THERMAL REGULATING THREE-DIMENSIONAL INSULATIVE STRUCTURES AND ARTICLES COMPRISING THE SAME
Insulation and filling material that includes a plurality of assemblages of a blend of a plurality of fiber are disclosed. The blend of fibers includes 20 to 80 wt % cellulosic fibers including a phase change material having a fiber size less than 6 denier and a specific latent heat of greater than 20 J/g in a temperature range from 15 to 45 degrees Celsius, and 20 to 80 wt % synthetic polymeric fibers having a fiber size less than 6 denier. The assemblages form three-dimensional structures with internal air spaces. The assemblages may be fiberballs or discrete longitudinally elongated floccules with a relatively open enlarged medial portion and relatively condensed twisted tail portions extending from opposing ends of the medial portion. The insulation or filling material has at least 0.8 clo/oz/sqyd.
1 . Insulation or filling material, comprising:
a plurality of discrete assemblages of a blend of a plurality of fibers,
wherein the blend of fibers comprises:
20 to 80 wt % cellulosic fibers including a phase change material, the fibers having a fiber size less than or equal to 6 denier and a specific latent heat of greater than 20 J/g in a temperature range from 15 to 45 degrees Celsius; and
20 to 80 wt % synthetic polymeric fibers having a fiber size less than or equal to 6 denier,
wherein the assemblages form three-dimensional structures with internal air spaces, and
wherein the insulation or filling material has at least 0.8 clo/oz/sqyd.
2 . The material according to claim 1 , the cellulosic phase change fibers comprising:
a cellulose matrix;
inclusions within the cellulose matrix comprising one or more nonpolar organic compounds stabilized with at least one hydrophobic thickener; and
a barrier material of nanoscale layered particles dispersed in the cellulose matrix.
3 . The material according to claim 2 , wherein the density of the barrier material is greater in a zone extending about the inclusions relative to the mean density of the barrier material in the cellulose matrix.
4 . The material according to claim 1 , wherein the one or more nonpolar organic compounds have a melting point of less than 100 degrees Celsius and are selected from the group consisting of hydrocarbons, waxes, beeswaxes, oils, fatty acids, fatty acid esters, stearic anhydrides and long-chain alcohols.
5 . The material according to claim 1 , wherein the one or more nonpolar organic compounds comprise stabilized paraffin with a melting point within the range of 28 degrees Celsius to 32 degrees Celsius, and wherein the barrier material comprises nanoscale layered silicates.
6 . The material according to claim 1 , wherein the cellulosic phase change fibers have a specific latent heat greater than or equal to 50 J/g.
7 . The material according to claim 1 , wherein the cellulosic phase change fibers have a fiber size within the range of 2 denier and 3 denier.
8 . The material according to claim 1 , wherein the synthetic polymeric fibers comprise first synthetic polymeric fibers having a fiber size of less than 2 denier, and wherein the first synthetic polymeric fibers comprise at least one of siliconized fibers and polyester fibers.
9 . (canceled)
10 . The material according to claim 8 , wherein the blend of fibers comprises 10 to 70 wt % the first synthetic polymeric fibers.
11 . The material according to claim 8 , wherein the synthetic polymeric fibers comprise second synthetic polymeric conjugate fibers, wherein the second synthetic polymeric fibers comprise at least one of siliconized fibers and polyester fibers.
12 . (canceled)
13 . The material according to claim 11 , wherein the second synthetic polymeric fibers are conjugate crimped fibers.
14 . The material according to claim 11 , wherein the blend of fibers comprises 10 to 70 wt % the second synthetic polymeric fibers.
15 . The material according to claim 1 , wherein at least one of the synthetic polymeric fibers and the cellulosic phase change fibers have a staple fiber length of 20 mm to 40 mm.
16 . The material according to claim 1 , having a fill power greater than 350 cubic centimeters.
17 . The material according to claim 1 , wherein the three-dimensional structures comprise fiberballs having an average diameter of 3 mm to 10 mm.
18 . (canceled)
19 . The material according to claim 17 , wherein the fiber blend further comprises binder fibers have a bonding temperature lower than a softening temperature of the cellulosic fibers and the synthetic polymeric fibers.
20 . The material according to claim 17 , comprising:
50 to 95 wt % of a plurality of the fiberballs formed of the fiber blend having an average diameter of 3.0 to 8.0 mm; and
5 to 50 wt % of the fiber blend being adjacent to one or more fiberballs but that do not themselves comprise one or more fiberballs or any portion thereof.
21 . The material according to claim 19 , wherein the fiberballs and the fiber blend adjacent to one or more fiberballs but that do not themselves comprise one or more fiberballs or any portion thereof forms a batting insulation.
22 . The material according to claim 1 , wherein the three-dimensional structures comprise discrete longitudinally elongated floccules, the floccules including a relatively open enlarged medial portion and relatively condensed twisted tail portions extending from opposing ends of the medial portion.
23 . The material according to claim 22 , wherein the longitudinal length of the floccules is within the range of 2 cm to 4.5 cm, the longitudinal length of the medial portion of the floccules is within the range of 0.1 cm to 2 cm, and the longitudinal length of the tail portions of the floccules is within the range of 0.8 cm to 1.8 cm.
24 . An article, comprising:
the insulation or filling material according to claim 1 positioned within a compartment of the article.
25 . The article according to claim 24 , wherein said article is selected from the group consisting of an outerwear product, clothing, footwear, headwear, a sleeping bag, bedding and a furniture product.
26 . A method of making the insulation or filling material according to claim 1 , said method comprising:
mixing the blend of fibers comprising:
20 to 80 wt % cellulosic fibers having phase change material, a fiber size less than 6 denier and a specific latent heat of greater than 20 J/g in a temperature range from 15 to 45 degrees Celsius; and
20 to 80 wt % synthetic polymeric fibers having a fiber size less than 6 denier, and
forming a plurality of assemblages from the fiber mixture having a three-dimensional structure with internal air spaces, and
wherein the insulation or filling material has at least 0.8 clo/oz/sqyd.
27 . The method according to claim 26 , wherein forming the plurality of assemblages from the fiber mixture comprises:
forming fiberballs having an average diameter of 3 mm to 10 mm from the fiber mixture; or
forming discrete longitudinally elongated floccules from the fiber mixture, the floccules including a relatively open enlarged medial portion and relatively condensed twisted tail portions extending from opposing ends of the medial portion.
28 . (canceled)