U.S. patent application number 16/342628 was filed with the patent office on 2019-09-05 for self-regulating batting insulation.
This patent application is currently assigned to PRIMALOFT, INC.. The applicant listed for this patent is PRIMALOFT, INC.. Invention is credited to Robert DEMPSEY, Vanessa MASON.
Application Number | 20190271104 16/342628 |
Document ID | / |
Family ID | 62241942 |
Filed Date | 2019-09-05 |
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United States Patent
Application |
20190271104 |
Kind Code |
A1 |
MASON; Vanessa ; et
al. |
September 5, 2019 |
SELF-REGULATING BATTING INSULATION
Abstract
Self-regulating insulative batting is provided. The batting
includes a blend of a plurality of fibers including functional
fibers and non-functional fibers. The plurality of fibers are
non-woven and oriented substantially vertically along a thickness
direction of the batting. The functional fibers are configured to
self-regulate at least one insulative quality of the batting based
on changes in at least one environmental condition interacting with
the batting. At least one of the length and thickness of the
functional fibers changes based on changes in at least one
environmental condition interacting with the batting. Articles
comprising the self-regulating batting and methods of making the
self-regulating batting are also provided.
Inventors: |
MASON; Vanessa; (Rexford,
NY) ; DEMPSEY; Robert; (Mechanicville, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
PRIMALOFT, INC. |
Latham |
NY |
US |
|
|
Assignee: |
PRIMALOFT, INC.
Latham
NY
|
Family ID: |
62241942 |
Appl. No.: |
16/342628 |
Filed: |
November 28, 2017 |
PCT Filed: |
November 28, 2017 |
PCT NO: |
PCT/US2017/063377 |
371 Date: |
April 17, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62427152 |
Nov 29, 2016 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D10B 2501/04 20130101;
D10B 2401/04 20130101; D04H 1/02 20130101; D04H 1/4382 20130101;
D10B 2503/06 20130101 |
International
Class: |
D04H 1/02 20060101
D04H001/02; D04H 1/4382 20060101 D04H001/4382 |
Claims
1. Self-regulating insulative batting, comprising: a blend of a
plurality of fibers including functional fibers and non-functional
fibers, the plurality of fibers being non-woven and oriented
substantially vertically along a thickness direction of the
batting, wherein the functional fibers are configured to
self-regulate at least one insulative quality of the batting based
on changes in at least one environmental condition interacting with
the batting.
2. The self-regulating batting according to claim 1, wherein the
batting is in the form of a sheet extending along width and length
directions.
3. The self-regulating batting according to claim 1, wherein the
functional fibers are configured to self-regulate the insulative
quality of the batting with respect to heat based changes in at
least one environmental condition interacting with the batting.
4. The self-regulating batting according to claim 1, wherein the
functional fibers are configured to self-regulate the insulative
quality of the batting with respect to moisture based changes in at
least one environmental condition interacting with the batting.
5. The self-regulating batting according to claim 1, wherein the
functional fibers are configured to self-regulate at least one
insulative quality of the batting based changes in humidity of an
environment interacting with the batting.
6. The self-regulating batting according to claim 5, wherein the
functional fibers are configured to self-regulate insulative
quality of the batting with respect to at least heat based changes
in humidity of the environment interacting with the batting.
7. The self-regulating batting according to claim 6, wherein the
functional fibers are configured to self-regulate insulative
quality of the batting with respect to at least heat based changes
in humidity of the environment interacting with the batting by
varying the thickness of the batting.
8. The self-regulating batting according to claim 7, wherein the
functional fibers are configured to vary the thickness of the
batting by self-varying their length along the thickness direction
based changes in humidity of the environment interacting with the
batting.
9. The self-regulating batting according to claim 8, wherein the
functional fibers self-vary their length along the thickness
direction by forming a crimp therein or increasing a crimp
thereof.
10. The self-regulating batting according to claim 7, wherein the
functional fibers are configured to decrease the insulative quality
of the batting with respect to at least heat based of increases in
humidity of the environment interacting with the batting by
decreasing the thickness of the batting.
11. The self-regulating batting according to claim 10, wherein the
functional fibers are configured to decrease the insulative quality
of the batting with respect to at least heat based of increases in
humidity of the environment interacting with the batting above a
predetermined threshold humidity level by decreasing the thickness
of the batting.
12. The self-regulating batting according to claim 1, wherein the
plurality of fibers are vertically lapped.
13. The self-regulating batting according to claim 1, wherein the
plurality of fibers comprises staple fibers of a staple length
within the range of 12 mm to 70 mm and a denier within the range of
0.5 D to 8 D.
14. (canceled)
15. (canceled)
16. The self-regulating batting according to claim 1, functional
fibers include a hygroscopic component and a non-hygroscopic
component.
17. The self-regulating batting according to claim 1, wherein the
non-functional fibers include binder fibers.
18. The self-regulating batting according to claim 1, wherein the
non-functional fibers comprise synthetic fibers.
19. The self-regulating batting according to claim 18, wherein the
synthetic fibers comprise polyester fibers.
20. The self-regulating batting according to claim 18, wherein the
synthetic fibers comprise siliconized fibers.
21. The self-regulating batting according to claim 1, wherein the
functional fibers comprise at least 15% of the blend of fibers.
22. An article, comprising: the self-regulating insulative batting
according to claim 1.
23. The article according to claim 22, wherein said article is
selected from the group consisting of an outerwear product,
clothing, a sleeping bag, and bedding.
24. The article according to claim 22, wherein the article is
configured to be used by a user such that a micro climate
interacting with the batting is formed between the user and the
self-regulating insulative batting extending along the thickness
direction.
25. The article according to any of claims 22, wherein the article
includes at least one outer protection layer that prevents the
environment exterior to the self-regulating batting from
interacting with the self-regulating batting.
26. A method of making self-regulating batting, comprising: forming
at least one nonwoven web from a blend of a plurality of fibers
including functional fibers and non-functional fibers; and
vertically lapping the at least one nonwoven web such that the
fibers are oriented substantially vertically along a thickness
direction of the batting, wherein the functional fibers are
configured to self-regulate at least one insulative quality of the
batting based on changes in at least one environmental condition
interacting with the batting.
27. A method of making self-regulating insulative batting,
comprising: obtaining a plurality of opened and blended fibers
including functional fibers and non-functional fibers, the
functional fibers being configured to self-regulate at least the
length thereof based on changes in at least one environmental
condition interacting with the fiber; parallelizing the plurality
of opened and blended fibers into at least one non-woven, carded
web layer; and vertically lapping the at least one non-woven,
carded web layer to form a self-regulating insulative batting with
the lengths of the fibers being oriented substantially vertically
along thickness direction of the batting so that at least one
insulative quality of the batting self-regulates based on changes
in at least one environmental condition interacting with the
batting.
28. (canceled)
29. The method according to claim 27, wherein obtaining a plurality
of opened and blended fibers comprises opening a plurality of the
functional fibers and non-functional fibers and blending a
plurality of the opened functional fibers and non-functional
fibers.
30. (canceled)
31. The method according to claims 27, further comprising
positioning the self-regulating insulative batting within an
article configured to be used by a user such that a micro climate
interacting with the batting is formed between the user and the
self-regulating insulative batting extending along the thickness
direction.
32. The method according to claim 31, wherein the article includes
at least one outer protection layer that prevents the environment
exterior to the self-regulating batting from interacting with the
self-regulating batting.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional
Application No. 62/427,152, filed on Nov. 29, 2016, the entire
contents of which are hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present disclosure generally relates to self-regulating
batting insulation, to articles comprising the batting, and to
methods of making the batting.
BACKGROUND OF THE INVENTION
[0003] Insulative articles, such as clothing, footwear, bedding
(comforters, pillows, mattresses, mattress pads, etc.), sleeping
bags, etc., are typically utilized to regulate, at least in part,
the environment on one side of the articles. For example, an
insulative article may be used to retain heat and/or humidity on
one side of the article, such as by resisting the flow of heat
and/or humidity through the article. In this way, insulative
articles are commonly utilized to regulate the temperature and/or
humidity of a user on one side of the articles as compared to
another side of the articles.
[0004] Many insulative articles make use of non-woven batted
insulation (referred to herein as "batting") as an insulating
material. Several types of non-woven batting exist. Cross-lapped
non-woven batting, for example, is formed of fibers that are
parallelized into carded web layers via one or more carding
machine. A typical cross-lapping process consists of laying a
carded web layer onto a conveyor, and then traversing the conveyor
back and forth across a secondary conveyer that moves perpendicular
to the first conveyor. The first and second conveyors are
configured such that multiple carded webs are lapped over each on
the secondary conveyor in a cross-wise direction. Cross-lapped
non-woven batting thereby includes fibers that are aligned
horizontally in a 2 dimensional, x-y axis orientation, and a
thickness formed in the z direction via overlapped portions of a
plurality of carded webs.
[0005] Current batting, such as, but not limited to, cross-lapped
batting, is designed to provide a certain pre-determined, static
insulative quality, such as a certain pre-determined capacity to
resist heat flow therethrough (i.e., R-value) and/or a certain
pre-determined capacity to resist liquid/moisture flow
therethrough. Insulative articles utilizing current batting are
thereby also designed to provide a certain pre-determined, static
insulative quality. Users of current insulative articles must
therefore choose an article of a particular insulative quality, and
the particular insulative quality remains static during the
duration of each use or from use to use.
[0006] However, the insulative needs or desires of a user may not
remain static during the duration of a particular use or differing
uses. For example, a user's body may release heat and/or water
vapor (i.e., moisture) during a use of an insulative article, which
may thereby increase the temperature and/or humidity in the space
between the user's body and the insulation. This increase in
temperature and/or humidity in the micro climate between the user's
body and the insulation during the particular use may make the user
uncomfortable.
[0007] Thus, a need exists for new batting, processes of making the
batting, and insulative articles that include the batting, that
self- or automatically regulate their insulative quality based on
one or more change in the environment interacting with the batting,
such as the micro climate between a user's body and the insulation.
In this way, a need exists for batting, processes of making the
batting, and insulative articles that include the batting, that
react to a change in the climate between a user's body and the
insulation by appropriately moderating or regulating the insulative
quality of the insulation to ensure the comfort and/or desired
micro climate of the user.
[0008] While certain aspects of conventional technologies have been
discussed to facilitate disclosure, Applicant in no way disclaims
these technical aspects, and it is contemplated that the claimed
inventions may encompass one or more conventional technical
aspects.
[0009] In this specification, where a document, act or item of
knowledge is referred to or discussed, this reference or discussion
is not an admission that the document, act or item of knowledge or
any combination thereof was, at the priority date, publicly
available, known to the public, part of common general knowledge,
or otherwise constitutes prior art under the applicable statutory
provisions; or is known to be relevant to an attempt to solve any
problem with which this specification is concerned.
SUMMARY OF THE INVENTION
[0010] Briefly, the present disclosure satisfies the need for
improved batting, processes of making the same, and insulative
articles including same, that self- or automatically regulate their
insulative quality based on at least one change in the environment
interacting with the batting, such as the micro climate between a
user's body and the batting. The insulative quality of the batting
may change over time in response to a particular user and/or a
particular activity of the user by reacting to changes in the micro
climate between a user's body and the insulation. The batting may
thereby regulate its insulative quality to ensure the comfort of
the user and/or to achieve a desired micro climate. In some
embodiments, the batting may automatically and dynamically regulate
its insulative quality to provide comfort and/or micro climate
management by regulating the heat and/or or humidity within the
micro climate.
[0011] The present disclosure may address one or more of the
problems and deficiencies of the art discussed above. However, it
is contemplated that the present disclosure may prove useful in
addressing other problems and deficiencies in a number of technical
areas.
[0012] Therefore, the claimed inventions and present disclosure
should not necessarily be construed as limited to addressing any of
the particular problems or deficiencies discussed herein.
[0013] In a first aspect, the present disclosure provides
self-regulating batting comprising a blend of a plurality of fibers
including functional fibers and non-functional fibers, the
plurality of fibers being non-woven and oriented substantially
vertically along a thickness direction of the batting, wherein the
functional fibers are configured to self-regulate at least one
insulative quality of the batting based on changes in at least one
environmental condition interacting with the batting.
[0014] In some embodiments, the self-regulating batting is in the
form of a sheet extending along width and length directions that
extend perpendicularly to the thickness direction and each other.
In some embodiments, the functional fibers are configured to
self-regulate the insulative quality of the batting with respect to
heat based changes in at least one environmental condition
interacting with the batting. In some embodiments, the functional
fibers are configured to self-regulate the insulative quality of
the batting with respect to moisture based changes in at least one
environmental condition interacting with the batting.
[0015] In some embodiments, the functional fibers are configured to
self-regulate at least one insulative quality of the batting based
changes in humidity of an environment interacting with the batting.
In some such embodiments, the functional fibers are configured to
self-regulate insulative quality of the batting with respect to at
least heat based changes in humidity of the environment interacting
with the batting. In some such embodiments, the functional fibers
are configured to self-regulate insulative quality of the batting
with respect to at least heat based changes in humidity of the
environment interacting with the batting by varying the thickness
of the batting. In some such embodiments, the functional fibers are
configured to vary the thickness of the batting by self-varying
their length along the thickness direction based changes in
humidity of the environment interacting with the batting. In some
such embodiments, the functional fibers self-vary their length
along the thickness direction by forming a crimp therein or
increasing a crimp thereof.
[0016] In some such embodiments where the functional fibers are
configured to self-regulate insulative quality of the batting with
respect to at least heat based changes in humidity of the
environment interacting with the batting by varying the thickness
of the batting, the functional fibers are configured to decrease
the insulative quality of the batting with respect to at least heat
based of increases in humidity of the environment interacting with
the batting by decreasing the thickness of the batting. In some
such embodiments, the functional fibers are configured to decrease
the insulative quality of the batting with respect to at least heat
based of increases in humidity of the environment interacting with
the batting above a predetermined threshold humidity level by
decreasing the thickness of the batting.
[0017] In some embodiments, the plurality of fibers are vertically
lapped. In some embodiments, the plurality of fibers comprise
staple fibers of a staple length within the range of 12 mm to 70
mm. In some embodiments, the plurality of fibers comprise a denier
within the range of 0.5 D to 8 D. In some embodiments, the
functional fibers include at least two components of differing
materials. In some such embodiments, the functional fibers include
a hygroscopic component and a non-hygroscopic component.
[0018] In some embodiments, the non-functional fibers include
binder fibers. In some embodiments, the non-functional fibers
comprise synthetic fibers. In some such embodiments, the synthetic
fibers comprise polyester fibers. In some embodiments, the
synthetic fibers comprise siliconized fibers. In some embodiments,
the functional fibers comprise at least 15% of the blend of
fibers.
[0019] In another aspect, the present disclosure provides an
article comprising the self-regulating batting according to the
first aspect of the present disclosure. In some embodiments, the
article is selected from the group consisting of an outerwear
product, clothing, a sleeping bag, and bedding. In some
embodiments, the article is configured to be used by a user such
that a micro climate interacting with the batting is formed between
the user and the self-regulating insulative batting extending along
the thickness direction. In some such embodiments, the article
includes at least one outer protection layer that prevents the
environment exterior to the self-regulating batting from
interacting with the self-regulating batting.
[0020] In another aspect, the present disclosure provides a method
of making the self-regulating batting according to the first aspect
of the present disclosure. The method comprises forming at least
one nonwoven web from the blend of the plurality of fibers
including the functional fibers and the non-functional fibers, and
vertically lapping the at least one nonwoven web such that the
fibers are oriented substantially vertically along the thickness
direction of the batting. The functional fibers are configured to
self-regulate at least one insulative quality of the batting based
on changes in at least one environmental condition interacting with
the batting.
[0021] In another aspect, the present disclosure provides a method
of making self-regulating insulative batting. The method comprises
obtaining a plurality of opened and blended fibers including
functional fibers and non-functional fibers, the functional fibers
being configured to self-regulate at least the length thereof based
on changes in at least one environmental condition interacting with
the fiber. The method also comprises parallelizing the plurality of
opened and blended fibers into at least one non-woven, carded web
layer. The method also comprises vertically lapping the at least
one non-woven, carded web layer to form a self-regulating
insulative batting with the lengths of the fibers being oriented
substantially vertically along thickness direction of the batting
so that at least one insulative quality of the batting
self-regulates based on changes in at least one environmental
condition interacting with the batting.
[0022] In some embodiments, the self-regulating insulative batting
comprises self-regulating insulative batting of the first aspect of
the present disclosure. In some embodiments, obtaining a plurality
of opened and blended fibers comprises opening a plurality of the
functional fibers and non-functional fibers. In some embodiments,
obtaining a plurality of opened and blended fibers comprises
blending a plurality of the opened functional fibers and
non-functional fibers
[0023] In some embodiments, the method further comprises
positioning the self-regulating insulative batting within an
article configured to be used by a user such that a micro climate
interacting with the batting is formed between the user and the
self-regulating insulative batting extending along the thickness
direction. In some such embodiments, the article includes at least
one outer protection layer that prevents the environment exterior
to the self-regulating batting from interacting with the
self-regulating batting.
[0024] Certain embodiments of the presently-disclosed
self-regulating batting, articles comprising the self-regulating
batting, and methods of making the self-regulating batting have
several features, no single one of which is solely responsible for
their desirable attributes. Without limiting the scope of the
batting, articles, and methods as defined by the claims that
follow, their more prominent features will now be discussed
briefly. After considering this discussion, and particularly after
reading the section of this specification entitled "Detailed
Description of the Invention," one will understand how the features
of the various embodiments disclosed herein provide a number of
advantages over the current state of the art. For example,
embodiments of the batting offer self-regulating batting that is
capable of automatically and dynamically reacting to changes in the
environment interacting with the batting, such as the micro climate
between a user's body and the batting, by appropriately moderating
or regulating the insulative quality of the batting to ensure the
comfort and/or desired micro climate of the user. The batting may
self-regulate its insulative quality to provide automatic and
dynamic comfort and/or micro climate management, such as by
regulating the transfer of heat and/or humidity through the batting
and, thereby, within the micro climate. Embodiments of the
self-regulating batting can be used to make various articles,
including clothing, outerwear, footwear, etc.
[0025] These and other features and advantages of the present
disclosure will become apparent from the following detailed
description of the various aspects of the present disclosure taken
in conjunction with the appended claims and the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The present disclosure will hereinafter be described in
conjunction with the following drawing figures, wherein like
numerals denote like elements, and:
[0027] FIG. 1 is a cross-sectional view of exemplary batting
incorporated in an exemplary insulative article and being utilized
by a user according to the present disclosure.
[0028] FIG. 2 is a top view the exemplary batting and exemplary
insulative article of FIG. 1.
[0029] FIG. 3 is a cross-sectional photograph of exemplary batting
according to the present disclosure.
[0030] FIG. 4 is an elevational perspective view of exemplary
batting being formed according to the present disclosure.
[0031] FIGS. 5 and 6 are side views of an exemplary functional
fiber in un-activated and activated states of batting according to
the present disclosure.
[0032] FIGS. 7 and 8 are side views of another exemplary functional
fiber in un-activated and activated states of batting according to
the present disclosure.
[0033] FIGS. 9 and 10 are cross-sectional views of exemplary
batting in un-activated and activated states incorporated in an
exemplary insulative article and being utilized by a user according
to the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0034] Aspects of the present disclosure and certain features,
advantages, and details thereof are explained more fully below with
reference to the non-limiting embodiments illustrated in the
accompanying drawings. Descriptions of well-known materials,
fabrication tools, processing techniques, etc., are omitted so as
to not unnecessarily obscure the present disclosure in detail. It
should be understood, however, that the detailed description and
the specific example(s), while indicating embodiments of the
present disclosure, are given by way of illustration only, and are
not by way of limitation. Various substitutions, modifications,
additions and/or arrangements within the spirit and/or scope of the
underlying inventive concepts will be apparent to those skilled in
the art from this disclosure.
[0035] The present disclosure provides for non-woven batting,
processes of making the batting, and insulative articles including
the batting, that self-regulate or automatically regulate their
insulative quality, at least to a certain extent with respect to at
least one environmental variable, based on one or more change in
environmental conditions interacting with at least a portion of the
batting (and thereby interacting with at least a portion of the
article including the batting). As shown in FIG. 1, in some
embodiments the batting 10 of the present disclosure may
self-regulate its insulative quality, at least to a certain extent
with respect to at least one environmental variable, based on at
least one change in environmental conditions in a micro climate 16
between an outer surface 24 of a user's body or person 14 and an
interior side or surface 20 of the batting 10 (or an article 12
including the batting 10). The micro climate 16 may thereby
interact with at least a portion of the batting 10 (and/or the
article 12 including and the batting) via the interior side 20. The
batting 10 may self-regulate its insulate quality or effectiveness
in resisting the flow of at least one environmental variable of the
micro climate 16 through the batting 10 from the interior side 20
to an exterior side 22 (e.g., in the z direction) thereof and,
thereby, out of the micro climate 16 based on at least one change
of a parameter of the micro climate 16. The batting 10 may likewise
self-regulate its insulate quality or effectiveness in resisting
the flow of at least one environmental variable of an exterior
environment 18 interacting with the exterior surface 22 of the
batting 10 through the batting 10 (e.g., in the z direction) and,
thereby, into the micro climate 16 (e.g., based on at least one
change in environmental conditions in the micro climate 16).
[0036] As a non-limiting example of at least one environmental
variable that may be resisted differently or regulated by the
batting 10 in response to at least one environmental change of the
micro climate 16, the batting 10 may self-regulate its insulative
quality or effectiveness with respect to heat and/or moisture based
on moisture changes within the micro climate 16. In such an
embodiment, the batting 10 may thereby self-regulate the rate at
which heat or temperature and/or moisture of the micro climate 16
flows through the batting 10 and out of the micro climate 16, and
thereby the temperature and/or moisture of the micro climate 16
itself, based on changes in humidity/moisture within the micro
climate 16. For example, the batting 10 may decrease its insulative
effectiveness to temperature and/or moisture in response to an
increase in moisture within the micro climate 16 to allow a greater
amount or rate of heat and/or moisture to flow therethrough (and
thereby out of the micro climate 16) to cool and/or dry the micro
climate 16 and, thereby, the user 14. The greater then the increase
in moisture within the micro climate 16, the greater the batting 10
may decrease its insulative effectiveness to temperature and/or
moisture. Similarly, the batting 10 may increase its insulative
effectiveness to temperature and/or moisture (e.g., from a previous
increased effectiveness) in response decreases in moisture within
the micro climate 16 to resist a greater amount or rate of heat
and/or moisture to flow therethrough (and thereby out of the micro
climate 16) to provide a comfortable or desired temperature and/or
moisture level or range to the user 14. The greater then the
decrease in moisture within the micro climate 16, the greater the
batting 10 may increase its insulative effectiveness to temperature
and/or moisture. In this way, the batting 10 of the present
disclosure may react to the moisture within the micro climate 16,
which may directly or indirectly result from the amount of moisture
emitted by a user 14 of an article 12 containing the batting 10,
and may indicate that the body temperature of the user 14 needs to
cool down, by regulating or adapting the temperature and/or
moisture resistance of the batting 10.
[0037] In some embodiments, the batting 10 may be configured, as
explained further below, to regulate its insulative effectiveness
to temperature and/or moisture based on corresponding changes in
moisture levels or humidity in the micro climate 16 only when above
a pre-determined threshold, set point or maximum humidity level.
For example, in some embodiments the batting 10 may be configured
to regulate its insulative effectiveness to temperature and/or
moisture based on changes in moisture levels or humidity in the
micro climate 16 only when above a threshold humidity level (e.g.,
a humidity level deemed comfortable). The batting 10 may also have
a self-regulating range of moisture levels (i.e., a range of
moisture levels from the threshold humidity level) at which the
insulative effectiveness is regulated.
[0038] As shown in the cross-sectional view of the illustration of
FIG. 1, the top view of the illustration of FIG. 2, and the
cross-sectional view of the photograph of FIG. 3, the batting 10 of
the present disclosure may be formed of non-woven elongate fibers
30 that extend substantially or primarily vertically or along the
z-axis of the batting 10 (i.e., the third dimension of the batting
10). As shown in FIG. 1, the z-axis of the batting 10 may
correspond or extend parallel to the thickness T1 direction of the
batting 10 extending between the interior surface 20 and the
exterior surface 22 of the batting 10. As noted above, the batting
10 may be positioned within or otherwise utilized with an
insulative article 12. The plurality of fibers 30 of the batting 10
may be arranged or positioned (rather than extend) along the x axis
(e.g., a length L1 direction) and the y axis (e.g., a width
direction W1), as shown in FIGS. 1 and 2.
[0039] The fibers 30 of the batting 10 may be substantially
elongate, and may extend substantially parallel to or be aligned
with the z-axis (along the thickness T1 direction) of the batting
10, as shown in FIG. 1. The fibers 30 may thereby extend, at least
partially, between the interior surface 20 and the exterior surface
22 of the batting 10. The fibers 30 may be substantially smaller
along the x-axis (the length L1 direction) and the y-axis (the
width W1 direction) than the z-axis (the thickness T1 direction).
The fibers 30 of the batting 10 may thus extend predominately along
the z-axis (the thickness T1 direction). The fibers 30 of the
batting 10 may thereby be referred to as vertically oriented.
[0040] The fibers 30 may extend at least along a portion of the
thickness T1 of the batting 10 and be oriented substantially
parallel to or along the z-axis, as shown in FIG. 1. In some
embodiments, the batting 10 may include fibers 30 that extend along
only a portion of the thickness T1 of the batting 10 and/or fibers
30 that traverse the entirety of the thickness T1 of the batting 10
at least once. For example, the batting 10 may include fibers 30
that extend along only a portion of the thickness T1 of the batting
10 in the z direction. Such fibers 30 may be fully positioned
between and spaced from the interior surface 20 and the exterior
surface 22 of the batting 10, or may extend from one of the
interior surface 20 or the exterior surface 22. For example, a
fiber 30 may extend from one of the interior surface 20 or the
exterior surface 22 along the z direction (i.e., the thickness T1
direction) and only along a portion of the thickness T1 of the
batting 10 (i.e., and not reach the other of the interior surface
20 or the exterior surface 22). As another example, a fiber 30 may
extend from the interior of the thickness T1 of the batting 10
along the z-axis and to one of the interior surface 20 or the
exterior surface 22, bend or curved back towards the other of the
interior surface 20 or the exterior surface 22 therefrom, and
extend along the z-axis through a portion of the thickness T1 of
the batting 10.
[0041] The batting 30 may be formed via any process capable of
forming the batting 10 with the vertical or z-axis orientated
non-woven fibers 30. For example, the batting 30 may be formed via
a vertical lapping process (sometimes referred to as Struto or
V-lap process). In one non-limiting example, a plurality of
differing fibers 30 may be opened and then blended together. The
opened and blended fibers 30 may be parallelized into a non-woven,
carded web layer via a carding machine and process. The non-woven
web of fibers 30 (and optionally two or more web layers) may be
carried on a conveyor from the carding machine and process to a
vertical lapping device, such as a Struto.RTM. lapping device or
V-lap .RTM. lapping device for example. The vertical lapping
machine/process may fold the web back and forth in an accordion or
serpentine manner along the z axis into a substantially uniform
structure on a second conveyor, as illustrated in FIGS. 3 and 4.
The web layer may bend back and forth along the z-axis such that
the bends are relative smooth arcs or curved portions of the web
layer and the fibers 30 themselves. In other embodiments, the bends
may be formed by the web layer being folded over itself such that
they are relatively sharp arcs or curved portions of the web layer
and the fibers 30 themselves.
[0042] The folded or serpentine web may thereby extend along the
z-axis and the x-axis, with the fibers 30 predominantly or
primarily extending along the z-axis (i.e., height H1 direction),
as shown in FIGS. 3 and 4. The folds may be compressed together,
such as along the x-axis, to form a continuous batting structure
with the vertically oriented fibers 30. The parallelized fibers 30
may thereby be arranged in a vertical position within the batting
10 giving the fibers 30 a three-dimensional, z-axis orientation,
while being arranged or spaced along the x-axis and y-axis.
[0043] The batting structure with the vertically oriented fibers 30
may then be heated, and subsequently cooled such that at least some
of the fibers 30 are bonded to other fibers 30. The batting
structure with the vertically oriented fibers 30, or a portion
thereof, may be heated via any mechanism. In one embodiments, the
structure may be heated in a thermal bonding oven. The batting
structure with the vertically oriented fibers 30 may be heated such
that fibers 30 of adjacent passes or sections of the serpentine
shape extending along the z-axis become bonded, such that batting
10 has structural integrity that imparts handleability of the
batting 10 in sheet form. As explained further below, the blend of
fibers 30 may include such a binder fiber that is configured bond
to other fibers 30 when heated to relatively high temperatures and
cooled. After bonding, the batting structure with the non-woven
fibers 30 that are bonded and primarily vertically extending may be
a permanent structure that can be further processed (e.g.,
slitting, cutting, winding, etc.) into the batting 10. In some
embodiments, the batting 10 may be formed by a process flow
including fiber blending, opening, carding, vertical lapping, bond
(e.g., thermal bonding), slitting, cutting, and winding, or a
combination thereof. The batting 10 may be incorporated into an
insulative article in a myriad of differing ways.
[0044] Due to the vertical orientation of the fibers 30 (i.e.,
predominantly extending along the z-axis or thickness directions),
the batting 10 may provide improved resiliency, compression
resistance and recovery from compression, while still maintaining a
light weight, as compared to batting with other fiber orientations.
In addition to improved resiliency, compression resistance and
recovery from compression, the batting 10 may have the ability to
automatically or self-regulate its insulative quality, at least to
a certain extent with respect to at least one environmental
variable, based at least one change in environmental conditions
interacting with the batting. An insulative article including the
batting 10 can thereby be worn in a wider variety of environments
and enhance the comfort of the user. In this way, the batting 10
(and thereby an insulative article including the batting 10) may
provide dynamic comfort management to a user. For example, the
batting 10 (and thereby an insulative article including the batting
10) may automatically regulate its temperature and/or moisture
insulative quality in response to changes in humidity conditions in
the micro climate between the batting 10 and a user. In such an
example, the batting 10 may automatically regulate its temperature
and/or moisture insulative quality in response to corresponding
changes in humidity conditions in the micro climate between the
batting 10 and a user by substantially changing its thickness T1
along the z-axis. As one or ordinary skill in the art would
appreciate, the thickness T1 of the batting 10 extending along the
z-axis may directly (or indirectly) effect the temperature and/or
moisture insulative quality (e.g., resistance) of the batting
10.
[0045] As noted above, the fibers 30 making up the batting 10 may
be a blend of differing fibers 30 (e.g., fibers of differing
compositions and/or physical characteristics). In some embodiments
of the batting 10, the blend of fibers 30 may be homogenously
mixed, meaning the fiber mixture has a substantially uniform (i.e.,
90-100% uniform) composition throughout the batting 10. In some
embodiments, the blend of fibers 30 may include fibers of the same
physical configurations or characteristics, such as the same
lengths and/or deniers. Denier is a unit of measure defined as the
weight in grams of 9000 meters of a fiber or yarn. It is a common
way to specify the weight (or size) of the fiber or yarn. For
example, polyester fibers that are 1.0 denier typically have a
diameter of approximately 10 micrometers. Micro-denier fibers are
those having a denier of 1.0 or less, while macro-denier fibers
have a denier greater than 20.
[0046] In some other embodiments, the blend of fibers 30 may
include fibers of differing physical configurations or
characteristics. For example, the blend of fibers 30 may include
fibers of differing lengths and/or deniers. In some embodiments,
the blend of fibers 30 may include fibers with deniers within the
range of about 0.5 D to about 0.8 D (e.g., 0.5 D, 0.6 D, 0.7 D or
0.8 D), including any and all ranges and subranges therein. In some
embodiments, the blend of fibers 30 may include at least one type
of fibers including a first denier, and at least one differing type
of fibers (e.g., made from a differing material) including a second
denier that is smaller or larger than the first denier. In some
embodiments, the blend of fibers 30 may include at least one type
of fibers including differing deniers. In some embodiments, the
fibers 30 include at least some micro-denier fibers (e.g., fibers
having a denier of 0.7 to 1.0 denier). In some embodiments, the
fibers 30 include at least some macro-denier fibers (e.g., fibers
having a denier of 1.1 to 8.0 denier). In some embodiments, the
blend of fibers 30 may include micro-denier fibers and macro-denier
fibers.
[0047] In some embodiments, the fibers 30 making up the blend may
be staple fibers (i.e., fibers of standardized length). In some
embodiments, the blend of fibers 30 may include fibers of differing
staple lengths, such as within the range of about 12 mm to about 70
mm (e.g., 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm,
20 mm, 21 mm, 22 mm, 23 mm, 24 mm, 25 mm, 26 mm, 27 mm, 28 mm, 29
mm, 30 mm, 31 mm, 32 mm, 33 mm, 34 mm, 35 mm, 36 mm, 37 mm, 38 mm,
39 mm, 40 mm, 41 mm, 42 mm, 43 mm, 44 mm, 45 mm, 46 mm, 47 mm, 48
mm, 49 mm, 50 mm, 51 mm, 52 mm, 53 mm, 54 mm, 55 mm, 56 mm, 57 mm,
58 mm, 59 mm, 60 mm, 61 mm, 62 mm, 63 mm, 64 mm, 65 mm, 66 mm, 67
mm, 68 mm, 69 mm or 70 mm), including any and all ranges and
subranges therein.
[0048] In some embodiments, the blend of fibers 30 may include at
least one type of fibers including a first staple length, and at
least one differing types of fibers (e.g., made from a differing
material) including a second staple length that is shorter or
longer than the first staple length. In some embodiments, the blend
of fibers 30 may include at least one type of fibers including
differing staple lengths. In some embodiments, the blend of fibers
30 may include differing types of fibers (e.g., made from a
differing material) including the same denier but differing staple
lengths. In some embodiments, the blend of fibers 30 may include
differing types of fibers (e.g., made from a differing material)
including the same staple length but differing deniers.
[0049] In some embodiments, the blend of fibers 30 may include
fibers made from differing materials. For example, the blend of
fibers 30 making up the batting 10 may include binder fiber made
form a material that configures the fibers to bond to other fibers,
as discussed above. In some embodiments, the blend of fibers 30 may
include at least about 10% binder fiber. However, in some other
embodiments the blend of fibers 30 making up the batting 10 may be
void of a binder fiber configured to melt and bond to other fibers
30 in the batting 10. In such an embodiment, the fibers 30 may
still none the-less be sufficiently adhered or bonded to one
another so as to form a discrete batting structure that has
structural integrity and is capable of being handled and used
as-is, without falling apart or otherwise compromising the
structural integrity of the batting so as to make it unfit for end
use. For example, in some embodiments a resin may be used to adhere
the fibers 30 together. In some embodiments, a resin including a
cross-linked copolymer of butyl acrylate and methyl methacrylate
may be utilized to adhere fibers 30 together, rather than or in
addition to the use of binder fibers and heat.
[0050] In some embodiments, the blend of fibers 30 making up the
batting 10 may include siliconized fibers (as described further
below), may be void of siliconized fibers, or may include both
siliconized fibers and non-siliconized fibers. Generally speaking,
the fibers 30 may be crimped or uncrimped. Various crimps,
including spiral and standard (e.g., planar) crimp, are known in
the art. In some embodiments, the blend of fibers 30 making up the
batting 10 may include hollow fibers and/or conjugate, such as
hollow conjugate fibers.
[0051] In some embodiments, the blend of fibers 30 may fibers that
include a water repellent treatment. Durable water repellant (DWR)
treatments are well known in the art, and provide water repellent
properties to treated components. Persons having ordinary skill in
the art are familiar with a variety of DWR treatments, any of which
may optionally be used on fiber populations in connection with the
present disclosure. In some embodiments, fibers 30 used in the
inventive batting 10 (which may be referred to as DWR-treated
fibers 30 or water repellant fibers 30) may have been treated with
a polymer solution of zirconium acetate, which can impart durable
water repellant properties while minimizing and/or avoiding
negative effects on fiber performance. In some embodiments, fibers
30 treated with a durable water repellant may be treated with a
water-repellant, bacterial-resistant, low friction cured zirconium
acetate finish, such that the fibers have improved driability
following washing and enhanced handle and resistance to clumping.
An example of a zirconium acetate solution that may be used as a
DWR treatment in connection with the present disclosure is
disclosed in U.S. Pat. No. 4,537,594. In some embodiments, a fiber
30 treated with a durable water repellant may be treated in a wet
bath or dry spraying process. In some embodiments, the treatment
includes a surface energy modification technique, which, as is
known in the art, may include, e.g., plasma treatment. Such
treatments or processes are explained in U.S. Pat. Nos. 4,869,922,
5,262,208, 5,895,558, 6,416,633, 7,510,632, 8,309,033, and U.S.
Pat. No. 8,298,627.
[0052] The blend of fibers 30 making up the batting 10 may include
fibers made from differing materials or the same material(s). In
some embodiments, the blend of fibers 30 making up the batting 10
may include fibers made from virgin and/or post-consumer recycled
polyester (which may be siliconized, may not be siliconized, or may
include a combination of siliconized and non-siliconized fibers).
In some embodiments, the blend of fibers 30 making up the batting
10 may include fibers made from at least one of poly(lactic acid)
(PLA), polypropylene, polyurethane, nylon (e.g., nylon 6,6),
poly(butyl acrylate) (PBA), acrylic, mod-acrylic, rayon, wool,
alpaca, kapok or milkweed, or combinations thereof.
[0053] In some embodiments, the blend of fibers 30 may include
synthetic fibers and natural fibers. In some embodiments, the blend
of fibers 30 may be a mixture of synthetic fibers. Persons having
ordinary skill in the art are readily familiar with many synthetic
fibers, and it is well within their purview to select an
appropriate synthetic fiber for use in inventive batting 10
embodiments depending on desired properties of the batting and/or
article within which it is intended to be employed. Embodiments of
the inventive batting 10 can may include any synthetic fiber known
in the art as being conducive to the preparation of textile
materials. In some embodiments, nonexclusive synthetic fibers 30
that may be used to form the batting 10 are selected from nylon,
polyester, polypropylene, polylactic acid (PLA), poly(butyl
acrylate) (PBA), polyamide, acrylic, acetate, polyolefin, nylon,
rayon, lyocell, aramid, spandex, viscose, and modal fibers, and
combinations thereof. In particular embodiments, synthetic fibers
may be polyester fibers. For example, in some embodiments, the
polyester is selected from poly(ethylene terephthalate),
poly(hexahydro-p-xylylene terephthalate), poly(butylene
terephthalate), poly-1,4-cyclohexelyne dimethylene (PCDT) and
terephthalate copolyesters in which at least 85 mole percent of the
ester units are ethylene terephthalate or hexahydro-p-xylylene
terephthalate units. In a particular embodiment, the polyester is
polyethylene terephthalate. In some embodiments, the synthetic
fibers are virgin fibers. In some embodiments, the synthetic fibers
are recycled fibers (e.g., recycled polyester fibers).
[0054] The blend of fibers 30 may be a mixture with 0 to 100 wt %
synthetic fibers, for example, 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10,
11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27,
28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44,
45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61,
62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78,
79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95,
96, 97, 98, 99, or 100 wt %, including any and all ranges and
subranges therein (e.g., 10 to 100 wt %, 30 to 100 wt %, 51 to 100
wt %, 40 to 90 wt %, 20 to 80 wt %, etc.). In some embodiments, the
blend of fibers 30 includes greater than 50, 55, 60, 65, 70, or 75
wt % synthetic fiber.
[0055] In some embodiments, the synthetic fibers of the blend of
fibers 30 may be siliconized fibers. 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. Pat. No. 3,454,422. The
silicon-comprising composition may be applied using any method
known in the art, e.g., spraying, mixing, dipping, padding, etc.
The silicon-comprising (e.g., silicone) composition, which may
include an organosiloxane or polysiloxane, bonds to an exterior
portion of the fiber. In some embodiments, the silicone coating is
a polysiloxane such as a methylhydrogenpolysiloxane, modified
methylhydrogenpolysiloxane, polydimethylsiloxane, or amino modified
dimethylpolysiloxane. As is known in the art, 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. As is
known in the art, 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. In some embodiments, following
siliconization, the fiber may be dried to remove residual solvent
and then optionally heated to between 65.degree. and 200.degree. C.
to cure.
[0056] In the blend of fibers 30, 0 to 100 wt % of the fibers may
be siliconized fibers, for example, 0, 1, 2, 3, 4, 5, 6, 7, 8, 9,
10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26,
27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43,
44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60,
61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77,
78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94,
95, 96, 97, 98, 99, or 100 wt %, including any and all ranges and
subranges therein (e.g., 20 to 95 wt %, 25 to 90 wt %, 30 to 90 wt
%, 40 to 85 wt %, 51 to 90 wt %, etc.). In some embodiments, the
siliconized fibers are polyethylene fibers.
[0057] In some embodiments, the blend of fibers 30 may include up
to 15 wt % of particles or material that is different from the
synthetic material that the synthetic fiber is primarily comprised
of For example, in some embodiments, the synthetic fibers may
include 0, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1,
1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4,
2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7,
3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0,
5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3,
6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6,
7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9,
9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, 10.0, 10.1, 10.2,
10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 11.0, 11.1, 11.2, 11.3,
11.4, 11.5, 11.6, 11.7, 11.8, 11.9, 12.0, 12.1, 12.2, 12.3, 12.4,
12.5, 12.6, 12.7, 12.8, 12.9, 13.0, 13.1, 13.2, 13.3, 13.4, 13.5,
13.6, 13.7, 13.8, 13.9, 14.0, 14.1, 14.2, 14.3, 14.4, 14.5, 14.6,
14.7, 14.8, 14.9, or 15.0 wt % of particles or material different
from the synthetic material that the synthetic fiber is primarily
comprised of, including any and all ranges and subranges therein.
In some embodiments, said particles or material is comprised within
(e.g., encapsulated within) a polymer matrix that represents the
synthetic material of which the synthetic fiber is primarily
comprised. In some embodiments, the synthetic fibers in the fiber
mixture comprise aerogel fiber, as described in U.S. Provisional
Application No. 62/256,374.
[0058] In some embodiments, the blend of fibers 30 forming the
batting 10 includes natural fibers. For example, in some
embodiments, the blend of fibers 30 includes 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).
[0059] The blend of fibers 30 may include 0 to 100 wt % natural
fibers, for example, 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13,
14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30,
31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47,
48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64,
65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81,
82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98,
99, or 100 wt %, including any and all ranges and subranges therein
(e.g., 0 to 50 wt %, 1 to 40 wt %, 5 to 25 wt %, 30 to 60 wt %,
etc.). In some embodiments, the blend of fibers 30 includes less
than 50, 40, 30, 20, or 10 wt % synthetic fiber.
[0060] The blend of fibers 30 may also include a plurality of at
least one type of reactive or functional fibers. In some
embodiments, the blend of fibers 30 may include at least about 15%
functional fibers. In some embodiments, the blend of fibers 30 may
include at least about 20% functional fibers. In some embodiments,
the blend of fibers 30 may include within the range of about 15% to
about 40% functional fibers, such as within the range of about 25%
to about 40% functional fibers. The reactive fibers of the blend of
fibers 30 may be configured to automatically or dynamically react
to the environment around or interacting with them by
correspondingly changing at least one characteristic or function
thereof based on one or more change in the environment. The effect
between the activated and un-activated state of the functional
fibers may be reversible. At least one characteristic or variable
of the environment (or climate) interacting with the functional
fibers may thereby be a stimulus that causes the functional fibers
to react by correspondingly changing at least one characteristic or
function thereof accordingly. The reactive fibers may thereby be
configured such that they have a particular behavior when exposed
to an external predetermined stimulus or trigger. For example,
reactive fibers with two chemically differing components may be
activated by one or more stimulus. The reactive fibers may release
heat, change shape (e.g., shrink or expand), change wicking
ability, etc. in response to a change in at least one
characteristic or variable of the environment (or climate)
interacting with the functional fibers. Activating stimuli are not
limited, and may be determined through the choice of fiber
compositions, for example. In some embodiments, an activating
stimulus may be moisture/humidity, temperature, light, pH,
electrical current, force field, microbes, or biological matter.
When exposed to such stimulus (or stimuli), the functional/reactive
fibers may thereby become active fibers that actively change at
least one characteristic or function thereof correspondingly in
response to the stimulus. The batting 10 may utilize such
functional fibers as a portion of the vertically oriented non-woven
fibers 30 to automatically or self-regulate the insulative quality
of the batting 10, at least to a certain extent with respect to at
least one environmental variable, based at least one change in
environmental conditions interacting with the batting 10 (i.e.,
interacting with the functional fibers of the batting 10). An
example of functional fibers that may be utilized to form the
batting 10 with the present disclosure are disclosed in
International Patent Application Publication No. WO/2013/186528. In
some embodiments, the functional fibers may be INOTEK.TM.
bi-component fibers sold by MMT Textiles Limited of the United
Kingdom.
[0061] In some embodiments, the functional fibers may have a first
configuration in an un-activated state, and in response to
activation by changes in the external stimulus (e.g., above a
minimum threshold) the fibers bend or twist to adopt a second,
increased crimp or twist configuration relative to the first
configuration. The degree of activation or movement of the fibers
may be proportional to the amount of change of the external
stimulus. Stated differently, the greater the change in the
stimulus, the greater the fibers may crimp or twist.
[0062] The functional fibers may be arranged in a helix in the
second configuration with a relatively decreased radius and pitch
as respect to the first configuration. The functional fibers may be
arranged in a helix in the first configuration (or otherwise
crimped) or may be substantially linear or straight in the first
configuration. The increase in twist in the second configuration as
compared to the first configuration may allow for functional fibers
that are relatively long and wide when un-activated and relatively
short and narrow when activated. The functional fibers may move
between the first and second configurations in proportion to the
external stimulus, at least in a workable range. For example, the
functional fibers may be configured to activate at a certain
set-point or activation level of the external stimuli, and crimp or
twist to the second configuration up to a certain set-point or
maximum level of the external stimuli. In conditions between the
activation and maximum levels of the external stimuli, the
functional fibers may adopt a number of transitional configuration
between the first and second configurations or shapes.
[0063] In some embodiments, the functional fibers may be made from
a shape-memory material. The shape-memory material may include at
least two components having differing physical reaction to the
external stimulus. The components may be in any ratio range and may
be arranged in any configuration (such as, for example, an
eccentric or asymmetric configuration). The shape of the fibers
and/or the arrangement of the components or portions of the fibers
may affect the mechanical configuration reaction to the activation
stimuli. Shape-memory materials are able to retain two or more
shapes and transition between those shapes when triggered by an
external or environmental stimulus. The activating external
stimulus or trigger for the functional fibers may be determined, at
least in part, by the chemistry of the material forming the
fibers.
[0064] For example, the functional fibers may be configured such
that the external stimulus is moisture/humidity. In such
embodiments, the shape-memory material of the fibers may have a
relatively quick rate of reacting to changes in humidity so that
they quickly change from the first configuration or shape to the
second configuration or shape. In some humidity-reactive functional
fiber embodiments, the fibers may be made from at least two
polymers as bi-component fibers. For example, a minimum of two
polymers may be utilized to form humidity-reactive functional
fibers, with the at least two polymers having different thermal
shrinking properties, Young's modulus and/or moisture absorption
properties. Humidity-reactive functional fibers may include a
hygroscopic component or portion and a non-hygroscopic component or
portion. For example, in one non-limiting exemplary embodiment the
functional fibers may be co-extruded fibers with a circular
cross-section comprising Nylon 6 as the hygroscopic component and
polypropylene (PP) as the non-hygroscopic component in a ratio
70:30 Nylon:Polypropylene ratio in an eccentric sheath core
configuration.
[0065] In humidity-reactive functional fiber embodiments where
humidity is the external stimulus (i.e., the function fibers are
configured to react to humidity/moisture as the external trigger),
in an active state the fibers are in a humid environment and in the
active or second configuration or shape, in an un-activated state
the fibers are in a relatively drier environment and an
un-activated or first configuration or state. In such embodiments,
when exposed to humid conditions above the set-point or minimum
humidity level, the functional fibers may proportionally or
gradually shrink at least along their length (and, potentially,
along their width) as the humidity increases. In some embodiments,
the when exposed to humid conditions above the set-point or minimum
humidity level, the humidity-reactive functional fibers may be more
tightly twisted in an activated configuration as compared with dry
conditions in the un-activated configuration, and more tightly
twist or crimp as the humidity increases from the activation
humidity level to the maximum humidity level. In some embodiments,
the activation humidity level may be a level which is deemed
uncomfortable to a user and/or a humidity level that indicates the
user may want or need less thermal insulation, as described further
below.
[0066] An example of a physical mechanism leading to at least
proportional shortening of a functional fiber 50 according to the
present disclosure, such as a humidity-reactive functional fiber,
is shown in FIGS. 5 and 6. As shown in FIG. 5, the functional fiber
50 may include a crimp or helix configuration in the activated
state (and, potentially, in the un-activated state). As discussed
above, the crimp or helix of the functional fiber 50 may be a
heat-set or otherwise formed during and/or after formation of the
fiber 50. The crimp or helix of the functional fiber 50 may be
measured by the number of bends of the fiber per unit length and
the radius of the bends. For example, a functional fiber 50 with a
fine crimp may have many bends of a relatively small radius, and a
functional fiber 50 with a course crimp may have relatively fewer
bends of a relatively larger radius. A helix crimp, as shown in
FIGS. 5 and 6, may be described as a three-dimensional curve around
an axis. The pitch of the helix is the length of one complete turn
measured along the axis of the helix. A circular helix has a
constant curvature and constant torsion.
[0067] FIG. 5 illustrates the humidity-reactive functional fiber 50
in or exposed to a relatively dry environment of a humidity or
moisture level below the set-point or minimum humidity level of the
fiber. Thus, FIG. 5 illustrates the humidity-reactive functional
fiber 50 in its un-activated or first configuration or shape. In
the un-activated state, the functional fiber 50 has an oblong form
factor with a length T2 (e.g., along the z axis) substantially
greater than the length L2 (e.g., along the x axis) and width W2
(e.g., along the y axis). Upon exposure to a humid or moist
environment of a humidity or moisture level at or above the
set-point or minimum humidity level of the humidity-reactive
functional fiber 50, the crimp of the fiber 50 may increase as
shown in FIG. 6. As shown in FIG. 6, upon exposure of the
humidity-reactive functional fiber 50 to a humid environment of a
humidity/moisture level at or above the set-point humidity level
the number of bends per length may increase and the radius of the
bends may decrease (i.e. the helix becomes tighter, the radius and
pitch of the helix decreases). In this way, the humidity-reactive
functional fiber 50 may become more substantially shorter along the
z-axis (and potentially smaller along the x axis and the y axis).
The crimp of the fiber 50 may increase proportionally with respect
to the increase in humidity of the environment. Stated differently,
the greater that the humidity of the environment increases, the
greater the crimp of the fiber 50 may increase.
[0068] The increase in crimp or helix configuration of the
functional fiber 50 may be effectuated by the bi-component nature
or composition of the fiber 50. For example, the humidity-reactive
functional fiber 50 may include a hygroscopic polymer or component
that is selected to have less thermal shrinkage and to be less
stiff than a non-hygroscopic polymer or component. During the
crimping process of the functional fiber 50, the hygroscopic
component may want or be urged to elongate. However, elongation of
the hygroscopic component may be restricted by the non-hygroscopic
component, which may result in the crimp or helix configuration or
arrangement of the fiber 50. Similarly, when the functional fiber
50 is exposed to a humid environment of a humidity/moisture level
at or above the set-point humidity level the hygroscopic component
may want or be urged to further elongate. Again, elongation of the
hygroscopic component may be restricted by the non-hygroscopic
component, and the relatively stiffer non-hygroscopic component may
cause the crimp or helix angle to tighten into the activated
configuration, as shown in FIG. 6. As shown in comparison of FIGS.
5 and 6, the increase or tightening of the crimp or helix structure
of the functional fiber 50 may result in a substantial decrease in
the length T2 (e.g., along the z axis) of the fiber 50, and
relatively smaller decreases in the length L2 (e.g., along the x
axis) and width W2 (e.g., along the y axis) of the fiber 50. When
the humid environment decreases from the increased
humidity/moisture level, the fiber 50 may return to the
un-activated configuration.
[0069] Another embodiment of a functional fiber 150, such as a
humidity-reactive functional fiber 150, is shown in FIGS. 7 and 8.
The functional fiber 150 of FIGS. 7 and 8 is substantially similar
to the functional fiber 50 of FIGS. 5 and 6, and therefore the
description herein to the functional fiber 50 of FIGS. 5 and 6
equally applies to the functional fiber 150 of FIGS. 7 and 8. The
functional fiber 150 of FIGS. 7 and 8 differs from the functional
fiber 50 of FIGS. 5 and 6 with respect to the un-activated
configuration or state of the functional fiber 150. As shown in
FIG. 7, in the un-activated configuration the functional fiber 150
may be substantially linear or straight, and in the activated
configuration the functional fiber 150 may crimped or in a helix
configuration. As described above, the humidity of the environment
acting on the fiber 150 may be below the set-point humidity level
such that the fiber 150 is in the straight un-activated
configuration. When the humidity of the environment acting on the
fiber 150 increases to at or above the set-point humidity level, a
hygroscopic component of the fiber 150 may want or be urged to
elongate. This elongation of the hygroscopic component may be
restricted by a non-hygroscopic component of the fiber 150, and the
relatively stiffer non-hygroscopic component may cause the fiber
150 to crimp or curl into the activated helix configuration as
shown in FIG. 8. The linear-to-helix reconfiguration (e.g.,
twisting) of the fiber 150 (i.e., the un-activated and activated
states) may substantially decrease the length T3 (e.g., along the z
axis) of the fiber 150, as shown in FIGS. 7 and 8. In some
embodiments, the linear-to-helix reconfiguration of the fiber 150
may slightly increase the length L3 (e.g., along the x axis) and
width W3 (e.g., along the y axis) of the fiber 150. In this way,
the bends or twists of the fiber 150 may increase the travel of the
fiber 150 in the length L3 and width W3 directions, and thereby
decrease the length L3 of the fiber 150.
[0070] The batting of the present disclosure may utilize the
functional fibers to self-regulate or automatically regulate its
insulative quality, at least to a certain extent with respect to at
least one environmental variable, based on one or more change in
environmental conditions interacting with at least a portion of the
batting (and thereby interacting with at least a portion of an
article including the batting). As discussed above, the batting may
be configured such that the blend of fibers making up the batting
are substantially vertically oriented along the thickness or z axis
of the batting. As also explained above, the blend of fibers making
up the batting may include functional fibers that proportionally
vary length between un-activated and activated states based on
changes in an environmental stimulus. The batting may thereby
utilize the vertically-aligned, length-varying functional fibers to
effectuate variations in the thickness of the batting, which
effectuates proportional changes in the insulative quality of the
batting.
[0071] An example of such a self-regulating batting 210 is shown in
FIGS. 9 and 10. The batting 210 may be incorporated in an article
212 that is worn or otherwise utilized by a user 214 for insulative
purposes, as shown in FIGS. 9 and 10. As discussed above and shown
in FIGS. 9 and 10, a micro climate 216 may exist between an outer
surface 224 of the article 214 and an interior side or surface 220
of the batting 210 (or an article 212 including the batting 210).
The micro climate 216 may thereby interact with at least a portion
of an interior side 220 of the batting 210, and the batting 210 may
self-regulate its insulate quality or effectiveness in resisting
the flow of at least one environmental variable of the micro
climate 216 through the batting 210 from the interior side 220 to
an exterior side 222 (e.g., in the z direction) thereof based on
changes in at least one environmental variable of the micro climate
216, and, thereby, out of the micro climate 216.
[0072] As a non-limiting example of at least one environmental
variable that may be resisted differently by the batting 210 in
response to at least one environmental change of the micro climate
216, the batting 210 may self-regulate its insulative quality or
effectiveness with respect to heat and/or moisture based on
humidity/moisture changes within the micro climate 216. In such an
embodiment, the batting 210 may thereby self-regulate the rate at
which heat and/or moisture of the micro climate 216 flows or
travels through the batting 210 and out of the micro climate 216
based on the humidity/moisture within the micro climate 216. For
example, the batting 216 may decrease its insulative effectiveness
to temperature and/or moisture in response to an increase in
moisture within the micro climate 216 above a defined threshold
humidity level to allow a greater amount or rate of heat and/or
moisture to flow therethrough and out of the micro climate 216 to
cool and/or dry the micro climate 216 and, thereby, the user 214.
Similarly, the batting 210 may increase its insulative
effectiveness to temperature and/or moisture (e.g., from a previous
increased effectiveness) in response to a decrease in moisture
therefrom within the micro climate 216 to resist a greater amount
or rate of heat and/or moisture to flow therethrough and thereby
out of the micro climate 216. It is noted that when a user 214
initially wears or otherwise utilizes the article 214/batting 210,
the conditions of the micro climate 216 may initially be
substantially similar to the conditions of the environment about
the user 214. In this way, the micro climate 216 may change from
the exterior environmental conditions based on any heat and/or
moisture emitted by the user 214 during use, and the batting 210
may react thereto to regulate its insulative effectiveness
accordingly. The article 212 and/or batting 210 may include a layer
or member that prevents moisture from interacting with the batting
210 other than via the micro climate 216. In this way, the article
212 and/or the batting 210 may be configured to ensure the moisture
level of the micro climate 216 controls the thickness regulation,
and thereby the regulation of the insulative effectiveness to
temperature and/or moisture, of the batting 210.
[0073] As shown in FIGS. 9 and 10, the batting 216 may decrease its
insulative effectiveness to temperature and/or moisture in response
to an increase in moisture within the micro climate 216 above a
defined threshold humidity level by decreasing its thickness along
the z axis from a first thickness T4 to a second thickness T5 that
is less than the first thickness T4 to allow a greater amount or
rate of heat and/or moisture to flow therethrough and out of the
micro climate 216 to cool and/or dry the micro climate 216 and,
thereby, the user 214. The greater thickness T4 of the batting 210
along the z axis in the un-activated state (FIG. 9) as compared to
the thinner thickness T5 in the activated state (FIG. 10) provides
a greater insulative effectiveness to temperature and/or moisture.
Likewise, the thinner thickness T5 of the batting 210 along the z
axis in the activated state includes as compared to the greater
thickness T4 in the un-activated state provides a reduced
insulative effectiveness to temperature and/or moisture. In this
way, the batting 210 of the present disclosure may react to the
moisture within the micro climate 216 (e.g., when above a threshold
moisture level), which may directly or indirectly result from the
amount of moisture emitted by a user 214 of an article 212
containing the batting 210, by changing the thickness of the
batting 210 along the z axis to regulate or adapt the temperature
and/or moisture resistance of the batting 210. The degree of the
change in thickness of the batting 210 may be proportional or
depend upon the degree of the change in humidity/moisture of the
micro climate 216--the greater the increase in humidity the thinner
the batting 210 may become.
[0074] The batting 210 may change the thickness of the batting 210
along the z axis to regulate or adapt the temperature and/or
moisture resistance of the batting 210 via the functional fibers.
As discussed above, the functional fibers of the fibers 230 making
up the batting 210 may proportionally change in length in response
to changes in humidity or moisture level of the environment
interacting or surrounding the fibers 230/batting 210, such as the
moisture level of the micro climate 216. For example, the
functional fibers of the fibers 230 making up the batting 210 may
crimp or helix, or increase in crimp or helix tightness, from an
un-activated shape to an activated state in response to an increase
in the humidity or moisture level of the micro climate 216 above a
above a defined threshold humidity level. The crimp, or increase in
crimp, may effectuate a decrease in the length of the functional
fibers, as discussed above. The crimp or helix may tighten as the
moisture level of the micro climate 216 increases to gradually
decrease the length of the fibers.
[0075] As the functional fibers may be integrated and/or bonded to
the other fibers of the blend of fibers 230 making up the batting
210 and may be oriented substantially vertically along the z axis,
the "shrinking" and "growing" functional fibers may act to decrease
and increase the thickness T4/T5 of the batting 210 along the z
axis, respectively, and thereby decrease and increase the
insulative effectiveness of the batting 210 with respect to
temperature and/or moisture proportionally in response to
variations in the humidity/moisture within the micro climate 215.
The amount of change in insulative effectiveness of the batting 210
with respect to temperature and/or moisture may depend upon the
configuration of the functional fibers, the amount of functional
fibers in the blend of fibers 230 comprising the batting 210,
and/or the configuration of the non-functional fibers in the blend
of fibers 230, for example. Similarly, the amount of change in
thickness of the batting 210 with respect to a particular change in
humidity may depend upon the configuration of the functional
fibers, the amount of functional fibers in the blend of fibers 230
comprising the batting 210, and/or the configuration of the
non-functional fibers in the blend of fibers 230, for example. In
some embodiments, the change in thickness of the batting from the
first thickness T4 in the un-activated state (FIG. 9) as compared
to the second thickness T5 in a fully activated state (FIG. 10) may
be at least about 10%. In some embodiments, the change in thickness
of the batting from the first thickness T4 in the un-activated
state (FIG. 9) as compared to the second thickness T5 in a fully
activated state (FIG. 10) may be at least about 15%. In some
embodiments, the change in thickness of the batting from the first
thickness T4 in the un-activated state (FIG. 9) as compared to the
second thickness T5 in a fully activated state (FIG. 10) may be at
least about 20%. In some embodiments, the change in thickness of
the batting from the first thickness T4 in the un-activated state
(FIG. 9) as compared to the second thickness T5 in a fully
activated state (FIG. 10) may be within the range of about 15% to
about 40%. In some embodiments, the change in thickness of the
batting from the first thickness T4 in the un-activated state (FIG.
9) as compared to the second thickness T5 in a fully activated
state (FIG. 10) may be within the range of about 25% to about 40%.
The change in thickness of the batting 210 may affect the clo of
the batting 210. For example, as the thickness of the batting
decreases, the clo may correspondingly decrease. The amount of
change in clo of the batting 210 may depend upon the configuration
of the functional fibers, the amount of functional fibers in the
blend of fibers 230 comprising the batting 210, and/or the
configuration of the non-functional fibers in the blend of fibers
230, for example.
EXAMPLES
[0076] The present disclosure will now be illustrated, but not
limited, by reference to the specific embodiment described in the
following example.
Example 1
[0077] A fiber mixture is prepared by mixing the following: [0078]
At least 15% 2.2 denier, 51 mm low melt binder staple fiber; [0079]
At least 25% 2.0 denier, 51 mm moisture-activated functional staple
fiber; [0080] At least 20% 1.4 denier, 51 mm siliconized polyester
staple fiber; and [0081] At least 20% 7.0 denier, 64 mm siliconized
polyester hollow conjugate staple fiber.
[0082] After being mixed/blended, the fiber mixture is then
processed into web form on a traditional carding machine to form a
nonwoven web. The web is then sent through a vertical-lapper in
order to vertically orient the fibers along the z axis and to
achieve a thickness and weight. The batting structure may then be
heated to effectuate bonding of the binder fiber and to form
batting.
[0083] The functional fibers are configured such that the defined
threshold humidity level is about 60%, and the maximum reactive
humidity level is about 98%. The batting is therefore active when
exposed to changes in environment between 60% and 98% humidity
(i.e., the batting includes an activation zone between 60% and 98%
humidity). The batting is formed such that in an un-activated state
(i.e., in an environment less than 60% humidity), the batting
includes a thickness of about 19.6 mm and a weight of about 105
g/m2 (3.09 oz/yd2). The un-activated batting includes a total clo
of about 2.453 and a clo/oz/yd2 of about 0.794 in the un-activated
state. In the fully activated state (i.e., exposed to 98% humidity
or greater), the batting includes a thickness of about 14.9 mm (a
decrease in thickness along the z axis of about 24%). The activated
batting includes a total clo of about 1.864 and a clo/oz/yd2 of
about 0.603. The weight between the un-activated and fully
activated states of the batting remains substantially the same.
[0084] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the present disclosure. As used herein, the singular forms "a",
"an" and "the" are intended to include the plural forms as well,
unless the context clearly indicates otherwise. It will be further
understood that the terms "comprise" (and any form of comprise,
such as "comprises" and "comprising"), "have" (and any form of
have, such as "has" and "having"), "include" (and any form of
include, such as "includes" and "including"), "contain" (and any
form contain, such as "contains" and "containing"), and any other
grammatical variant thereof, are open-ended linking verbs. As a
result, 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. Likewise, 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.
[0085] As used herein, the terms "comprising," "has," "including,"
"containing," and other grammatical variants thereof encompass the
terms "consisting of" and "consisting essentially of."
[0086] The phrase "consisting essentially of" or grammatical
variants thereof when used herein are to be taken as specifying the
stated features, integers, steps or components but do not preclude
the addition of one or more additional features, integers, steps,
components or groups thereof but only if the additional features,
integers, steps, components or groups thereof do not materially
alter the basic and novel characteristics of the claimed
compositions or methods.
[0087] All publications cited in this specification are herein
incorporated by reference as if each individual publication were
specifically and individually indicated to be incorporated by
reference herein as though fully set forth.
[0088] Subject matter incorporated by reference is not considered
to be an alternative to any claim limitations, unless otherwise
explicitly indicated.
[0089] Where one or more ranges are referred to throughout this
specification, 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.
[0090] While several aspects and embodiments of the present
disclosure have been described and depicted herein, alternative
aspects and embodiments may be affected by those skilled in the art
to accomplish the same objectives. Accordingly, this disclosure and
the appended claims are intended to cover all such further and
alternative aspects and embodiments as fall within the true spirit
and scope of the present disclosure.
* * * * *