FIBERFILL CLUSTERS AND METHODS OF MANUFACTURING SAME

CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application claims priority to U.S. provisional application number 63/211,792, filed on June 17, 2021, to U.S. provisional application number 63/264,426, filed on November 22, 2021, and to U.S. provisional application number 63/362,484, filed on April 5, 2022, the entire contents of each of which are hereby incorporated by reference herein.

FIELD OF THE DISCLOSURE

[0002] The present invention generally relates to a fiberfill cluster, to articles comprising the cluster, to methods of making the cluster. The fiberfill cluster is particularly useful in the textile field.

BACKGROUND

[0003] There have been attempts to achieve an insulating and/or filling material having down-like qualities for use in textile articles.

[0004] For example, U.S. Patent No. 5,851,665 relates to a filling material comprising clusters of bonded crimped thermoplastic fibers, wherein fibers are bonded at differing locations in different clusters of the filling material. U.S. Patent No. 5,851,665 emphasizes, for the sake of developing fibers’ bulk fully and achieving resultant properties, the importance that the fibers in its clusters are fully opened with no restriction (e.g., entanglement) to the complete development of the fibers’ bulk (besides the small bonding point). The filling material is made from a stack of webs of carded fibers or from continuous filaments in tow which, after bonding, is cut and separated into the resulting clusters. Tow refers to a large strand of continuous manufactured fiber filaments without definite twist, collected in loose, rope-like form, usually held together by crimp. Tow typically comprises thousands of filaments. For example, the tow used in U.S. Patent No. 5,851,665 had about 122,000 filaments and a total denier of 48.9 ktex (440,100 denier), which would result in a cluster having high fiber density.

[0005] Generally speaking, prior efforts to develop an insulating and/or filling material having down-like qualities have most often yielded insulation and/or filling materials that, in the Applicant’s assessment, are too heavy and dense to be considered down-like and/or cannot properly be utilized by conventional blowing equipment. For example, these materials may tend to clog conventional blowing equipment and/or resist being fed or loaded into such equipment. Or, where blowable, the materials often simply fall short of emulating the desired down-like properties.

[0006] An exception is U.S. Patent No. 10,633,244, which relates to blowable insulation or filling material made up of a plurality of discrete, longitudinally elongated floccules having a longitudinal length of about 2-4.5 cm and formed of a plurality of fibers, the floccules including a relatively open enlarged medial portion and only a pair of relatively condensed twisted tail portions, the tail portions extending from opposing longitudinal ends of the medial portion. The insulation/filling material of U.S. Patent No. 10,633,244 is able to be utilized in typical current garment fill blowing machines and has down-like qualities, such as the hand feel, launderability, fill power and blowing efficiency of down insulation.

[0007] Nevertheless, there remains a need for additional improved fiberfill materials that are blowable on conventional blowing equipment and that have desirable downlike properties.

[0008] While certain aspects of conventional technologies have been discussed to facilitate disclosure of the invention, Applicant in no way disclaims these technical aspects, and it is contemplated that the claimed invention may encompass one or more of the conventional technical aspects discussed herein.

[0009] In this specification, where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge or any combination thereof was, at the priority date, publicly available, known to the public, part of common general knowledge, or otherwise constitutes prior art under the applicable statutory provisions; or is known to be relevant to an attempt to solve any problem with which this specification is concerned.

SUMMARY

[0010] Briefly, the present invention satisfies the need for a blowable fiberfill material that has desirable downlike properties.

[0011] The present invention may address one or more of the problems and deficiencies of the art discussed above. However, it is contemplated that the invention may prove useful in addressing other problems and deficiencies in a number of technical areas. Therefore, the claimed invention should not necessarily be construed as limited to addressing any of the particular problems or deficiencies discussed herein.

[0012] Applicant has surprisingly found that embodiments of the inventive fiberfill cluster emulate both the structure and performance of natural down.

[0013] In a first aspect, the invention provides a method of making at least one fiberfill cluster. The method comprises obtaining a bundle (e.g., a discrete bundle) of a plurality of 25 to 3600 fibers having a denier of 0.2 to 12.0 dpf (denier per fiber/filament) and a length of 8to 160 mm, the plurality of fibers being longitudinally arranged together. The method further comprises disrupting the longitudinal arrangement of at least some of the plurality of fibers of the bundle such that they extend irregularly three-dimensionally and intermingle to form a fiberfill cluster (e g., a discrete fiberfdl cluster).

[0014] In some embodiments, the discrete bundle consists essentially of the plurality of 25 to 3600 fibers. In some embodiments, the discrete bundle consists of the plurality of 25 to 3600 fibers.

[0015] In some embodiments, the disrupting the longitudinal arrangement of at least some of the plurality of fibers of the bundle comprises disrupting the longitudinal arrangement of only some of the plurality of fibers of the bundle such that a bundle remnant portion of the plurality of fibers of the bundle remain longitudinally arranged together and are intermingled with the fibers that extend irregularly three-dimensionally. In some such embodiments, the fibers that extend irregularly three-dimensionally form an outer region that extends outwardly from the bundle remnant portion. In some such embodiments, the bundle remnant portion comprises a higher density of fibers than the outer region.

[0016] In some embodiments, disrupting the longitudinal arrangement of at least some of the plurality of fibers of the bundle comprises disrupting the longitudinal arrangement of all of the plurality of fibers of the bundle such that none of the plurality of fibers remain longitudinally arranged together. In some such embodiments, disrupting the longitudinal arrangement of all of the plurality of fibers of the bundle forms at least one inner relatively densely populated three-dimensional region of fibers, and an outer relatively less densely population region of fibers extending three-dimensionally outwardly from the at least one inner relatively densely populated region.

[0017] In some embodiments, disrupting the longitudinal arrangement of at least some of the plurality of fibers of the bundle comprises intermingling only some of the disrupted fibers such that some of the disrupted fibers form a fiberfill cluster and some of the disrupted fibers do not form a fiberfill cluster.

[0018] In some embodiments, disrupting of the longitudinal arrangement of at least some of the plurality of fibers of the bundle comprises positioning the bundle between engagement sides of at least a pair of disrupting members such that the disrupting sides contact the bundle, and translating at least one first disrupting member with respect to at least one second disrupting member along a pathway that extends both longitudinally along a longitudinal length of the fibers of the bundle and laterally along a lateral direction oriented perpendicular to the longitudinal direction. In some such embodiments, a distance between the disrupting sides remains substantially constant during the disrupting. In some such embodiments, the at least one first disrupting member translates along an arcuate pathway for at least a first portion of time. In some such embodiments, the at least one first disrupting member translates along an elliptical pathway for at least a first portion of time. In some such embodiments, the at least one first disrupting member translates along a random orbital pattern for at least a first portion of time. In some such embodiments, at least one of the engagement sides comprises a substantially flat and smooth surface. In some such embodiments, at least one of the engagement sides comprises a substantially planar array of particles or projections. In some such embodiments, disrupting of the longitudinal arrangement of at least some of the plurality of fibers of the bundle comprises subjecting the bundle to at least one stream of a gas and/or liquid.

[0019] In some embodiments, the method further comprises, prior to the disrupting, bonding at least some of the plurality of fibers of the bundle together at least one point along the longitudinal length of the bundle to form at least one bonding point. In some such embodiments, the bonding point is formed by heating at least some of the plurality of fibers at the at least one point to adhere the fibers together at the at least one bonding point. In some such embodiments, the heating of at least some of the plurality of fibers at the at least one point comprises contacting the plurality of fibers at the at least one point with a material that is at a temperature that is above the melting temperature of the fibers.

[0020] In some embodiments, disrupting the longitudinal arrangement of at least some of the plurality of fibers of the bundle comprises entangling some of the disrupted fibers together. In some such embodiments, less than about 50% of the disrupted fibers are entangled with at least one other fiber. In some such embodiments, less than about 25% of the disrupted fibers are entangled with at least one other fiber.

[0021] In some embodiments, disrupting the longitudinal arrangement of at least some of the plurality of fibers of the bundle comprises twisting some of the disrupted fibers together. In some such embodiments, less than about 50% of the disrupted fibers are twisted with at least one other fiber. In some such embodiments, less than about 25% of the disrupted fibers are twisted with at least one other fiber.

[0022] In some embodiments, the method comprises obtaining a plurality of bundles each of a plurality of 25 to 3600 fibers having a denier of 0.2 to 12.0 dpf and a length of 8 to 160 mm, the plurality of fibers of each bundle being longitudinally arranged together, and disrupting the longitudinal arrangement of at least some of the plurality of fibers of each of the bundles such that they extend irregularly three-dimensionally and intermingle to form a plurality of discrete fiberfill clusters.

[0023] In some embodiments, the plurality of fibers of the bundle extend substantially linearly along their longitudinal length. In some embodiments, the plurality of fibers of the bundle extend substantially parallel to each other along their longitudinal length. In some embodiments, the plurality of fibers of the bundle are non-texturized linear fibers. [0024] In some embodiments, the plurality of fibers of the bundle extend non-linearly along their longitudinal length. In some embodiments, the plurality of fibers of the bundle extend irregularly along their longitudinal length. In some embodiments, the plurality of fibers of the bundle are texturized fibers. In some embodiments, the plurality of fibers of the bundle comprises about 50 to about 500 fibers. In some embodiments, the plurality of fibers comprises about 80 to about 300 fibers.

[0025] In some embodiments, the bundle comprises more fibers than the fiberfill cluster. In some embodiments, the fiberfill cluster comprises at least one secondary fiber that was not part of the bundle. In some such embodiments, the at least one secondary fiber is intermingled with the plurality of fibers of the fiberfill cluster during the disrupting.

[0026] In some embodiments, the plurality of fibers have a denier of about 0.7 to about 1.7 dpf. In some embodiments, the plurality of fibers have substantially the same deniers. In some embodiments, the plurality of fibers of the bundle have a longitudinal length of about 20 to about 50 mm. In some embodiments, the plurality of fibers of the bundle have substantially the same longitudinal lengths. In some embodiments, the plurality of fibers have substantially the same lengths.

[0027] In some embodiments, the plurality of fibers are synthetic polymeric fibers. In some embodiments, the plurality of fibers are fibers selected from polyamide, polyester, polypropylene, polylactic acid (also known as polylactide) (PLA), poly(butyl acrylate) (PBA), acrylic, acrylate, acetate, polyolefin, nylon, rayon, lyocell, aramid, spandex, viscose, and modal fibers, or a combination thereof. In some embodiments, the plurality of fibers are polyester fibers. In some such embodiments, the polyester fibers are selected from polyethylene terephthalate (PET), poly(hexahydro-p-xylylene terephthalate), polybutylene terephthalate (PBT) fibers, polytrimethylene terephthalate (PTT) fibers, copolyester fibers (e.g., copolyester fibers comprising PET structural units), or a combination thereof. In some such embodiments, the polyester fibers are PET fibers.

[0028] In some embodiments, the fibers comprise recycled polymeric material. In some embodiments, the plurality of fibers comprise siliconized fibers. In some embodiments, the plurality of fibers comprise non-siliconized fibers. In some embodiments, the plurality of fibers comprise solid fibers. In some embodiments, the plurality of fibers comprise hollow fibers.

[0029] In some embodiments, the fiberfill cluster defines a length, a width and a thickness, and wherein the length and width are greater than the thickness. In some such embodiments, the length is greater than the width.

[0030] In some embodiments, the fiberfill cluster defines a length, a width and a thickness, and wherein the length is within the range of about 0.5 to about 6.5 cm (e g., about 0.90 to about 4 cm). In some embodiments, the fiberfill cluster defines a length, a width and a thickness, and wherein the width is within the range of about 0.5 to about 6.5 cm (e.g., about 0.70 to about 3 cm). In some embodiments, the fiberfill cluster has a density of about 0.08 to about 0.70 mg/cm ³ (e.g., about 0.10 to about 0.50 mg/cm ³ ). In some embodiments, the fiberfill cluster defines a substantially ovoidal shape. In some embodiments, the fiberfill cluster defines a substantially spherical shape.

[0031] In some embodiments, the bundle is a segment of a filament yarn. In some such embodiments, obtaining the bundle comprises cutting the segment from the filament yarn. In some embodiments, the filament yarn is a textured filament yarn. In such some embodiments, the filament yam is a flat filament yarn.

[0032] In some embodiments, the bundle is a segment of intermingled filament yarn. In some such embodiments, obtaining the bundle comprises cutting the segment from the intermingled filament yarn.

[0033] In a second aspect, the invention provides a fiberfill cluster (e.g., a discrete fiberfill cluster), which may be made according to the first aspect of the invention. The discrete fiberfill cluster comprises a plurality of fibers that are intermingled with one another, the plurality of fibers comprising 25 to 3600 fibers having a denier of 0.2 to 12.0 dpf and a length of 8 to 160 mm. The plurality of fibers form: a bundle remnant portion comprising some or all of the plurality of fibers being longitudinally arranged together; and an outer region of fibers extending three-dimensionally outwardly from the bundle remnant portion comprising some of the plurality of fibers randomly and non-uniformly oriented with respect to one another. The bundle remnant portion comprises a higher density of fibers than the outer region.

[0034] In some embodiments, the discrete fiberfill cluster consists essentially of the plurality of fibers. In some embodiments, the discrete fiberfill cluster consists of the plurality of fibers. In some embodiments, the discrete fiberfill cluster consists essentially of the bundle remnant portion and the outer region. In some embodiments, the discrete fiberfill cluster consists of the bundle remnant portion and the outer region.

[0035] In some embodiments, the bundle remnant portion comprises fewer fibers than the outer region. In some such embodiments, the bundle remnant portion comprises at least 25% fewer fibers than the outer region. In some such embodiments, the bundle remnant portion comprises at least 50% fewer fibers than the outer region. In some such embodiments, the bundle remnant portion comprises at least 75% fewer fibers than the outer region.

[0036] In some embodiments, the bundle remnant portion extends non-linearly along its length. In some embodiments, the bundle remnant portion is a portion of a segment of a filament yarn. In some such embodiments, the bundle remnant portion is a portion of a segment of a textured filament yarn. In some other such embodiments, the bundle remnant portion is a portion of a segment of a flat filament yarn.

[0037] In some embodiments, the plurality of fibers of the bundle remnant portion extend substantially parallel to each other along their longitudinal length. In some embodiments, the plurality of fibers are non-texturized linear fibers. In some embodiments, the plurality of fibers are texturized linear fibers. In some embodiments, the plurality of fibers extend non-linearly along their longitudinal length. In some embodiments, the plurality of fibers extend irregularly along their longitudinal length.

[0038] In some embodiments, some of the plurality of fibers of the outer region are entangled together or with at least one fiber of the bundle remnant portion. In some such embodiments, less than about 50% of the plurality of fibers of the outer region are entangled together or with at least one fiber of the bundle remnant portion. In some such embodiments, less than about 25% of the plurality of fibers of the outer region are entangled together or with at least one fiber of the bundle remnant portion.

[0039] In some embodiments, the plurality of fibers of the outer region are twisted together or with at least one fiber of the bundle remnant portion. In some such embodiments, less than about 50% of the plurality of fibers of the outer region are twisted together or with at least one fiber of the bundle remnant portion. In some such embodiments, less than about 25% of the plurality of fibers of the outer region are twisted together or with at least one fiber of the bundle remnant portion.

[0040] In some embodiments, the discrete fiberfill cluster comprises at least one bonding point wherein at least some of the plurality of fibers are bonded together. In some such embodiments, the at least one bonding point includes some fibers of the remnant portion and some fibers of the outer region. In some such embodiments, the at least one bonding point includes only some fibers of the remnant portion and only some fibers of the outer region.

[0041] In some embodiments, the fiberfill cluster defines a length, a width and a thickness, and wherein the length and width are greater than the thickness. In some such embodiments, the length is greater than the width. In some embodiments, the fiberfill cluster defines a length, a width and a thickness, and wherein the length is within the range of about 0.5 to about 6.5 cm (e.g., about 0.90 to about 4 cm). In some embodiments, the fiberfill cluster defines a length, a width and a thickness, and wherein the width is within the range of about 0.5 to about 6.5 cm (e.g., about 0.70 to about 3 cm).

[0042] In some embodiments, the fiberfill cluster defines a substantially ovoidal shape. In some embodiments, the fiberfill cluster defines a substantially spherical shape. In some embodiments, the plurality of fibers have a denier of about 0.7 to about 1.7 dpf. In some embodiments, the plurality of fibers have substantially the same deniers. In some embodiments, the plurality of fibers of the bundle have a longitudinal length of about 20 to about 50 mm. In some embodiments, the plurality of fibers of the bundle remnant portion have substantially the same longitudinal lengths. In some embodiments, the plurality of fibers have substantially the same lengths. In some embodiments, the fiberfill cluster has a density of about 0.08 to 0.70 mg/cm ³ (e.g., about 0.10 to about 0.50 mg/cm ³ ). In some embodiments, the plurality of fibers comprises about 50 to about 500 fibers. In some embodiments, the plurality of fibers comprises about 80 to about 300 fibers.

[0043] In some embodiments, the plurality of fibers are synthetic polymeric fibers. In some embodiments, the plurality of fibers are fibers selected from polyamide, polyester, polypropylene, polylactic acid (also known as polylactide) (PLA), poly(butyl acrylate) (PBA), acrylic, acrylate, acetate, polyolefin, nylon, rayon, lyocell, aramid, spandex, viscose, and modal fibers, or a combination thereof. In some embodiments, the plurality of fibers are polyester fibers. In some such embodiments, the polyester fibers are selected from polyethylene terephthalate (PET), poly(hexahydro-p-xylylene terephthalate), polybutylene terephthalate (PBT) fibers, polytrimethylene terephthalate (PTT) fibers, copolyester fibers (e.g., copolyester fibers comprising PET structural units), or a combination thereof. In some such embodiments, the polyester fibers are PET fibers. In some embodiments, the fibers comprise recycled polymeric material.

[0044] In some embodiments, the plurality of fibers comprise siliconized fibers. In some embodiments, the plurality of fibers comprise non-siliconized fibers. In some embodiments, the plurality of fibers comprise solid fibers. In some embodiments, the plurality of fibers comprise hollow fibers.

[0045] In some embodiments, the plurality of fibers are a segment of intermingled filament yarn, said segment having at least one mingled nip portion wherein the plurality of fibers are entangled with each other. Following disruption to form the fiberfill cluster, the mingled nip portion may be referred to as a mingled nip portion, or, alternatively, as a bundle remnant portion.

[0046] In a third aspect, the invention provides another fiberfill cluster (e.g., a discrete fiberfill cluster), which may be made according to the first aspect of the invention. The discrete fiberfill cluster comprises a plurality of fibers that are randomly intermingled with one another, the plurality of fibers comprising 25 to 3600 fibers having a denier of 0.2 to 12.0 dpf and a length of 8 to 160 mm. The plurality of fibers are randomly and non-uniformly oriented with respect to one another. The plurality of fibers form: at least one inner relatively densely populated region of fibers; and, an outer relatively less densely population region of fibers extending three-dimensionally outwardly from the at least one inner relatively densely populated region. The discrete fiberfill cluster has a length of about 0.5 to 6.5 cm (e.g., about 0.90 to 4 cm), a width of about 0.5 to 6.5 cm (e g., about 0.70 to 3 cm), and density of about 0.08 to 0.70 mg/cm ³ (e.g., about 0.10 to 0.50 mg/cm ³ ).

[0047] In some embodiments, the fiberfill cluster consists essentially of the plurality of fibers. In some embodiments, the discrete fiberfill cluster consists of the plurality of fibers. In some embodiments, the fiberfill cluster consists essentially of the bundle remnant portion and the outer region. In some embodiments, the discrete fiberfill cluster consists of the bundle remnant portion and the outer region.

[0048] In some embodiments, the inner region comprises fewer fibers than the outer region. In some such embodiments, the inner region comprises at least 25% fewer fibers than the outer region. In some such embodiments, the inner region comprises at least 50% fewer fibers than the outer region.

[0049] In some embodiments, the outer region comprises fewer fibers than the inner region. In some such embodiments, the outer region comprises at least 25% fewer fibers than the inner region. In some such embodiments, the outer region comprises at least 50% fewer fibers than the inner region.

[0050] In some embodiments, the plurality of fibers extend non-linearly along their length.

In some embodiments, the plurality of fibers are non-texturized fibers. In some embodiments, the plurality of fibers are texturized fibers.

[0051] In some embodiments, some of the plurality of fibers are entangled together. In some such embodiments, less than about 50% of the plurality of fibers are entangled together. In some such embodiments, less than about 25% of the plurality of fibers are entangled together.

[0052] In some embodiments of the inventive fiberfill cluster, less than 70% (e.g., less than 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30,

31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55,

56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, or 70%) of the plurality of fibers in the at least one outer region are entangled together.

[0053] In some embodiments, some of the plurality of fibers are twisted together. In some such embodiments, less than about 50% of the plurality of fibers are twisted together. In some such embodiments, less than about 25% of the plurality of fibers are twisted together.

[0054] In some embodiments, the fiberfill cluster comprises at least one bonding point wherein at least some of the plurality of fibers are bonded together. In some such embodiments, the at least one bonding point includes some fibers of the inner region and some fibers of the outer region. In some such embodiments, the at least one bonding point includes only some fibers of the inner portion and only some fibers of the outer region.

[0055] In some embodiments, the fiberfill cluster defines a length, a width and a thickness, and wherein the length and width are greater than the thickness. In some such embodiments, the length is greater than the width. In some embodiments, the fiberfill cluster defines a length, a width and a thickness, and wherein the length is within the range of about 0.5 to 6.5 cm (e g., about 0.90 to about 4 cm). In some embodiments, the fiberfill cluster defines a length, a width and a thickness, and wherein the width is within the range of about 0.5 to 6.5 cm (e.g., about 0.70 to about 3 cm).

[0056] In some embodiments, the fiberfill cluster defines a substantially ovoidal shape. In some embodiments, the fiberfill cluster defines a substantially spherical shape.

[0057] In some embodiments, the plurality of fibers have a denier of about 0.7 to about 1.7.

In some embodiments, the plurality of fibers have substantially the same deniers.

[0058] In some embodiments, the plurality of fibers of the bundle have a longitudinal length of about 20 to about 50 mm. In some embodiments, the plurality of fibers have substantially the same longitudinal lengths. In some embodiments, the fiberfill cluster has a density of about 0.10 to about 0.50 mg/cm ³ . In some embodiments, the plurality of fibers comprises about 50 to about 500 fibers. In some such embodiments, the plurality of fibers comprises about 80 to about 300 fibers.

[0059] In some embodiments, the plurality of fibers are synthetic polymeric fibers. In some embodiments, the plurality of fibers are fibers selected from polyamide, polyester, polypropylene, polylactic acid (also known as polylactide) (PLA), poly(butyl acrylate) (PBA), acrylic, acrylate, acetate, polyolefin, nylon, rayon, lyocell, aramid, spandex, viscose, and modal fibers, or a combination thereof. In some embodiments, the plurality of fibers are polyester fibers. In some such embodiments, the polyester fibers are selected from polyethylene terephthalate (PET), poly(hexahydro-p-xylylene terephthalate), polybutylene terephthalate (PBT) fibers, polytrimethylene terephthalate (PTT) fibers, copolyester fibers (e.g., copolyester fibers comprising PET structural units), or a combination thereof. In some embodiments, copolyester fibers comprising PET structural units refer to fibers made of a polymer chain comprising PET structural units as shown below, together with units of one or more (e.g., one) other non-PET polyester structural units.

PET Structural Unit

[0060] In some such embodiments, the polyester fibers are PET fibers. In some embodiments, the fibers comprise recycled polymeric material.

[0061] In some embodiments, the plurality of fibers comprise siliconized fibers. In some embodiments, the plurality of fibers comprise non-siliconized fibers. In some embodiments, the plurality of fibers comprise solid fibers. In some embodiments, the plurality of fibers comprise hollow fibers.

[0062] In some embodiments, the plurality of fibers are a segment of intermingled filament yarn, said segment having at least one mingled nip portion wherein the plurality of fibers are entangled with each other. In such embodiments, the mingled nip portion represents the at least one inner relatively densely populated region of fibers.

[0063] In a fourth aspect, the invention provides insulation or filling material comprising a plurality of the fiberfill clusters according to the second and/or third aspects of the invention (which may have been made by the first aspect of the invention).

[0064] In some embodiments, the insulation or filling material consists essentially of the fiberfill clusters according to the second and/or third aspects of the invention. In some embodiments, the insulation or filling material consists essentially of the fiberfill clusters according to the second aspect of the invention. In some embodiments, the insulation or filling material consists essentially of the fiberfill clusters according to the third aspect of the invention. In some embodiments, the insulation or filling material consists of the fiberfill clusters according to the second and/or third aspects of the invention. In some embodiments, the insulation or filling material consists of the fiberfill clusters according to the second aspect of the invention. In some embodiments, the insulation or filling material consists of the fiberfill clusters according to the third aspect of the invention.

[0065] In some embodiments, the insulation or filling material comprises a plurality of first discrete fiberfill clusters according to the second aspect of the invention, and a plurality of second discrete fiberfill clusters according to the third aspect of the invention.

[0066] In some embodiments, the plurality of fiberfill clusters include first fiberfill clusters formed of fibers of a first length and second fiberfill clusters formed of fibers of a second length that differs from the first length. In some embodiments, the plurality of fiber clusters include first clusters formed of a first total number of fibers and second clusters formed of a second total number of fibers that differs from the first total number of fibers. In some embodiments, the plurality of fiberfill clusters include first fiberfill clusters formed of fibers of a first synthetic material and second fiberfill clusters formed of fibers of a second synthetic material that differs from the first synthetic material. In some embodiments, the plurality of fiberfill clusters include first fiberfill clusters formed of fibers of a first denier and second fiberfill clusters formed of fibers of a second denier that differs from the first denier.

[0067] In some embodiments, the plurality of fiberfill clusters include fiberfill clusters of a first size and fiberfill clusters of a second size that differs from the first size. In some embodiments, the plurality of fiberfill clusters include fiberfill clusters of a first three dimensional shape and fiberfill clusters of a second three dimensional shape that differs from the first three dimensional shape. In some embodiments, the plurality of fiberfill clusters include fiberfill clusters within a first density range and fiberfill clusters within a second density range that that differs from and does not overlap with the first density range.

[0068] In a fifth aspect, the invention provides an article comprising a plurality of the insulation or filling material according to the fourth aspect of the invention. In some embodiments, the article is selected from footwear, outerwear, clothing, a sleeping bag, and bedding.

[0069] Certain embodiments of the presently-disclosed fiberfill cluster, articles comprising the cluster, and methods of making the cluster have several features, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of the fiberfill cluster, articles and methods as defined by the claims that follow, their more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section of this specification entitled “Detailed Description of the Invention,” one will understand how the features of the various embodiments disclosed herein provide a number of advantages over the current state of the art. For example, embodiments of the inventive fiberfill cluster are blowable on conventional blowing equipment and emulate properties of down. Incorporation of embodiments of the inventive fiberfill cluster into articles gives the resultant article an increased softness as sensed by the hand or skin as compared to others’ prior attempts at synthetic down products. Articles comprising embodiments of the disclosed fiberfill cluster may include an improved fill power resulting in improved thermal performance, improved blowing efficiency, as well as improved launderability as compared to others’ prior attempts at synthetic down products.

Embodiments of the fiberfill cluster may also be configured to be utilized by conventional blowing equipment without clogging or other loading issues typically encountered with others’ synthetic down materials.

[0070] These and other features and advantages of this invention will become apparent from the following detailed description of the various aspects of the invention taken in conjunction with the appended claims and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0071] The present invention will hereinafter be described in conjunction with the following drawing figures, which are not necessarily drawn to scale, wherein like numerals denote like elements, and:

[0072] FIG. 1 illustrates a fiber bundle for forming a discrete fiber cluster according to an embodiment of the present invention; [0073] FIG. 2 illustrates an enlarged view of a portion of a textured fiber bundle according to an embodiment of the present invention;

[0074] FIG. 3 illustrates an enlarged view of a portion of a linear fiber bundle according to an embodiment of the present invention;

[0075] FIG. 4A illustrates a non-bonded fiber bundle for forming a discrete fiber cluster according to an embodiment of the present invention;

[0076] FIG. 4B illustrates a bonded fiber bundle for forming a discrete fiber cluster according to an embodiment of the present invention;

[0077] FIG. 5A and 5B illustrate disrupting members of a discrete fiber cluster manufacturing method according to an embodiment of the present invention;

[0078] FIG. 6 illustrates a top view of an exemplary embodiment of a discrete fiber cluster with a fiber bundle remnant portion according to the present invention;

[0079] FIG. 7 illustrates a top view of another exemplary embodiment of a discrete fiber cluster with a fiber bundle remnant portion according to the present invention;

[0080] FIG. 8 illustrates a top view of another exemplary embodiment of a discrete fiber cluster with a fiber bundle remnant portion according to the present invention;

[0081] FIG. 9 illustrates a top view of another exemplary embodiment of a discrete fiber cluster with a fiber bundle remnant portion according to the present invention;

[0082] FIG. 10 illustrates a top view of an exemplary embodiment of a discrete fiber cluster with an inner intermingled fiber region according to the present invention;

[0083] FIG. 11 illustrates a top view of another exemplary embodiment of a discrete fiber cluster with an inner intermingled fiber region according to the present invention;

[0084] FIG. 12 illustrates a top view of another exemplary embodiment of a discrete fiber cluster with an inner intermingled fiber region according to the present invention;

[0085] FIG. 13 illustrates a top view of another exemplary embodiment of a discrete fiber cluster with an inner intermingled fiber region according to the present invention;

[0086] FIG. 14 is a photograph of a top view of an example of a discrete fiber cluster according to the present invention;

[0087] FIG. 15 is a photograph of a side view of the example of the discrete fiber cluster of FIG. 12;

[0088] FIG. 16 is a photograph of a top view of another example of a discrete fiber cluster according to the present invention;

[0089] FIG. 17 is a photograph of a top view of another example of a discrete fiber cluster according to the present invention;

[0090] FIG. 18 is a photograph of a top view of another example of a discrete fiber cluster according to the present invention; [0091] FIG. 19 is a photograph of a top view of another example of a discrete fiber cluster according to the present invention;

[0092] FIG. 20 is a photograph of a top view of a plurality of exemplary discrete fiber clusters according to the present invention;

[0093] FIG. 21 is a photograph of a front elevational view of the plurality of exemplary discrete fiber clusters of FIG. 20;

[0094] FIG. 22 is a photograph of a top view of a plurality of exemplary discrete fiber clusters according to the present invention;

[0095] FIG. 23 is a photograph of a top view of a plurality of exemplary discrete fiber clusters according to the present invention;

[0096] FIG. 24 is a photograph of a top view of a plurality of exemplary discrete fiber clusters engaging each other according to the present invention;

[0097] FIG. 25 is a photograph of a top view of a plurality of exemplary discrete fiber clusters according to the present invention; and

[0098] FIG. 26 is a photograph of a top view of a plurality of exemplary discrete fiber clusters engaging each other according to the present invention.

[0099] FIG. 27 is an enlarged photograph of a portion of intermingled filament yarn.

[00100] FIG. 28 is a simplified schematic showing arrangement of filaments before and after formation of intermingled filament yarn.

[00101] FIG. 29 is an enlarged photograph of a cut section, or “bundle” of intermingled filament yarn.

[00102] FIG. 30 is an enlarged photograph of an embodiment of the inventive fiberfill cluster.

[00103] FIG. 31 is an enlarged photograph of an embodiment of the inventive fiberfill cluster.

[00104] FIG. 32 is an enlarged photograph of an embodiment of the inventive fiberfill cluster.

[00105] FIG. 33 A is an enlarged photograph of intermingled filament yam (left) and a plurality of fiberfill clusters according to an embodiment of the invention formed therefrom. FIGS. 33B and 33C are enlarged photographs of the fiberfill clusters from FIG. 33A.

[00106] FIG. 34 is a drawing showing a process of cutting intermingled filament yarn to form a bundle that is disrupted to form an embodiment of an inventive fiberfill cluster.

[00107] FIG. 35 is a simplified drawing of an embodiment of the inventive fiberfill cluster. DETAILED DESCRIPTION OF THE INVENTION [00108] Aspects of the present invention and certain features, advantages, and details thereof, are explained more fully below with reference to the non-limiting embodiments illustrated in the accompanying drawings. Descriptions of well-known materials, fabrication tools, processing techniques, etc., are omitted so as to not unnecessarily obscure the invention in detail. It should be understood, however, that the detailed description and the specific example(s), while indicating embodiments of the invention, are given by way of illustration only, and are not by way of limitation. Various substitutions, modifications, additions and/or arrangements within the spirit and/or scope of the underlying inventive concepts will be apparent to those skilled in the art from this disclosure.

[00109] In one aspect, the disclosure provides a method of making or manufacturing one or more fiberfill clusters that, surprisingly and/or unexpectedly, have been found to closely emulate down in terms of blowability, size, weight, and/or density, and other properties, while at the same time providing for improved launderability as compared to down.

[00110] As shown in FIG. 1, the method may include obtaining a discrete bundle 10 of a plurality of 25 to 3600 fibers 12 having a denier of 0.2 to 12.0 and a length of 8 to 160 mm, the plurality of fibers 12 being longitudinally arranged together (i.e., along their length). The method further comprises disrupting the longitudinal arrangement of at least some of the plurality of fibers 12 of the bundle 10 such that they extend irregularly three-dimensionally and intermingle to form a discrete fiberfill cluster 1, as shown in FIGS. 6-26.

[00111] In some embodiments, obtaining the bundle comprises cutting the bundle 10 from a yarn or tow of the fibers 12. For example, the yarn or tow may be spooled or otherwise contain numerous consecutive bundles which are cut or otherwise separated from the yam or tow. In this way, numerous bundles 10 can be formed from the yarn or tow.

[00112] In some embodiments, disrupting the longitudinal arrangement of at least some of the plurality of fibers 12 of the bundle 10 disrupts the longitudinal arrangement of only some of the plurality of fibers 12 of the bundle 10 such that a bundle remnant portion 16 of the plurality of fibers 12 of the bundle 10 remain longitudinally arranged together in the formed fiber cluster 1, as shown in, for example, FIGS. 6-9, 14, 15 and 20-26. In such embodiments, the disrupting also disrupts the longitudinal arrangement of some of the plurality of fibers 12 of the bundle 10 such that they intermingle with the fibers 12 of the remnant portion 16 and extend irregularly three-dimensionally outwardly therefrom, as also shown in FIGS. 6-9, 14, 15 and 20-26. The fibers 12 that extend irregularly three-dimensionally from the remnant portion 16 thereby form an outer region 18 that extends outwardly from the bundle remnant portion 16. The bundle remnant portion 16 may comprise a higher density of fibers 12 than the outer region (i.e., is more densely populated with fibers 12 or portions thereof). [00113] In some other embodiments, disrupting the longitudinal arrangement of at least some of the plurality of fibers 12 of the bundle 10 comprises disrupting the longitudinal arrangement of all of the plurality of fibers 12 of the bundle 10 such that essentially none of the plurality of fibers 12 remain longitudinally arranged together in the formed fiber cluster 1, as shown in FIGS. 10-13 and 16-29. In some such embodiments, disrupting the longitudinal arrangement of essentially all of the plurality of fibers 12 of the bundle 10 forms at least one inner relatively densely populated three-dimensional region of fibers 14, and an outer relatively less densely population region 18 of fibers 16 extending three-dimensionally outwardly from the at least one inner relatively densely populated region 14.

[00114] As shown in FIG. 4A, the plurality of fibers 12 of the bundle 10 may not be mechanically coupled or bonded together. Rather, the fibers 12 of the bundle 10 may be intermingled and the natural forces and/or arrangement of the fibers 12 from the yam or tow making or process may act to keep the fibers 12 of the bundle 10 arranged together.

[00115] In some other embodiments, as shown in FIG. 4B, the at least some of the fibers 12 of the bundle 10 may be bonded together at a bonding point or region 22. For example, the method may include, prior to the disrupting, bonding at least some of the plurality of fibers 12 of the bundle 10 together at least one point 22 along the longitudinal length of the bundle/fibers 10/12 to form at least one bonding point 22. In some such embodiments, the bonding point is formed by heating at least some of the plurality of fibers 12 at the at least one point so that the fibers adhere or bond together at the at least one bonding point. In some such embodiments, the heating of at least some of the plurality of fibers 12 at the at least one point comprises contacting the plurality of fibers 12 at the at least one point with a material or member that is at a temperature that is above the melting temperature of the fibers 12. The bonding point 22 may be formed by any acceptable means (e.g., with hot metal, ultrasonic bonding, laser treatment, soldering iron, heated air jet, etc.). In some other embodiments, the bonding point 22 may be formed by a glue, adhesive or other material that acts to couple or bond the fibers together. It is noted that while a single bonding point 22 is shown in exemplary fiber bundle 10 in FIG. 4B, a fiber bundle 10 may include two or more bonding points 22. In some embodiments, the bonding point 22 is a size of 0.10 to 0.50 mm (e.g.,

0.10, 0.15, 0.20, 0.25, 0.30, 0.35, 0.40, 0.45, or 0.50 mm), including any and all ranges and subranges therein.

[00116] As shown in FIGS. 5A and 5B, in some embodiments, disrupting of the longitudinal arrangement of at least some of the plurality of fibers 12 of the bundle 10 comprises positioning the bundle 10 between engagement sides 32 of at least a pair of disrupting members 30 such that the disrupting sides 32 contact the bundle 10, and translating at least one first disrupting member 30 with respect to at least one second disrupting member 30 along a pathway that extends both longitudinally along a longitudinal length of the fibers 12 of the bundle 10 and laterally along a lateral direction oriented perpendicular to the longitudinal direction. In some such embodiments, a distance between the disrupting sides 32 remains substantially constant during the disrupting. However, the disrupting sides 32 may move together or apart during the disrupting process. In some such embodiments, at least one of the disrupting members 30 may translate along an arcuate pathway for at least a portion of time and/or a linear or rectilinear pathway for at least a portion of time. In some such embodiments, at least one disrupting member 30 may translate along an elliptical pathway for at least a portion of time. In some embodiments, at least one disrupting member 30 translates along a random orbital pattern for at least a portion of time.

[00117] The engagement side 32 of at least one of the disrupting members 30 may be a substantially flat and smooth surface. In some embodiments, an engagement side 32 may comprise a substantially planar array of particles or projections that extend outward/inwardly toward the bundle 10 and act to pick or grab or otherwise contact the fibers 12 to disrupt the longitudinal arrangement of the fibers 12 from the bundle 10 In some other embodiments (not shown), disrupting of the longitudinal arrangement of at least some of the plurality of fibers 12 of the bundle 10 comprises subjecting the bundle 10 to at least one stream of a gas and/or liquid. The disrupting process of the disruption of longitudinal arrangement of at least some of the plurality of fibers 12 of the bundle 10 (and thus rearranging of such fibers 12) may comprise rubbing the bundle 10, sanding the bundle 10, abrading the bundle 10, buffing the bundle 10, or subjecting the bundle to a stream of a gas and/or liquid, or a combination thereof.

[00118] It is noted that the disrupting process may remove some one or more of the fibers 12 from the bundle 10 and not entangle the fibers 12 into the fiberfill cluster 1. In other words, one or more fibers 12 of the bundle 10 may become disrupted, and not entangled with the other fibers that form the fiberfill cluster 1. Similarly, one or more fiber 12 that is separated from another bundle 10 during the disruption process, may be included (i.e., entangled) with the fibers 10 of another bundle 10 and incorporated into the fiberfill cluster 1 that is formed thereby. The disrupting process may thereby include adding at least one additional fiber to the plurality of fibers 12, or removing/eliminating a fiber from the plurality of fibers 12. [00119] The disrupting acts to entangle the plurality of fibers 12 together and form the fiberfill clusters. The term “intermingle” and the like is used herein to refer to fibers that cross or extend past each other at least once (i.e., intermingled fibers cross at least one other fiber at least once). In some embodiments, the disrupting also acts to entangle at least some of the disrupted fibers 12 together. The term “entangle” and the like is used herein to refer to fibers that cross and extend about or wrap around each other at least once (i.e., entangled fibers cross and extend about or wrap at least one other fiber at least once). In some such embodiments, less than about 50% of the disrupted fibers are entangled with at least one other fiber. In some such embodiments, less than about 25% of the disrupted fibers are entangled with at least one other fiber. In some embodiments, the disrupting also acts to twist at least some of the disrupted fibers 12 together. The term “twist” and the like is used herein to refer to fibers that cross and extend about or wrap around each other more than once (i.e., twisted fibers cross and extend about or wrap at least one other fiber more than once). In some such embodiments, less than about 50% of the disrupted fibers 12 are twisted with at least one other fiber. In some such embodiments, less than about 25% of the disrupted fibers 12 are twisted with at least one other fiber.

[00120] As shown in FIG. 3, the plurality of fibers 12 of a bundle 10 may extend substantially linearly along their longitudinal length. The plurality of fibers 12 of the bundle 10 may extend substantially parallel to each other along their longitudinal length. In some embodiments, the plurality of fibers of the bundle are non-texturized linear fibers, as shown in FIG. 3.

[00121] In some other embodiments, as shown in FIG. 2, the plurality of fibers 12 of a bundle 10 may extend non-linearly along their longitudinal length. In some embodiments, the plurality of fibers of the bundle extend irregularly along their longitudinal length, as shown in FIG. 2. For example, as depicted in FIG. 2, the plurality of fibers 12 of a bundle may be texturized fibers. Texturizing techniques are well known in the art, and typically disrupt the parallelization of fibers/filaments. Such techniques may serve, for example, to add bulk without adding weight, which can make the resultant fibers seem lighter in weight, have improved hand-feel (softness), appear more opaque, and/or have improved temperature insulating properties. While any art-acceptable texturizing processes may be employed, examples of texturizing processes to which the fibers 12 in the bungles 10 and inventive discrete fiberfill clusters 1 may have been subjected include crimping, looping, coiling, crinkling, twisting then untwisting and knitting then deknitting. In some embodiments, the plurality of fibers 12 of a bundle 10 and/or a discrete fiberfill cluster 1 formed thereby comprises, based on the total weight of the plurality of fibers 12, 0-100 wt% (e.g., 0, 1, 2, 3,

4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30,

31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55,

56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80,

81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100 wt%) texturized fibers, including any and all ranges and subranges therein. [00122] In some embodiments (for example, embodiments using filament yam, such as intermingled filament yarn), the invention provides a method of making the fiberfill cluster comprising: obtaining from filament yarn a bundle comprising a plurality of 25 to 3600 fibers having a denier of 0.2 to 12.0 and a length of 8 to 51 mm, the plurality of fibers being longitudinally arranged together, said fibers having a mingled nip portion wherein the plurality of fibers are entangled with each other; and subjecting the bundle to treatment to disrupt the plurality of fibers adjacent to the mingled nip portion, thereby forming the at least one outer region of fibers extending three- dimensionally outwardly from the mingled nip portion, thereby forming the fiberfill cluster.

[00123] As used herein, that the fibers are “longitudinally arranged together” refers to fibers running along the same direction as one another, whether straight, twisted, etc. The term includes texturized and nontexturized fibers, and likewise covers the fibers of filament yarn (including intermingled filament yarn having nip portions therein). For example, the intermingled filament yarn shown in FIGS. 27 and 33A, and the bundle shown in FIG. 29 all have fibers that are longitudinally arranged together.

[00124] Subjecting the bundle to treatment to disrupt the plurality of fibers comprises any manner of disrupting the parallelization/alignment of fibers adjacent to a nip portion such that the fibers are no longer longitudinally aligned and extend three-dimensionally outwardly from the nip. For example, in some embodiments, disrupting the plurality of fibers adjacent to the nip comprises subjecting the bundle to at least one stream of a gas and/or liquid. In some embodiments, the disrupting process may comprise rubbing the bundle, sanding the bundle, abrading the bundle, buffing the bundle, or subjecting the bundle to treatment using a gas and/or liquid (e.g., a stream of gas - such as air - and/or liquid, or other treatment using gas and/or liquid), or a combination thereof.

[00125] Persons having ordinary skill in the art, after reviewing this disclosure, will be readily able to select equipment capable of disrupting the plurality of fibers in the bundle (e.g., of filament), and it is contemplated that any and all such equipment may be used in the inventive method. For example, non-limiting machines that may be used include fiber or fine opening machines (e.g., Masias Maquinaria SL’s (hereinafter, “Masias”) Opener AD-160-TP, OCTIR Fine Opener, Rolando Bale Opener, Masias Recycling Opening Machine, TGB Opener-Garnett, Triitzschler Bale Opener, ), fiberball forming machines (e.g., The Bolcard or CMM Ball Fibres Forming Machine, both by Masias), etc.

[00126] In some embodiments, subjecting the bundle to treatment to disrupt the plurality of fibers adjacent to the mingled nip portion comprises subjecting the bundle to: - treatment in a fiber opening machine; treatment in a garnet machine; or air treatment.

[00127] In some embodiments, subjecting the bundle to air treatment comprises subjecting the bundle to air-tumbling, which can take place in a variety of ways including, for example, air-tumbling in a drum, in a Lorch or modified Lorch machine, or in other equipment. Non limiting examples of air-tumbling include that described in, e.g., WO 2017/058986 and U.S. Patent Nos. 6,613,431, 4,618,531 and 4,794,038.

[00128] The plurality of fibers 12 may be crimped or uncrimped. Various crimps, including spiral and standard crimp, are known in the art, and it contemplated that where the fibers are crimped, any desired crimp may be present. The plurality of fibers 12 in a bundle 10 and/or a discrete fiberfill cluster 1 formed thereby may comprise, based on the total weight of the plurality of fibers 12, 0-100 wt% (e.g., 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42,

43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67,

68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92,

93, 94, 95, 96, 97, 98, 99, or 100 wt%) crimped fibers, including any and all ranges and subranges therein.

[00129] In some embodiments, a bundle 10 of the plurality of longitudinally aligned fibers 12 has a total denier of 30 to 500 denier (e.g., 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41,

42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66,

67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91,

92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111,

112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129,

130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147,

148, 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159, 160, 161, 162, 163, 164, 165,

166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177, 178, 179, 180, 181, 182, 183,

184, 185, 186, 187, 188, 189, 190, 191, 192, 193, 194, 195, 196, 197, 198, 199, 200, 201,

202, 203, 204, 205, 206, 207, 208, 209, 210, 211, 212, 213, 214, 215, 216, 217, 218, 219,

220, 221, 222, 223, 224, 225, 226, 227, 228, 229, 230, 231, 232, 233, 234, 235, 236, 237,

238, 239, 240, 241, 242, 243, 244, 245, 246, 247, 248, 249, 250, 251, 252, 253, 254, 255,

256, 257, 258, 259, 260, 261, 262, 263, 264, 265, 266, 267, 268, 269, 270, 271, 272, 273,

274, 275, 276, 277, 278, 279, 280, 281, 282, 283, 284, 285, 286, 287, 288, 289, 290, 291,

292, 293, 294, 295, 296, 297, 298, 299, 300, 301, 302, 303, 304, 305, 306, 307, 308, 309,

310, 311, 312, 313, 314, 315, 316, 317, 318, 319, 320, 321, 322, 323, 324, 325, 326, 327,

328, 329, 330, 331, 332, 333, 334, 335, 336, 337, 338, 339, 340, 341, 342, 343, 344, 345, 346, 347, 348, 349, 350, 351, 352, 353, 354, 355, 356, 357, 358, 359, 360, 361, 362, 363,

364, 365, 366, 367, 368, 369, 370, 371, 372, 373, 374, 375, 376, 377, 378, 379, 380, 381,

382, 383, 384, 385, 386, 387, 388, 389, 390, 391, 392, 393, 394, 395, 396, 397, 398, 399,

400, 401, 402, 403, 404, 405, 406, 407, 408, 409, 410, 411, 412, 413, 414, 415, 416, 417,

418, 419, 420, 421, 422, 423, 424, 425, 426, 427, 428, 429, 430, 431, 432, 433, 434, 435, 436, 437, 438, 439, 440, 441, 442, 443, 444, 445, 446, 447, 448, 449, 450, 451, 452, 453

454, 455, 456, 457, 458, 459, 460, 461, 462, 463, 464, 465, 466, 467, 468, 469, 470, 471,

472, 473, 474, 475, 476, 477, 478, 479, 480, 481, 482, 483, 484, 485, 486, 487, 488, 489,

490, 491, 492, 493, 494, 495, 496, 497, 498, 499, or 500 denier), including all ranges and subranges therein. Denier is a unit of measure defined as the weight in grams of 9000 meters of a fiber or yam. It is a common way to specify the weight (or size) of the fiber or yam. For example, polyester fibers that are 1.0 denier typically have a diameter of approximately 10 micrometers (mm). Micro-denier fibers are those having a denier of 1.0 or less, while macro denier fibers have a denier greater than 1.0.

[00130] In some embodiments, the plurality of fibers 12 have a denier of 0.2 to 12.0 (e.g., 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3,

2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5,

4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7,

6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9,

9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, 10.0, 10.1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8,

10.9, 11.0, 11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, or 12.0 denier), including any and all ranges and subranges therein (e.g., 0.2 to 10.0 denier, 0.5 to 8.0 denier, 0.6 to 5.0 denier, 0.7 to 3.0 denier, 0.7 to 1.7 denier, etc.).

[00131] In some embodiments, the plurality of fibers 12 have an average denier of 0.2 to

12.0 (e.g., 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2,

4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4,

6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6,

8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, 10.0, 10.1, 10.2, 10.3, 10.4, 10.5, 10.6,

10.7, 10.8, 10.9, 11.0, 11.1, 11.2, 11.3, 11.4, 11.5, 11.6, 11.7, 11.8, 11.9, or 12.0 denier), including any and all ranges and subranges therein (e g., 0.5 to 8.0 denier, 0.6 to 5.0 denier, 0.7 to 3.0 denier, 0.7 to 1.7 denier, etc.).

[00132] In some embodiments, the plurality of fibers 12 in a bundle 10 and/or a discrete fiberfill cluster formed thereby comprises, based on the total weight of the plurality of fibers 12: 0-100 wt% (e.g., 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97,

98, 99, or 100 wt%) microdenier polymeric fibers 12 having a denier of less than or equal to 1.0 denier (e.g., 0.4 to 1.0 denier, such as 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, or 1.0 denier); and 0-100 wt% (e.g., 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75,

76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or

100 wt%) macrodenier polymeric fibers 12 having a denier of greater than 1.0 (e.g., 1.1 to 15.0 denier, such as 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.5, 8.0,

8.5, 9.0, 9.5, 10.0, 10.5, 11.0, 11.5, 12.0, 12.5, 13.0, 13.5, 14.0, 14.5, or 15.0 denier).

[00133] In some embodiments, the plurality of fibers 12 of a bundle 10 have a denier of about 0.7 to about 1.7. In some embodiments, the plurality of fibers 12 of a bundle 10 have substantially the same deniers. In some other embodiments, the plurality of fibers 12 of a bundle 10 have at least two differing deniers.

[00134] In some embodiments, a bundle 10 and/or discrete fiberfill cluster made therefrom may comprise 25 to 3600 individual fibers (e.g., 25, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120,

130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360, 370, 380, 390, 400, 410, 420, 430, 440, 450, 460, 470, 480, 490, 500, 510, 520, 530, 540, 550, 560, 570, 580, 590, 600, 610, 620, 630, 640, 650, 660, 670, 680, 690, 700, 710, 720, 730, 740, 750, 760, 770, 780, 790, 800, 810, 820, 830, 840, 850, 860, 870, 880, 890, 900, 910, 920, 930, 940, 950, 960, 970, 980, 990, 1000, 1010, 1020, 1030, 1040, 1050, 1060, 1070, 1080, 1090, 1100, 1110, 1120, 1130, 1140, 1150, 1160, 1170, 1180, 1190, 1200, 1210, 1220, 1230, 1240, 1250, 1260, 1270, 1280, 1290, 1300, 1310, 1320, 1330, 1340, 1350, 1360, 1370, 1380, 1390, 1400, 1410, 1420, 1430, 1440, 1450, 1460, 1470, 1480, 1490, 1500, 1510, 1520, 1530, 1540, 1550, 1560, 1570, 1580, 1590, 1600, 1610, 1620, 1630, 1640, 1650, 1660, 1670, 1680, 1690, 1700, 1710, 1720, 1730, 1740, 1750, 1760, 1770, 1780, 1790, 1800, 1810, 1820, 1830, 1840, 1850, 1860, 1870, 1880, 1890, 1900, 1910, 1920, 1930, 1940, 1950, 1960, 1970, 1980, 1990, 2000, 2010, 2020, 2030, 2040, 2050, 2060, 2070, 2080, 2090, 2100, 2110, 2120, 2130, 2140, 2150, 2160, 2170, 2180, 2190, 2200, 2210, 2220, 2230, 2240, 2250, 2260, 2270, 2280, 2290, 2300, 2310, 2320, 2330, 2340, 2350, 2360, 2370, 2380, 2390, 2400, 2410, 2420, 2430, 2440, 2450, 2460, 2470, 2480, 2490, 2500, 2510, 2520, 2530, 2540, 2550, 2560, 2570, 2580, 2590, 2600, 2610, 2620, 2630, 2640, 2650, 2660, 2670, 2680, 2690, 2700, 2710, 2720, 2730, 2740, 2750, 2760, 2770, 2780, 2790, 2800, 2810, 2820, 2830, 2840, 2850, 2860, 2870, 2880, 2890, 2900, 2910, 2920, 2930, 2940, 2950, 2960, 2970, 2980, 2990, 3000,

3010, 3020, 3030, 3040, 3050, 3060, 3070, 3080, 3090, 3100, 3110, 3120, 3130, 3140, 3150,

3160, 3170, 3180, 3190, 3200, 3210, 3220, 3230, 3240, 3250, 3260, 3270, 3280, 3290, 3300,

3310, 3320, 3330, 3340, 3350, 3360, 3370, 3380, 3390, 3400, 3410, 3420, 3430, 3440, 3450,

3460, 3470, 3480, 3490, 3500, 3510, 3520, 3530, 3540, 3550, 3560, 3570, 3580, 3590, or 3600 fibers), including any and all ranges and subranges therein (e.g., 50 to 500 fibers, 80 to 300 fibers, etc.).

[00135] In some embodiments, a discrete bundle 10 comprises about 25 to 3600 fibers 12.

In some embodiments, a discrete bundle 10 comprises about 50 to about 500 fibers. In some embodiments, a discrete bundle 10 comprises about 80 to about 300 fibers. As noted above, a fiberflll cluster 1 formed from a bundle 10 may include several more fibers 12 than the bundle 10 that forms the fiberflll cluster 1, or several less fibers 12 than the bundle 10 that forms the fiberflll cluster 1, due to the nature or mechanics of the disrupting process.

[00136] In some embodiments, the plurality of fibers 12 of a bundle 10 and/or a fiberflll cluster 1 formed thereby have a length of 8 to 160 mm (e.g., 8, 9, 10, 11, 12, 13, 14, 15, 16, 17,

18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42,

43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67,

68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92,

93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145, 146, 147, 148, 149, 150, 151,

152, 153, 154, 155, 156, 157, 158, 159, or 160 mm), including any and all ranges and subranges therein (e.g., 8 to 75 mm, 15 to 115 mm, 20 to 50 mm, etc.). In some embodiments, the plurality of fibers 12 of a bundle 10 and/or a cluster 1 formed thereby have a longitudinal length of about 20 to about 50 mm. In some embodiments, the plurality of fibers 12 of a bundle 10 and/or a cluster 1 formed thereby have substantially the same longitudinal lengths. [00137] In some embodiments, the plurality of fibers we comprise polymeric fibers.

[00138] In some embodiments, the plurality of fibers we comprise synthetic polymeric fibers. It is within the purview of the person having ordinary skill in the art to select an appropriate polymeric material for polymeric fibers comprised within the inventive discrete fiberflll cluster 1, and it is contemplated that any such material may be used in embodiments of the invention. However, in particular embodiments, nonexclusive polymers that may be used in polymeric fiber are selected from nylon, polyester, polypropylene, polylactic acid (PLA), poly(butyl acrylate) (PBA), polyamide (e.g., nylon/polyamide 6.6, polyamide 6, polyamide 4, polyamide 11, and polyamide 6.10, etc.), acrylic, acetate, polyolefin, rayon, lyocell, aramid, spandex, viscose, modal fibers, biopolymer fibers (e g , polyhydroxyalkanoates (PHA), poly- (hydroxybutyrate-covalerate) (PHBV)), protein-based synthetic material fibers (e.g., plant- based artificial protein fiber materials, Spiber, etc.), and combinations thereof. In some embodiments, the fiber comprises polyester selected from poly(ethylene terephthalate) (PET), poly(hexahydro-p-xylylene terephthalate), poly(butylene terephthalate) (PBT), poly- 1,4- cyclohexelyne dimethylene (PCDT), polytrimethylene terephthalate (PTT), and copolyesters, such as terephthalate copolyesters in which at least 30 mole percent (e.g., at least 35, 36, 37,

38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62,

63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, or 85 mole percent) of the ester units are ethylene terephthalate or hexahydro-p-xylylene terephthalate units.

[00139] In some embodiments, the fibers 12 comprise virgin polymer material. In some embodiments, the fibers 12 comprise recycled polymer material, such as post-consumer recycled (PCR) polymer material.

[00140] Of the fibers in the plurality of fibers 12, 0 to 100 wt% (e.g., 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83,

84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 100 wt%) may be siliconized, including any and all ranges and subranges therein (e g., 0%, 50%, 100%, etc.).

[00141] Siliconization techniques are well known in the art. The term “siliconized” means that the fiber is coated with a silicon-comprising composition (e.g., a silicone). Siliconization techniques are well known in the art, and are described, e.g., in U.S. Patent No. 3,454,422. The silicon-comprising composition may be applied using any method known in the art, e.g., spraying, mixing, dipping, padding, etc. The silicon-comprising (e.g., silicone) composition, which may include an organosiloxane or polysiloxane, bonds to an exterior portion of the fiber. In some embodiments, the silicone coating is a polysiloxane such as a methylhydrogenpolysiloxane, modified methylhydrogenpolysiloxane, polydimethylsiloxane, or amino modified dimethylpolysiloxane. As is known in the art, the silicon-comprising composition may be applied directly to the fiber, or may be diluted with a solvent as a solution or emulsion, e.g., an aqueous emulsion of a polysiloxane, prior to application. Following treatment, the coating may be dried and/or cured. As is known in the art, a catalyst may be used to accelerate the curing of the silicon-comprising composition (e.g., polysiloxane containing Si — H bonds) and, for convenience, may be added to a silicon comprising composition emulsion, with the resultant combination being used to treat the synthetic fiber. Suitable catalysts include iron, cobalt, manganese, lead, zinc, and tin salts of carboxylic acids such as acetates, octanoates, naphthenates and oleates. In some embodiments, following siliconization, the fiber may be dried to remove residual solvent and then optionally heated to between 65° and 200° C to cure.

[00142] In some embodiments, the plurality of fibers 12 of a bundle 10 and/or a discrete fiberfill cluster 1 formed thereby comprises, based on the total weight of the plurality of fibers 12, 0-100 wt% (e.g., 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20,

21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45,

46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70,

71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95,

96, 97, 98, 99, or 100 wt%) of polymeric fibers containing one or more additives (e.g., aerogel, as described in U.S. Publication No. U.S. 2018-0313001, microcapsules, as described in U.S. Publication No. U.S. 2020-0141029, etc.), including any and all ranges and subranges therein.

[00143] In some embodiments, the plurality of fibers comprises, based on the total weight of the plurality of fibers, 0-100 wt% (e.g., 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16,

17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41,

42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66,

67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91,

92, 93, 94, 95, 96, 97, 98, 99, or 100 wt%), including any and all ranges and subranges therein, of fibers that are doped with a desirable chemistry. As used herein, the term “doped” refers to the presence of one or more desirable dopants (which may also be referred to as a chemistries) which have been incorporated into the fiber (e.g., within the polymer matrix of polymeric fiber). In some embodiments, the dopants/chemistries are homogenously dispersed within the fiber matrix.

[00144] Desirable fiber surface chemistries are known in the art. While embodiments of the invention include fibers having surface chemistries applied to their surface (e.g., siliconization, as discussed above), the plurality of fibers may also (and/or alternatively) be formed to include desirable chemistries therein. For example, in some embodiments, the plurality of fibers have been doped with durable water repellency (DWR) and/or silicone chemistries. This can be accomplished, for example, but adding desirable chemistries to liquid polymer during a melt-spinning process before fiber is formed after the liquid polymer is passed through a spinneret, and/or by functionalizing polymer(s) that form the plurality of fibers.

[00145] In some embodiments, the plurality of fibers are doped with DWR chemistry and have certain desirable performance attributes as a result thereof. For example, in some embodiments, DWR-doped fibers have a surface that remains dry and/or have a high coefficient of friction that is ideal for clusterization of the fiber but also have low water adsorption less of than 150 wt% for wet thermal performance and/or improved launderability. [00146] Binder fibers are well known in the art, and typically have a bonding temperature lower than the softening temperature of one or more other polymeric fiber constituents in a product (e.g., fiberfill). In some embodiments, the plurality of fibers 12 of a bundle 10 and/or a discrete fiberfill cluster 1 formed thereby do not contain binder fibers (i.e., are void of binder fibers), or contains less than 5 wt% binder fibers (e g., less than 5, 4, 3, 2, or 1 wt%). [00147] The fibers used in the plurality of fibers 12 may have any desired shape for a cross section (e.g., circular or other).

[00148] The plurality of fibers 12 may comprise, based on the total weight of the plurality of fibers 12, 0-100 wt% (e.g., 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20,

21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45,

46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70,

71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95,

96, 97, 98, 99, or 100 wt%) solid fibers, including any and all ranges and subranges therein. The plurality of fibers 12 may comprises, based on the total weight of the plurality of fibers,

0-100 wt% (e.g., 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22,

23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47,

48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72,

73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97,

98, 99, or 100 wt%) hollow fibers, including any and all ranges and subranges therein. In some embodiments, the plurality of fibers 23 comprises splittable fibers.

[00149] Embodiments of the inventive fiberfill cluster are blowable using conventional equipment, or for short, “blowable”. “Blowable” is a term that is commonly used in the textile industry, and persons having ordinary skill in the art readily understand what “blowable using conventional equipment” means. The term “blowable” refers to a material’s ability to be readily processed through conventional blowing (or “blow injecting”) equipment, and injected therefrom as insulation into an article (e.g., pockets, channels, or baffles of clothing, bedding, sleeping bags, etc.). For example, the light, discrete structure of down and embodiments of the inventive fiberfill cluster make them very amenable for blowing using conventional equipment, whereas many other fiberfill materials clump, stick to one another, jam conventional equipment, or result in other processing difficulties, and thus are not blowable. It is well within the purview of those skilled in the textile industry to determine whether a material is blowable, and if there is a question as to blowability, it is easily answered by testing the material on conventional equipment. Conventional blowing equipment is described, for example, in U S. Patent No. 6,329,051. Consistent with the disclosure ofU.S. Patent No. 6,329,051, conventional equipment for blowing typically includes a blowing system that has a means (e.g., a duct) for material uptake (e g., through a metering system that may receive material from, e.g., a tank such as a mixing tank).

Blowable material is able to readily pass through the means for material uptake without clogging, or causing other problems, such as prohibitive static resistance. The material is then blown via a nozzle into its intended destination. It is well known in the art that if material cannot be processed on conventional blowing equipment for use in articles, then it is not “blowable using conventional equipment” (or “blowable”).

[00150] The fiberfill clusters 1 may form, at least generally, a regular or irregular shape. It has been discovered that the configuration of the longitudinal arrangement disrupting process (such as the amount of time of the disrupting, the mechanism of the disrupting, and the pattern of the disrupting) and the configuration of the bundle 10 (such as the number of fibers 12, the texture/non-texture of the fibers 12, and the lengths of the fiber 12) may affect the as- formed shape of the clusters 1. For example, as shown in FIGS. 6-26, a fiberfill cluster 1 may have an elongated shape, such as an ovoidal or elliptical shape. In some embodiments, a fiberfill cluster 1 may have a substantially spherical shape.

[00151] In some embodiments, the fiberfill clusters 1 may defines a length LI, a width W1 and a thickness Tl. As the fiberfill clusters 1 are formed by protruding or extended fiber 12, the dimensions of the fiberfill clusters 1 may be defined by the furthest extents of the fibers 12, and average of the extents of the fibers 12 or an approximation of the average of the extents of the fibers 12. For example, the dimensions of the fiberfill clusters 1 may be measured by disregarding the 3, 5, 10 or 15 fibers 12 that extents to the furthest extent along a particular dimension or direction.

[00152] In some embodiments, the length LI and width W 1 may be greater than the thickness Tl, as shown in FIGS. 14 and 15. In some such embodiments, the length LI may be greater than the width Wl, as also shown in FIGS. 14 and 15. In some embodiments, a discrete fiberfill cluster 1 may have a length LI of 0.5 cm to 6.5 cm (e.g., 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9,

3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0,

5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, or 6.5 cm), including any and all ranges and subranges therein (e.g., 0.90 to 4 cm).

[00153] In some embodiments, a fiberfill cluster 1 may have a width Wl of 0.5 cm to 6.5 cm (e.g., 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3,

2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4,

4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, or 6.5 cm), including any and all ranges and subranges therein (e.g., 0.70 to 3 cm). [00154] In some embodiments, a fiberfill cluster may have a thickness (or height) T1 of 0.70 to 4 cm (e.g., 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, or 4.0 cm), including any and all ranges and subranges therein. In some embodiments, a fiberfill cluster 1 may define a length LI within the range of about 0.90 to about 4 cm. In some embodiments, a fiberfill cluster 1 may define a width LI that is within the range of about 0.70 to about 3 cm.

[00155] In some embodiments, the inventive discrete fiberfill clusters 1 may have a volume of 0.125 to 12 cm ³ (e.g., 0.125, 0.15, , 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3,

1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4,

3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5,

5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6,

7.7, 7.8, 7.9, 8.0, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9.0, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7,

9.8, 9.9, 10.0, 10.1, 10.2, 10.3, 10.4, 10.5, 10.6, 10.7, 10.8, 10.9, 11.0, 11.1, 11.2, 11.3, 11.4,

11.5, 11.6, 11.7, 11.8, 11.9, or 12.0 cm ³ ), including any and all ranges and subranges therein (e.g., 0.80 to 12 cm ³ ).

[00156] In some embodiments, the inventive discrete fiberfill clusters may have a weight of

0.2 to 3 mg (e.g., 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8,

1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, or 3.0 mg), including any and all ranges and subranges therein.

[00157] In some embodiments, the inventive discrete fiberfill clusters may have a density of 0.08 to 0.70 mg/cm ³ (e.g., 0.08, 0.09, 0.10, 0.11, 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18, 0.19,

0.20, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28, 0.29, 0.30, 0.31, 0.32, 0.33, 0.34, 0.35,

0.36, 0.37, 0.38, 0.39, 0.40, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, 0.50, 0.51,

0.52, 0.53, 0.54, 0.55, 0.56, 0.57, 0.58, 0.59, 0.60, 0.61, 0.62, 0.63, 0.64, 0.65, 0.66, 0.67,

0.68, 0.69, or 0.70 mg/cm ³ ), including any and all ranges and subranges therein (e g., 0.10 to

0.50 mg/cm ³ ).

[00158] As shown in FIGS. 6-9, 14, 15 and 20-26, in one aspect of the present disclosure, inventive discrete fiberfill clusters 1 that include the remnant portion 16 and the outer region 18 are provided. As explained above, the remnant portion 16 of the clusters 1 is a portion of the bundle 10 of fibers 12 after some of the fibers 12 thereof were disrupted or removed from the bundle 10 (via the disrupting process). In this way, the remnant portion 16 is a remnant of the bundle 10 itself. It is noted, however, that the shape, size and/or configuration of the bundle 10 may be modified by the disrupting process to form the remnant portion 16. For example, the disrupting process may bend or shape the bundle 10 into a non-linear shape, such as into the various nonlinear shapes shown in FIGS. 6-9, 14, 15 and 20-26. However, in some embodiments, remnant portion 16 may extend substantially linearly (along its longitudinal length). As another example, the disrupting process may act to open up the bundle 10 such that the fibers 12 thereof are less densely populated or closely situated/spaced as compared to the pre-disrupted bundle 10. For example, as shown in FIG. 7 and 8, the disrupting process may act to substantially open up the bundle 10, such as compared to other cluster 1 shown in FIGS. 6 and 9 where the disrupting process may act to only slightly open up the bundle 10.

[00159] As also shown in FIGS. 6-9, 14, 15 and 20-26 and described above, the disrupting process disrupts some of the plurality of fibers 12 of the bundle 10 such that they extend three-dimensionally from the remnant portion 16 to form the outer portion or region 18. The disrupted fibers 12 forming the outer region 18 are intermingled (and potentially entangled and twisted, to some extent) with each other and/or the fibers 12 of the remnant portion 16 such that the discrete fiberfill cluster 1 are formed, and that they stay together as a single discrete unit during use (and laundering, for example) thereof. As shown in FIGS. 6-9, 14,

15 and 20-26 the outer region 18 is substantially less densely populated with fiber 12 than the bundle remnant portion 16 (i.e., the bundle remnant portion 16 is more densely populated with fibers 12 than the outer region 18). The combination of the bundle remnant portion 16 and the outer region 18, surprisingly and/or unexpectedly, form a discrete fiberfill cluster 1 that closely emulates down in terms of blowability, size, weight, and/or density, and other properties, while at the same time providing for improved use and launderability as compared to down.

[00160] As shown in FIG. 6, in some embodiments, the remnant portion 16 may be substantially long, such as at least about 75% of the length of the fiberfill cluster 1. In some other embodiments, as shown in FIG. 9, the remnant portion 16 may be substantially short, such as at less than about 75% of the length of the fiberfill cluster 1. In some other embodiments, as shown in FIGS. 7 and 8, the remnant portion 16 may about 25% to about 75% the length of the fiberfill cluster 1.

[00161] As shown in FIGS. 10-13 and 16-29, in one aspect of the present disclosure, inventive discrete fiberfill clusters 1 that do not include a remnant portion 16, but rather at least one inner relatively densely populated region 14 of fibers 16 and an outer relatively 18 less densely population region of fibers 12 extending three-dimensionally outwardly from the at least one inner relatively densely populated region. The fibers 12 of the inner relatively densely populated region 14 extends randomly/non -uniformly, and intermingle with each other randomly/non-uniformly, and are thus not arranged together along their longitudinal lengths (i.e., longitudinally arranged together) as in the remnant portion 16, as shown in FIGS. 10-13 and 16-29. The disrupting process thereby removes or disrupts all of the longitudinal arrangement of the fibers 12 of the bundle 10, and intermingles (and potentially entangles and twists, to some extent) the fibers 12 with each other and such that the discrete fiberfill cluster 1 is formed with the inner relatively densely populated region 14 and the outer relatively less densely population region 18, as shown in FIGS. 10-13 and 16-29. The fibers 12 of the inner relatively densely populated region 14 and the outer relatively less densely population region 18 are intermingled (and potentially entangled and twisted, to some extent) the with each other so that they form the discrete fiberfill clusters 1 that stays together as a single discrete unit during use (and laundering, for example) thereof.

[00162] As shown in FIG. 10, in some embodiments, a discrete fiberfill cluster 1 may include a gradual transition between the inner relatively densely populated region 14 and the outer relatively less densely population region 18. Alternatively, as shown in FIGS. 11-13, in some embodiments, a discrete fiberfill cluster 1 may include a more defined or identifiable variation or border between the inner relatively densely populated region 14 and the outer relatively less densely population region 18.

[00163] As shown in FIGS. 11 and 12, in some embodiments the inner relatively densely populated region 14 and the outer relatively less densely population region 18 may be about the same size (e.g., three-dimensional size, e.g., length, width and/or thickness). Conversely, as shown in FIG. 13, in some embodiments the inner relatively densely populated region 14 may be a substantially smaller size (e.g., three-dimensional size, e.g., length, width and/or thickness) than the outer relatively less densely population region 18.

[00164] In some embodiments, as shown in FIG. 11, the inner relatively densely populated region 14 may be a slightly more densely populated than the outer relatively less densely population region 18 (e.g., less than about 50% more densely populated). Conversely, as shown in FIG. 12, in some embodiments the inner relatively densely populated region 14 may be a substantially more densely populated than the outer relatively less densely population region 18 (e.g., greater than about 50% more densely populated).

[00165] In some embodiments, the invention provides a fiberfill cluster comprising: a plurality of fibers comprising 25 to 3600 fibers having a denier of 0.2 to 12.0 and a length of 8 to 76 mm, said plurality of fibers being cut from filament yarn (e.g., intermingled filament yarn), wherein the plurality of fibers form: a mingled nip portion wherein the plurality of fibers are entangled with each other; and at least one outer region of fibers extending three- dimensionally outwardly from the mingled nip portion wherein the plurality of fibers are randomly and non-uniformly oriented with respect to one another, and wherein the mingled nip portion has a higher density of fibers than the at least one outer region. Such embodiments may correspond, for example, to the second or third aspects of the invention, wherein the mingled nip portion represents the fiber bundle remnant or the at least one inner relatively densely populated region of fibers, respectively. [00166] A filament is a single long threadlike continuous textile fiber/strand. Unlike staple fibers, which are of finite length, filaments are of indefinite length, and can mn for yards or miles (or e.g., where employed in yarn, can mn the entire length of yam). In some embodiments, the filament ranges in length from 5 inches to several miles, including any and all ranges and subranges therein. For example, in some embodiments, the filament may be at least 5 inches in length (e.g., at least 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21,

22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46,

47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71,

72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96

97, 98, 99, or 100 inches in length, or any range or subrange therein). In some embodiments, the filaments may be at least 1 foot in length (e.g., at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12,

13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37,

38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62,

63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87,

88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290, 300, 310, 320, 330, 340, 350, 360,

370, 380, 390, 400, 410, 420, 430, 440, 450, 460, 470, 480, 490, 500, 510, 520, 530, 540,

550, 560, 570, 580, 590, 600, 610, 620, 630, 640, 650, 660, 670, 680, 690, 700, 710, 720,

730, 740, 750, 760, 770, 780, 790, 800, 810, 820, 830, 840, 850, 860, 870, 880, 890, 900,

910, 920, 930, 940, 950, 960, 970, 980, 990, or 1000 feet in length, or any range or subrange therein).

[00167] Filament yam is yam composed of a plurality of continuous filaments assembled with or without twist.

[00168] In some embodiments, the plurality of fibers are cut from intermingled filament yarn, which is described, for example, in Baykal et al, “The effects of intermingling process parameters and number of filaments on intermingled”, The Journal of The Textile Institute,

2013.

[00169] Intermingled filament yarn is typically formed by subjecting filament yarn (or a pre yarn form thereof, e.g., a plurality of longitudinally aligned filaments) to an air intermingling process that uses an air jet to form intermittent mingled nip portions (also referred to herein as “nips” or “nip portions”), which are knot-like entangled nodes in the yarn, thereby imparting interfilament cohesion. In another embodiment of intermingled yam, the nip is formed by, e.g., a pulse laser (as opposed to an air jet), which forms a fused nip having fibers bound to one another (from at least partial melting of fibers in the nip) as opposed to an entangled nip. Such embodiments of intermingled yarn can also be used in the invention. In some such embodiments, bound, and/or at least partially melted fibers are only present in one or more nip portions of the inventive cluster.

[00170] FIG. 27 is an enlarged photograph of a portion of texturized intermingled filament yarn 100, which has a plurality of intermittent nips 42, which are equally spaced apart in the yarn. The depicted filament yam 100 has 99 nips per meter, which equates to about 1 nip every 10.1 mm in the length of yarn. Nips are separated from one another by open portions 44.

[00171] In some embodiments of the invention, the filament yarn has evenly spaced apart nips at a nip frequency of 13 to 125 nips per meter (e.g., 13, 14, 15, 16, 17, 18, 19, 20, 21, 22,

23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47,

48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72,

73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97,

98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116,

117, 118, 119, 120, 121, 122, 123, 124, or 125 nips per meter), including any and all ranges and subranges therein.

[00172] FIG. 28 is a simplified schematic showing a loose bundle of flat filament yam 48 which is composed of a plurality of filaments 12, which is subjected to air intermingling to form intermingled filament yam 100 having evenly spaced apart intermittent nips 42 separated by open portions 44, wherein the nips and open portions are composed of the plurality of filaments 12.

[00173] The nips in embodiments of intermingled filament yarn (and likewise in the inventive fiberfill cluster) have an entangled structure that imparts interfilament cohesion to the yam. The structure of some nip embodiments has been analyzed and discussed by Miao et ah, “Air interlaced yarn structure and properties”, Textile Research Journal , 65, 433-440, 1995. Of course, where intermingled filament yarn is made using, e.g., a pulse laser, nips do not have an entangled structure, but rather a structure wherein a plurality of filaments are bound to one another.

[00174] In some embodiments, nips have a size of 0.1 mm to 8 mm (e.g., 0.1, 0.2, 0.3, 0.4,

0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5,

2.6, 2.7, 2.8, 2.9, 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4.0, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6,

4.7, 4.8, 4.9, 5.0, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7,

6.8, 6.9, 7.0, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, or 8.0 mm), including any and all ranges and subranges therein (e g., 0.4 to 3 mm, 0.5 to 2.5 mm, etc.).

[00175] FIG. 29 is an enlarged photograph of an embodiment of a cut section (“bundle”) of intermingled filament yarn 140, which has a single nip 42. Such cut sections, which may be referred to as bundles, are subjected to treatment to disrupt the plurality of fibers 12 adjacent a nip portion, thereby forming the inventive fiberfill cluster.

[00176] FIG. 30 is an enlarged photograph of an embodiment of an inventive fiberfill cluster 160 having a single nip 42. FIG. 31 is an enlarged photograph of another embodiment of an inventive fiberfill cluster 180 having a single nip 42. As is apparent, while the cluster embodiment of FIG. 4 has a nip at the center of the bundle, the cluster embodiment of FIG. 5 has a nip at an outer portion of the bundle. The nip may be located at any location along the length of the bundle. Also as shown, the inventive fiberfill clusters are discrete clusters, meaning they are individually separate and distinct clusters.

[00177] In embodiments of the invention, sections of filament yam are cut to have one or two nips per section, thus resultant fiberfill clusters likewise have one or two nips. In a preferred embodiment, sections are cut to have a single nip, thus resultant fiberfill clusters have a single nip.

[00178] FIG. 32 is an enlarged photograph of an embodiment of an inventive fiberfill cluster 200 having two nips 42.

[00179] FIG. 33 A is an enlarged photograph of intermingled filament yam (left) and a plurality of fiberfill clusters according to an embodiment of the invention formed therefrom. FIGS. 33B and 33C are enlarged photographs of the fiberfill clusters from FIG. 33A. The yarn shown in FIG. 33A is 300 denier intermingled filament yam (formed by an air jet that entangles the nip portion) that is made up of a plurality of fibers - specifically, 288 filaments (each filament having a denier of 1.04). The yarn was cut into bundles of equal length which were subjected to treatment to disrupt the plurality of fibers adjacent to a mingled nip portion in each bundle, thereby forming the depicted clusters.

[00180] As discussed herein, after the filament yarn is cut into one or more bundles such as bundle 140 shown in FIG. 29 (wherein such bundles may be considered embodiments that correspond to bundle 10), the bundle(s) are subjected to treatment to disrupt the plurality of fibers adjacent to a nip, thereby forming at least one outer region of fibers extending three- dimensionally outwardly from the nip. In the at least one outer region of fibers, the plurality of fibers are randomly and non-uniformly oriented with respect to one another. The nip portion has a higher density of fibers than the at least one outer region. Referring to FIG. 30, two outer regions of fibers 46 extend three-dimensionally outwardly from the nip 42. FIG. 34 is a drawing showing a process of cutting intermingled filament yarn to form a bundle that is disrupted to form a fiberfill cluster 24 having two outer regions of fibers extending three- dimensionally outwardly from the nip (indicated by dashed lines).

[00181] FIG. 35 is a drawing of an inventive cluster embodiment from a bundle that was cut with the nip at a far end therefrom. [00182] As discussed above, in some embodiments of the invention, the fiberfill cluster is formed from intermingled filament yarn. For example, in some embodiments, the fiberfill cluster is formed from texturized intermingled filament yarn, and thus the plurality of fibers in the cluster are texturized. In other embodiments, the fiberfill cluster is formed from non- texturized intermingled filament yam, and thus the plurality of fibers in the cluster are non- texturized.

[00183] In some embodiments of the inventive fiberfill cluster, as a result of fiber entanglement in the nip, the plurality of fibers in the mingled nip portion extend non-linearly along their longitudinal length. It is because of both the entanglement in the nip and the disruption of fibers after a bundle is cut, that the nip has a higher density of fibers than the at least one outer region.

[00184] In some embodiments, the invention provides a plurality of fiberfill clusters as described herein.

[00185] In some embodiments of the plurality of fiberfill clusters, at least 90% of the fiberfill clusters (e g., at least 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 99.5%) have the same number of fibers therein, or the same number of fibers within ±10% of the average number of fibers (e.g., ± 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1% of the average number of fibers in the plurality of fiberfill clusters). In some embodiments of the plurality of fiberfill clusters, 100% of the clusters have the same number of fibers therein, or the same number of fibers within ±10% of the average number of fibers.

[00186] In some embodiments of the plurality of fiberfill clusters, at least 90% of the fiberfill clusters (e g., at least 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 99.5%) have the same length fibers therein. In some embodiments of the plurality of fiberfill clusters, 100% of the clusters have the same length fibers therein.

[00187] In some embodiments of the plurality of fiberfill clusters, at least 90% of the fiberfill clusters (e g., at least 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, or 99.5%) have only one bundle remnant portion (or nip) therein.

[00188] In another aspect of the present disclosure, insulation or filling material comprising a plurality of the inventive fiberfill clusters is provided. The insulation or filling material may be formed of (e g., comprise, consist essentially of, or consist of) a plurality of the discrete fiberfill clusters 1 with the remnant portion 16 and the outer region 18 and/or the plurality of the discrete fiberfill clusters 1 with the inner region 14 and the outer region 18. [00189] In some embodiments, the insulation or filling material is formed of (e g., comprise, consist essentially of, or consist of) a plurality of the discrete fiberfill clusters 1 with the remnant portion 16 and the outer region 18. In some embodiments, the insulation or filling material is formed of (e.g., comprise, consist essentially of, or consist of) a plurality of the discrete fiberfill clusters 1 with the inner region 14 and the outer region 18.

[00190] In some embodiments, the plurality of fiberfill clusters 1 of the insulation or filling material may include first fiberfill clusters 1 formed of fibers 12 of a first length and second fiberfill clusters 1 formed of fibers 12 of a second length that differs from the first length. In some embodiments, the plurality of fiberfill clusters 1 of the insulation or filling material may include first clusters 1 formed of a first total number of fibers 12 and second clusters formed of a second total number of fibers 12 that differs from the first total number of fibers.

[00191] In some embodiments, the plurality of fiberfill clusters 1 of the insulation or filling material may include first fiberfill clusters 1 formed of fibers 12 of a first synthetic material and second fiberfill clusters 1 formed of fibers 12 of a second synthetic material that differs from the first synthetic material. Similarly, in some embodiments, the plurality of fiberfill clusters 1 of the insulation or filling material may include first fiberfill clusters 1 formed of fibers 12 of a first denier and second fiberfill clusters 1 formed of fibers 12 of a second denier that differs from the first denier.

[00192] In some embodiments, the plurality of fiberfill clusters 1 of the insulation or filling material may include fiberfill clusters 1 of a first size and fiberfill clusters 1 of a second size that differs from the first size. Similarly, in some embodiments, the plurality of fiberfill clusters 1 of the insulation or filling material may include fiberfill clusters 1 of a first three dimensional shape and fiberfill clusters 1 of a second three dimensional shape that differs from the first three dimensional shape. In some embodiments, the plurality of fiberfill clusters 1 of the insulation or filling material may include fiberfill clusters 1 that are within a first density range and fiberfill clusters 1 that are within a second density range that that differs from and does not overlap with the first density range.

[00193] In another aspect of the present disclosure, an article comprising the insulation or filling material (i.e., a plurality of the discrete fiberfill clusters 1) is provided. In some embodiments, the article is selected from footwear, outerwear, clothing, a sleeping bag, and bedding. In some embodiments, the article is a home furnishing item (e.g., bedding, such as a comforter or quilt, pillow, cushion, upholstered chair, etc ).

CLAUSES

[00194] Non-limiting embodiments of the present invention are described in the following clauses.

[00195] Clause 1. A method of making at least one discrete fiberfill cluster, the method comprising: obtaining a discrete bundle of a plurality of 25 to 3600 fibers having a denier of 0.2 to 12.0 and a length of 8 to 160 mm, the plurality of fibers being longitudinally arranged together; and disrupting the longitudinal arrangement of at least some of the plurality of fibers of the bundle such that they extend irregularly three-dimensionally and intermingle to form a discrete fiberfill cluster.

[00196] Clause 2. The method according to clause 1, wherein disrupting the longitudinal arrangement of at least some of the plurality of fibers of the bundle comprises disrupting the longitudinal arrangement of only some of the plurality of fibers of the bundle such that a bundle remnant portion of the plurality of fibers of the bundle remain longitudinally arranged together and are intermingled with the fibers that extend irregularly three-dimensionally. [00197] Clause 3. The method according to clause 2, wherein the fibers that extend irregularly three-dimensionally form an outer region that extends outwardly from the bundle remnant portion.

[00198] Clause 4. The method according to clause 3, wherein the bundle remnant portion comprises a higher density of fibers than the outer region.

[00199] Clause 5. The method according to clause 1, wherein disrupting the longitudinal arrangement of at least some of the plurality of fibers of the bundle comprises disrupting the longitudinal arrangement of all of the plurality of fibers of the bundle such that none of the plurality of fibers remain longitudinally arranged together.

[00200] Clause 6. The method according to clause 5, wherein disrupting the longitudinal arrangement of all of the plurality of fibers of the bundle forms at least one inner relatively densely populated three-dimensional region of fibers, and an outer relatively less densely population region of fibers extending three-dimensionally outwardly from the at least one inner relatively densely populated region.

[00201] Clause 7. The method according to any one of the preceding clauses, wherein disrupting the longitudinal arrangement of at least some of the plurality of fibers of the bundle comprises intermingling only some of the disrupted fibers such that some of the disrupted fibers form a fiberfill cluster and some of the disrupted fibers do not form a fiberfill cluster.

[00202] Clause 8. The method according to any one of the preceding clauses, wherein the disrupting of the longitudinal arrangement of at least some of the plurality of fibers of the bundle comprises positioning the bundle between engagement sides of at least a pair of disrupting members such that the disrupting sides contact the bundle, and translating at least one first disrupting member with respect to at least one second disrupting member along a pathway that extends both longitudinally along a longitudinal of the fibers of the bundle and laterally along a lateral direction oriented perpendicular to the longitudinal direction.

[00203] Clause 9. The method according to clause 8, wherein a distance between the disrupting sides remains substantially constant during the disrupting.

[00204] Clause 10. The method according to clauses 8 or 9, wherein: the at least one first disrupting member translates along an arcuate pathway for at least a first portion of time; and/or the at least one first disrupting member translates along an elliptical pathway for at least a first portion of time; and/or the at least one first disrupting member translates along a random orbital pattern for at least a first portion of time; and/or at least one of the engagement sides comprises a substantially flat and smooth surface; and/or at least one of the engagement sides comprises a substantially planar array of particles or projections.

[00205] Clause 11. The method according to any one of clauses 8-10, wherein the disrupting of the longitudinal arrangement of at least some of the plurality of fibers of the bundle comprises subjecting the bundle to at least one stream of a gas and/or liquid.

[00206] Clause 12. The method according to any one of clauses 8-11, wherein the discrete bundle is obtained from filament yam, and is a bundle comprising a plurality of 25 to 3600 fibers having a denier of 0.2 to 12.0 and a length of 8 to 76 mm, the plurality of fibers being longitudinally arranged together, said fibers having a mingled nip portion wherein the plurality of fibers are entangled with each other; and wherein said disrupting the longitudinal arrangement disrupts the plurality of fibers adjacent to the mingled nip portion, thereby forming at least one outer region of fibers extending three-dimensionally outwardly from the mingled nip portion, wherein, following said disrupting, the plurality of fibers are randomly and non-uniformly oriented with respect to one another, and the mingled nip portion, which corresponds to a bundle remnant portion of the plurality of fibers, has a higher density of fibers than the at least one outer region.

[00207] Clause 13. The method according to clause 12, wherein said disrupting the longitudinal arrangement comprises subjecting the bundle to: treatment in a fiber opening machine; treatment in a garnet machine; or air treatment.

[00208] Clause 14. The method according to clause 13, wherein subjecting the bundle to air treatment comprises subjecting the bundle to air-tumbling. [00209] Clause 15. The method according to any one of clauses 12 to 14, wherein:

[00210] the plurality of fibers forming the fiberfill cluster are from a segment of intermingled filament yarn, and the mingled nip portion of the cluster corresponds to a mingled nip portion of the intermingled filament yam;

[00211] the plurality of fibers in the mingled nip portion extend non-linearly along their longitudinal length; and

[00212] no fibers within the cluster are bonded together.

[00213] Clause 16. The method according to any one of clauses 1 to 14, further comprising, prior to the disrupting, bonding at least some of the plurality of fibers of the bundle together at at least one point along the longitudinal length of the bundle to form at least one bonding point.

[00214] Clause 17. The method according to clause 16, wherein the bonding point is formed by heating at least some of the plurality of fibers at the at least one point to adhere the fibers together at the at least one bonding point.

[00215] Clause 18. The method according to clause 17, wherein the heating of at least some of the plurality of fibers at the at least one point comprises contacting the plurality of fibers at the at least one point with a material that is at a temperature that is above the melting temperature of the fibers.

[00216] Clause 19. The method according to any one of the preceding clauses, wherein disrupting the longitudinal arrangement of at least some of the plurality of fibers of the bundle comprises entangling some of the disrupted fibers together.

[00217] Clause 20. The method according to clause 19, wherein less than about 50% of the disrupted fibers (e.g., less than about 25%) are entangled with at least one other fiber.

[00218] Clause 21. The method according to any one of the preceding clauses, wherein disrupting the longitudinal arrangement of at least some of the plurality of fibers of the bundle comprises twisting some of the disrupted fibers together.

[00219] Clause 22. The method according to clause 21, wherein less than about 50% (e.g., less than about 25%) of the disrupted fibers are twisted with at least one other fiber.

[00220] Clause 23. The method according to any one of the preceding clauses, comprising: obtaining a plurality of discrete bundles each of a plurality of 25 to 3600 fibers having a denier of 0.2 to 12.0 and a length of 8 to 160 mm, the plurality of fibers of each bundle being longitudinally arranged together; and disrupting the longitudinal arrangement of at least some of the plurality of fibers of each of the bundles such that they extend irregularly three-dimensionally and intermingle to form a plurality of discrete fiberfill clusters. [00221] Clause 24. The method according to any one of the preceding clauses, wherein, prior to said disrupting, the plurality of fibers of the bundle extend substantially linearly along their longitudinal length.

[00222] Clause 25. The method according to any one of the preceding clauses, wherein the plurality of fibers of the bundle extend substantially parallel to each other along their longitudinal length.

[00223] Clause 26. The method according to any one of the preceding clauses, wherein the plurality of fibers of the bundle are non-texturized fibers.

[00224] Clause 27. The method according to clause 26, wherein the bundle is non- texturized intermingled filament yam.

[00225] Clause 28. The method according to any one of clauses 1-23, wherein the plurality of fibers of the bundle extend non-linearly along their longitudinal length.

[00226] Clause 29. The method according to any one of clauses 1-23 and 28, wherein the plurality of fibers of the bundle extend irregularly along their longitudinal length.

[00227] Clause 30. The method according to any one of clauses 1-25, 28, and 29, wherein the plurality of fibers of the bundle are texturized fibers.

[00228] Clause 31. The method according to clause 30, wherein the bundle is texturized intermingled filament yarn.

[00229] Clause 32. The method according to any one of the preceding clauses, wherein the plurality of fibers of the bundle comprises about 50 to about 500 fibers.

[00230] Clause 33. The method according to any one of the preceding clauses, wherein the plurality of fibers comprises about 80 to about 300 fibers.

[00231] Clause 34. The method according to any one of the preceding clauses, wherein the bundle comprises more fibers than the fiberfill cluster.

[00232] Clause 35. The method according to any one of the preceding clauses, wherein the fiberfill cluster comprises at least one secondary fiber that was not part of the bundle.

[00233] Clause 36. The method according to clause 35, wherein the at least one secondary fiber is intermingled with the plurality of fibers of the fiberfill cluster during the disrupting. [00234] Clause 37. The method according to any one of the preceding clauses, wherein the plurality of fibers have a denier of about 0.7 to about 1.7.

[00235] Clause 38. The method according to any one of the preceding clauses, wherein the plurality of fibers have substantially the same denier.

[00236] Clause 39. The method according to any one of the preceding clauses, wherein the plurality of fibers of the bundle have a longitudinal length of about 20 to about 50 mm. [00237] Clause 40. The method according to any one of the preceding clauses, wherein the plurality of fibers of the bundle are doped with a durable water repellent or silicone chemistry.

[00238] Clause 41. The method according to any one of the preceding clauses, wherein the plurality of fibers have substantially the same lengths.

[00239] Clause 42. The method according to any one of the preceding clauses, wherein the plurality of fibers are synthetic polymeric fibers.

[00240] Clause 43. The method according to any one of the preceding clauses, wherein the plurality of fibers are fibers selected from polyamide, polyester, polypropylene, polylactic acid, poly(butyl acrylate), acrylic, acrylate, acetate, polyolefin, nylon, rayon, lyocell, aramid, spandex, viscose, and modal fibers, or a combination thereof.

[00241] Clause 44. The method according to any one of the preceding clauses, wherein the plurality of fibers are polyester fibers.

[00242] Clause 45. The method according to clause 44, wherein the polyester fibers are selected from polyethylene terephthalate (PET), poly(hexahydro-p-xylylene terephthalate), polybutylene terephthalate (PBT) fibers, polytrimethylene terephthalate (PTT) fibers, copolyester fibers (e g., copolyester fibers comprising PET structural units), or a combination thereof.

[00243] Clause 46. The method according to clause 44, wherein the polyester fibers are PET fibers.

[00244] Clause 47. The method according to any one of the preceding clauses, wherein the fibers comprise recycled polymeric material.

[00245] Clause 48. The method according to any one of the preceding clauses, wherein the plurality of fibers comprise siliconized fibers.

[00246] Clause 49. The method according to any one of the preceding clauses, wherein the plurality of fibers comprise non-siliconized fibers.

[00247] Clause 50. The method according to any one of the preceding clauses, wherein the plurality of fibers comprise solid fibers.

[00248] Clause 51. The method according to any one of the preceding clauses, wherein the plurality of fibers comprise hollow fibers.

[00249] Clause 52. The method according to any one of the preceding clauses, wherein the fiberfill cluster defines a length, a width and a thickness, and wherein the length and width are greater than the thickness.

[00250] Clause 53. The method according to clause 52, wherein the length is greater than the width. [00251] Clause 54. The method according to any one of the preceding clauses, wherein the fiberfill cluster defines a length, a width and a thickness, and wherein the length is within the range of about 0.90 to about 4 cm.

[00252] Clause 55. The method according to any one of the preceding clauses, wherein the fiberfill cluster defines a length, a width and a thickness, and wherein the width is within the range of about 0.70 to about 3 cm.

[00253] Clause 56. The method according to any one of the preceding clauses, wherein the fiberfill cluster has a density of about 0.08 to 0.70 mg/cm3 (e.g., about 0.10 to about 0.50 mg/cm3).

[00254] Clause 57. The method according to any one of the preceding clauses, wherein the fiberfill cluster defines a substantially ovoidal shape.

[00255] Clause 58. The method according to any one of clauses 1-51 and 54-57, wherein the fiberfill cluster defines a substantially spherical shape.

[00256] Clause 59. The method according to any one of the preceding clauses, wherein the bundle is a segment of a filament yarn.

[00257] Clause 60. The method according to clause 59, wherein obtaining the bundle comprises cutting the segment from the filament yam.

[00258] Clause 61. The method according to clause 59 or 60, wherein the filament yam is a textured filament yam.

[00259] Clause 62. The method according to clause 59 or 60 wherein the filament yarn is a flat filament yarn.

[00260] Clause 63. A discrete fiberfill cluster comprising: a plurality of fibers that are intermingled with one another, the plurality of fibers comprising 25 to 3600 fibers having a denier of 0.2 to 12.0 and a length of 8 to 160 mm, wherein the plurality of fibers form: a bundle remnant portion comprising some of the plurality of fibers being longitudinally arranged together; and an outer region of fibers extending three-dimensionally outwardly from the bundle remnant portion comprising some of the plurality of fibers randomly and non-uniformly oriented with respect to one another, and wherein the bundle remnant portion comprises a higher density of fibers than the outer region.

[00261] Clause 64. The discrete fiberfill cluster according to clause 63, wherein the bundle remnant portion comprises fewer fibers than the outer region. [00262] Clause 65. The discrete fiberfill cluster according to clause 63 or 64, wherein the bundle remnant portion comprises at least 25% (e.g., at least 50%, or at least 75%) fewer fibers than the outer region.

[00263] Clause 66. The discrete fiberfill cluster according to any one of clauses 63-65, wherein the plurality of fibers are from a segment of intermingled filament yarn, and the bundle remnant portion of the discrete fiberfill cluster corresponds to a mingled nip portion from the intermingled filament yarn.

[00264] Clause 67. The discrete fiberfill cluster according to clause 66, wherein the plurality of fibers in the bundle remnant portion are entangled with each other.

[00265] Clause 68. The discrete fiberfill cluster according to any one of clauses 63-67, wherein the bundle remnant portion extends non-linearly along its length.

[00266] Clause 69. The discrete fiberfill cluster according to any one of clauses 63-68, wherein the bundle remnant portion is a portion of a segment of a filament yarn.

[00267] Clause 70. The discrete fiberfill cluster according to clause 69, wherein the bundle remnant portion is a portion of a segment of a textured filament yam.

[00268] Clause 71. The discrete fiberfill cluster according to clause 69, wherein the bundle remnant portion is a portion of a segment of a flat filament yarn.

[00269] Clause 72. The discrete fiberfill cluster according to any one of clauses 63-71, wherein the plurality of fibers of the bundle remnant portion extend substantially parallel to each other along their longitudinal length.

[00270] Clause 73. The discrete fiberfill cluster according to any one of clauses 63-72, wherein the plurality of fibers are non-texturized linear fibers.

[00271] Clause 74. The discrete fiberfill cluster according to any one of clauses 63-72, wherein the plurality of fibers are texturized linear fibers.

[00272] Clause 75. The discrete fiberfill cluster according to any one of clauses 63-74, wherein the plurality of fibers extend non-linearly along their longitudinal length.

[00273] Clause 76. The discrete fiberfill cluster according to any one of clauses 63-75, wherein the plurality of fibers extend irregularly along their longitudinal length.

[00274] Clause 77. The discrete fiberfill cluster according to any one of clauses 63-76, wherein some of the plurality of fibers of the outer region are entangled together or with at least one fiber of the bundle remnant portion.

[00275] Clause 78. The discrete fiberfill cluster according clause 77, wherein less than about 50% of the plurality of fibers of the outer region are entangled together or with at least one fiber of the bundle remnant portion. [00276] Clause 79. The discrete fiberfill cluster according clause 77, wherein less than about 25% of the plurality of fibers of the outer region are entangled together or with at least one fiber of the bundle remnant portion.

[00277] Clause 80. The discrete fiberfill cluster according to any of the preceding clauses, wherein at least some of the plurality of fibers of the outer region are twisted together or with at least one fiber of the bundle remnant portion.

[00278] Clause 81. The discrete fiberfill cluster according to clause 80, wherein less than about 50% of the plurality of fibers of the outer region are twisted together or with at least one fiber of the bundle remnant portion.

[00279] Clause 82. The discrete fiberfill cluster according to clause 80, wherein less than about 25% of the plurality of fibers of the outer region are twisted together or with at least one fiber of the bundle remnant portion.

[00280] Clause 83. The discrete fiberfill cluster according to any one of clauses 63-82, comprising at least one bonding point wherein at least some of the plurality of fibers are bonded together.

[00281] Clause 84. The discrete fiberfill cluster according to clause 83, wherein the at least one bonding point includes some fibers of the remnant portion and some fibers of the outer region.

[00282] Clause 85. The discrete fiberfill cluster according to clause 83 or 84, wherein the at least one bonding point includes only some fibers of the bundle remnant portion and only some fibers of the outer region.

[00283] Clause 86. The discrete fiberfill cluster according to any one of clauses 63-85, wherein the fiberfill cluster defines a length, a width and a thickness, and wherein the length and width are greater than the thickness.

[00284] Clause 87. The discrete fiberfill cluster according to clause 86, wherein the length is greater than the width.

[00285] Clause 88. The discrete fiberfill cluster according to any one of the preceding clauses, wherein the fiberfill cluster defines a length, a width and a thickness, and wherein the length is within the range of about 0.90 to about 4 cm.

[00286] Clause 89. The discrete fiberfill cluster according to any one of the preceding clauses, wherein the fiberfill cluster defines a length, a width and a thickness, and wherein the width is within the range of about 0.70 to about 3 cm.

[00287] Clause 90. The discrete fiberfill cluster according to any one of the preceding clauses, wherein the fiberfill cluster defines a substantially ovoidal shape.

[00288] Clause 91. The discrete fiberfill cluster according to any one of clauses 63-85 and 88-90, wherein the fiberfill cluster defines a substantially spherical shape. [00289] Clause 92. The discrete fiberfill cluster according to any one of clauses 63-91, wherein the plurality of fibers have a denier of about 0.7 to about 1.7.

[00290] Clause 93. The discrete fiberfill cluster according to any one of clauses 63-92, wherein the plurality of fibers have substantially the same deniers.

[00291] Clause 94. The discrete fiberfill cluster according to any one of clauses 63-93, wherein the plurality of fibers of the bundle have a longitudinal length of about 20 to about 50 mm.

[00292] Clause 95. The discrete fiberfill cluster according to any one of clauses 63-94, wherein the plurality of fibers of the bundle remnant portion have substantially the same longitudinal lengths.

[00293] Clause 96. The discrete fiberfill cluster according to any one of clauses 63-95, wherein the plurality of fibers have substantially the same lengths.

[00294] Clause 97. The discrete fiberfill cluster according to any one of clauses 63-96, wherein the fiberfill cluster has a density of about 0.08 to 0.70 mg/cm3 (e.g., about 0.10 to about 0.50 mg/cm3).

[00295] Clause 98. The discrete fiberfill cluster according to any one of clauses 63-97, wherein the plurality of fibers comprises about 50 to about 500 fibers.

[00296] Clause 99. The discrete fiberfill cluster according to any one of clauses 63-98, wherein the plurality of fibers comprises about 80 to about 300 fibers.

[00297] Clause 100. The discrete fiberfill cluster according to any one of clauses 63-99, wherein the plurality of fibers are synthetic polymeric fibers.

[00298] Clause 101. The discrete fiberfill cluster according to any one of clauses 63-100, wherein the plurality of fibers are fibers selected from polyamide, polyester, polypropylene, polylactic acid, poly(butyl acrylate), acrylic, acrylate, acetate, polyolefin, nylon, rayon, lyocell, aramid, spandex, viscose, and modal fibers, or a combination thereof.

[00299] Clause 102. The discrete fiberfill cluster according to any one of clauses 63-101, wherein the plurality of fibers are polyester fibers.

[00300] Clause 103. The discrete fiberfill cluster according to clause 102, wherein the polyester fibers are selected from polyethylene terephthalate (PET), poly(hexahydro-p- xylylene terephthalate), polybutylene terephthalate (PBT) fibers, polytrimethylene terephthalate (PTT) fibers, copolyester fibers (e.g., copolyester fibers comprising PET structural units), or a combination thereof.

[00301] Clause 104. The discrete fiberfill cluster according to clause 102, wherein the polyester fibers are PET fibers.

[00302] Clause 105. The discrete fiberfill cluster according to any one of clauses 63-104, wherein the fibers comprise recycled polymeric material. [00303] Clause 106. The discrete fiberfill cluster according to any one of clauses 63-105, wherein the plurality of fibers comprise siliconized fibers.

[00304] Clause 107. The discrete fiberfill cluster according to any one of clauses 63-106, wherein the plurality of fibers comprise non-siliconized fibers.

[00305] Clause 108. The discrete fiberfill cluster according to any one of clauses 63-107, wherein the plurality of fibers comprise solid fibers.

[00306] Clause 109. The discrete fiberfill cluster according to any one of clauses 63-108, wherein the plurality of fibers comprise hollow fibers.

[00307] Clause 110. A discrete fiberfill cluster comprising: a plurality of fibers that are randomly intermingled with one another, the plurality of fibers comprising 25 to 3600 fibers having a denier of 0.2 to 12.0 and a length of 8 to 160 mm, wherein the plurality of fibers are randomly and non-uniformly oriented with respect to one another, wherein the plurality of fibers form: at least one inner relatively densely populated region of fibers; and, an outer relatively less densely population region of fibers extending three- dimensionally outwardly from the at least one inner relatively densely populated region, and wherein the discrete fiberfill cluster has a length of 0.5 cm to 6.5 cm, a width of 0.5 cm to 6.5 cm, and density of 0.08 to 0.70 mg/cm3. mg/cm3.

[00308] Clause 111. The discrete fiberfill cluster according to clause 110, wherein the inner region comprises fewer fibers than the outer region (e.g., at least 25% or at least 50% fewer fibers than the outer region).

[00309] Clause 112. The discrete fiberfill cluster according to clause 110, wherein the outer region comprises fewer fibers than the inner region (e.g., at least 25% or at least 50% fewer fibers than the inner region).

[00310] Clause 113. The discrete fiberfill cluster according to any one of clauses 111-112, wherein the plurality of fibers extend non-linearly along their length.

[00311] Clause 114. The discrete fiberfill cluster according to any one of clauses 110-113, wherein the plurality of fibers are non-texturized fibers.

[00312] Clause 115. The discrete fiberfill cluster according to any one of clauses 110-113, wherein the plurality of fibers are texturized fibers.

[00313] Clause 116. The discrete fiberfill cluster according to any one of clauses 110-115, wherein the plurality of fibers are from a segment of intermingled filament yarn, and the at least one inner relatively densely populated region of fibers of the discrete fiberfill cluster corresponds to a mingled nip portion from the intermingled filament yam. [00314] Clause 117. The discrete fiberfill cluster according to clause 116, wherein the plurality of fibers in the at least one inner relatively densely populated region of fibers are entangled with each other.

[00315] Clause 118. The discrete fiberfill cluster according to clause 116 or clause 117, wherein no fibers within the cluster are bonded together.

[00316] Clause 119. The method according to any one of the preceding clauses, wherein the plurality of fibers of the bundle are doped with a durable water repellent or silicone chemistry.

[00317] Clause 120. The discrete fiberfill cluster according to any one of clauses 110-119, wherein some of the plurality of fibers are entangled together.

[00318] Clause 121. The discrete fiberfill cluster according clause 120, wherein less than about 50% of the plurality of fibers are entangled together.

[00319] Clause 122. The discrete fiberfill cluster according clause 120, wherein less than about 25% of the plurality of fibers are entangled together.

[00320] Clause 123. The discrete fiberfill cluster according to any of clauses 110-122, wherein some of the plurality of fibers are twisted together.

[00321] Clause 124. The discrete fiberfill cluster according to clause 123, wherein less than about 50% of the plurality of fibers are twisted together.

[00322] Clause 125. The discrete fiberfill cluster according to clause 123, wherein less than about 25% of the plurality of fibers are twisted together.

[00323] Clause 126. The discrete fiberfill cluster according to any one of clauses 110-117 or 119-125, comprising at least one bonding point wherein at least some of the plurality of fibers are bonded together.

[00324] Clause 127. The discrete fiberfill cluster according to clause 126, wherein the at least one bonding point includes some fibers of the inner region and some fibers of the outer region.

[00325] Clause 128. The discrete fiberfill cluster according to clause 126 or clause 127, wherein the at least one bonding point includes only some fibers of the inner portion and only some fibers of the outer region.

[00326] Clause 129. The discrete fiberfill cluster according to any one of clauses 110-128, wherein the fiberfill cluster defines a length, a width and a thickness, and wherein the length and width are greater than the thickness.

[00327] Clause 130. The discrete fiberfill cluster according to clause 129, wherein the length is greater than the width. [00328] Clause 131. The discrete fiberfill cluster according to any one of clauses 110-130, wherein the fiberfill cluster defines a length, a width and a thickness, and wherein the length is within the range of about 0.90 to about 4 cm.

[00329] Clause 132. The discrete fiberfill cluster according to any one of clauses 110-131, wherein the fiberfill cluster defines a length, a width and a thickness, and wherein the width is within the range of about 0.70 to about 3 cm.

[00330] Clause 133. The discrete fiberfill cluster according to any one of clauses 110-132, wherein the fiberfill cluster defines a substantially ovoidal shape.

[00331] Clause 134. The discrete fiberfill cluster according to any one of clauses 110-128 and 131-132, wherein the fiberfill cluster defines a substantially spherical shape.

[00332] Clause 135. The discrete fiberfill cluster according to any one of clauses 110-134, wherein the plurality of fibers have a denier of about 0.7 to about 1.7.

[00333] Clause 136. The discrete fiberfill cluster according to any one of clauses 110-135, wherein the plurality of fibers have substantially the same deniers.

[00334] Clause 137. The discrete fiberfill cluster according to any one of clauses 110-136, wherein the plurality of fibers of the bundle have a longitudinal length of about 20 to about 50 mm.

[00335] Clause 138. The discrete fiberfill cluster according to any one of clauses 110-137, wherein the plurality of fibers have substantially the same longitudinal lengths.

[00336] Clause 139. The discrete fiberfill cluster according to any one of clauses 110-138, wherein the fiberfill cluster has a density of about 0.10 to about 0.50 mg/cm3.

[00337] Clause 140. The discrete fiberfill cluster according to any one of clauses 110-139, wherein the plurality of fibers comprises about 50 to about 500 fibers.

[00338] Clause 141. The discrete fiberfill cluster according to any one of clauses 110-140, wherein the plurality of fibers comprises about 80 to about 300 fibers.

[00339] Clause 142. The discrete fiberfill cluster according to any one of clauses 110-141, wherein the plurality of fibers are synthetic polymeric fibers.

[00340] Clause 143. The discrete fiberfill cluster according to any one of clauses 110-142, wherein the plurality of fibers are fibers selected from polyamide, polyester, polypropylene, polylactic acid, poly(butyl acrylate), acrylic, acrylate, acetate, polyolefin, nylon, rayon, lyocell, aramid, spandex, viscose, and modal fibers, or a combination thereof..

[00341] Clause 144. The discrete fiberfill cluster according to any one of clauses 110-143, wherein the plurality of fibers are polyester fibers.

[00342] Clause 145. The discrete fiberfill cluster according to clause 144, wherein the polyester fibers are selected from polyethylene terephthalate (PET), poly(hexahydro-p- xylylene terephthalate), polybutylene terephthalate (PBT) fibers, polytrimethylene terephthalate (PTT) fibers, copolyester fibers (e.g., copolyester fibers comprising PET structural units), or a combination thereof.

[00343] Clause 146. The discrete fiberfill cluster according to clause 144, wherein the polyester fibers are PET fibers.

[00344] Clause 147. The discrete fiberfill cluster according to any one of clauses 110-146, wherein the fibers comprise recycled polymeric material.

[00345] Clause 148. The discrete fiberfill cluster according to any one of clauses 110-147, wherein the plurality of fibers comprise siliconized fibers.

[00346] Clause 149. The discrete fiberfill cluster according to any one of clauses 110-148, wherein the plurality of fibers comprise non-siliconized fibers.

[00347] Clause 150. The discrete fiberfill cluster according to any one of clauses 110-149, wherein the plurality of fibers comprise solid fibers.

[00348] Clause 151. The discrete fiberfill cluster according to any one of clauses 110-150, wherein the plurality of fibers comprise hollow fibers.

[00349] Clause 152. Insulation or filling material, comprising a plurality of the discrete fiberfill clusters according to any one of clauses 63-151.

[00350] Clause 153. The insulation or filling material of clause 152, comprising a plurality of first discrete fiberfill clusters according to any one of clauses 63-109, and a plurality of second discrete fiberfill clusters according to any one of clauses 110-151.

[00351] Clause 154. The insulation or filling material of clause 152, consisting of a plurality of the discrete fiberfill clusters according to any one of clauses 63-109.

[00352] Clause 155. The insulation or filling material of clause 152, consisting of a plurality of the discrete fiberfill clusters according to any one of clauses 110-151.

[00353] Clause 156. The insulation or filling material according to any one of clauses 152-

155, wherein the plurality of fiberfill clusters include first fiberfill clusters formed of fibers of a first length and second fiberfill clusters formed of fibers of a second length that differs from the first length.

[00354] Clause 157. The insulation or filling material according to any one of clauses 152-

156, wherein the plurality of fiber clusters include first clusters formed of a first total number of fibers and second clusters formed of a second total number of fibers that differs from the first total number of fibers.

[00355] Clause 158. The insulation or filling material according to any one of clauses 152-

157, wherein the plurality of fiberfill clusters include first fiberfill clusters formed of fibers of a first synthetic material and second fiberfill clusters formed of fibers of a second synthetic material that differs from the first synthetic material. [00356] Clause 159. The insulation or filling material according to any one of clauses 152- 158, wherein the plurality of fiberfill clusters include first fiberfill clusters formed of fibers of a first denier and second fiberfill clusters formed of fibers of a second denier that differs from the first denier.

[00357] Clause 160. The insulation or filling material of according to any one of clauses 152-159, wherein the plurality of fiberfill clusters include fiberfill clusters of a first size and fiberfill clusters of a second size that differs from the first size.

[00358] Clause 161. The insulation or filling material of according to any one of clauses 152-160, wherein the plurality of fiberfill clusters include fiberfill clusters of a first three dimensional shape and fiberfill clusters of a second three dimensional shape that differs from the first three dimensional shape.

[00359] Clause 162. The insulation or filling material of according to any one of clauses 152-161, wherein the plurality of fiberfill clusters include fiberfill clusters within a first density range and fiberfill clusters within a second density range that that differs from and does not overlap with the first density range.

[00360] Clause 163. An article comprising a plurality of discrete fiberfill clusters according to any one of clauses 63-151 or the insulation or filling material according to any one of clauses 152-162.

[00361] Clause 164. The article according to clause 163, wherein the article is selected from footwear, outerwear, clothing, a sleeping bag, and bedding.

[00362] The invention will now be illustrated, but not limited, by reference to the specific embodiments described in the following examples.

EXAMPLES

[00363] The invention will now be illustrated, but not limited, by reference to the specific embodiments described in the following examples.

Example 1

[00364] Comparative testing was performed on individual embodiments of the inventive discrete fiberfill cluster and down clusters (1000 fill power (FP) goose down plumes and 550 FP duck down plumes). The inventive discrete fiberfill clusters were prepared by obtaining a drawn textured polyester yam or tow of 136 filaments having a denier per filament (dpf) of about 1.10 (the bundle thus having a total denier of about 150) in substantial parallel arrangement (i.e., longitudinally arranged/aligned). The yam was cut to provide a plurality of 1”, 2”, and 4” long longitudinally aligned fiber bundles. Further, additional inventive discrete fiberfill clusters were prepared by obtaining a drawn textured polyester yarn or tow of 96 filaments having a denier per filament (dpi) of about 2.08 (the bundle having a total denier of about 200) in substantial parallel arrangement (i.e., longitudinally arranged/aligned). The inventive discrete fiberfill clusters were then disrupted between two distributing members to form a plurality of the discrete fiberfill clusters. The 1” 1.1 dpf fiber bundle clusters were tested for length, width, heigh, and volume, as were the 2” 1.1 dpf fiber bundle clusters, the 4” 1.1 dpf fiber bundle clusters and the 2” 2.08 dpf fiber bundle clusters. The down clusters were likewise tested. The results for each cluster type were averaged, and are presented below in Table I.

Table I: Comparison of Real Down Plumes to Synthetic Down Clusters

Example 2

[00365] Weight and volume testing were performed on the samples from Example 1 (both on single clusters and on groups of 10 clusters). Results are presented below in Table II. Weight (g) measurements for “1 Plume (g)” and density measurements for “Density (g/cm ³ )” are average measurements for a single plume based on the average of ten tested plumes.

Table II: Weights and Volumes of Example 1 Synthetic Down Cluster Samples

[00366] It is noted that, as shown in Table II, the 4" 1.1 dpf Synthetic Clusters resulted in an about 27% increase in density as compared to the 1,000 FP Goose Down Plumes, the 2" 1.1 dpf Synthetic Clusters resulted in an about 17% increase in density as compared to the 550 FP Goose Down Plumes, and the 2" 2.08 dpf Synthetic Clusters resulted in an about 17% decrease in density as compared to the 1,000 FP Goose Down Plumes.

[00367] As will be readily appreciated by persons having ordinary skill in the art, properties tested in the examples may vary significantly depending upon the fibers constituting the discrete fiberflll cluster, and the foregoing examples are nonlimiting.

[00368] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”), “contain” (and any form contain, such as “contains” and “containing”), and any other grammatical variant thereof, are open-ended linking verbs. As a result, a method or article that “comprises”, “has”, “includes” or “contains” one or more steps or elements possesses those one or more steps or elements, but is not limited to possessing only those one or more steps or elements. Likewise, a step of a method or an element of an article that “comprises”, “has”, “includes” or “contains” one or more features possesses those one or more features, but is not limited to possessing only those one or more features.

[00369] As used herein, the terms “comprising,” "has," “including,” "containing," and other grammatical variants thereof encompass the terms “consisting of’ and “consisting essentially of.”

[00370] The phrase “consisting essentially of’ or grammatical variants thereof when used herein are to be taken as specifying the stated features, integers, steps or components but do not preclude the addition of one or more additional features, integers, steps, components or groups thereof but only if the additional features, integers, steps, components or groups thereof do not materially alter the basic and novel characteristics of the claimed compositions or methods.

[00371] Approximating language, as used herein throughout disclosure, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” or “substantially,” is not limited to the precise value specified. For example, these terms can refer to less than or equal to ±5%, such as less than or equal to ±2%, such as less than or equal to ±1%, such as less than or equal to ±0.5%, such as less than or equal to ±0.2%, such as less than or equal to ±0.1%, such as less than or equal to ±0.05%. In some instances, the approximating language may correspond to the precision of an instrument for measuring the value.

[00372] All publications cited in this specification are herein incorporated by reference as if each individual publication were specifically and individually indicated to be incorporated by reference herein as though fully set forth.

[00373] Subject matter incorporated by reference is not considered to be an alternative to any claim limitations, unless otherwise explicitly indicated.

[00374] Where one or more ranges are referred to throughout this specification, each range is intended to be a shorthand format for presenting information, where the range is understood to encompass each discrete point within the range as if the same were fully set forth herein.

[00375] While several aspects and embodiments of the present invention have been described and depicted herein, alternative aspects and embodiments may be affected by those skilled in the art to accomplish the same objectives. Accordingly, this disclosure and the appended claims are intended to cover all such further and alternative aspects and embodiments as fall within the true spirit and scope of the invention.