Fiberball batting and articles comprising the same

Abstract

The invention provides batting that includes a nonwoven web comprising a specified fiber mixture, the non-woven web having 50 to 95 wt % of a plurality of fiberballs having an average diameter of 3.0 to 8.0 mm; and 5 to 50 wt % of a plurality of portions of the nonwoven web that are adjacent to one or more fiberballs but that do not themselves comprise one or more fiberballs or any portion thereof. The batting has a density of 2 to 12 kg/m3. Also provided are articles comprising the batting and methods of making the batting.

1 . A batting comprising a nonwoven web comprising a fiber mixture having:
 40 to 95 wt % synthetic fibers having a denier of 0.5 to 6.5, and a length of 18 mm to 51 mm; and   5 to 40 wt % binder fibers having a denier of 1.0 to 5.0 and a length of 18 mm to 71 mm, said binder fibers have a bonding temperature lower than the softening temperature of the synthetic fibers,   
       wherein, structurally, said nonwoven web comprises:
 50 to 95 wt % of a plurality of fiberballs having an average diameter of 3.0 to 8.0 mm; and 
 5 to 50 wt % of a plurality of portions of the nonwoven web that are adjacent to one or more fiberballs but that do not themselves comprise one or more fiberballs or any portion thereof, 
 
       and wherein the batting has a density of 2 to 12 kg/m3. 
     
     
         2 . The batting according to  claim 1 , wherein the synthetic fibers comprise polyester fibers. 
     
     
         3 . The batting according to  claim 1 , wherein the synthetic fibers have a denier of 1.0 to 2.0. 
     
     
         4 . The batting according to  claim 1 , wherein the synthetic fibers have a length of 20 mm to 30 mm. 
     
     
         5 . The batting according to  claim 1 , wherein the fiberballs have an average diameter of 4.0 mm to 6.0 mm. 
     
     
         6 . The batting according to  claim 5 , wherein the fiberballs have an average diameter of 5.0 mm to 6.0 mm. 
     
     
         7 . The batting according to  claim 1 , wherein the binder fibers have a denier of 1.5 to 3.5. 
     
     
         8 . The batting according to  claim 7 , wherein the binder fibers have a denier of 1.9 to 2.5. 
     
     
         9 . The batting according to  claim 1 , wherein the binder fibers have a length of 18 mm to 51 mm. 
     
     
         10 . The batting according to  claim 1 , wherein the binder fibers have a bonding temperature of less than or equal to 200° C. 
     
     
         11 . The batting according to  claim 10 , wherein the binder fibers have a bonding temperature of 80° C. to 150° C. 
     
     
         12 . The batting according to  claim 11 , wherein the binder fibers have a bonding temperature of 100° C. to 125° C. 
     
     
         13 . The batting according to  claim 1 , wherein the fiber mixture comprises:
 75 to 90 wt % of the synthetic fibers; and   10 to 25 wt % of the binder fibers.   
     
     
         14 . The batting according to  claim 13 , wherein the nonwoven web comprises:
 70 to 90 wt % of the plurality of fiberballs; and   10 to 30 wt % of the plurality of portions of the nonwoven web that are adjacent to one or more fiberballs but that do not themselves comprise one or more fiberballs or any portion thereof.   
     
     
         15 . The batting according to  claim 1 , wherein the synthetic fibers are siliconized. 
     
     
         16 . The batting according to  claim 1 , wherein the synthetic fibers are crimped fibers. 
     
     
         17 . The batting according to  claim 16 , wherein the crimped fibers have a spiral crimp or a standard crimp. 
     
     
         18 . The batting according to  claim 1 , wherein the batting does not comprise spirally crimped fibers. 
     
     
         19 . The batting according to  claim 1 , wherein the binder fibers are bicomponent fibers comprising a sheath and a core, wherein the sheath comprises a material having a lower melting point than the core. 
     
     
         20 . An article comprising the batting according to  claim 1 . 
     
     
         21 . The article according to  claim 20 , wherein said article is selected from the group consisting of an outerwear product, clothing, a sleeping bag, and bedding. 
     
     
         22 . A method of making the batting according to  claim 1 , said method comprising:
 mixing fibers comprising:
 40 to 95 wt % synthetic fibers having a denier of 0.5 to 7.0, and a length of 18 mm to 51 mm; and 
 5 to 40 wt % binder fibers having a denier of 1.0 to 5.0 and a length of 18 mm to 71 mm, said binder fibers have a bonding temperature lower than the softening temperature of the synthetic fibers, 
   
       thereby forming a fiber mixture;
 forming a plurality of fiberballs from the fiber mixture; 
 forming a nonwoven web from the fiber mixture, wherein said nonwoven web comprises:
 50 to 95 wt % of a plurality of fiberballs having an average diameter of 3.0 to 8.0 mm; and 
 5 to 50 wt % of a plurality of portions of the nonwoven web that are adjacent to one or more fiberballs but that do not themselves comprise one or more fiberballs or any portion thereof; and 
 
 heating the non-woven web to or in excess of the bonding temperature of the binder fibers, thereby forming the batting. 
 
     
     
         23 . (canceled)