US20180010272A1 - Filling material and process for making same - Google Patents

Filling material and process for making same Download PDF

Info

Publication number
US20180010272A1
US20180010272A1 US15207255 US201615207255A US2018010272A1 US 20180010272 A1 US20180010272 A1 US 20180010272A1 US 15207255 US15207255 US 15207255 US 201615207255 A US201615207255 A US 201615207255A US 2018010272 A1 US2018010272 A1 US 2018010272A1
Authority
US
Grant status
Application
Patent type
Prior art keywords
fibers
down
particles
filling material
filled
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.)
Pending
Application number
US15207255
Inventor
Gabor Zombori
Carmen Rodrguez
Tracy Laskowski Miller
Joseph Crawford
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Hollander Sleep Products LLC
Original Assignee
Hollander Sleep Products LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date

Links

Images

Classifications

    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • AHUMAN NECESSITIES
    • A41WEARING APPAREL
    • A41DOUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00Selection of special materials for outerwear
    • A41D31/0011Selection of special materials for protective garments
    • A41D31/0033Selection of special materials for protective garments with thermal protective materials
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47GHOUSEHOLD OR TABLE EQUIPMENT
    • A47G9/00Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows
    • A47G9/02Bed linen; Blankets; Counterpanes
    • A47G9/0207Blankets; Duvets
    • A47G9/0223Blankets
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47GHOUSEHOLD OR TABLE EQUIPMENT
    • A47G9/00Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows
    • A47G9/08Sleeping bags
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47GHOUSEHOLD OR TABLE EQUIPMENT
    • A47G9/00Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows
    • A47G9/10Pillows
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B68SADDLERY; UPHOLSTERY
    • B68GMETHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G1/00Loose filling materials for upholstery
    • B68G2001/005Loose filling materials for upholstery for pillows or duvets

Abstract

The filling material includes down with synthetic fibers having particles present on the surface of the fibers. The particles are characterized by a configuration which allows attachment of the down to the fibers.
The associated method of manufacturing the filling material includes steps of obtaining a quantity of down and a quantity of synthetic fibers having particles on the surface thereof, wherein the particles allow attachment of the down to the fibers. The down and fibers are blended together to produce the filling material.

Description

    TECHNICAL FIELD
  • This invention generally relates to a combination of down and a selected synthetic fiber to produce a blended filling material which remains blended during use, and also relates to a process for blending the down and fibers.
  • BACKGROUND OF THE INVENTION
  • Down is a well-known waterfowl or land fowl material, such as from geese or duck, located close to the body of the animal, generally beneath the feathers. Down is a soft material that typically traps the natural warmth of the body. Feathers can also have this characteristic. Down provides warmth and comfort generally superior to other natural and synthetic fibers and has good moisture management characteristics. Although down is known to have a natural ability to shed water, this ability can be compromised. Various improvements to the characteristics of down are desirable, including, for instance, that the down material dry faster after a filled article, such as a comforter or clothing, is laundered or becomes wet in use.
  • Down is known to compress and lose its effective fill power over time; however, fill power can often be restored through laundering. Fill power is defined herein as cubic inches displaced by one ounce of filling material.
  • There are fibers, including polyester fibers, which have desirable characteristics not present in down, such as better moisture management, better resistance to matting and compression, anti-microbial capability and lower cost, but they do not possess the light-weight warmth and comfort of natural down. Heretofore, blending or mixing of natural down with polyester fibers to provide improvements in characteristics such as moisture management and fill power has not previously been successful because the down, particularly over time, will not remain blended or otherwise secured to the polyester fibers, resulting in a decrease in performance, i.e. loss of fill power, and a loss of loft. A combination of a natural down and polyester fibers which would improve moisture management and/or other performance features and which would remain blended during use, such as in a bedding article or clothing, and during laundering, would be advantageous, and also could be a blend of polyester fibers and down which would not significantly reduce the fill power of down.
  • SUMMARY OF THE INVENTION
  • Accordingly, in one aspect of the invention, the filling material comprises down and synthetic fibers having particles present on the surface of the fibers, the particles characterized by a configuration or other structural or spatial characteristics which allows attachment of the down and fibers and results in a blended filling material which remains blended during use in a bedding or clothing or other filled article.
  • Another aspect of the invention is a bedding article comprising a blend of down and synthetic fibers wherein the fibers have particles present on the surface of the fibers, the particles characterized by a configuration or other structural or spatial characteristic which allows attachment of the down and fibers; and a bedding article filled with the blend of down and fibers.
  • Another aspect of the invention is a clothing article comprising a blend of down and synthetic fibers wherein the fibers have particles present on the surface of the fibers, the particles characterized by a configuration or other structural or spatial characteristic which allows attachment of the down and fibers; and a clothing article filled with the blend of down and fibers.
  • Another aspect of the invention is a sleeping bag comprising a blend of down and synthetic fibers wherein the fibers have particles present on the surface of the fibers, the particles characterized by a configuration or other structural or spatial characteristic which allows attachment of the down and fibers; and a sleeping bag filled with the blend of down and fibers.
  • Another aspect of the invention is a method of manufacturing a filling material, comprising the steps of obtaining a quantity of down; obtaining a quantity of fibers having particles on the surface thereof, the particles characterized by a configuration which allows attachment of the down and fibers; and blending the down and fibers together.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a schematic view of natural down fibers.
  • FIG. 2 is a magnified view of a particular polyester fiber, namely a single yarn filament of a fiber known as 37.5 manufactured by Cocona.
  • FIG. 3 shows a magnified bundle of the filaments of FIG. 2.
  • FIG. 4 is a significantly magnified view of a filament showing an active particle and the 37.5 filament.
  • BEST MODE FOR CARRYING OUT THE INVENTION
  • The filling material of the invention described herein is a combination of natural down or feathers and the 37.5® fiber manufactured by Cocona, or a synthetic fiber having similar characteristics, as herein described and simply referred to hereinafter as a blending fiber. As indicated above, natural down is waterfowl or land fowl fiber material that used in many products/articles to provide warmth and comfort. Among them are numerous bedding items, such as comforters, pillows and blankets, as well as certain clothing items, such as jackets, and also sleeping bags, as well as other filled items. The filling material is prepared by blending the natural down with the blending fiber. The 37.5 fiber shown is a polyester (synthetic) fiber with active carbon particles or other mineral particles attached thereto. The particles have an irregular and/or complex surface, which includes configuration or other structural or spatial characteristics. A single filament of the fiber is shown in FIG. 2, with the filament at 12, and active particles at 14. In the embodiment shown, a typical filament of the 37.5 fiber or other blending fiber will vary in length and thickness from approximately ½-3 inches long, and a size of 0.9-10 denier. In one particular embodiment, the fiber length is 38 mm, with a denier of 1-4. In the arrangement shown, the individual filaments of the blending fiber have the activated carbon particles or other mineral particles, such as volcanic sand, silver, copper or titanium, among others, present on the surface thereof. The particles are typically embedded in the surface of the filaments. In the embodiment shown, the diameter of the individual particles is within the range of 100 nm-50 microns. The density of the individual particles in the surface of the fibers is within the range of 5-10%. The percentage of surface exposure of the individual particles is within the range of 5-15%. The particles are porous, with a porosity which varies in accordance with the particular particle.
  • In making the filling material, down is first separated or sorted from other materials, such as normal residue, and in some cases feathers, as well as other fibers. Generally, down which is imported from foreign countries has already been satisfactorily sorted, cleaned and dried. That process for imported down as well as processing the down locally is accomplished by first using any of various sorting techniques. The down is then thoroughly washed to remove any dirt or other impurities. This is done with conventional washing machines and techniques. In one embodiment, the down is processed in 275-350 lb batches. The down is washed in water at a temperature of 50-56° C. Washing and rinsing occurs until the desired cleansing is achieved. The down is then transferred to a drier and dried at a temperature of approximately 110° C. The down is now ready for blending.
  • The down is then blended with the blending fiber as follows: generally, the process begins with baled fiber and fully-washed down. They are then loaded into two separate hoppers for measurement and transfer into the processing machinery. The processing machinery includes typical raw-fiber opening equipment common to the bedding industry. The opened fiber is then sent to a mixing chamber. The mixing chamber is a conventional down/feather-mixing chamber common in the industry. In the embodiment shown, the blending is done in 55 lb batches, but this could vary. In the mixing chamber, down is added to the blending fiber to achieve the desired ratio of opened fiber and washed down. The fiber is then mixed thoroughly with the down. This mixing typically takes about 8 minutes with an 80% down, 20% fiber ratio. The mixture is then discharged and packaged for storage and shipment. The present filling comprises a blend of 80% natural down and 20% blending fiber. More generally, the range can be 60-90% for natural down and 40-10% for fiber. It should be understood that the blend can be adjusted by weight for different compositions and for different applications.
  • The above filling has advantages over either natural down or the blending fiber alone. While the fiber is polyester, the combination disclosed herein provides the comfort and feel of down with improvements upon the natural characteristics of down, including moisture management. The improvement in moisture management is associated with both usage, i.e. reduction and/or removal of moisture from perspiration associated with actual use and product care, i.e. faster drying when laundering or recovery from rain or snow.
  • The characteristics of the selected fiber, with the porosity of the particles, results in a continuing attachment of the down with the fibers. The particles also provide a rough surface for the fiber, regardless of the porosity. The filaments with particles are shown in FIGS. 3 and 4. FIG. 3 includes a plurality of filaments 20, with particles 22, while FIG. 4 shows a high magnification of a single filament 26 and a porous particle 28. The down has natural surface node-like characteristics, which results in maintaining the blending, e.g. attachment of the natural down with the blending fibers. The physical characteristics of the down mate with the particles on the fibers to maintain blending. Porous particles are helpful for attachment, but the particles themselves also rough the surface of the fiber, which also helps to maintain the down attachment. The combination of the natural down with the synthetic blending fibers, having the configuration or structural or spatial characteristics discussed above, results in a filling material which remains blended during use and following washing. The resulting filling blend has advantages in addition to moisture management. These include improvements in radiant insulation as well as antimicrobial capability, order management and cost reduction.
  • The blended filling maintains its mix during use. Typical blends separate as smooth synthetic fibers slip through the down due to gravity and agitation.
  • The fill power of the present blend does not decrease during use so the performance of the blended filling is maintained as the down and synthetic fibers with the particles remain attached. As discussed above, fill power is typically defined as cubic inches displaced by one ounce of filling material. A lattice-like structure results, offsetting the decrease in fill power caused by blending synthetic fibers with down. The loft of the filled articles is maintained, which is important.
  • Clumping of the blended filling is reduced or eliminated. This is ordinarily a result of the down and the fibers separating. Clumping interferes with efficient production of the finished product, as well as the performance and the appearance of the finished product.
  • Accordingly, a filling material and associated process for making the filling has been described which combines natural down and in some cases feathers with a fiber having particular structural physical characteristics, namely, the use of porous particles embedded in the surface of the fibers, of which the 37.5 fiber produced by Cocona is but one example.
  • Although a preferred embodiment has been disclosed for purposes of illustration, it should be understood that various changes, modifications and substitutions may be incorporated in the preferred embodiment without departing from the spirit of the invention as defined by the claims which follow:

Claims (17)

    What is claimed is:
  1. 1. A filling material, comprising:
    down; and
    synthetic fibers having particles present in or on the surface of the fibers, the particles characterized by a configuration or other structural or spatial characteristic which allows attachment of the down and fibers and results in a blended filling material which remains blended during use in a bedding or clothing or other filled article.
  2. 2. The filling material of claim 1, wherein the attachment is mechanical.
  3. 3. The filling material of claim 1, wherein the particles are a mineral.
  4. 4. The filling material of claim 3, wherein the particles are one or more of the following: carbon, volcanic sands, titanium, silver and copper.
  5. 5. The filling material of claim 1, wherein the down is 50-90% and the fibers are 50-10% of the filling material.
  6. 6. The filling material of claim 1, wherein the particles are porous.
  7. 7. A filled bedding article, comprising:
    a blend of down and fibers wherein the fibers have particles present in or on the surface of the fibers, the particles characterized by a configuration or other structural or spatial characteristic which allows attachment of the down and fibers; and
    a bedding article filled with the blend of down and fibers.
  8. 8. The bedding article of claim 7, wherein the bedding article is a pillow, comforter or blanket.
  9. 9. A filled clothing article, comprising:
    a blend of down and fibers wherein the fibers have particles present in or on the surface of the fibers, the particles characterized by a configuration or other structural or spatial characteristic which allows attachment of the down and fibers; and
    a clothing article filled with the blend of down and fibers.
  10. 10. The clothing article of claim 9, wherein the clothing article is a jacket.
  11. 11. A filled sleeping bag, comprising:
    a blend of down and fibers, wherein the fibers have particles present in or on the surface thereof, the particles characterized by a configuration or other structural or spatial characteristic which allows attachment of the down and the fibers; and
    a sleeping bag product filled with the blend of down and fibers.
  12. 12. A method of manufacturing a filling material, comprising the steps of:
    obtaining a quantity of down;
    obtaining a quantity of synthetic fibers having particles on the surfaces thereof, the particles characterized by a configuration or other structural or spatial characteristic which allows attachment of the down and fibers; and
    blending the down and fibers together.
  13. 13. The method of claim 12, wherein the down comprises 50-90% of the filling material and the fiber comprises 50-10% of the filling material.
  14. 14. The method of claim 12, wherein the method steps are predetermined.
  15. 15. The method of claim 12, including the step of opening the fibers, and adding down to the opened fibers.
  16. 16. The method of claim 12, wherein the blending step is dry.
  17. 17. The method of claim 12, wherein the down is cleaned and rinsed enough times to produce a clean down and then dried.
US15207255 2016-07-11 2016-07-11 Filling material and process for making same Pending US20180010272A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US15207255 US20180010272A1 (en) 2016-07-11 2016-07-11 Filling material and process for making same

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US15207255 US20180010272A1 (en) 2016-07-11 2016-07-11 Filling material and process for making same
PCT/US2017/041411 WO2018084903A1 (en) 2016-07-11 2017-07-10 Filling material and process for making same

Publications (1)

Publication Number Publication Date
US20180010272A1 true true US20180010272A1 (en) 2018-01-11

Family

ID=60893232

Family Applications (1)

Application Number Title Priority Date Filing Date
US15207255 Pending US20180010272A1 (en) 2016-07-11 2016-07-11 Filling material and process for making same

Country Status (2)

Country Link
US (1) US20180010272A1 (en)
WO (1) WO2018084903A1 (en)

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1900880C3 (en) * 1969-01-09 1974-04-11 Artlaender Bettfedernfabrik, Karl Rosenstengel Kg, 4559 Kettenkamp
US4477515A (en) * 1981-10-29 1984-10-16 Kanebo, Ltd. Wadding materials
JP2929269B2 (en) * 1995-11-21 1999-08-03 生命エネルギー工業株式会社 Bedding with electret function
US6824819B2 (en) * 1998-09-04 2004-11-30 Milliken & Company Wash-durable, down-proofed metallized fabric
US9380893B2 (en) * 2014-01-13 2016-07-05 Ronie Reuben Thermally insulating stretchable down feather sheet and method of fabrication
CN106231939A (en) * 2014-04-01 2016-12-14 北面服饰公司 Synthetic fill materials having composite fiber structures
EP3165654A1 (en) * 2015-11-09 2017-05-10 Carl Freudenberg KG Use of endless filament non-woven fabrics for preventing the escape of down in down- filled textile products

Also Published As

Publication number Publication date Type
WO2018084903A1 (en) 2018-05-11 application

Similar Documents

Publication Publication Date Title
US4783364A (en) Polyester fiberfill and process
US5571592A (en) Puffed insulative material
US4418103A (en) Filling material and process for manufacturing same
US4259400A (en) Fibrous padding material and process for its manufacture
US7247374B2 (en) Encapsulated active particles and methods for making and using the same
US4477515A (en) Wadding materials
US6329052B1 (en) Blowable insulation
US6232249B1 (en) Short fiber-containing down-feather wadding and process for producing the same
US3395066A (en) Fiberfill for pillows and method of making same
CN102808226A (en) Method for processing washing down feather
Burns et al. 5—CASHMERE AND THE UNDERCOAT OF DOMESTIC AND WILD ANIMALS
US5779950A (en) Method of making a synthetic fiber containing infrared energy powder
US20040235705A1 (en) Method for imparting substantive fragrance and, optionally, anti-static properties to fabrics during washing and/or drying procedure and compositions useful for effecting such processes
US4400426A (en) Thermal insulation material comprising a mixture of silk and synthetic fiber staple
US3952134A (en) Continuous filament product
WO1999016705A1 (en) Filling comprising a polyester fibre
US3889638A (en) Method for making a bait bedding composition
WO1997024484A1 (en) Covering for beds and similar items and method for its manufacture
JP2004141255A (en) Wet wiper
JP2005068565A (en) Cotton-blended yarn comprising bamboo charcoal powder, method for producing the same and fabric using the same cotton-blended yarn
US20010008690A1 (en) Composite molding and process for the production of the same
JPH10280261A (en) Nonwoven fabric for wet tissue paper
CN101952525A (en) Modified mineral-based fillers
JP2006115987A (en) Wadding
US20030046765A1 (en) Polyurehane foam and down filling

Legal Events

Date Code Title Description
AS Assignment

Owner name: PACIFIC COAST FEATHER COMPANY, WASHINGTON

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:ZOMBORI, GABOR;RODRIGUEZ, CARMEN;MILLER, TRACY LASKOWSKI;AND OTHERS;SIGNING DATES FROM 20170511 TO 20170607;REEL/FRAME:042955/0394

AS Assignment

Owner name: HOLLANDER SLEEP PRODUCTS, LLC, FLORIDA

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:PACIFIC COAST FEATHER COMPANY;REEL/FRAME:044513/0608

Effective date: 20171017