Blowable natural down alternative

Abstract

A blend of polyester staple fibers and insulation fill materials useful as a replacement for natural down in articles such as outdoor apparel, sleeping bags, bedding, etc. The blend includes first, second and optionally third polyester staple fiber formats that differing in terms of average diameter. A length of substantially all the fibers of the blend is in the range of about 16 to about 63 mm, alternatively 20-40 mm. At least a majority of the fibers of the blend are opened. In some embodiments, some or substantially all of the fibers of the blend are crimped and/or include a lubricant (e.g., siliconized). One non-limiting example blend includes 20-30 weight percent of not greater than 1 Denier fibers, 20-30 weight percent of greater than 1 up to 2 Denier fibers, and 40-60 weight percent of greater than 2 Denier fibers.

1 . A blowable insulation material comprising:
 a blend of polyester staple fibers including a plurality of first polyester staple fibers and a plurality of second polyester staple fibers;   wherein a Denier of each of the second polyester staple fibers is greater than a Denier of each of the first polyester staple fibers;   and further wherein a length of substantially all of the polyester staple fibers of the blend is in the range of about 16 to about 63 mm;   and even further wherein at least a majority of the polyester staple fibers of the blend are opened.   
     
     
         2 . The blowable insulation material of  claim 1 , wherein the blend further comprises a plurality of third polyester staple fibers, and further wherein a Denier of each of the third polyester staple fibers is greater than a Denier of each of the second polyester staple fibers. 
     
     
         3 . The blowable insulation material of  claim 2 , wherein each of the first polyester staple fibers has a Denier of not greater than about 1 Denier, each of the second polyester staple fibers has a Denier in the range of not less than about 1 Denier to not greater than about 2 Denier, and each of the third polyester staple fibers has a Denier of not less than about 2 Denier. 
     
     
         4 . The blowable insulation material of  claim 3 , wherein the blend comprises about 20 to about 40 weight percent of the first polyester staple fibers, about 20 to about 30 weight percent of the second polyester staple fibers, and about 40 to about 60 weight percent of the third polyester staple fibers. 
     
     
         5 . The blowable insulation material of  claim 1 , wherein the length of each of the polyester staple fibers of the blend is in the range of about 20 to about 30 mm. 
     
     
         6 . The blowable insulation material of  claim 1 , wherein at least about 95% of the polyester staple fibers of the blend are opened. 
     
     
         7 . The blowable insulation material of  claim 1 , wherein the insulation material is a loose fill material. 
     
     
         8 . The blowable insulation material of  claim 1 , wherein the fibers of at least one of the first polyester staple fibers and the second polyester staple fibers includes a lubricant. 
     
     
         9 . The blowable insulation material of  claim 8 , wherein the lubricant is silicone. 
     
     
         10 . The blowable insulation material of  claim 1 , wherein the fibers of at least one of the first polyester staple fibers and the second polyester staple fibers are crimped. 
     
     
         11 . The blowable insulation material of  claim 1 , wherein the blend exhibits a heat transfer resistance comparable to a heat transfer resistance of typical 700 fill power down. 
     
     
         12 . The blowable insulation material of  claim 1 , wherein the blend exhibits of heat transfer resistance of not less than about 90% of a heat transfer resistance of typical 700 fill power down. 
     
     
         13 . The blowable insulation material of  claim 1 , wherein the fibers of at least one of the first and second polyester staple fibers are polyethylene terephthalate. 
     
     
         14 . An article comprising an outer shell containing a volume of the blowable insulation material of  claim 1 . 
     
     
         15 . (canceled) 
     
     
         16 . A supply of insulation material for filling at least a segment of a shell of a garment via a blowing apparatus, the insulation material comprising:
 a blend of polyester staple fibers including a plurality of first polyester staple fibers and a plurality of second polyester stable fibers;   wherein a Denier of each of the second polyester stable fibers is greater than a Denier of each of the first polyester staple fibers;   and further wherein a length of each of the polyester staple fibers of the blend is in the range of about 16 to about 63 mm;   and even further wherein at least a majority of the polyester staple fibers of the blend are opened.   
     
     
         17 . A method for preparing a supply of blowable insulation material, the method comprising:
 obtaining a quantity of first polyester staple fibers;   obtaining a quantity of second polyester staple fibers;   wherein an average Denier of each of the second polyester staple fibers is greater than an average Denier of each of the first polyester staple fibers;   and further wherein each of the first polyester staple fibers and each of the second polyester staple fibers has a length in the range of about 16 to about 63 mm;   mixing the quantities of first and second polyester staple fibers to provide a blend of polyester staple fibers useful as a supply of blowable insulation material.   
     
     
         18 . The method of  claim 17 , further comprising the step of:
 obtaining a quantity of third polyester staple fibers, wherein an average Denier of each of the third polyester staple fibers is less that an average Denier of each of the second polyester staple fibers, and further wherein each of the third polyester staple fibers has a length in the range of about 16 to about 63 mm;   wherein the step of mixing further includes mixing the quantity of third polyester staple fibers with the quantities of first and second polyester staple fibers.   
     
     
         19 . The method of  claim 17 , further comprising the step of opening the blend of polyester staple fibers. 
     
     
         20 . The method of  claim 19 , wherein the step of opening includes opening the fibers simultaneously with the step of mixing the quantities of first and second polyester staple fibers. 
     
     
         21 . The method of  claim 19 , wherein the step of opening includes subjecting the blend of polyester staple fibers to an opening operation after the step of mixing the quantities of first and second polyester staple fibers.