Bulk fill material

Abstract

Among other things, the inventive subject matter generally relates to bulk fill materials suitable for an insulative or cushioning material. The bulk fill material consists of a plurality of discrete units comprising clusters or loose webs of fibers. The fibers consist of superfine fibers and/or fibers in a range of 1 to 5 denier; the fibers being entangled to form the clusters or loose webs. In some embodiments the clusters or webs are multinode fiber structures that mimic natural down. The inventive subject matter is also directed to related methods of production.

1 .- 13 . (canceled) 
     
     
         14 . A bulk fill material suitable for use as an insulative or cushioning material in footwear, outdoor apparel, and/or outdoor equipment, the bulk fill material comprising:
 a plurality of discrete units comprising clusters or loose webs of fibers, the fibers comprising superfine fibers and/or fibers in a range of 1 to 5 denier; the fibers being entangled to form the clusters or loose webs.   
     
     
         15 . The bulk fill material of  claim 14  wherein the clusters or webs of fibers comprise a plurality of fibers, the fibers each being a multinode fiber structure formed of fiber material formed into a unitary, multinode fiber structure, the multinode fiber structures being agglomerated as clusters or webs. 
     
     
         16 . The bulk fill material of  claim 14  wherein a combination of fiber types are included in the clusters or webs, the fiber types being selected from one or more of the following fiber type variations: (1) variation in fiber material and/or (2) variation in fiber diameters or cross-sectional geometries. 
     
     
         17 . The bulk fill material of  claim 16  wherein the fibers in a cluster or web comprise superfine fibers. 
     
     
         18 . The bulk fill material of  claim 17  wherein the fibers in the clusters or webs comprise a blend of superfine fibers and fibers having of at least 1 denier. 
     
     
         19 . The bulk fill material of  claim 14  wherein the fill material has a fill power equivalent of 450 to 1,000. 
     
     
         20 . The bulk fill material of  claim 14  wherein the average fiber diameter is less than 100 nm. 
     
     
         21 . The bulk fill material of  claim 14  wherein the average fiber diameter is less than 50 nm. 
     
     
         22 . The bulk fill material of  claim 15  wherein the fibers comprise fibers having tubular or otherwise non-solid cores. 
     
     
         23 . A construct comprising an item of footwear, outdoor apparel, and/or outdoor equipment, the item containing a bulk fill material comprising: a plurality of discrete units comprising clusters of fibers, the fibers comprising superfine fibers and/or fibers in a range of 1 to 5 denier; and the fibers being entangled to form the clusters. 
     
     
         24 . The construct of  claim 23  wherein the item comprises an item of apparel. 
     
     
         25 . The construct of  claim 23  wherein the item comprises an item of outdoor equipment that is a sleeping bag. 
     
     
         26 . The construct of  claim 23  wherein the item comprises an item of footwear. 
     
     
         27 . A construct comprising an item of footwear, outdoor apparel, and/or outdoor equipment, the item containing a bulk fill material comprising: a plurality of loose webs of fibers, the fibers comprising superfine fibers and/or fibers in a range of 1 to 5 denier; the fibers being entangled to form the loose webs. 
     
     
         28 . The construct of  claim 27  wherein the item comprises an item of apparel. 
     
     
         29 . The construct of  claim 27  wherein the item comprises an item of outdoor equipment that is a sleeping bag. 
     
     
         30 . The construct of  claim 27  wherein the item comprises an item of footwear.