WO2022126008A1 - Construction isolante multicouche perméable à l'air - Google Patents

Construction isolante multicouche perméable à l'air Download PDF

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Publication number
WO2022126008A1
WO2022126008A1 PCT/US2021/063049 US2021063049W WO2022126008A1 WO 2022126008 A1 WO2022126008 A1 WO 2022126008A1 US 2021063049 W US2021063049 W US 2021063049W WO 2022126008 A1 WO2022126008 A1 WO 2022126008A1
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WO
WIPO (PCT)
Prior art keywords
layer
air
outer pliable
insulative
permeable multi
Prior art date
Application number
PCT/US2021/063049
Other languages
English (en)
Inventor
Vanessa Mason
Original Assignee
Primaloft, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Primaloft, Inc. filed Critical Primaloft, Inc.
Publication of WO2022126008A1 publication Critical patent/WO2022126008A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/026—Knitted fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B32B5/265—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary characterised by one fibrous or filamentary layer being a non-woven fabric layer
    • B32B5/266—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary characterised by one fibrous or filamentary layer being a non-woven fabric layer next to one or more non-woven fabric layers
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
    • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
    • A41D31/06—Thermally protective, e.g. insulating
    • A41D31/065—Thermally protective, e.g. insulating using layered materials
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
    • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
    • A41D31/14—Air permeable, i.e. capable of being penetrated by gases
    • A41D31/145—Air permeable, i.e. capable of being penetrated by gases using layered materials
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G9/00—Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows
    • A47G9/08—Sleeping bags
    • A47G9/086—Sleeping bags for outdoor sleeping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2437/00—Clothing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2601/00—Upholstery

Definitions

  • the present invention generally relates to an air-permeable multi-layer insulative construct, to articles comprising the construct, and to methods of making the construct.
  • the construct is particularly useful in the textile field.
  • Microfibers are those fibers having a denier of less than or equal to 1.0 denier ("denier” being a measure of the weight in grams per 9,000 meters length of fiber).
  • Synthetic microfiber insulations have been available in the commercial marketplace for decades now. Siliconized hydrophobic microfiber insulation is also known. Such fiber is described, for example, in U.S. Patent No. 4,588,635, and is available in the performance outdoor marketplace under the brand name PrimaLoft®.
  • Fibers and fill material including microfibers and natural fill materials (e.g., down) have long been used as insulative materials in the textile field.
  • the outdoor industry has utilized fibers, including microfibers, and down in cold weather apparel, sleeping bags, etc. for many years.
  • a disadvantage to using such fibers has been that this type of insulation is highly prone to display severe fiber migration through fabric surfaces, even when combined with low air permeability downproof fabrics and/or protected by nonwoven scrim materials.
  • Scrim is an interlining that is often used as a protective layer between insulation and a shell or liner fabric of an article.
  • Fiber migration is the penetration of fiber through the fabric surface such that fiber is present on the face side of the article, which is typically the outside of the article that is exposed to the external environment.
  • Downproof fabrics are typically defined as fabrics that are tightly woven with thread counts greater than 250 and have an air permeability rating according to ASTM D737 less than 1 cubic feet per minute (CFM).
  • fabrics have coatings applied to them or are calendared to seal their surface as a means to reduce fiber migration and/or achieve downproofness.
  • These treatments further reduce the air permeability of the fabric, which has a direct effect on the overall comfort of an article. The lower the air permeability of the fabric, the less breathable and comfortable it is. The higher the air permeability of the fabric, the more breathable and comfortable it is.
  • the present invention satisfies the need for improved migration resistant textile constructs.
  • 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.
  • Applicant has surprisingly found that embodiments of the air-permeable multi-layer insulative construct as described herein having at least one outer pliable layer with an air permeability of 1 to 500 CFM and made up of a tight polymeric web of fibers having a diameter of less than 10 pm offers remarkable resistance to and/or prevention of fiber migration (including down migration).
  • DE 202016008757 discloses absorbent hygiene products such as disposable diapers, sanitary napkins, and panty liners having a particular absorbent core that can be used for absorbing bodily fluids and exudates.
  • the absorbent core contains channels concretely designed to enhance uniform liquid distribution and comfort.
  • the core is positioned and held between a topsheet and backsheet.
  • the backsheet/outer shell of the absorbent article (which can be a breathable backsheet material, such as a nonwoven, e.g., meltblown, layer) does not allow liquid to pass therethrough.
  • US 7,118,558 also discloses absorbent articles such as diapers, the backsheet of which comprises a substantially liquid impervious material.
  • US 8,129,450 discloses disposable articles that include a thermoplastic polymer composition containing a modified polymer having covalently bonded pendant substituents derived from cyclodextrin.
  • the disposable article may comprise a nonwoven web comprising a spunbond fabric, a meltblown fabric, an electrospun fabric, and combinations thereof.
  • US 5,399,423 discloses an ignition resistant fibrous material for use as insulation.
  • the material comprises a multiplicity of meltblown or spunbonded thermoplastic filaments in combination with a multiplicity of nonlinear, nongraphitic carbonaceous fibers.
  • US 4,433,024 discloses vapor-sorbing particle-filled sheet material having a low insulation value.
  • the inner layer of the material can comprise a melt-blown fiber web that contains vapor-sorptive particles.
  • None of the aforesaid art contemplates use of a web as described herein in an air- permeable multi-layer insulative construct capable of reducing fiber migration. While aspects of the aforesaid art may be included in certain embodiments of the invention, it is also contemplated that certain embodiments of the invention may exclude aspects of the aforesaid art.
  • the invention provides an air-permeable multi-layer insulative construct comprising:
  • - comprises a nonwoven polymeric web comprising a plurality of fibers having a diameter of less than 10 pm;
  • the air-permeable multi-layer insulative construct has a thickness greater than 2 mm, wherein the air-permeable multi-layer insulative construct has a migration resistance of less than 20 fibers when tested according to the INS-17 Fiber Migration Test.
  • the invention provides an article comprising the air-permeable multi-layer construct according to the first aspect of invention.
  • the invention provides a method of making the air-permeable multilayer construct according to the first aspect of invention or the article according to the second aspect of the invention, the method comprising assembling the construct by disposing the inner insulation material layer between the first outer pliable layer and the second outer pliable layer.
  • Certain embodiments of the presently-disclosed air-permeable multi-layer insulative construct, articles comprising the construct, and methods of making the construct have several features, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of the air-permeable multi-layer insulative construct, articles and methods as defined by the claims that follow, their more prominent features will now be discussed briefly.
  • embodiments of the invention provide air-permeable, comfortable insulative constructs that significantly reduce and/or prevent fiber migration from the inner layer through one or more outer layers.
  • Such constructs find use in, inter alia, the textile field, for example, in clothing, outerwear, home furnishings, bedding, etc.
  • FIG. 1 illustrates a side cross-sectional view of an embodiment of the inventive air- permeable multi-layer insulative construct.
  • FIG. 2 illustrates a top-view of an embodiment of the inventive air-permeable multilayer insulative construct.
  • FIG. 3 illustrates a side cross-sectional view of an embodiment of the inventive air- permeable multi-layer insulative construct.
  • FIG. 4 illustrates a multi-layer insulative construct not according to an embodiment of the invention.
  • FIGS. 5A-C are enlarged photographs of a portion of a meltblown web that can be used as the first and/or second outer pliable layer.
  • the invention provides an air-permeable multi-layer insulative construct comprising:
  • - comprises a nonwoven polymeric web comprising a plurality of fibers having a diameter of less than 10 pm;
  • the inner insulation material layer has an air permeability of 1 to 500 CFM, wherein the inner insulation material layer: has a thermal performance warmth to weight ratio of at least 0.50 CLO/oz/sq yd. (.5 to 1.8), according to ISO 11092; and
  • the air-permeable multi-layer insulative construct has a migration resistance of less than 20 fibers when tested according to the INS-17 Fiber Migration Test.
  • FIG. 1 illustrates a side cross-sectional view of an embodiment of the inventive air- permeable multi-layer insulative construct 10.
  • the inner insulation material layer 6 is disposed (or sandwiched) between the first outer pliable layer 2 and the second outer pliable layer 4.
  • the inner insulation material layer 6, the first outer pliable layer 2, and the second outer pliable layer 4 are all parallel to one another.
  • the first outer pliable layer 2 when construct 10 is contained within an article (e.g., a textile article, for example, clothing, outerwear, home goods, bedding, etc.), the first outer pliable layer 2 will face toward an outer portion (e.g., fabric or other material or liner) of the article, e.g., a jacket, and the second outer pliable layer 4 will face toward an inner portion (e.g., fabric or other material or liner) of the article.
  • the outer portion is the environmentally-facing portion
  • the inner portion is the wearer-facing portion.
  • the first outer pliable layer 2 faces toward an inner portion of an article and the second outer pliable layer 4 faces toward an outer portion of an article.
  • FIG. 2 illustrates a top-view of an embodiment of the inventive air-permeable multilayer insulative construct wherein the inner insulation material layer 6 comprises batting that contains a plurality of bonded nonwoven polymeric webs including elastomeric and spiralcrimped synthetic fibers.
  • FIG. 3 illustrates a side cross-sectional view of an embodiment of the inventive air- permeable multi-layer insulative construct, wherein the construct is in the form of a baffle. Depicted are a plurality of baffles made by sewing through the first outer pliable layer 2 and the second outer pliable layer 4 along seams 8, then filling the baffles with inner insulation material layer 6, which is blowable insulation material.
  • FIG. 4 illustrates a multi-layer insulative construct not according to an embodiment of the invention.
  • fibers 12 which can be polymeric fibers, natural fibers such as down, etc.
  • fiber migration can be a particular problem following laundering of textile articles. It is a major problem for both polymeric fibers (natural and synthetic) and other natural fibers (e.g., down).
  • Truly down-proof fabric is typically a fabric having an air permeability of less than 1 cubic foot per square meter (CFM).
  • CFM cubic foot per square meter
  • inventions of the inventive air-permeable multi-layer insulative construct rival down-proof fabric in terms of resisting or preventing fiber migration, yet are much more comfortable and breathable, making for highly improved textiles.
  • the feature results from at least one of the first outer pliable layer and the second outer pliable layer comprising a nonwoven polymeric web that comprises a plurality of fibers having a diameter of less than (or less than or equal to) 10 pm.
  • the first outer pliable layer comprises a nonwoven polymeric web comprising a plurality of fibers having a diameter of less than 10 pm and has an air permeability of 1 to 500 CFM.
  • Such configuration may be particularly desirable for embodiments having only one surface or layer through which fiber migration is a problem (e.g., upholstered furniture, etc.).
  • the second outer pliable layer comprises a nonwoven polymeric web comprising a plurality of fibers having a diameter of less than 10 pm and has an air permeability of 1 to 500 CFM.
  • both the first and second outer pliable layers comprise a nonwoven polymeric web comprising a plurality of fibers having a diameter of less than 10 pm and has an air permeability of 1 to 500 CFM.
  • the first and second outer pliable layers comprise the same material. In other embodiments, the first and second outer pliable layers comprise different materials.
  • One or both of the first and second outer pliable layers has an air permeability 1 to 500 CFM (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26,
  • one or both of the first and second outer pliable layers has an air permeability of at least 1 CFM (e.g., at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 CFM).
  • One or both of the first outer pliable layer and the second outer pliable layer comprises a nonwoven polymeric web comprising a plurality of fibers having a diameter of less than or equal to 10 pm.
  • the fibers have a diameter of 0.3 pm to 10 pm (e.g., 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,
  • one or both of the first outer pliable layer and the second outer pliable layer comprises 50 to 100 wt% (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, 99.1, 99.2, 99.3, 99.4, 99.5, 99.6, 99.7, 99.8, 99.9, or 100 wt%), including any and all ranges and subranges therein, of the said plurality of fibers having a diameter of less than or equal to 10 pm.
  • the nonwoven polymeric web of the first outer pliable layer and/or the second outer pliable layer is a sheet of material having a structure of individual fibers or threads which are laid in, but not in a regular manner as would be the case for web formed by a knitting or weaving process.
  • the nonwoven polymeric web makes up (i.e., accounts for) 80 to 100 wt% (e.g., 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 99.1,
  • the first outer pliable layer and/or the second outer pliable layer are pliable, meaning that they can be folded without cracking or breaking the layer.
  • the first outer pliable layer and/or the second outer pliable layer has good drape (i.e., the layer hangs under its own weight).
  • the insulation has a drape of 1.5 cm to 10.0 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,
  • the first outer pliable layer and/or the second outer pliable layer has a basis weight range of 8-35 grams per square meter (gsm) (e.g., 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, or 35 gsm) including any and all ranges and subranges therein (e.g., 20 to 30 gsm, 23-27 gsm, etc.).
  • gsm grams per square meter
  • the first and/or second outer pliable layers may be made by any technique capable of making the layer(s) as described herein.
  • the first and/or second outer pliable layers comprise a nonwoven web formed via a meltblown process, electrospun process, forcespun, or bonded card web process.
  • the first and/or second outer pliable layer comprises a nonwoven web selected from a meltblown web, an electrospun web, a forcespun web, and a bonded carded web.
  • meltblown web comprises meltblown fibers
  • an electrospun web comprises electrospun fibers
  • a forcespun web comprises forcespun fibers
  • a bonded carded web comprises bonded barded fibers (typically staple fibers, i.e., fibers having a standardized length, as opposed to filaments, which are continuous fibers that can be of indefinite length).
  • meltblown fibers are fibers formed via a meltblown process, which typically involves extruding a molten thermoplastic material through a plurality of fine, usually circular die capillaries (or spinnerets) as molten threads or filaments into a high velocity gas (e.g., air) stream containing the filaments of the melt fused thermoplastic material to reduce its diameter. After the fibers are formed, the meltblown fibers are carried by the gas stream at high speed and deposited on a collecting surface to form a web of randomly dispensed meltblown fibers.
  • a meltblown process typically involves extruding a molten thermoplastic material through a plurality of fine, usually circular die capillaries (or spinnerets) as molten threads or filaments into a high velocity gas (e.g., air) stream containing the filaments of the melt fused thermoplastic material to reduce its diameter.
  • a high velocity gas e.g., air
  • first and/or second outer pliable layer comprises a meltblown web or other type of nonwoven polymeric web formed by collection of discrete fibers in a web on a collection surface
  • the web will typically have a first face (also known as a “back side”, which is the face formed adjacent to the collecting surface, on which a pattern from the collecting surface can in some embodiments be seen) and a second face (also known as a “face side”, which is the face formed facing away from the collection surface, for which randomly oriented fibers are typically most visible).
  • first face also known as a “back side”
  • face side also known as a “face side”
  • FIG. 5A and 5B are enlarged photographs (at magnification 6x and 60x, respectively) of the first face of a portion of a polypropylene meltblown web that can be used as the first and/or second outer pliable layer.
  • FIG. 5C is a photograph (at 60x magnification) of the second face of a portion of a polypropylene meltblown web that can be used as the first and/or second outer pliable layer.
  • the first outer pliable layer and/or the second outer pliable layer comprises a nonwoven polymeric web having a first face and a second face, wherein, for one or both of the layers, the second face is adjacent to the inner insulation material layer.
  • the first outer pliable layer and/or the second outer pliable layer comprises a nonwoven polymeric web having a first face and a second face, wherein, for one or both of the layers, the first face is adjacent to the inner insulation material layer.
  • the first outer pliable layer and/or the second outer pliable layer comprises a plurality of randomly discontinuous polymeric fibers that form the nonwoven polymeric web.
  • the first outer pliable layer and/or the second outer pliable layer has a thickness of 100 to 1000 pm (e.g., 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,
  • 100 to 1000 pm e.g., 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
  • the chemical nature/composition of the fibers in the first and second outer pliable layers are not intended to be limited, provided that one or both layers is otherwise as described herein.
  • the first outer pliable layer and/or the second outer pliable layer comprises fiber that can be processed in a meltblown process, electrospun process, forcespun, or bonded card web process.
  • the first outer pliable layer and/or the second outer pliable layer allows water to pass therethrough.
  • the first outer pliable layer and/or the second outer pliable layer are not substantially liquid impervious as described in U.S. Patent No. 7,118,558.
  • the first outer pliable layer and/or the second outer pliable layer comprises polymeric fiber.
  • nonexclusive polymers that may be used in polymeric fiber of the first outer pliable layer and/or the second outer pliable layer (or of the inner insulation material layer) are selected from nylon, polyester, polypropylene, polylactic acid (PLA), poly(butyl acrylate) (PBA), polyamide (e.g., nylon/polyamide 6.6, polyamide 6, polyamide 4, polyamide 11, and polyamide 6.10, etc.), acrylic, acetate, polyolefin, rayon, lyocell, aramid, spandex, viscose, modal fibers, biopolymer fibers (e.g., polyhydroxyalkanoates (PHA), poly- (hydroxybutyrate-coval erate) (PHBV)), and combinations thereof.
  • PHA polylactic acid
  • PBA poly(butyl acrylate)
  • polyamide e.g., nylon/polyamide 6.6, polyamide 6, polyamide 4, polyamide 11, and polyamide 6.10, etc.
  • the fiber comprises polyester selected from polyethylene terephthalate) (PET), poly(hexahydro-p-xylylene terephthalate), poly(butylene terephthalate) (PBT), poly- 1,4- cyclohexelyne dimethylene (PCDT), polytrimethylene terephthalate (PTT), and terephthalate copolyesters in which at least 85 mole percent of the ester units are ethylene terephthalate or hexahydro-p-xylylene terephthalate units.
  • the fibers comprise polypropylene or polyester, e.g., polyethylene terephthalate (PET).
  • the fibers comprise virgin polymer material.
  • the fibers comprise recycled polymer material, such as post-consumer recycled (PCR) polymer material.
  • the polymer(s) used in the first outer pliable layer and/or second outer pliable layer and/or inner insulation material layer of the air-permeable multi-layer insulative construct does not have covalently bonded pendant substituents derived from cyclodextrin, as described for example in U.S. Patent No. 8,129,450.
  • the first and/or second outer pliable layers comprises a web containing fibers having a length of 0.5 to 85 mm (e.g., 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 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.
  • 0.5 to 85 mm
  • the first and/or second outer pliable layers have a water uptake of less than or equal to 150 wt% based on the weight of the pliable layer when dry.
  • the first and/or second outer pliable layers have a water uptake of 50 to 150 wt% (e.g., 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71,
  • the inner insulation material layer is disposed between the first outer pliable layer and the second outer pliable layer.
  • the inner insulation material layer has a thermal performance warmth to weight ratio of at least 0.50 CLO/oz/sq yd (e.g., at least 0.5, 0.6, 0.7, or 0.8 CLO) according to ISO 11092.
  • Clo is a unit used to measure the thermal resistance of clothing.
  • a value of 1.0 clo is defined as the amount of insulation that allows a person at rest to maintain thermal equilibrium in an environment at 21°C (70°F) in a normally ventilated room (0.1 m/s air movement). Typically, above this temperature the person so dressed will sweat, whereas below this temperature the person will feel cold.
  • Articles such as clothing and/or its components can be assigned a clo value. Higher clo indicates an article is warmer than another article with a comparatively lower clo.
  • the air-permeable multi-layer insulative construct has a CLO of 0.5 to 1.8 CLO (e.g., 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, or 1.8 CO), according to ISO 11092, including any and all ranges and subranges therein.
  • the inner insulation material layer has a thickness greater than 2 mm.
  • different insulation material layer thicknesses are conducive to different textile articles.
  • the inner insulation material layer has a thickness or average thickness of at least 3 mm (e.g., at least 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, or 4 mm).
  • the inner insulation material layer has a thickness or average thickness of 3 mm to 310 mm (e.g., 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,
  • 306, 307, 308, 309, or 310 mm including any and all range and subranges therein (e.g., 3 to 250 mm, 3.5 to 200 mm, 3.5 to 150 mm, etc.).
  • the inner insulation material layer can comprise any desirable insulation material suitable for use in textiles, which is a matter within the purview of a person having ordinary skill in the art.
  • the inner insulation material is loose insulation material, which includes blowable insulation.
  • blowable is a term that is commonly used in the textile industry, and persons having ordinary skill in the art readily understand what is meant by blowable insulation.
  • blowable refers to a material’s ability to be readily processed through conventional blowing (or “blow injecting”) equipment, and injected therefrom as insulation into an insulative construct and/or an article (e.g., sacks, pockets, channels, or baffles etc. of pillows, clothing, bedding, sleeping bags, etc.).
  • blowing or “blow injecting”
  • the light, discrete structure of down makes it very amenable for blowing using conventional equipment.
  • the inner insulation material layer comprises blowable floccules as described in U.S. Patent No. 10,633,244.
  • the inner insulation material layer comprises batting, which is also well known within the textile field.
  • batting conducive for use in embodiments of the inventive air-permeable multi-layer insulative construct is described in U.S. Publication No. 2017-0370037.
  • the inner insulation material layer comprises, based on the total weight of the inner insulation material layer:
  • - 0-100 wt% e.g., 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20,
  • microdenier polymeric fibers having a denier of less than or equal to 1.0 denier (e.g., 0.4 to 1.0 denier, such as 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, or 1.0 denier);
  • - 0-100 wt% e.g., 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20,
  • macrodenier polymeric fibers having a denier of greater than 1.0 (e.g., 1.1 to 15.0 denier, such as 1.1, 1.2, 1.3, 1.4,
  • - 0-100 wt% e.g., 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43,
  • natural fibers which include, for example, one or more members selected from wool, cotton, tencel, kapok (cotton-like fluff obtained from seeds of a Kapok tree, which may optionally be further processed before use), flax, animal hair, silk, and down (e.g., duck or goose down).
  • the inner insulation material layer comprises 0-100 wt% (e.g., 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55,
  • polymeric fibers having a diameter of 5 to 100 pm (e.g., 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21,
  • the inner insulation material layer comprises polymeric fibers, whether microdenier or macrodenier, 0-100 wt% (e.g., 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37,
  • the polymeric fibers are fibers containing one or more additives (e.g., aerogel, as described in U.S. Publication No. U.S. 2018-0313001, microcapsules, as described in U.S. Publication No. U.S. 2020-0141029, etc.).
  • additives e.g., aerogel, as described in U.S. Publication No. U.S. 2018-0313001, microcapsules, as described in U.S. Publication No. U.S. 2020-0141029, etc.
  • the inner insulation material layer comprises 0-25 wt% (e.g., 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, or 25 wt%) binder fibers.
  • Binder fibers are well known in the art, and typically have a bonding temperature lower than the softening temperature of one or more other polymeric fiber constituents that may be present in the inner insulation material layer.
  • the inner insulation material layer has been heat treated so as melt all or a portion of the binder fibers (e.g., to form a bonded web-type batting).
  • Binder fibers may be wholly or partially melted fibers, as opposed to binder fibers in their original, pre-heat treatment form.
  • 0 to 100 wt% e.g., 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40,
  • any polymeric fibers used are siliconized.
  • Siliconization techniques are well known in the art.
  • the term “siliconized” means that the fiber is coated with a silicon-comprising composition (e.g., a silicone). Siliconization techniques are well known in the art, and are described, e.g., in U.S. Patent No. 3,454,422.
  • the silicon- comprising composition may be applied using any method known in the art, e.g., spraying, mixing, dipping, padding, etc.
  • the silicon-comprising (e.g., silicone) composition which may include an organosiloxane or poly siloxane, 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.
  • Fibers used in the inventive air-permeable multi-layer insulative construct may be crimped or uncrimped. Various crimps, including spiral and standard crimp, are known in the art.
  • the first outer pliable layer and/or the second outer pliable layer is elastic. In some embodiments, the first outer pliable layer and/or the second outer pliable layer is inelastic.
  • the term "elastic” is used herein to mean any material which, upon application of a biasing force, is stretchable, that is, elongatable, to a stretched, biased length which is at least about 150 percent of its relaxed unbiased length, and which will recover at least 50 percent of its elongation upon release of the stretching, elongating force in less than one minute.
  • a hypothetical example would be a one (1) inch sample of a material which is elongatable to at least 1.50 inches and which, upon being elongated to 1.50 inches and released, will recover to a length of not more than 1.25 inches in less than one minute.
  • Many elastic materials may be stretched by much more than 50 percent of their relaxed length, for example, 80 percent or more, and many of these will recover to substantially their original relaxed length, for example, to within 105 percent of their original relaxed length, upon release of the stretching force.
  • the term “inelastic” refers to materials that do not fall within the definition of "elastic" above.
  • the inner insulation material layer does not comprise one or more super absorbent polymers (SAP’s) or other materials that are intended to retain liquid, as in personal care items such as diapers, sanitary napkins/pads, etc.
  • SAP super absorbent polymers
  • the inner insulation material layer is not laminated to the first outer pliable layer and/or the second outer pliable layer.
  • the air-permeable multi-layer insulative construct additionally comprising a first fabric layer and a second fabric layer, wherein the first outer pliable layer, the second outer pliable layer, and the inner insulation material layer are disposed between said first fabric layer and said second fabric layer.
  • the first fabric layer and/or the second fabric layer is a woven or knit fabric layer.
  • One test method for determining a construct’s migration resistance is the IDFL (International Down and Feather Testing Laboratory) Downproofness - International Rotation Box standard test method.
  • IDFL International Down and Feather Testing Laboratory
  • a motor rotates the box at a speed of 48 +/- 2 revolutions per minute.
  • Twenty -four No. 6.5 solid silicone stoppers are used in the box.
  • a clean sample article is placed in the box, and the box is rotated for 30 minutes. All fibers and clusters are collected from the surface of the article, tumbler box and silicone stoppers.
  • Collection material is evaluated and counted, and a numerical rating of 1 (significant fiber migration) to 5 (little or no fiber migration) is assigned, as shown in Table I, based on the amount of fibers (only fibers > 4 mm are counted) that escape or protrude through the fabric of the article after the 30 minute tumbling period.
  • the inventive air-permeable multi-layer insulative construct has a fiber migration rating of 5 in accordance with the IDFL Downproofness - International Rotation Box standard test method.
  • Applicant has developed a migration resistance test standard (the “INS-17 Fiber Migration Test”) that is even more strenuous and exacting than the IDFL Downproofness - International Rotation Box standard test method.
  • the INS-17 Fiber Migration Test determines the potential for migration of fibers through various types of fabric and utilizes the following equipment:
  • Rubber stoppers such as Herco Black Rubber One-Hole Stoppers, Part Number ST1H-04-BK sold by Hecht Rubber Corporation.
  • the testing procedure entails:
  • the inventive air-permeable multi-layer insulative construct has a migration resistance of “Migration Resistant” (i.e., 0 fibers counted) or “Acceptable Migration” (i.e., less than 3 fibers counted) according to the INS-17 Fiber Migration Test.
  • the invention provides an article comprising the air-permeable multi-layer construct according to the first aspect of invention.
  • the article is a garment, sleeping bag, sleeping pad, or footwear. [00129] In some embodiments, the article is a garment selected from a coat, jacket, vest, glove, mitten, and headwear.
  • the article is a home furnishing item (e.g., bedding, such as a comforter or quilt, pillow, cushion, upholstered chair, etc.).
  • bedding such as a comforter or quilt, pillow, cushion, upholstered chair, etc.
  • the article has an air permeability of 1 CFM to 500 CFM.
  • the invention provides a method of making the air-permeable multilayer construct according to the first aspect of invention or the article according to the second aspect of the invention.
  • each pillow contained the same outer pillow fabric (109 CFM) and the same inner insulation material layer - a loose fill mixture, which consisted of 80 wt% goose down and 20 wt% 1.2 denier siliconized PET fiber.
  • Pillow 1 consistent of only the loose fill and outer pillow fabric.
  • Pillow 2 was identical to Pillow 1, but included a commercially available spunbond polypropylene scrim layer on each side of the fill mixture, the scrim layer having a basis weight of 28 gsm, a thickness of 0.4 mm, and an air permeability 744 CFM.
  • Pillow 3 was identical to Pillow 2, but in place of the scrim layers, included pliable layers according to embodiments of the invention that were meltblown non-woven webs having a basis weight of 27 gsm, a thickness of 0.4 mm, and an air permeability 42.8 CFM.
  • Pillow 3 enclosing an embodiment of the inventive air- permeable multi-layer insulative construct significantly outperformed Pillows 1 and 2 from a fiber migration perspective.
  • Pillow 3 demonstrated downproofness.
  • the ability to achieve this level of reduced/prevented fiber migration without the need for downproof fabric ( ⁇ 1 CFM) allows for articles having severely reduced and/or prevented fiber migration, whilst offering breathability and comfort unparalleled by state-of-the-art and competing technologies.
  • the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.
  • a method or article that “comprises”, “has”, “includes” or “contains” one or more steps or elements possesses those one or more steps or elements, but is not limited to possessing only those one or more steps or elements.
  • a step of a method or an element of an article that “comprises”, “has”, “includes” or “contains” one or more features possesses those one or more features, but is not limited to possessing only those one or more features.
  • each range is intended to be a shorthand format for presenting information, where the range is understood to encompass each discrete point within the range as if the same were fully set forth herein.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention concerne une construction isolante multicouche perméable à l'air comprenant : une première couche pliable externe ; une seconde couche pliable externe ; et une couche de matériau d'isolation interne disposée entre la première couche pliable externe et la seconde couche pliable externe. Au moins l'une de la première couche pliable externe et de la seconde couche pliable externe : contient une bande polymère non tissée qui comprend une pluralité de fibres ayant un diamètre inférieur à 10 µm ; et a une perméabilité à l'air de 1 à 500 PCM. La couche de matériau d'isolation interne : a un rapport chaleur de performance thermique/poids d'au moins 0,50 CLO/oz/sq yd., selon la norme ISO 11092 ; et a une épaisseur supérieure à 2 mm. La construction isolante multicouche perméable à l'air a une résistance à la migration inférieure à 20 fibres lorsqu'elle est testée selon le test de migration de fibre INS -17.
PCT/US2021/063049 2020-12-11 2021-12-13 Construction isolante multicouche perméable à l'air WO2022126008A1 (fr)

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US4433024A (en) 1982-07-23 1984-02-21 Minnesota Mining And Manufacturing Company Reduced-stress vapor-sorptive garments
US4588635A (en) 1985-09-26 1986-05-13 Albany International Corp. Synthetic down
US5399423A (en) 1993-07-28 1995-03-21 The Dow Chemical Company Ignition resistant meltblown or spunbonded insulation material
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WO2014087161A1 (fr) * 2012-12-04 2014-06-12 Herbert Parkinson Limited Perfectionnements apportés et se rapportant à des tissus
US20170370037A1 (en) 2015-01-21 2017-12-28 Primaloft, Inc. Migration resistant batting with stretch and methods of making and articles comprising the same
US20180313001A1 (en) 2015-11-17 2018-11-01 Primaloft, Inc. Synthetic fiber containing aerogel and polymer material, and methods of making and articles comprising the same
DE202016008757U1 (de) 2016-12-27 2019-07-08 Ontex Bvba Saugfähiger Kern sowie Artikel mit einem solchen Kern
WO2020081285A1 (fr) * 2018-10-15 2020-04-23 Primaloft, Inc. Structures isolantes tridimensionnelles à régulation thermique et articles comprenant celles-ci
US10633244B2 (en) 2015-09-29 2020-04-28 Primaloft, Inc. Blowable floccule insulation and method of making same
US20200141029A1 (en) 2017-11-15 2020-05-07 Primaloft, Inc. Reduced density synthetic fiber utilizing hollow microcapsules

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3454422A (en) 1964-03-13 1969-07-08 Du Pont Organopolysiloxane coated filling materials and the production thereof
US4433024A (en) 1982-07-23 1984-02-21 Minnesota Mining And Manufacturing Company Reduced-stress vapor-sorptive garments
US4588635A (en) 1985-09-26 1986-05-13 Albany International Corp. Synthetic down
US5399423A (en) 1993-07-28 1995-03-21 The Dow Chemical Company Ignition resistant meltblown or spunbonded insulation material
US6329051B1 (en) 1999-04-27 2001-12-11 Albany International Corp. Blowable insulation clusters
US7118558B2 (en) 2001-11-06 2006-10-10 Tyco Healthcare Retail Services Ag Cloth-like laminate and absorbent garment
US8129450B2 (en) 2002-12-10 2012-03-06 Cellresin Technologies, Llc Articles having a polymer grafted cyclodextrin
WO2014087161A1 (fr) * 2012-12-04 2014-06-12 Herbert Parkinson Limited Perfectionnements apportés et se rapportant à des tissus
US20170370037A1 (en) 2015-01-21 2017-12-28 Primaloft, Inc. Migration resistant batting with stretch and methods of making and articles comprising the same
US10633244B2 (en) 2015-09-29 2020-04-28 Primaloft, Inc. Blowable floccule insulation and method of making same
US20180313001A1 (en) 2015-11-17 2018-11-01 Primaloft, Inc. Synthetic fiber containing aerogel and polymer material, and methods of making and articles comprising the same
DE202016008757U1 (de) 2016-12-27 2019-07-08 Ontex Bvba Saugfähiger Kern sowie Artikel mit einem solchen Kern
US20200141029A1 (en) 2017-11-15 2020-05-07 Primaloft, Inc. Reduced density synthetic fiber utilizing hollow microcapsules
WO2020081285A1 (fr) * 2018-10-15 2020-04-23 Primaloft, Inc. Structures isolantes tridimensionnelles à régulation thermique et articles comprenant celles-ci

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