Thermal regulating three-dimensional insulative structures and articles comprising the same

Abstract

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)