U.S. patent application number 14/456967 was filed with the patent office on 2015-02-12 for down and fiber blend and method.
This patent application is currently assigned to ALLIED FEATHER & DOWN CORP.. The applicant listed for this patent is Allied Feather & Down Corp.. Invention is credited to Jian Huang, Daniel Uretsky.
Application Number | 20150044393 14/456967 |
Document ID | / |
Family ID | 52448879 |
Filed Date | 2015-02-12 |
United States Patent
Application |
20150044393 |
Kind Code |
A1 |
Uretsky; Daniel ; et
al. |
February 12, 2015 |
Down and Fiber Blend and Method
Abstract
An exemplary down and fiber blend may comprise a first weight of
down having a water-resistant coating applied thereto, and a second
weight of water-resistant fiber. The water-resistant treated down
is preferably dried prior to mixing with the chosen fiber. The
fiber in the blend may preferably be a polyester fiber, such as a
polyester staple microfiber. A method of forming a down and fiber
blend may include the gradual introduction of the fiber into a
mixing box in which the water-resistant treated down is being
stirred. Fiber and mixing parameters are also provided which have
been determined to result in optimal performance characteristics of
the fiber blend. In the microfiber blend embodiments, each strand
may preferably have 6 to 9 crimps per inch, and the microfiber
strands may preferably be 0.8 to 1.4 denier.
Inventors: |
Uretsky; Daniel; (Los
Angeles, CA) ; Huang; Jian; (Los Angeles,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Allied Feather & Down Corp. |
Montebello |
CA |
US |
|
|
Assignee: |
ALLIED FEATHER & DOWN
CORP.
Montebello
CA
|
Family ID: |
52448879 |
Appl. No.: |
14/456967 |
Filed: |
August 11, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61864408 |
Aug 9, 2013 |
|
|
|
Current U.S.
Class: |
428/6 ; 19/145.5;
19/66R; 19/66.1 |
Current CPC
Class: |
B68G 1/00 20130101; D04H
1/541 20130101; D04H 1/54 20130101; D04H 1/732 20130101; D04H 1/02
20130101; D01G 13/00 20130101; B68G 2001/005 20130101; D01C 3/00
20130101; D02G 1/00 20130101; D02J 3/00 20130101 |
Class at
Publication: |
428/6 ; 19/66.R;
19/145.5; 19/66.1 |
International
Class: |
D06M 19/00 20060101
D06M019/00; D02J 3/00 20060101 D02J003/00; D01C 3/00 20060101
D01C003/00; D02G 1/00 20060101 D02G001/00; D01G 13/00 20060101
D01G013/00 |
Claims
1. A down and fiber blend comprising: a first weight of down having
a water-resistant coating applied thereto; and a second weight of
water-resistant-fiber; wherein the first weight and the second
weight form a blend with one another.
2. A down and fiber blend as defined in claim 1 in which the fiber
is a polyester fiber.
3. A down and fiber blend as defined in claim 2 wherein the
polyester fiber is a polyester microfiber.
4. A down and fiber blend as defined in claim 3 wherein each strand
of the fiber is a solid fiber.
5. A down and fiber blend as defined in claim 3 wherein each strand
of the fiber is 0.8 to 1.4 denier.
6. A down and fiber blend as defined in claim 3 in which each
strand of the fiber has a length ranging from 8 mm to 32 mm.
7. A down and fiber blend as defined in claim 3 in which each
strand of the fiber has 6 to 9 crimps per inch.
8. A down and fiber blend as defined in claim 1 wherein each strand
of the fiber is a hollow conjugated fiber.
9. A method of forming a down and fiber blend, the method
comprising the following steps: selecting a first weight of down;
treating the down with a water-resistant coating; drying the first
weight of down; choosing a second weight of fiber, the second
weight of fiber consisting of fiber strands; introducing the second
weight of fiber into a fiber opener, thereby fluffing the second
weight of fiber; vacuuming the first weight of down into a mixing
box for stirring therein; gradually re-introducing the second
weight of fiber through the fiber opener; during the step of
re-introducing and simultaneously with the down being stirred
within the mixing box, blowing the fiber strands into the mixing
box upon their exiting the fiber opener, thereby forming a mixture
of the down and the fiber; and agitating the mixture while it is
being stirred.
10. A down and fiber blend as defined in claim 9 wherein each
strand of the fiber is a solid fiber.
11. The method defined in claim 9 wherein, once all of the fiber
strands have existed the fiber opener, the stirring continues for
at least 5 minutes.
12. The method defined in claim 9, further comprising the step of
sucking the mixture out of the mixing box and into one or more
down-proof bags.
13. A method as defined in claim 9 in which each strand of the
fiber has 6 to 9 crimps per inch.
14. A method of forming a down and fiber blend, the method
comprising the following steps: selecting a first weight of down;
treating the down with a water-resistant coating; drying the first
weight of down; choosing a second weight of fiber, the second
weight of fiber consisting of fiber strands; converting the second
weigh of fiber into fiber ball precursor; vacuuming the first
weight of down into a mixing box for stirring therein;
simultaneously with the down being stirred within the mixing box,
blowing the fiber ball precursor into the mixing box, thereby
forming a mixture of the down and the fiber; and agitating the
mixture while it is being stirred.
15. A method defined in claim 14 wherein each strand of the fiber
is a hollow conjugated fiber.
16. The method defined in claim 14 wherein, once all of the fiber
ball precursor has been blown into the mixing box, the stirring
continues for at least 5 minutes.
17. A method as defined in claim 14 wherein each strand of the
fiber is 1 to 8 denier.
18. A method as defined in claim 14 wherein each strand of the
fiber is 3 to 5 denier.
19. A method as defined in claim 14 in which each strand of the
fiber has a length ranging from 32 mm to 64 mm.
20. A method as defined in claim 14 wherein each strand includes
multi-dimensional crimping.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/864,408 filed Aug. 9, 2013, the content of which
is incorporated by this reference in its entirety for all purposes
as if fully set forth herein.
TECHNICAL FIELD
[0002] The present invention relates generally to downs and fibers
for use in the construction of garments, sleeping bags, bedding and
the like.
BACKGROUND
[0003] Down is a natural feather product that has been used for
hundreds of years as a fine thermal insulator and padding in goods
such as jackets, bedding, pillows and sleeping bags. Polyester
fiber has also been around for many years. However, simply
combining the two materials has been found to yield a deficient
result in that the blends tend to clump together over an extended
period of time, and especially when the end products containing the
blends are washed or otherwise wetted.
[0004] What is needed is an improved down and fiber blend, and a
method for manufacturing such a blend, wherein the goods comprising
the improved blend can be washed or otherwise wetted without
resulting in clumping.
SUMMARY
[0005] Certain deficiencies of the prior art may be overcome by the
provision of one or more embodiments of an improved down and fiber
blend, and one or more embodiments of methods for manufacturing
such improved blends. A down and fiber blend may comprise a first
weight of down having a water-resistant coating applied thereto and
a second weight of water resistant fiber, wherein the first weight
and the second weight form a blend with one another.
[0006] In a first method of forming a down and fiber blend, down
may be selected, treated with water-resistant coating and dried.
Next, a fiber may be chosen, and introduced into a fiber opener,
thereby fluffing the second weight of fiber. The down may be
vacuumed into a mixing box for stirring therein. The fiber may
gradually be re-introduced through the fiber opener. During the
step of re-introducing and simultaneously with the down being
stirred within the mixing box, the fiber strands may be blown into
the mixing box upon their exiting the fiber opener, thereby forming
a mixture of the down and the fiber.
[0007] In a second method of forming a down and fiber blend, down
may be also selected, treated with water-resistant coating and
dried. A fiber may be chosen which consists of fiber strands. The
fiber may be converted into fiber ball precursor. The down may be
vacuumed into a mixing box for stifling therein. Simultaneously
with the down being stirred within the mixing box, the fiber ball
precursor may be blown into the mixing box, thereby forming a
mixture of the down and the fiber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Further advantages of the present invention may become
apparent to those skilled in the art with the benefit of the
following detailed description of the preferred embodiments and
upon reference to the accompanying drawings in which:
[0009] FIG. 1 is a photograph of one example embodiment of a down
and fiber blend in accordance with the present invention;
[0010] FIG. 2 is a photograph of one example embodiment of a pillow
stuffed with an embodiment of the blend discussed herein;
[0011] FIG. 3 is a photograph of one example embodiment of a
singular fiber ball in accordance with the present invention;
and
[0012] FIG. 4 is a photograph of one example embodiment of a
cluster of fiber balls in accordance with the present
invention;
[0013] FIG. 5 is a diagrammatic flow chart depicting an embodiment
of a first method of forming a down and fiber blend, which is
particularly suited for producing blends using microfiber;
[0014] FIG. 6 is a diagrammatic flow chart depicting an embodiment
of a second method of forming a down and fiber blend, which is
particularly suited for producing blends using fiber balls; and
[0015] FIG. 7 is a block diagram of a system relied on in
performance of one or more methods in accordance with the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] The present invention comprises, at least in part, a blend
of down and polymer fiber. Moreover, a method is provided by which
such an improved blend may be manufactured.
[0017] In accordance with embodiments of the present invention, a
down and fiber blend may comprise a first weight of down having a
water-resistant coating applied thereto, and a second weight of
water resistant fiber. The first weight and the second weight
preferably form a blend with one another. The ratio between the
first weight and the second weight in the blend may be selected by,
for example, the manufacturer or a buyer, depending upon the
desired performance of the blend.
[0018] In certain embodiments of the down and fiber blend, the
fiber is a polyester fiber. In particular embodiments, the fiber is
a polyester microfiber. In such microfiber embodiments, each strand
of the microfiber may be a solid fiber. Each strand of the
microfiber may be 0.8 to 1.4 denier. Moreover, each strand of the
microfiber may preferably have a length ranging from 8 mm to 32 mm.
Further, each strand of the microfiber may preferably have 6 to 9
crimps per inch. Alternatively to embodiments having microfiber,
each strand of the fiber may be a hollow conjugated fiber.
[0019] A first method 100 of forming a down and fiber blend may
comprise one or more steps as illustrated, for example in FIG. 5.
At block 102, a first weight of down may be selected, treated with
water-resistant coating and dried. At block 104, a second weight of
fiber may be chosen. At block 106, the second weight of fiber may
be introduced into a fiber opener, thereby fluffing the second
weight of fiber. At block 108, the first weight of down may be
vacuumed into a mixing box for stifling therein. At block 110, the
second weight of fiber may gradually be re-introduced through the
fiber opener (which in some embodiments may take the form of a
separate fiber opener). At block 112, during the step of
re-introducing and simultaneously with the down being stirred
within the mixing box, the fiber strands may be blown into the
mixing box upon their exiting the fiber opener, thereby forming a
mixture of the down and the fiber. In certain preferred embodiments
of this method, the mixture may be agitated while being
stirred.
[0020] In certain embodiments of the first method of forming a down
and fiber blend, each strand of the fiber may be a solid fiber. In
particular embodiments of the first method, once all of the fiber
strands have exited the fiber opener, the stifling may preferably
continue for at least 5 minutes.
[0021] As illustrated at block 114 of FIG. 5 for example,
particular embodiments of the first method of forming a down and
fiber blend may further comprise the step of sucking the mixture
out of the mixing box and into one or more down-proof bags.
Moreover, each strand of the fiber may preferably have 6 to 9
crimps per inch. A crimped microfiber strand may typically take on
the appearance of a saw-tooth configuration.
[0022] A second method 116 of forming a down and fiber blend may
comprise one or more respective steps as illustrated for example in
FIG. 6. Similarly to the first method 100 described above, at block
102 a first weight of down may be selected, treated with
water-resistant coating and dried. At block 104, a second weight of
fiber may be chosen, wherein the second weight of fiber consists of
fiber strands. At block 118, the second weight of fiber may be
converted into fiber ball precursor. At block 108, the first weight
of down may be vacuumed into a mixing box for stifling therein. At
block 120, simultaneously with the down being stirred within the
mixing box, the fiber ball precursor may be blown into the mixing
box, thereby forming a mixture of the down and the fiber. The
mixture may be agitated, for example by blown air, while it is
being stirred.
[0023] In certain preferred embodiments of the second method of
forming a down and fiber blend, each strand of the fiber may be a
hollow conjugated fiber. Particular embodiments of the second
method may further comprise the step of continuing the stirring for
at least 5 minutes once all of the fiber ball precursor has been
blown into the mixing box. Each strand of the fiber may preferably
be 1 to 8 denier. More particularly, in particular embodiments,
each strand of the fiber may preferably be 3 to 5 denier. Further,
in certain embodiments of the second method, each strand of the
fiber may have a length ranging from 32 mm to 64 mm. In particular
embodiments, each strand may include multi-dimensional crimping,
such as the cork-screw-like configuration seen in certain crimped
hollow conjugated fibers.
[0024] FIG. 7 illustrates one non-limiting example of a system 130
which may be relied on by the first and second methods described
above. The down may receive water-resistant treatment in a down
treatment wash 132. The treated and dried down may then be weighed
out to result in a first weight of treated down 134. The second
weight of fiber 136 may be weighed out. In the first method
described above, the second weight of fiber may be introduced and
possibly re-introduced into a fiber opener 138, the dashed lines
and boxes representing potentially optional components in the
system 130. With the first weight of down having been fed into the
mixing box 140 for stirring, the fiber may be gradually fed into
the mixing box 140 by way of, for example, multiple points of entry
to keep the fiber more evenly distributed throughout the mixture.
During the stifling process, the mixture may be agitated by an
agitator 142, which may rely on one or more air hoses connected to
the mixing box 140 to agitate the position of the mixture within
the mixing box, and possibly to blow the mixture toward the exit of
the mixing box 140. A bagging station 144 may be, for example, a
clean area where a large capacity bag can be attached to the end of
a hose from the mixing box 140, and collect the newly-produced down
and fiber blend exiting the mixing box.
[0025] In preferred embodiments of an improved down and fiber
blend, both the down and the fiber are independently water
resistant. The down may be, for example, a premium down treated to
be water resistant. Such treatment may involve, for example,
applying a water resistant coating to the down. One of ordinary
skill in the relevant art could select and obtain such a water
resistant coating from those made available from large chemical
companies. The fiber may be, for example, a polyester fiber. More
specifically, in certain embodiments, the fiber may be a polyester
staple microfiber. Experimentally, we have found the useful size
range of the fiber to be approximately 1 denier, although this can
be increased or reduced depending on the desired loft and size of
the end product (e.g., jacket, bedding, etc.). The length of the
fiber may preferably be anywhere in the range of 8 mm to 32 mm. It
may be preferable for the fibers to feature varying degrees of
crimping in order to provide the best loft for the finished
product.
[0026] In preferred embodiments of a method in accordance with the
present invention, a water resistant treatment may be applied to
the down during a washing process. The down chosen for placement
into the wash can be of varying qualities. Separately, a polyester
fiber is selected and run through a specialized machine that uses
teeth to "open" the fiber, which essentially pulls the fiber apart,
making it open so as to accept mixing with the down. The
aforementioned teeth may reside, for example, on the barrel of the
machine through which the fiber is introduced to the process and
"opened." In certain such embodiments, the barrel may feature, for
example, approximately 35 wire "teeth" per square inch. In further
such embodiments, the barrel may feature approximately 56 wire
teeth per square inch. Characteristics of the resulting product may
be improved as a result of the increased number of teeth per square
inch, due for example to the additional teeth providing the ability
to more fully and finely pull apart (or open) the fiber so that it
will be more hospitable to marrying with the down clusters in our
mixing tank. Once the fiber has been opened, it is then blown into
a mixing machine along with the treated down. The machine slowly
mixes the fiber and the down, creating a blend that is ready for
use as, for example, insulation and padding in respective
goods.
[0027] In particular preferred embodiments, both the polyester
fiber and the down are water resistant prior to being mixed with
one another. As a result, the fibers can maintain their integrity
during the mixing process with the down so the blend does not get
tangled together and clumpy during the mixing step.
[0028] In addition or alternatively to using the microfibers
mentioned above, larger denier fibers may be used to make `fiber
balls` for blending with down through a similar process as
described in connection with the microfibers. The preferred fiber
to turn into a fiber ball may be, for example, a polyester staple
fiber that is in the range of approximately or exactly 1 to 8
denier, and length of approximately or exactly 32 mm to 64 mm.
These fibers are preferably hollow conjugated fibers. These fibers
do not necessarily have to be treated with water-resistant coating,
but it is preferable to help ensure the end product maintains its
quality throughout wash and use cycles.
[0029] To make the larger denier fibers into balls, they may be run
through, for example, a ball-fiber machine. That machine opens the
fibers, and then rolls them into balls, producing what are referred
to herein as fiber balls. FIGS. 3 and 4 illustrate a singular fiber
ball and a cluster of fiber balls, respectively. Once formed, the
fiber balls can then be blended with down using the same mixing
process as described herein for microfibers. However, since the
fiber balls are already opened in the above mentioned fiber ball
process, the opening step may be skipped and the process instead
may proceed to slowly blowing the fiber balls into the mixing
cylinder with, for example, the water resistant treated down for
blending. After mixing has occurred, for example, for approximately
5 minutes, the down and fiber ball blend results. These fiber balls
may be useful as an alternative option to microfibers, each
presenting different benefits. The beneficial attributes of fiber
balls may be, for example, additional loft and springiness as
compared to microfibers, which provide a feeling of more
softness.
[0030] The blends described herein are customizable depending upon
the need of the customer. By way of example, regarding the down
portion of the blend, customers can choose material based on
several attributes, including fill power, color, quality, regional
origin or treatment. These attributes come with differing benefits
and costs. The customer can optionally choose the ratio of down
versus fiber. For example, a customer may request 70% down and 30%
fiber, or 60% down and 40% fiber, etc. Procedurally, in order to
achieve these ratios, it is preferable to use weight as a guide.
With this in mind, before mixing the down with the fiber, the down
and fiber are typically pre-weighed to ensure the ratio is
correct
[0031] As compared with the prior art, the improved blends and
methods described herein result in products which feel and perform
better without clumping over time, or as a result of exposure to
moisture.
[0032] While embodiments of the invention have been illustrated and
described, it is not intended that these embodiments illustrate and
describe all possible forms of the invention. Rather, the words
used in the specification are words of description rather than
limitation, and it is understood that various changes may be made
without departing from the spirit and scope of the invention.
* * * * *