DE112018000440T5 - INSULATION WITH REACTIVE FLAPS - Google Patents

Abstract

An insulation comprises a plurality of reactive valves which are responsive to one or more external stimuli, e.g. As moisture, react. The flaps are comprised of a fiber blend that includes: 20-80% by weight of reactive bicomponent fibers that are responsive to an external stimulus and have a first configuration in a non-activated state and a second configuration in an activated state, and wherein the bicomponent fibers reversibly switch back and forth between the non-activated and the activated state; 5-40% by weight of synthetic binder fibers having a denier of 1.5 to 4.0 denier; 0-75% by weight of a first population of synthetic fibers which are synthetic polymer fibers having a denier of less than 2.0 denier; and 0-75% by weight of a second population of synthetic fibers which are synthetic polymer fibers having a denier of 4.0 to 10.0 denier. Related articles and methods are also provided.

Description

REFERENCE TO RELATED APPLICATIONS

This application claims priority over the provisional one U.S. Patent Application No. 62 / 448,182 , filed Jan. 19, 2017, the entire disclosure of which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to insulation, to articles comprising insulation, and to methods of making the insulation.

STATE OF THE ART

Often, the environment in which an individual is located can change quickly. For example, during exercise times, and even in everyday activities, one can quickly move from a state of relative inactivity to high activity. Likewise, people often move from a controlled indoor climate to a dramatically different outdoor climate. In addition, climate change has resulted in weather conditions that can be unpredictable and that can vary widely within a single day, even within a short space of time. In view of the various humidity and temperature variations that people are regularly exposed to, it is desirable to have adaptable articles (eg, of clothing and outerwear) that can conform to improve the comfort of the wearer / user.

Therefore, there is a need for new insulations and articles which are easily susceptible to external stimuli such as skin irritation. B. Temperature and / or humidity can be adjusted.

While certain aspects of conventional technology are discussed to facilitate disclosure of the invention, applicant does not dispute these technical aspects in any way, and it is contemplated that the claimed invention may include one or more conventional technical aspects.

If reference is made or is made to a document, act, or knowledge element in this specification, that reference or discussion is not an admission to the public that the document, act or knowledge element, or a combination thereof, was publicly available on the priority date was part of common knowledge or otherwise constitutes the state of the art under applicable law; or known to be relevant in an attempt to solve a problem that addresses this specification.

BRIEF SUMMARY OF THE INVENTION

Briefly, embodiments of the present invention address the need for insulation and articles that readily conform to an external stimulus, such as an external stimulus. As temperature and / or humidity adjust.

The present invention can overcome one or more of the problems and deficiencies of the prior art discussed above. It is contemplated, however, that the invention may prove useful in overcoming other problems and deficiencies in a number of technical areas. Therefore, the claimed invention should not necessarily be construed to be limited to remedying any of the particular problems or deficiencies discussed herein.

• - 20-80 Gew.-% Zweikomponentenfasern mit einem Kern und einer Hülle, wobei die Fasern ein Denier von 2,0 bis 8,0 Denier und eine Stapelschnittlänge von 38 bis 105 mm aufweisen, wobei die Zweikomponentenfasern gegenüber einem äußeren Reiz reagieren und eine erste Konfiguration in einem nicht aktivierten Zustand und eine zweite Konfiguration in einem aktivierten Zustand aufweisen, und wobei die Zweikomponentenfasern reversibel zwischen dem nicht aktivierten und dem aktivierten Zustand hin- und herwechseln können;
• - 5-40 Gew.-% synthetische Bindefasern mit einem Denier von 1,5 bis 4,0 Denier und einer Stapelschnittlänge von 38 bis 105 mm;
• - 0-75 Gew.-% einer ersten Population von synthetischen Fasern, die synthetische Polymerfasern mit einem Denier von weniger als 2,0 Denier und einer Stapelschnittlänge von 38 bis 105 mm sind; und
• - 0-75 Gew.-% einer zweiten Population von synthetischen Fasern, die synthetische Polymerfasern mit einem Denier von 4,0 bis 10,0 Denier und einer Stapelschnittlänge von 38 bis 105 mm sind.

In a first aspect, the invention provides isolation with a plurality of slots therein forming a plurality of reactive flaps in the insulation such that the insulation comprises the flaps and also a non-flaps portion, the reactive flaps comprising a fl ap fiber blend comprising includes:

• 20-80% by weight of bicomponent fibers having a core and a sheath, the fibers having a denier of 2.0 to 8.0 denier and a staple cut length of 38 to 105 mm, the bicomponent fibers reacting against an external stimulus and a first configuration in a non-activated state and a second configuration in an activated state, and wherein the bicomponent fibers reversibly between the non-activated and the activated state can switch back and forth;
• 5-40% by weight of synthetic binder fibers having a denier of 1.5 to 4.0 denier and a staple cut length of 38 to 105 mm;
• 0-75% by weight of a first population of synthetic fibers which are synthetic polymer fibers having a denier of less than 2.0 denier and a staple cut length of 38 to 105 mm; and
• 0-75% by weight of a second population of synthetic fibers which are synthetic polymer fibers having a denier of 4.0 to 10.0 denier and a staple cut length of 38 to 105 mm.

In a second aspect, the invention provides an article comprising the inventive insulation according to the first aspect of the invention.

• - Bilden einer Zwischenisolierung aus einer Fasermischung, wobei die Zwischenisolierung mehrere Klappenbereiche umfasst, die die nach dem ersten Aspekt der Erfindung erörterte Klappenfasermischung umfassen;
• - Erwärmen der Zwischenisolierung über die Bindungstemperatur der Bindefasern in der Klappenfasermischung hinaus; und
• - Bilden mehrerer Schlitze in der Zwischenisolierung, wodurch mehrere reaktive Klappen erzeugt werden.

In a third aspect, the invention provides a method of making the inventive insulation according to the first aspect of the invention, the method comprising:

• Forming an intermediate insulation from a fiber mixture, the intermediate insulation comprising a plurality of flap regions comprising the flap fiber blend as discussed in the first aspect of the invention;
• Heating the intermediate insulation beyond the bonding temperature of the binder fibers in the valve fiber blend; and
• Forming a plurality of slots in the intermediate insulation, thereby producing a plurality of reactive flaps.

Certain embodiments of the presently disclosed insulation, articles comprising the insulation, and methods of making the insulation have several features, none of which alone is responsible for their desirable properties. Without limiting the scope of isolation, articles and methods as defined by the following claims, their more important features will now be briefly discussed. After reviewing this discussion and particularly after reading the section of this specification entitled "Detailed Description of the Invention", it will be understood 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 insulation provide reactive insulation that adapts quickly to maximize user / wearer comfort. Embodiments of the insulation may be used to make various articles, including clothing, outerwear, shoes, bedding, etc.

These and other features and advantages of this invention will become apparent from the following detailed description of the various aspects of the invention when taken in conjunction with the appended claims and the accompanying drawings.

list of figures

• 1 eine Draufsicht-Aufnahme einer Ausführungsform 10 der erfindungsgemäßen Isolierung ist.
• 2 eine vereinfachte Darstellung der Draufsicht-Aufnahme von 1 ist, bei der die reaktiven Klappen 4 schwarz schattiert gezeigt sind.
• 3A und 3B stellen eine Ausführungsform einer Zweikomponentenfaser dar, die in bestimmten Ausführungsformen der erfindungsgemäßen Isolierung in ihrem nicht aktivierten bzw. aktivierten Zustand verwendet wird.
• 4A-F stellen nicht einschränkende Beispiele von Querschnitten dar, die in bestimmten Ausführungsformen der Erfindung verwendete Zweikomponentenfasern aufweisen können.

The present invention will be described below in conjunction with the following drawing figures, which are not necessarily drawn to scale, and in which like numerals denote like elements, and in which:

• 1 is a plan view of an embodiment 10 of the insulation according to the invention.
• 2 a simplified representation of the top view shot of 1 is where the reactive valves are 4 shaded black are shown.
• 3A and 3B Figure 1 illustrates one embodiment of a bicomponent fiber used in certain embodiments of the isolation of the invention in its unactivated or activated state.
• 4A-F are non-limiting examples of cross-sections that may include bicomponent fibers used in certain embodiments of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Aspects of the present invention and certain features, advantages, and details thereof will now be described in more detail, with reference to the non-limiting embodiments illustrated in the accompanying drawings. Descriptions of known materials, manufacturing tools, processing techniques, etc. will be omitted so as not to unnecessarily obscure the invention in detail. It should be understood, however, that the detailed description and specific example (s), while indicating embodiments of the invention, are given by way of illustration and not of limitation. Various substitutions, changes, additions and / or arrangements in the spirit and / or scope of the underlying inventive concepts will be apparent to those skilled in the art from this disclosure.

• - 20-80 Gew.-% Zweikomponentenfasern mit einem Kern und einer Hülle, wobei die Fasern ein Denier von 2,0 bis 8,0 Denier und eine Stapelschnittlänge von 38 bis 105 mm aufweisen, wobei die Zweikomponentenfasern gegenüber einem äußeren Reiz reagieren und eine erste Konfiguration in einem nicht aktivierten Zustand und eine zweite Konfiguration in einem aktivierten Zustand aufweisen, und wobei die Zweikomponentenfasern reversibel zwischen dem nicht aktivierten und dem aktivierten Zustand hin- und herwechseln können;
• - 5-40 Gew.-% synthetische Bindefasern mit einem Denier von 1,5 bis 4,0 Denier und einer Stapelschnittlänge von 38 bis 105 mm;
• - 0-75 Gew.-% einer ersten Population von synthetischen Fasern, die synthetische Polymerfasern mit einem Denier von weniger als 2,0 Denier und einer Stapelschnittlänge von 38 bis 105 mm sind; und
• - 0-75 Gew.-% einer zweiten Population von synthetischen Fasern, die synthetische Polymerfasern mit einem Denier von 4,0 bis 10,0 Denier und einer Stapelschnittlänge von 38 bis 105 mm sind.

In a first aspect, the invention provides isolation with a plurality of slots therein forming a plurality of reactive flaps in the insulation such that the insulation comprises the flaps and also a non-flaps portion, the reactive flaps comprising a fl ap fiber blend comprising includes:

• 20-80% by weight of bicomponent fibers having a core and a sheath, the fibers having a denier of 2.0 to 8.0 denier and a staple cut length of 38 to 105 mm, the bicomponent fibers reacting against an external stimulus and a first configuration in a non-activated state and a second configuration in an activated state, and wherein the bicomponent fibers reversibly between the non-activated and the activated state can switch back and forth;
• - 5-40% by weight of synthetic binder fibers having a denier of 1.5 to 4.0 denier and a staple cut length of 38 to 105 mm;
• 0-75% by weight of a first population of synthetic fibers which are synthetic polymer fibers having a denier of less than 2.0 denier and a staple cut length of 38 to 105 mm; and
• 0-75% by weight of a second population of synthetic fibers which are synthetic polymer fibers having a denier of 4.0 to 10.0 denier and a staple cut length of 38 to 105 mm.

Denier is a unit of measure defined as the weight of a fiber or yarn in grams per 9000 meters. It is a common method to indicate the weight (or size) of the fiber or yarn. For example, 1.0 denier polyester fibers typically have a diameter of about 10 microns. Micro-denier fibers are those having a denier of 1.0 or less, while macro-denier fibers have a denier of more than 1.0.

In some embodiments, the components of the flap fiber blend are homogeneously mixed, i. H. the mixture has a substantially uniform (i.e., 90-100% uniform, e.g., greater than or equal to 90, 91, 92, 93, 94, 95, 96, 97, 98, or 99% uniform) composition.

In various embodiments of the invention, the reactive flaps shrink and expand upon exposure to an external stimulus (eg, moisture). For example, in some embodiments, the flaps shrink when exposed to relatively higher humidity and expand when exposed to relatively lower humidity. This reactive functionality essentially results in isolation embodiments being able to open / close flaps based on changing humidity levels. For example, when used in z. For example, certain embodiments of a garment or outerwear article at times of general inactivity will close the flaps (here, the bicomponent fibers are considered to be in an unactivated state), while at times of activity in which moisture is generated that results in a moisture increase, the flaps will shrink (in the activated state of the bicomponent fibers), effectively venting the insulation and providing a more breathable and / or less insulating article.

1 is a plan view of an embodiment 10 the isolation of the invention. As you can see, the insulation includes 10 several slots 2 , In the illustrated embodiment, each slot forms 2 a flap (also referred to herein as a "reactive flap") 4 , and the insulation 10 includes several flaps 4 , The insulation 10 includes in addition to the flaps additionally at least one non-flap section 6 , As can be seen, in the illustrated embodiment, the insulation 10 the non-flap section 6 a continuous section of insulation 10 with slits 2 in it, the more reactive valves 4 in the insulation. In the isolation 10 include the reactive valves 4 a flapper fiber blend as described herein and the non-flapper portion 6 includes the same flap fiber blend.

2 is a simplified / marked version of the top view shot of 1 , For better visualization are in 2 the slots 2 shown in white. The through the slots 2 defined reactive valves 4 are shown in black, and the non-flap section 6 is shown in light gray.

While the slots 2 in the insulation 10 C-shaped slots are the semicircular flaps 4 The insulation may comprise slots of any shape. Those of ordinary skill in the art will recognize that there are a variety of shapes that reactive flaps may take, as the shape of the slots and flaps is generally non-limiting with respect to the inventive concept. In fact, in light of the disclosure herein, those of ordinary skill in the art will understand that the flaps will respond due to the composition of the flap fiber blend, and will readily be able to determine various shapes / configurations that slits and flaps may take. Generally speaking, the flaps are attached to the insulation on one side. In some non-limiting examples, the slots are configured to form flaps that are semi-circular (or otherwise circular but remain attached to the insulation), oval, square, rectangular, or triangular in shape.

The size and density of the valves may be altered depending on the size of the desired potential reactivity to the external stimulus (eg, moisture). In some non-limiting embodiments the flaps have a maximum dimension of 2.5 cm (ie, if the size of a flap is measured in any two-dimensional direction of the shape of the flap formed by the slot, the maximum dimension is 2.5 cm). For example, in some embodiments, the flaps have a maximum dimension of 0.5 cm to 2.5 cm (eg, 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 or 2.5 cm), including all areas and subregions in it. In some embodiments, the flaps have a maximum dimension of 0.5 to 2 cm, including all areas and portions therein (eg, 0.75 to 1.25 cm).

The density of the flaps in the insulation can be varied as desired to increase / decrease the clearance in the insulation when exposed to an external stimulus (eg high humidity levels). For example, in some embodiments, the flaps make up 5 to 80% of the surface area of the insulation (eg, 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 or 80%), including all areas and subregions therein. In some embodiments, the non-flap portions of the insulation make up 20 to 95% of the surface area of the insulation (e.g., 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 or 95%), including all regions and subregions therein. In 1 makes the area of the entire visible surface of the insulation 10 the surface area of the insulation. In some embodiments, the flaps are 1.5 to 5 cm apart, including all areas and portions therein (e.g., 2 to 3 cm apart).

• - 20-80 Gew.-% Zweikomponentenfasern mit einem Kern und einer Hülle, wobei die Fasern ein Denier von 2,0 bis 8,0 Denier und eine Stapelschnittlänge von 38 bis 105 mm aufweisen, wobei die Zweikomponentenfasern gegenüber einem äußeren Reiz reagieren und eine erste Konfiguration in einem nicht aktivierten Zustand und eine zweite Konfiguration in einem aktivierten Zustand aufweisen, und wobei die Zweikomponentenfasern reversibel zwischen dem nicht aktivierten und dem aktivierten Zustand hin- und herwechseln können;
• - 5-40 Gew.-% synthetische Bindefasern mit einem Denier von 1,5 bis 4,0 Denier und einer Stapelschnittlänge von 38 bis 105 mm;
• - 0-75 Gew.-% einer ersten Population von synthetischen Fasern, die synthetische Polymerfasern mit einem Denier von weniger als 2,0 Denier und einer Stapelschnittlänge von 38 bis 105 mm sind; und
• - 0-75 Gew.-% einer zweiten Population von synthetischen Fasern, die synthetische Polymerfasern mit einem Denier von 4,0 bis 10,0 Denier und einer Stapelschnittlänge von 38 bis 105 mm sind.

The flaps comprise a flap fiber blend. The flap fiber blend includes:

• 20-80% by weight of bicomponent fibers having a core and a sheath, the fibers having a denier of 2.0 to 8.0 denier and a staple cut length of 38 to 105 mm, the bicomponent fibers reacting against an external stimulus and a first configuration in a non-activated state and a second configuration in an activated state, and wherein the bicomponent fibers reversibly between the non-activated and the activated state can switch back and forth;
• 5-40% by weight of synthetic binder fibers having a denier of 1.5 to 4.0 denier and a staple cut length of 38 to 105 mm;
• 0-75% by weight of a first population of synthetic fibers which are synthetic polymer fibers having a denier of less than 2.0 denier and a staple cut length of 38 to 105 mm; and
• 0-75% by weight of a second population of synthetic fibers which are synthetic polymer fibers having a denier of 4.0 to 10.0 denier and a staple cut length of 38 to 105 mm.

As mentioned above, 20-80% by weight of the flap fiber blend is composed of the reactive bicomponent fibers.

The bicomponent fibers respond to an external stimulus. In some embodiments, the external stimulus is moisture, pH, temperature, light, electric current, force field, or microbes.

Some materials that respond to one or more external stimuli are described, for example, in International Application Publication No. WO / 2009106785 A1 treated.

The bicomponent fibers have a non-activated state. In the non-activated state, the bicomponent fibers have a first configuration. When exposed to the intended external stimulus, the bicomponent fibers change to a second configuration (activated state). When they are no longer exposed to the external stimulus, the bicomponent fibers return to the first configuration in the non-activated state. The bicomponent fibers oscillate between activated and non-activated states, depending on whether they are exposed to the external stimulus or not. Therefore, the bicomponent fibers can reversibly switch between the non-activated and the activated state. In some embodiments, when exposed to an intended external stimulus, the bicomponent fibers reversibly change from the non-activated to the activated state in less than or equal to 15 minutes (e.g., less than or equal to 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 minute). In some embodiments, after removal of the intended external stimulus, the bicomponent fibers reversibly change from activated to unactivated states for less than or equal to 15 minutes (eg, less than or equal to 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2 or 1 minute).

The 3A and 3B represent an embodiment of a bicomponent fiber 20 which is used in certain embodiments of the isolation according to the invention in its non-activated or activated state. The bicomponent fiber 20 has a helical (also known as helical) shape / crimp. A helix can be described as a three-dimensional curve around an axis. The pitch of a helix is the length of a complete revolution measured along the axis of the helix. A circular helix has a constant curvature and a constant torsion.

In a dry environment is the fiber embodiment 20 in the 3A displayed, not activated state. When exposed to an intended external stimulus, such as: B. increased humidity, the fiber changes 20 in the in 3B shown activated state, wherein the crimp of the fiber 20 increases so that the number of bends per length increases and the radius of the bends and / or the pitch decreases, ie, the helix becomes narrower, the radius and pitch of the helix decrease and the helical configuration of the fiber becomes more compact.

Those of ordinary skill in the art will understand that certain embodiments of the bicomponent fibers used herein (e.g., the bicomponent fiber 20 of the 3A and 3B with a helical structure) have a structure caused by a deliberate selection of the components of the fiber. For example, in some embodiments (eg, certain embodiments where the bicomponent fibers are to react to moisture as an external stimulus), one of the core and sheath of the bicomponent fiber is non-hygroscopic and the other is hygroscopic. For example, in some embodiments, the core comprises a non-hygroscopic material and the shell comprises a hygroscopic material. In some embodiments, the hygroscopic material is chosen to have less thermal shrinkage and be less stiff than the non-hygroscopic material. In some embodiments, e.g. For example, when coextruded and then heat shrunk, the hygroscopic material will expand. However, this is limited by the non-hygroscopic material, resulting in a helical structure. Under the influence of moisture, the hygroscopic material wants to expand further. Again, this action is counteracted by the non-hygroscopic material and the stiffer non-hygroscopic component causes the pitch angle to narrow. This leads to the in 3B shown activated configuration. Compared to the fiber 20 under relatively dry conditions ( 3A) is in 3B the width a is reduced and the length b is reduced. After removal of the external stimulus (eg moisture) the fiber returns 20 to her in 3A displayed, not activated configuration back. In some embodiments, the length b may be reduced by 5 to 40% (eg, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20) , 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39 or 40%), including all regions and subregions therein ( eg 10 to 20%) and the width a can be reduced by 2 to 30% (eg 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 or 30%), including all regions and subregions therein (eg 3 to 15%), under 100% wet conditions compared to dry conditions.

In some embodiments, the non-hygroscopic material comprises non-hygroscopic polyethylene, polypropylene, polystyrene and / or polyvinylchloride (PVC).

In some embodiments, the hygroscopic material comprises nylon, acrylonitrile, butadiene-styrene (ABS), an acrylic resin, polyurethane, polycarbonate, polyethylene terephthalate (PET), and / or polybutylene terephthalate (PBT).

In particular embodiments, the bicomponent fibers include nylon and polypropylene. For example, in some embodiments, the core comprises polypropylene and the sheath comprises nylon.

In some embodiments, the bicomponent fibers comprise 20 to 50 Weight% (wt%) of core material (eg 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49 or 50% by weight), including all regions and subregions therein (eg 20 to 40% by weight, 25 to 35% by weight, etc.).

In some embodiments, the bicomponent fibers comprise a majority (i.e.,> 50% by weight) of the shell material. For example, in some embodiments, the bicomponent fibers include 50 to 80 weight percent shell material (eg, 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 or 80 wt%), including all regions and subregions therein (e.g. to 80% by weight, 65 to 75% by weight, etc.).

In some embodiments, the bicomponent fibers have a first helix configuration and the second configuration is a helix of relatively reduced radius and / or pitch relative to the first configuration.

In some embodiments, the second configuration of the bicomponent fibers has increased twist compared to the first configuration. In some embodiments, the bicomponent fiber has a twist in both the first and second configurations.

In some embodiments, twisting is imparted to the shape of the bicomponent fibers by selective selection of the various materials composing the bicomponent fibers. Embodiments of the bicomponent fibers contain two or more Components, wherein the components consist of different materials. The components are usually combined in the production of the fibers and can be combined in any ratio. Known manufacturing methods make it possible to achieve different two-component cross-sections.

The 4A-F Figure 4 shows non-limiting examples of cross-sections illustrating the bicomponent fiber used in certain embodiments of the invention 20 ' can have. In 4A stand the core 42 and the shell 44 in a ratio of 50:50 to each other and are arranged side by side. As used herein, the term "core" refers to a fundamental part of the bicomponent fiber that is different from the cladding portion. In various embodiments, the core may be located in the middle innermost part of the bicomponent fiber. However, in other embodiments, the core may be eccentric or at least a portion of a peripheral surface of the bicomponent fiber. In 4B stand the core 42 and the shell 44 in an unequal relationship to each other and are arranged side by side. Furthermore, the interface is between core 42 and the shell 44 not plan. In the 4C-4F are the core 42 and the shell 44 concentrically arranged, the core 42 an inner portion of the bicomponent fiber 20 ' forms and is surrounded by the shell 44 , In the in the 4A to 4E The non-limiting embodiments shown are the core 42 asymmetrical to the shell 44 arranged (ie the core 42 is within the bicomponent fiber 20 ' ) offset symmetrically. In the 4C-4F is the core 42 eccentric (ie shifted from a center or axis of the fiber) but still completely surrounded by the sheath 44 , 4E shows a trilobal fiber 20 ' , The in the 4C-4F Arrangements shown are also referred to as "Sea Island" configurations. Those of ordinary skill in the art will understand that these are non-limiting arrangements that may include additional components or additional "islands."

In some embodiments, the bicomponent fibers in the first configuration are straight or relatively straight and, when exposed to the external stimulus (eg, moisture), are curled or twisted.

The bicomponent fibers have a denier of 2.0 to 8.0 denier (eg, 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 or 8.0 denier), including all areas and subregions therein. For example, in some embodiments, the bicomponent fibers have a denier of 2.0 to 7.0 denier, 2.0 to 4.5 denier, 2.0 to 3.0 denier, and so on.

The bicomponent fibers are staple fibers (ie, fibers of a standardized length) having a length of 38 to 105 mm (eg, 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, 100 , 101, 102, 103, 104 or 105 mm), including all areas and subregions therein.

In some embodiments, the bicomponent fibers comprise the active fiber as disclosed in International Application Publication No. Hei. WO / 2013186528 A1 described.

In some embodiments, the bicomponent fibers include commercial INOTEK fibers available from MMT Textiles Limited.

In addition to the bicomponent fibers, the flap fiber blend also comprises 0 to 75% by weight of a first population of synthetic fibers and 0 to 75% by weight of a second population of synthetic fibers.

One of ordinary skill in the art is well versed in many synthetic fibers, and it is their responsibility, depending on the desired properties of the insulation to be made and / or the article in which it is to be used, to use the appropriate synthetic fiber for use in the first and / or. or second population of synthetic fibers. Embodiments of the insulation according to the invention may comprise any synthetic fiber known in the art as being conducive to the manufacture of textile materials. In some embodiments, non-exclusive synthetic fibers that may be used in the invention (e.g., in the first and / or second population) are selected from nylon, polyester, polypropylene, polylactic acid (PLA), poly (butyl acrylate) ( PBA), polyamide, acrylic, acetate, polyolefin, nylon, rayon, lyocell, aramid, elastane, viscose and modal fibers, and combinations thereof. In particular embodiments, synthetic fibers include 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-cyclohexylene dimethylene (PCDT), and terephthalate copolyesters wherein at least 85 moles % 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 include primary fibers. In some embodiments, the synthetic fibers include recycled fibers (eg, recycled polyester fibers).

The flap fiber blend of the present invention contains 0 to 75% by weight of the first population of synthetic fibers (eg 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 or 75% by weight), including all areas and portions therein. The fibers of the first population have a denier of less than 2.0 denier (eg, 0.4 to 1.9 denier, eg, 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 or 1.9 denier, inclusive all areas and subareas in it). The fibers of the first population have a stack cut length of 38 to 105 mm (eg 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, 100, 101, 102, 103, 104 or 105 mm), including all areas and subranges therein.

The flap fiber blend of the present invention contains 0 to 75% by weight of the second population of synthetic fibers (eg 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 or 75% by weight), including all regions and portions therein. The fibers of the second population have a denier of 4.0 to 10.0 denier (e.g., 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), including all areas and subregions therein. The fibers of the second population have a stack cut length of 38 to 105 mm (eg, 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, 100, 101, 102, 103, 104 or 105 mm), including all areas and subranges therein.

The material of the fibers of the first and second populations is selected independently. In some embodiments, the fibers of the first population are the same material as the fibers of the second population. In other embodiments, the fibers of the first population are a different material than the fibers of the second population. In particular embodiments, the fibers of the first and second populations comprise polyethylene.

In some embodiments, the flap fiber blend includes siliconized fibers. The term "siliconized" means that the fiber is coated with a silicon-containing composition (eg, a silicone). Siliconization techniques are known in the art and are described e.g. In the U.S. Patent No. 3,454,422 described. The silicon-containing composition can be applied by any method known in the art, e.g. Spraying, mixing, dipping, padding, etc. The silicon-containing (eg, silicone) composition, which may include an organosiloxane or polysiloxane, combines with an outer portion of the fiber. In some embodiments, the silicone coating is a polysiloxane, such as a polysiloxane. Example, a methylhydrogenpolysiloxane, modified methylhydrogenpolysiloxane, polydimethylsiloxane or amino-modified dimethylpolysiloxane. As known in the art, the silicon-containing composition can be applied directly to the fiber or, before use, with a solvent as a solution or emulsion, e.g. As an aqueous emulsion of a polysiloxane be diluted. After the treatment, the coating can be dried and / or cured. As known in the art, a catalyst may be used to accelerate the cure of the silicon-containing composition (e.g., polysiloxane containing Si-H bonds), and may be added to a silicon-containing composition emulsion for convenience resulting combination is used to treat the synthetic fiber. Suitable catalysts are iron, cobalt, manganese, lead, zinc and tin salts of carboxylic acids such as acetates, octanoates, naphthenates and oleates. In some embodiments, after siliconization, the fiber may be dried to remove residual solvent and then optionally heated to 65 ° to 200 ° C to cure.

In some embodiments, the synthetic fibers of the first population are non-siliconized fibers. In some embodiments, the synthetic fibers of the first population are siliconized fibers. In some embodiments, the synthetic fibers include the first Population of both siliconized and non-siliconized fibers.

In some embodiments, the synthetic fibers of the second population are non-siliconized fibers. In some embodiments, the synthetic fibers of the second population are siliconized fibers. In some embodiments, the synthetic fibers of the second population include both siliconized and non-siliconized fibers.

In some embodiments, the synthetic fibers of both the first and second populations comprise non-siliconized fibers. In some embodiments, the synthetic fibers of both the first and second populations comprise siliconized fibers. In some embodiments, the synthetic fibers of the first and second populations include both siliconized and non-siliconized fibers.

In some embodiments, 0 to 100% by weight of each of the first and second fiber populations are siliconized fibers (the respective weight percentages of each population being independently selected), 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 all regions and portions therein (e.g. 20 to 95 wt%, 25 to 90 wt%, 30 to 90 wt%, 40 to 85 wt%, 51 to 90 wt%, etc.).

Generally speaking, fibers such. Those of the first and second populations, be curly or uncurled. Various crimps, including spiral and standard (eg, planar) crimping, are known in the art. Unless otherwise stated, the fiber lengths throughout this application are pre-rippling measurements (i.e., the length measurement of a fiber before it is crimped when the fiber has crimp).

In some embodiments, the fibers of the first population of synthetic fibers comprise fibers having a standard or feathery (eg, helical) crimp. In particular embodiments, the fibers of the first population of synthetic fibers comprise fibers with a standard crimp.

In some embodiments, the fibers of the second population of synthetic fibers comprise fibers having a standard or feathery (e.g., helical) crimp. In particular embodiments, the fibers of the second population of synthetic fibers include fibers having a feathery (e.g., helical) crimp.

Long-lasting water-repellent (DWR) treatments are known in the art and impart water-repellent properties to the treated components. Those of ordinary skill in the art will be familiar with a variety of DWR treatments, either of which may optionally be applied to fibers (eg, fibers of the first or second population) in the context of the present invention. In some embodiments, the fibers used in the inventive insulation (which may be referred to as DWR-treated fibers or water-repellent fibers) have been treated with a zirconium acetate polymer solution that can impart permanent water repellency while minimizing and / or avoiding adverse effects on fiber performance , In some embodiments, fibers treated with a durable water repellent are treated with a water repellent, bacteria resistant, low friction, cured zirconium acetate finish such that the fibers have improved dryness and feel and clog resistance after washing. An example of a zirconium acetate solution which can be used as a DWR treatment in connection with the present invention is disclosed in U.S. Pat U.S. Patent No. 4,537,594 disclosed. In some embodiments, the fiber treated with a permanent water repellent agent is treated in a wet bath or dry spray process. In some embodiments, the treatment comprises a surface energy modification technique which, as known in the art, e.g. B. may include a plasma treatment. Such treatments or procedures are in U.S. Patent No. 4,869,922 . U.S. Patent No. 5,262,208 . U.S. Patent No. 5,895,558 . US Pat. No. 6,416,633 . U.S. Patent No. 7,510,632 . U.S. Patent No. 8,309,033 and U.S. Patent No. 8,298,627 explained.

In some embodiments, synthetic fibers of the first and / or second populations comprise particles or materials that are different from the synthetic material of which the synthetic fiber mainly consists. In some embodiments, synthetic fibers of the first and / or second populations comprise up to 15% by weight of particles or material that is different from the synthetic material of which the synthetic fiber mainly consists. For example, in some embodiments, the synthetic fibers 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% by weight of particles or material other than the synthetic material of which the synthetic fiber mainly consists, including all regions and subregions therein. In some embodiments, the particles or material (eg, encapsulated) are contained in a polymer matrix that is the synthetic material of which the synthetic fiber is primarily composed. In some embodiments, the synthetic fibers in the fiber mix include aerogels as disclosed in International Application Publication No. Hei. WO / 2017/087511 are described. In some embodiments, the synthetic fibers in the fiber blend include microcapsules, as in the preliminary U.S. Application No. 62 / 586,507 described.

In addition to the bicomponent fibers and optionally the first and second populations of synthetic fibers, the flap fiber blend also comprises from 5 to 40 weight percent of synthetic binder fibers (e.g., 5, 6, 7, 8, 9, 10, 11, 12, 13, 14 , 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39 or 40% by weight), including all areas and portions therein (eg, 10 to 30% by weight). Generally speaking, the binder fibers have a bonding temperature which is lower than the softening temperature of other synthetic polymer fibers present in the valve fiber blend.

In some embodiments, the binder fibers have an adhesive temperature of less than or equal to 200 ° C. In some embodiments, the binder fibers have an adhesive temperature of 50 to 200 ° C, including all regions and portions. In some embodiments, the binder fibers have an adhesive temperature of 80 ° C to 150 ° C. In some embodiments, the binder fibers have an adhesion temperature of 100 ° C to 125 ° C.

In some embodiments, the binder fibers comprise low melting polyester fibers.

In some embodiments, the binder fibers are bicomponent fibers that include an outer and an inner surface (commonly known in the art as sheath and core), the outer surface comprising a material having a lower melting point than the interior.

The insulation of the invention has been heat treated in some embodiments to melt all or part of the binder fibers to form thermally bonded insulation. Those of ordinary skill in the art will understand that in such embodiments, although "binder fibers" are listed in the fiber blend, the fibers may be wholly or partially melted fibers, as opposed to binder fibers in their original form prior to heat treatment.

The binder fibers have a denier of 1.5 to 4.0 denier (eg, 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 or 4.0 denier), including all areas and portions therein.

The binding fibers have a staple cut length of 38 to 105 mm (eg, 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, 100, 101, 102, 103, 104 or 105 mm), including all areas and subranges therein.

As discussed above, the composition of the flapper fiber composition makes the flaps of the embodiments of the inventive insulation reactive to an external stimulus. The flap fiber mixture is thus the composition of the flaps within the insulation (eg the flaps 4 , shown in isolation 10 of the 1 and 2 ).

In some embodiments, the non-flap portion (s) of the insulation (eg, in the insulation 10 of the 1 and 2 illustrated non-flap section 6 ) a fiber blend other than the flap fiber blend (e.g., a blend of fibers corresponding to the flap fiber blend, but without the reactive bicomponent fibers discussed above, or even a completely different blend of fibers). Such embodiments may be formed, for example, according to a predetermined pattern for laying the fibers constituting the insulation. In other embodiments, the non-flap sections include a non-flapping fiber blend that is identical to the flap fiber blend.

In some embodiments, the insulation of the invention is nonwoven fabric.

In some embodiments, the insulation of the invention comprises a single nonwoven web. In other embodiments, the insulation of the invention comprises two or more (e.g., 2, 3, 4, etc.) nonwoven webs stacked one on top of the other. If a single nonwoven web is used in the insulation, the insulation may be referred to as non-stratified insulation. When a plurality (ie, 2 or more) of nonwoven webs are used, the insulation may be referred to as layered insulation. Embodiments of insulation according to the invention can also be referred to as padding.

In some embodiments, the flap fiber blend and / or non-fluff fiber blend additionally comprises other synthetic and / or natural fibers. Thus, in some embodiments, the fiber blend comprises one or more elements selected from wool, cotton, tencel, kapok (cotton-like fluff derived from seeds of a kapok tree which may optionally be further processed prior to use), flax, animal hair, silk and down ( eg duck or goose down).

In some embodiments, the insulation has a thickness of 4 to 30 mm (e.g., 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 or 30 mm), including all areas and subregions therein.

In some embodiments, the insulation has a density of 3.0 to 12.0 kg / m ³ (e.g., 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3 , 6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8 , 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6 , 1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3 , 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 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 or 12.0 kg / m ³ ), including all areas and sub-area therein ,

Embodiments of the insulation according to the invention have a first surface parallel to a second surface. For example, the entire top view of the in the 1 and 2 illustrated insulation 10 the first surface. The second surface of the insulation 10 is not visible because it is parallel to the first surface and is in contact with a table on which the insulation is 10 is placed.

In some embodiments, the first surface and / or the second surface of the insulation comprises a crosslinked resin. This is the case, for example, when a crosslinking solution comprising a crosslinking agent compound has been applied to the first and / or second surface. In various embodiments, the resin is a crosslinked (eg, by heat treatment) version of the crosslinking solution. In some embodiments, the crosslinked resin comprises a crosslinking agent that is a crosslinked acrylate (co) polymer. In some embodiments, the crosslinking solution and / or the crosslinking agent compound exhibit softness and hydrophobicity. In some embodiments, the crosslinking agent compound has a glass transition temperature (Tg) of less than 0 ° C.

In some embodiments, the insulation according to the invention has a weight of 25 to 200 g / m ² (eg 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, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, 180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190, 191, 192, 193, 194, 195, 196, 197, 198, 199 or 200 g / m ² ), including all regions and subregions therein (eg 25 to 100 g / m ² ) ² , 40 to 100 g / m ² , etc.).

In some embodiments, the insulation of the invention has a good case (the insulation depends on its own weight). The case of insulation can have a significant impact on properties such as comfort and aesthetics of an article in which the insulation can be used. In some embodiments, the insulation has a fall of 1.5 cm to 5.0 cm (e.g., 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1 , 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3 , 4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6 , 4.7, 4.8, 4.9 or 5.0 cm) including all areas and sub-areas therein measured by the method ASTM D1388.

In some embodiments, the insulation is in sheet form or suitable for being provided in sheet form (eg, suitable for use as a roll product) and has not been crushed.

In a second aspect, the invention provides an article comprising the inventive insulation according to the first aspect of the invention. Non-limiting examples of such articles include, for example, footwear, outerwear (eg, outerwear such as jackets, pants, etc.), clothing (eg, socks, underwear, apparel), pillows, cushions, sleeping bags, bedding (e.g. eg quilts, blankets), tents etc.

• - Bilden einer Zwischenisolierung aus einer Fasermischung, wobei die Zwischenisolierung mehrere Klappenbereiche umfasst, die die nach dem ersten Aspekt der Erfindung erörterte Klappenfasermischung umfassen;
• - Erwärmen der Zwischenisolierung über die Bindungstemperatur der Bindefasern in der Klappenfasermischung hinaus; und
• - Bilden mehrerer Klappen (z. B. mittels Schlitzen) in der Zwischenisolierung, wodurch mehrere reaktive Klappen erzeugt wird.

In a third aspect, the invention provides a non-exclusive method of making the inventive insulation according to the first aspect of the invention (or an article according to the second aspect of the invention), the method comprising:

• - Forming an intermediate insulation from a fiber blend, the intermediate insulation comprising a plurality of flap regions comprising the flap fiber blend as discussed in the first aspect of the invention;
• Heating the intermediate insulation beyond the bonding temperature of the binder fibers in the valve fiber blend; and
• Forming multiple flaps (eg, by slits) in the intermediate insulation, thereby creating multiple reactive flaps.

In some embodiments, the insulation is a nonwoven insulation comprising one or more nonwoven web layers. When the insulation comprises more than one nonwoven web, the method of the invention comprises the layers of nonwoven web layers.

This heating can be carried out, for example, with one or more heating cycles in a standard thermobonding furnace for textiles.

In some embodiments, the one or more nonwoven web layers in both the flapper portions and the non-flapper portions include the flapper fiber blend.

In some embodiments, the method additionally (eg, after heating) comprises applying a resin (eg, a crosslinked resin as discussed above) to the first surface and / or the second surface of the inter-wadding insulation structure. Resin treatment of one or both surfaces of the insulation can help to increase the stability and integrity of the interlayer wadding to improve durability and can help to make the material durable enough to withstand subsequent processing in the slot cutting process.

In some embodiments, the flaps are formed by forming slots, e.g. B. formed by cutting. In some embodiments, the cutting includes manual cutting or laser cutting using a laser cutting machine. Laser cutting machines suitable for use in the textile sector are well known to those of ordinary skill in the art.

In some non-limiting embodiments, the invention is as described in one of the following clauses:

• - 20-80 Gew.-% Zweikomponentenfasern mit einem Kern und einer Hülle, wobei die Fasern ein Denier von 2,0 bis 8,0 Denier und eine Stapelschnittlänge von 38 bis 105 mm aufweisen, wobei die Zweikomponentenfasern gegenüber einem äußeren Reiz reagieren und eine erste Konfiguration in einem nicht aktivierten Zustand und eine zweite Konfiguration in einem aktivierten Zustand aufweisen, und wobei die Zweikomponentenfasern reversibel zwischen dem nicht aktivierten und dem aktivierten Zustand hin- und herwechseln können;
• - 5-40 Gew.-% synthetische Bindefasern mit einem Denier von 1,5 bis 4,0 Denier und einer Stapelschnittlänge von 38 bis 105 mm;
• - 0-75 Gew.-% einer ersten Population von synthetischen Fasern, die synthetische Polymerfasern mit einem Denier von weniger als 2,0 Denier und einer Stapelschnittlänge von 38 bis 105 mm sind; und
• - 0-75 Gew.-% einer zweiten Population von synthetischen Fasern, die synthetische Polymerfasern mit einem Denier von 4,0 bis 10,0 Denier und einer Stapelschnittlänge von 38 bis 105 mm sind.

Clause 1. Insulation with multiple reactive flaps therein, such that the insulation comprises the flaps and also non-flap sections, the reactive flaps comprising a flap fiber blend comprising:

• 20-80% by weight of bicomponent fibers having a core and a sheath, the fibers having a denier of 2.0 to 8.0 denier and a staple cut length of 38 to 105 mm, the bicomponent fibers reacting against an external stimulus and a first configuration in a non-activated state and a second configuration in an activated state, and wherein the bicomponent fibers reversibly between the non-activated and the activated state can switch back and forth;
• 5-40% by weight of synthetic binder fibers having a denier of 1.5 to 4.0 denier and a staple cut length of 38 to 105 mm;
• 0-75% by weight of a first population of synthetic fibers which are synthetic polymer fibers having a denier of less than 2.0 denier and a staple cut length of 38 to 105 mm; and
• 0-75% by weight of a second population of synthetic fibers which are synthetic polymer fibers having a denier of 4.0 to 10.0 denier and a staple cut length of 38 to 105 mm.

Clause 2. Isolation by clause 1 wherein the insulation is nonwoven fabric.

Clause 3. Isolation by clause 1 or clause 2 wherein the fibers of the first population of synthetic fibers are siliconized.

Clause 4. Isolation according to one of the clauses 1 to 3 wherein the fibers of the second population of synthetic fibers are siliconized.

Clause 5. Isolation according to one of the clauses 1 to 4 wherein the fibers of the first population of synthetic fibers have a standard crimp.

Clause 6. Isolation according to one of the clauses 1 to 5 wherein the fibers of the second population of synthetic fibers have a feathery crimp.

Clause 7. Isolation by clause 6 wherein the fibers of the second population of synthetic fibers have a spiral crimp.

Clause 8. Isolation according to one of the clauses 1 to 7 wherein the non-flap sections of the insulation comprise a non-flap fiber blend identical to the flap fiber blend (the insulation is the same fiber blend for both flap and non-flap sections).

Clause 9. Isolation according to one of the clauses 1 to 8th , wherein the bicomponent fibers 20 to 50 Wt% core material and 50 to 80 wt% shell material.

Clause 10. Isolation according to one of the clauses 1 to 9 wherein the core of the bicomponent fibers comprises a non-hygroscopic core material and the sheath of the bicomponent fibers comprises a hygroscopic shell material.

Clause 11. Isolation according to one of the clauses 1 to 10 wherein the core of the bicomponent fibers comprises polypropylene and the sheath comprises nylon.

Clause 12. Isolation according to one of the clauses 1 to 11 wherein the bicomponent fibers 20 to 40 Wt% core material and 60 to 80 wt% shell material.

Clause 13. Isolation according to one of the clauses 1 to 12 wherein the core of the bicomponent fibers is an eccentric core.

Clause 14. Isolation according to one of the clauses 1 to 13 wherein the second configuration has increased twist compared to the first configuration.

Clause 15. Isolation according to one of the clauses 1 to 14 wherein the bicomponent fibers have a spiral crimp.

Clause 16. Isolation by clause 15 wherein the first configuration is a helix and the second configuration is a helix of relatively reduced radius and pitch compared to the first configuration.

• - 40-80 Gew.-% der Zweikomponentenfasern;
• - 10-40 Gew.-% der synthetischen Bindefasern; und
• - 5-50 Gew.-% der ersten Population von synthetischen Fasern, wobei die erste Population von synthetischen Fasern silikonisiert ist und ein Denier von weniger als 1,5 Denier aufweist.

Clause 17. Isolation according to one of the clauses 1 to 16 wherein the flap fiber mixture comprises:

• 40-80% by weight of the bicomponent fibers;
• 10-40% by weight of the synthetic binder fibers; and
• 5-50% by weight of the first population of synthetic fibers, wherein the first population of synthetic fibers is siliconized and has a denier of less than 1.5 denier.

Clause 18. Article that provides isolation according to one of the clauses 1 to 17 includes.

clause 19 , Article after clause 18 The article is selected from shoes, outer clothing, clothing, sleeping bags, tents and bed linen.

• - Bilden einer Zwischenisolierung aus einer Fasermischung, wobei die Zwischenisolierung mehrere Klappenbereiche umfasst, die die Klappenfasermischung umfassen;
• - Erwärmen der Zwischenisolierung über die Bindungstemperatur der Bindefasern in der Klappenfasermischung hinaus; und
• - Bilden mehrerer Klappen in der Zwischenisolierung, wodurch mehrere reaktive Klappen erzeugt werden.

clause 20 , Method for producing the insulation according to one of the clauses 1 to 17 the method comprising:

• Forming an intermediate insulation from a fiber mixture, the intermediate insulation comprising a plurality of flap regions comprising the flap fiber mixture;
• Heating the intermediate insulation beyond the bonding temperature of the binder fibers in the valve fiber blend; and
• Forming a plurality of flaps in the intermediate insulation, thereby producing a plurality of reactive flaps.

clause 21 , Procedure according to clause 20 wherein forming a plurality of flaps in the intermediate insulation comprises laser cutting flaps in the intermediate insulation.

EXAMPLES

The invention will now be illustrated by, but not limited to, the specific embodiment described in the following example.

example 1

An embodiment of the insulation according to the invention is produced as follows:

• - 20 % 2,2 Denier x 51MM niedrigschmelzende Bindefaser
• - 60 % 2,0 Denier x 51MM anpassungsfähige Zweikomponentenfaser - Nylon/Polypropylen
• - 20 % 1,4 Denier x 51MM silikonisierte Faser mit Standard-Kräuselung

Nach dem Mischen/Vermengen wird die Fasermischung dann auf einer herkömmlichen Karde zu einer bahnförmigen Form verarbeitet, um eine Vliesbahn zu bilden. Die Bahn wird dann durch einen Kreuzleger geführt, um das gewünschte Gewicht und die gewünschte Dicke zu erhalten. Das kreuzweise gelegte Gewebe wird dann thermisch verbunden und anschließend mit einer Harzlösung besprüht. C-förmige Schlitze werden in das Material geschnitten und bilden dadurch Klappen. Die endgültige Ausführungsform der Isolierung ist in 1 dargestellt.A fiber mixture is prepared by mixing:

• - 20% 2.2 denier x 51MM low melting binder fiber
• - 60% 2.0 denier x 51MM flexible two-component fiber - nylon / polypropylene
• - 20% 1.4 denier x 51MM siliconized fiber with standard crimp

After mixing / blending, the fiber blend is then processed on a conventional card into a sheet-like form to form a nonwoven web. The web is then passed through a cross-stacker to obtain the desired weight and thickness. The cross-laid fabric is then thermally bonded and then sprayed with a resin solution. C-shaped slots are cut into the material and thereby form flaps. The final embodiment of the insulation is in 1 shown.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms "a,""an," and "the" should also be plurals unless the context indicates otherwise. It is further to be understood that the terms "comprising" (and including any form of such as "comprising" and "comprising"), "having" (and having any form of having such as "having" and "having") "(And include any form of such as" including "and" including ")," containing "(and including any form such as" contains "and" containing ") and any other grammatical variant thereof are open linking verbs. As a result, a method or article that "includes,""includes,""includes," or "includes" one or more steps or elements has one or more steps or elements, but is not limited to just this one or to own these multiple steps or elements. Likewise, a step of a method or item of an article that "includes,""includes,""includes," or "includes" one or more features has, but is not limited to, only one or more features to own one or more features.

As used herein, the terms "comprising," "having," "including," "containing," and other grammatical variants thereof include the terms "consisting of" and "consisting essentially of."

The term "consisting essentially of" or grammatical variants thereof, as used herein, is to be understood as a specification of the specified features, integers, steps or components, but does not exclude 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.

All publications cited in this specification are hereby incorporated by reference as if each individual publication were expressly and individually indicated to be incorporated by reference to this specification as if fully set forth.

The item incorporated by reference shall not be construed as an alternative to any limitation of claims unless expressly stated otherwise.

When reference is made to one or more regions throughout this specification, each region is intended to be a shorthand for presenting information, which region is understood to encompass every single point within the region as if fully set forth herein.

While several aspects and embodiments of the present invention have been described and illustrated herein, alternative aspects and embodiments may be practiced by those skilled in the art to achieve the same objects. Accordingly, this disclosure and the appended claims are intended to cover all further and alternative aspects and embodiments that fall within the true spirit and scope of the invention.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• US 62448182 [0001]
• WO / 2009106785 A1 [0028]
• WO / 2013186528 A1 [0045]
• US 3454422 [0052]
• US 4537594 [0060]
• US 4869922 [0060]
• US 5262208 [0060]
• US 5895558 [0060]
• US 6416633 [0060]
• US 7510632 [0060]
• US 8309033 [0060]
• US 8298627 [0060]
• WO 2017/087511 [0061]
• US 62/586507 [0061]

Claims (21)

Insulation having multiple reactive flaps therein such that the insulation comprises the flaps and also non-flap sections, the reactive flaps comprising a flap fiber blend comprising: 20-80% by weight of bicomponent fibers having a core and a sheath, the fibers having a denier of 2.0 to 8.0 denier and a staple cut length of 38 to 105 mm, the bicomponent fibers reacting against an external stimulus and a first configuration in a non-activated state and a second configuration in an activated state, and wherein the two-component fibers reversibly between the non-activated and the activated state can switch back and forth; 5-40% by weight of synthetic binder fibers having a denier of 1.5 to 4.0 denier and a staple cut length of 38 to 105 mm; 0-75% by weight of a first population of synthetic fibers which are synthetic polymer fibers having a denier of less than 2.0 denier and a staple cut length of 38 to 105 mm; and 0-75% by weight of a second population of synthetic fibers which are synthetic polymer fibers having a denier of 4.0 to 10.0 denier and a staple cut length of 38 to 105 mm. Insulation after Claim 1 wherein the insulation is nonwoven fabric. Insulation after Claim 1 wherein the fibers of the first population of synthetic fibers are siliconized. Insulation after Claim 1 wherein the fibers of the second population of synthetic fibers are siliconized. Insulation after Claim 1 wherein the fibers of the first population of synthetic fibers have a standard crimp. Insulation after Claim 1 wherein the fibers of the second population of synthetic fibers have a feathery crimp. Insulation after Claim 6 wherein the fibers of the second population of synthetic fibers have a spiral crimp. Insulation after Claim 1 wherein the non-flap sections of the insulation comprise a non-flap fiber blend identical to the flap fiber blend. Insulation after Claim 1 wherein the bicomponent fibers comprise 20 to 50 wt% core material and 50 to 80 wt% shell material. Insulation after Claim 1 wherein the core of the bicomponent fibers comprises a non-hygroscopic core material and the sheath of the bicomponent fibers comprises a hygroscopic shell material. Insulation after Claim 1 wherein the core of the bicomponent fibers comprises polypropylene and the sheath comprises nylon. Insulation after Claim 1 wherein the bicomponent fibers comprise 20 to 40 wt% core material and 60 to 80 wt% shell material. Insulation after Claim 1 wherein the core of the bicomponent fibers is an eccentric core. Insulation after Claim 1 wherein the second configuration has increased twist compared to the first configuration. Insulation after Claim 1 wherein the bicomponent fibers have a spiral crimp. Insulation after Claim 15 wherein the first configuration is a helix and the second configuration is a helix of relatively reduced radius and pitch compared to the first configuration. Insulation after Claim 1 wherein the flap fiber blend comprises: 40-80% by weight of the bicomponent fibers; 10-40% by weight of the synthetic binder fibers; and 5-50% by weight of the first population of synthetic fibers, wherein the first population of synthetic fibers is siliconized and has a denier of less than 1.5 denier. Article that isolates according to one of Claims 1 to 17 includes. Article after Claim 18 , which is selected from footwear, outerwear, clothing, sleeping bags and bedding. Process for producing the insulation according to one of Claims 1 to 17 the method comprising: forming an intermediate insulation from a fiber blend, the intermediate insulation comprising a plurality of flap regions comprising the flap fiber blend; Heating the intermediate insulation beyond the bonding temperature of the binder fibers in the valve fiber blend; and - Forming multiple flaps in the intermediate insulation, creating multiple reactive flaps. Method according to Claim 20 wherein forming a plurality of flaps in the intermediate insulation comprises laser cutting flaps in the intermediate insulation.

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