NONWOVEN DOWN BATTING
The invention provides batting that includes a nonwoven web having a first surface parallel to a second surface. The nonwoven web is made up of a fiber mixture that includes: 25 to 75 wt % spiral-crimped siliconized synthetic polymeric fibers having a denier of greater than 4 denier and less than 10 denier; and 20 to 75 wt % down treated with a durable water repellant, said down having a fill power of at least 550 in 3 /oz, and having a down cluster content of at least 85 wt %. Articles comprising the batting and methods of making the batting are also provided.
1 . Batting comprising a nonwoven web having a first surface parallel to a second surface, said nonwoven web comprising a fiber mixture comprising:
25 to 75 wt % spiral-crimped siliconized synthetic polymeric fibers having a denier of greater than 4 denier and less than 10 denier; and
20 to 75 wt % down treated with a durable water repellant, said down having a fill power of at least 550 in 3 /oz, and having a down cluster content of at least 85 wt %.
2 . The batting according to claim 1 , wherein the fiber mixture additionally comprises:
5 to 25 wt % synthetic binder fibers having a denier of 1.5 to 4.0, said binder fibers having a bonding temperature lower than the softening temperature of the siliconized synthetic polymeric fibers.
3 . The batting according to claim 2 , wherein the binder fibers have a staple cut length of 38 mm to 105 mm.
4 . The batting according to claim 1 , wherein at least one of the first surface and second surface comprises a cross-linked resin.
5 . The batting according to claim 1 , wherein at least one of the first surface and second surface comprises a scrim layer.
6 . The batting according to claim 1 , wherein the fiber mixture additionally comprises:
natural fibers.
7 . The batting according to claim 1 , wherein the fiber mixture additionally comprises:
20 to 60 wt % untreated down.
8 . The batting according to claim 7 , wherein said untreated down has a fill power of at least 550 in 3 /oz, and has a down cluster content of at least 85 wt %.
9 . The batting according to claim 1 , wherein the fiber mixture additionally comprises:
1 to 30 wt % standard-crimped synthetic polymeric fibers having a denier of less than 2.0.
10 . (canceled)
11 . The batting according to claim 9 , wherein the standard-crimped synthetic polymeric fibers are siliconized.
12 . (canceled)
13 . The batting according to claim 9 , wherein the spiral-crimped siliconized synthetic polymeric fibers have a staple cut length of 51 mm to 74 mm, and the standard-crimped synthetic polymeric fibers have a staple cut length of 38 mm to 105 mm.
14 . The batting according to claim 1 , wherein the spiral-crimped siliconized synthetic polymeric fibers are polyester fibers.
15 . The batting according to claim 1 , said batting comprising a plurality of nonwoven web layers, wherein one or more of said layers comprises the fiber mixture.
16 . (canceled)
17 . The batting according to claim 1 , wherein the average fill power of all down present in the batting is at least 550 in 3 /oz.
18 . (canceled)
19 . The batting according to claim 1 , having a density of 5 to 8 kg/m 3 .
20 . The batting according to claim 1 , having a thermal performance rating of at least 0.80 clo/oz/yd 2 when tested according to ISO 11092.
21 . The batting according to claim 1 , having a water uptake of less than or equal to 30 wt %.
22 . An article comprising the 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 . A method of making the batting according to claim 1 , said method comprising:
preparing the fiber mixture;
forming a nonwoven web from the fiber mixture;
layering at least two web layers, at least one of which being the nonwoven web, thereby creating a layered batting insulation structure; and
heating the layered batting insulation structure, thereby bonding the layered batting insulation structure.
25 . (canceled)