mix for the sample is 90% 1.4 denier polyester fibers having a staple length of 28 mm, and 10% low-melt bi-component polyester/polyester binder fibers.
- the fiber mix is processed through a carding machine to obtain a non-woven web batting pre-cursor, which is heated at 110° C. to form an embodiment of the inventive batting.
- the final batting structure consists of 80% fiberballs having a diameter of 6 mm, and 20% plurality of portions of the nonwoven web that are adjacent to one or more fiberballs but that do not themselves comprise one or more fiberballs or any portion thereof.
- the batting has a weight of 175 gsm (grams per square meter), a thickness of 17.5 mm, and a density of 10 kg/m 3 .
- 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.
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Nonwoven Fabrics (AREA)
- Bedding Items (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Multicomponent Fibers (AREA)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US15/535,645 US20170362755A1 (en) | 2014-12-17 | 2015-12-17 | Fiberball batting and articles comprising the same |
Applications Claiming Priority (3)
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US201462093293P | 2014-12-17 | 2014-12-17 | |
PCT/US2015/066284 WO2016100616A1 (fr) | 2014-12-17 | 2015-12-17 | Nappe ouatée en boulettes de fibres et articles la comprenant |
US15/535,645 US20170362755A1 (en) | 2014-12-17 | 2015-12-17 | Fiberball batting and articles comprising the same |
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US20170362755A1 true US20170362755A1 (en) | 2017-12-21 |
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ID=56127577
Family Applications (1)
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US15/535,645 Abandoned US20170362755A1 (en) | 2014-12-17 | 2015-12-17 | Fiberball batting and articles comprising the same |
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US (1) | US20170362755A1 (fr) |
EP (1) | EP3234244B1 (fr) |
JP (1) | JP6669755B2 (fr) |
KR (1) | KR20170097067A (fr) |
CN (1) | CN107407027B (fr) |
DK (1) | DK3234244T3 (fr) |
ES (1) | ES2773473T3 (fr) |
PL (1) | PL3234244T3 (fr) |
RU (1) | RU2694282C2 (fr) |
TW (1) | TWI711731B (fr) |
WO (1) | WO2016100616A1 (fr) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20180230630A1 (en) * | 2015-08-18 | 2018-08-16 | Carl Freudenberg Kg | Volume nonwoven fabric |
Families Citing this family (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP3247826B1 (fr) | 2015-01-21 | 2019-05-01 | PrimaLoft, Inc. | Nappe ouatée résistant à la migration dotée d'une extensibilité et procédés de fabrication et articles comprenant celle-ci |
CN107667191A (zh) | 2015-05-22 | 2018-02-06 | 普莱玛有限公司 | 自热隔热材料 |
RU2670531C1 (ru) | 2015-09-29 | 2018-10-23 | Прималофт, Инк. | Вдуваемый изоляционный материал из флокул и способ его изготовления |
CN106835493A (zh) * | 2017-03-01 | 2017-06-13 | 杭州缔星纤维科技有限公司 | 一种多纤维层复合材料及其制作方法和应用 |
KR101965564B1 (ko) | 2017-10-27 | 2019-04-04 | 김명섭 | 패킷형 이불피 및 이를 포함하는 패킷형 이불 |
DE112019005157T5 (de) * | 2018-10-15 | 2021-07-01 | Primaloft, Inc. | Wärmeregulierende dreidimensionale isolierende strukturen und erzeugnisse, die diese umfassen |
EP4124684B1 (fr) | 2021-07-26 | 2024-04-03 | Carl Freudenberg KG | Rembourrage en boules de fibres avec différentes formes de boules de fibres pour assurer une meilleure isolation |
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US5238612A (en) * | 1985-05-15 | 1993-08-24 | E. I. Du Pont De Nemours And Company | Fillings and other aspects of fibers |
US20160355958A1 (en) * | 2014-02-18 | 2016-12-08 | Carl Freudenberg Kg | Volume nonwoven fabric |
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US4281042A (en) * | 1979-08-30 | 1981-07-28 | E. I. Du Pont De Nemours And Company | Polyester fiberfill blends |
US4794038A (en) * | 1985-05-15 | 1988-12-27 | E. I. Du Pont De Nemours And Company | Polyester fiberfill |
IN168824B (fr) * | 1986-10-21 | 1991-06-15 | Du Pont | |
US4837067A (en) * | 1987-06-08 | 1989-06-06 | Minnesota Mining And Manufacturing Company | Nonwoven thermal insulating batts |
AU7654091A (en) * | 1990-04-12 | 1991-11-11 | E.I. Du Pont De Nemours And Company | Fillings and other aspects of fibers |
US5458971A (en) * | 1994-09-30 | 1995-10-17 | E. I. Du Pont De Nemours And Company | Pillows and other filled articles and in their filling materials |
WO2003057962A2 (fr) * | 2002-01-04 | 2003-07-17 | Invista Technologies S.À.R.L. | Ouate en bourre de polyester non tissee avec surface exterieure scellee ayant une aptitude a l'etirage amelioree |
US6613431B1 (en) * | 2002-02-22 | 2003-09-02 | Albany International Corp. | Micro denier fiber fill insulation |
CN100564641C (zh) * | 2002-12-20 | 2009-12-02 | 宝洁公司 | 簇状的层压纤维网 |
JP4791175B2 (ja) * | 2005-12-26 | 2011-10-12 | 帝人ファイバー株式会社 | 高弾性繊維球状体からなる成型品 |
CN103031664B (zh) * | 2011-10-09 | 2015-11-18 | 上海南方寝饰用品有限公司 | 一种聚酯纤维和莱赛尔纤维混合的家纺填充物及其制备方法 |
-
2015
- 2015-12-17 DK DK15871047.5T patent/DK3234244T3/da active
- 2015-12-17 EP EP15871047.5A patent/EP3234244B1/fr active Active
- 2015-12-17 RU RU2017125235A patent/RU2694282C2/ru active
- 2015-12-17 KR KR1020177017946A patent/KR20170097067A/ko unknown
- 2015-12-17 WO PCT/US2015/066284 patent/WO2016100616A1/fr active Application Filing
- 2015-12-17 US US15/535,645 patent/US20170362755A1/en not_active Abandoned
- 2015-12-17 PL PL15871047T patent/PL3234244T3/pl unknown
- 2015-12-17 ES ES15871047T patent/ES2773473T3/es active Active
- 2015-12-17 JP JP2017532664A patent/JP6669755B2/ja active Active
- 2015-12-17 CN CN201580069020.7A patent/CN107407027B/zh active Active
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2016
- 2016-01-14 TW TW105101020A patent/TWI711731B/zh active
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US5238612A (en) * | 1985-05-15 | 1993-08-24 | E. I. Du Pont De Nemours And Company | Fillings and other aspects of fibers |
US20160355958A1 (en) * | 2014-02-18 | 2016-12-08 | Carl Freudenberg Kg | Volume nonwoven fabric |
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US20180230630A1 (en) * | 2015-08-18 | 2018-08-16 | Carl Freudenberg Kg | Volume nonwoven fabric |
US10876234B2 (en) * | 2015-08-18 | 2020-12-29 | Carl Freudenberg Kg | Volume nonwoven fabric |
Also Published As
Publication number | Publication date |
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EP3234244A1 (fr) | 2017-10-25 |
CN107407027A (zh) | 2017-11-28 |
JP2018500472A (ja) | 2018-01-11 |
KR20170097067A (ko) | 2017-08-25 |
RU2017125235A (ru) | 2019-01-17 |
CN107407027B (zh) | 2020-04-21 |
ES2773473T3 (es) | 2020-07-13 |
JP6669755B2 (ja) | 2020-03-18 |
DK3234244T3 (da) | 2020-03-02 |
PL3234244T3 (pl) | 2020-06-01 |
TWI711731B (zh) | 2020-12-01 |
TW201723262A (zh) | 2017-07-01 |
EP3234244B1 (fr) | 2020-02-05 |
RU2694282C2 (ru) | 2019-07-11 |
WO2016100616A1 (fr) | 2016-06-23 |
RU2017125235A3 (fr) | 2019-04-23 |
EP3234244A4 (fr) | 2018-07-11 |
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