CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. provisional application number 63/124,554, which was filed on December 11, 2020, the entire contents of which are hereby incorporated by reference herein.

FIELD OF THE INVENTION

[0002] The present invention generally relates to an air-permeable multi-layer insulative construct, to articles comprising the construct, and to methods of making the construct. The construct is particularly useful in the textile field.

BACKGROUND OF THE INVENTION

[0003] Microfibers are those fibers having a denier of less than or equal to 1.0 denier ("denier" being a measure of the weight in grams per 9,000 meters length of fiber). Synthetic microfiber insulations have been available in the commercial marketplace for decades now. Siliconized hydrophobic microfiber insulation is also known. Such fiber is described, for example, in U.S. Patent No. 4,588,635, and is available in the performance outdoor marketplace under the brand name PrimaLoft®.

[0004] Fibers and fill material, including microfibers and natural fill materials (e.g., down) have long been used as insulative materials in the textile field. For example, the outdoor industry has utilized fibers, including microfibers, and down in cold weather apparel, sleeping bags, etc. for many years. However, a disadvantage to using such fibers has been that this type of insulation is highly prone to display severe fiber migration through fabric surfaces, even when combined with low air permeability downproof fabrics and/or protected by nonwoven scrim materials.

[0005] Scrim is an interlining that is often used as a protective layer between insulation and a shell or liner fabric of an article. Fiber migration is the penetration of fiber through the fabric surface such that fiber is present on the face side of the article, which is typically the outside of the article that is exposed to the external environment.

[0006] Downproof fabrics are typically defined as fabrics that are tightly woven with thread counts greater than 250 and have an air permeability rating according to ASTM D737 less than 1 cubic feet per minute (CFM). Sometimes fabrics have coatings applied to them or are calendared to seal their surface as a means to reduce fiber migration and/or achieve downproofness. These treatments further reduce the air permeability of the fabric, which has a direct effect on the overall comfort of an article. The lower the air permeability of the fabric, the less breathable and comfortable it is. The higher the air permeability of the fabric, the more breathable and comfortable it is.

[0007] Certain types of migration resistant insulation for use in the textile field are known in the art. These insulations are typically comprised predominantly of higher denier fibers in excess of 1.0 denier and do not contain hydrophobic finishes. It is easy to create migration resistant surfaces on these types of commonly produced generic insulations using commercially available chemical resins as bonding agents on the surface of the insulation. However, there are a variety of disadvantages associated with this type of treatment, including the fact that the treatments make the insulation stiff and crunchy to the hand feel, reduce stretch, and are not comfortable to wear. Further, most commercially available chemical resins used to create migration resistant surfaces adsorb water quickly, which represents a considerable disadvantage for textiles such as outdoor articles that require both performance and comfort.

[0008] Thus, a need exists for improved insulative constructions that are air-permeable and comfortable, yet offer improved resistance or prevention of fiber migration.

[0009] 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.

[0010] 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 OF THE INVENTION

[0011] Briefly, the present invention satisfies the need for improved migration resistant textile constructs. 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 air-permeable multi-layer insulative construct as described herein having at least one outer pliable layer with an air permeability of 1 to 500 CFM and made up of a tight polymeric web of fibers having a diameter of less than 10 pm offers remarkable resistance to and/or prevention of fiber migration (including down migration).

[0013] Polymeric webs have been used in other applications, but to the best of Applicant’s knowledge, have not been employed as disclosed herein.

[0014] DE 202016008757 discloses absorbent hygiene products such as disposable diapers, sanitary napkins, and panty liners having a particular absorbent core that can be used for absorbing bodily fluids and exudates. The absorbent core contains channels concretely designed to enhance uniform liquid distribution and comfort. The core is positioned and held between a topsheet and backsheet. The backsheet/outer shell of the absorbent article (which can be a breathable backsheet material, such as a nonwoven, e.g., meltblown, layer) does not allow liquid to pass therethrough. US 7,118,558 also discloses absorbent articles such as diapers, the backsheet of which comprises a substantially liquid impervious material.

[0015] US 8,129,450 discloses disposable articles that include a thermoplastic polymer composition containing a modified polymer having covalently bonded pendant substituents derived from cyclodextrin. The disposable article may comprise a nonwoven web comprising a spunbond fabric, a meltblown fabric, an electrospun fabric, and combinations thereof.

[0016] US 5,399,423 discloses an ignition resistant fibrous material for use as insulation. The material comprises a multiplicity of meltblown or spunbonded thermoplastic filaments in combination with a multiplicity of nonlinear, nongraphitic carbonaceous fibers.

[0017] US 4,433,024 discloses vapor-sorbing particle-filled sheet material having a low insulation value. The inner layer of the material can comprise a melt-blown fiber web that contains vapor-sorptive particles.

[0018] None of the aforesaid art contemplates use of a web as described herein in an air- permeable multi-layer insulative construct capable of reducing fiber migration. While aspects of the aforesaid art may be included in certain embodiments of the invention, it is also contemplated that certain embodiments of the invention may exclude aspects of the aforesaid art.

[0019] In a first aspect, the invention provides an air-permeable multi-layer insulative construct comprising:

- a first outer pliable layer;

- a second outer pliable layer; and

- an inner insulation material layer disposed between the first outer pliable layer and the second outer pliable layer, wherein at least one of the first outer pliable layer and the second outer pliable layer:

- comprises a nonwoven polymeric web comprising a plurality of fibers having a diameter of less than 10 pm; and

- has an air permeability of 1 to 500 CFM, wherein the inner insulation material layer:

- has a thermal performance warmth to weight ratio of at least 0.50 CLO/oz/sq yd. (.5 to 1.8), according to ISO 11092; and

- has a thickness greater than 2 mm, wherein the air-permeable multi-layer insulative construct has a migration resistance of less than 20 fibers when tested according to the INS-17 Fiber Migration Test.

[0020] In a second aspect, the invention provides an article comprising the air-permeable multi-layer construct according to the first aspect of invention.

[0021] In a third aspect, the invention provides a method of making the air-permeable multilayer construct according to the first aspect of invention or the article according to the second aspect of the invention, the method comprising assembling the construct by disposing the inner insulation material layer between the first outer pliable layer and the second outer pliable layer. [0022] Certain embodiments of the presently-disclosed air-permeable multi-layer insulative construct, articles comprising the construct, and methods of making the construct have several features, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of the air-permeable multi-layer insulative construct, 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 invention provide air-permeable, comfortable insulative constructs that significantly reduce and/or prevent fiber migration from the inner layer through one or more outer layers. Such constructs find use in, inter alia, the textile field, for example, in clothing, outerwear, home furnishings, bedding, etc.

[0023] 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

[0024] 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:

[0025] FIG. 1 illustrates a side cross-sectional view of an embodiment of the inventive air- permeable multi-layer insulative construct.

[0026] FIG. 2 illustrates a top-view of an embodiment of the inventive air-permeable multilayer insulative construct.

[0027] FIG. 3 illustrates a side cross-sectional view of an embodiment of the inventive air- permeable multi-layer insulative construct.

[0028] FIG. 4 illustrates a multi-layer insulative construct not according to an embodiment of the invention.

[0029] FIGS. 5A-C are enlarged photographs of a portion of a meltblown web that can be used as the first and/or second outer pliable layer.

DETAILED DESCRIPTION OF THE INVENTION

[0030] 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.

[0031] In a first aspect, the invention provides an air-permeable multi-layer insulative construct comprising:

- a first outer pliable layer;

- a second outer pliable layer; and

- an inner insulation material layer disposed between the first outer pliable layer and the second outer pliable layer, wherein at least one of the first outer pliable layer and the second outer pliable layer:

- comprises a nonwoven polymeric web comprising a plurality of fibers having a diameter of less than 10 pm; and

- has an air permeability of 1 to 500 CFM, wherein the inner insulation material layer: has a thermal performance warmth to weight ratio of at least 0.50 CLO/oz/sq yd. (.5 to 1.8), according to ISO 11092; and

- has a thickness greater than 2 mm, and wherein the air-permeable multi-layer insulative construct has a migration resistance of less than 20 fibers when tested according to the INS-17 Fiber Migration Test.

[0032] The recitation “wherein at least one of the first outer pliable layer and the second outer pliable layer” means one or both of the first outer pliable layer and the second outer pliable layer.

[0033] FIG. 1 illustrates a side cross-sectional view of an embodiment of the inventive air- permeable multi-layer insulative construct 10. As shown, the inner insulation material layer 6 is disposed (or sandwiched) between the first outer pliable layer 2 and the second outer pliable layer 4. The inner insulation material layer 6, the first outer pliable layer 2, and the second outer pliable layer 4 are all parallel to one another.

[0034] In some embodiments, when construct 10 is contained within an article (e.g., a textile article, for example, clothing, outerwear, home goods, bedding, etc.), the first outer pliable layer 2 will face toward an outer portion (e.g., fabric or other material or liner) of the article, e.g., a jacket, and the second outer pliable layer 4 will face toward an inner portion (e.g., fabric or other material or liner) of the article. For example, in jackets, articles of clothing, etc., the outer portion is the environmentally-facing portion, whereas the inner portion is the wearer-facing portion. In other embodiments, the first outer pliable layer 2 faces toward an inner portion of an article and the second outer pliable layer 4 faces toward an outer portion of an article.

[0035] FIG. 2 illustrates a top-view of an embodiment of the inventive air-permeable multilayer insulative construct wherein the inner insulation material layer 6 comprises batting that contains a plurality of bonded nonwoven polymeric webs including elastomeric and spiralcrimped synthetic fibers.

[0036] FIG. 3 illustrates a side cross-sectional view of an embodiment of the inventive air- permeable multi-layer insulative construct, wherein the construct is in the form of a baffle. Depicted are a plurality of baffles made by sewing through the first outer pliable layer 2 and the second outer pliable layer 4 along seams 8, then filling the baffles with inner insulation material layer 6, which is blowable insulation material.

[0037] FIG. 4 illustrates a multi-layer insulative construct not according to an embodiment of the invention. As can be seen, fibers 12 (which can be polymeric fibers, natural fibers such as down, etc.) protrude from typically-used lining or scrim layers 3 and 5. This is known as fiber migration. Fiber migration can be a particular problem following laundering of textile articles. It is a major problem for both polymeric fibers (natural and synthetic) and other natural fibers (e.g., down).

[0038] In order to prevent the problem of fiber migration with down and other fine fibers, in the past down-proof fabric has been used in insulative constructs. Truly down-proof fabric is typically a fabric having an air permeability of less than 1 cubic foot per square meter (CFM). Unfortunately, the weight and low air permeability of the fabric in down-proof constructs sacrifices breathability and comfort in the interest of preventing fiber migration.

[0039] Applicant has surprisingly discovered that embodiments of the inventive air-permeable multi-layer insulative construct rival down-proof fabric in terms of resisting or preventing fiber migration, yet are much more comfortable and breathable, making for highly improved textiles. The feature results from at least one of the first outer pliable layer and the second outer pliable layer comprising a nonwoven polymeric web that comprises a plurality of fibers having a diameter of less than (or less than or equal to) 10 pm.

[0040] In some embodiments, the first outer pliable layer comprises a nonwoven polymeric web comprising a plurality of fibers having a diameter of less than 10 pm and has an air permeability of 1 to 500 CFM. Such configuration may be particularly desirable for embodiments having only one surface or layer through which fiber migration is a problem (e.g., upholstered furniture, etc.).

[0041] In some embodiments, the second outer pliable layer comprises a nonwoven polymeric web comprising a plurality of fibers having a diameter of less than 10 pm and has an air permeability of 1 to 500 CFM.

[0042] In some embodiments, both the first and second outer pliable layers comprise a nonwoven polymeric web comprising a plurality of fibers having a diameter of less than 10 pm and has an air permeability of 1 to 500 CFM.

[0043] In some embodiments, the first and second outer pliable layers comprise the same material. In other embodiments, the first and second outer pliable layers comprise different materials.

[0044] One or both of the first and second outer pliable layers has an air permeability 1 to 500 CFM (e.g., 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, 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 CFM), including any and all ranges and subranges therein (e.g., 1-400 CFM, 1-300 CFM, 1-200 CFM, 1-100 CFM, 5-500 CFM, 5-400 CFM, 5-300 CFM, 5-200 CFM, 5-100 CFM, etc.).

[0045] In some embodiments, one or both of the first and second outer pliable layers has an air permeability of at least 1 CFM (e.g., at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 CFM).

[0046] One or both of the first outer pliable layer and the second outer pliable layer comprises a nonwoven polymeric web comprising a plurality of fibers having a diameter of less than or equal to 10 pm. In some embodiments, the fibers have a diameter of 0.3 pm to 10 pm (e.g., 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 pm), including any and all ranges and subranges therein (e.g., 1 to 10 pm, 1 to 8 pm, 1 to 6 pm, 2 to 6 pm, etc.).

[0047] In some embodiments, one or both of the first outer pliable layer and the second outer pliable layer comprises 50 to 100 wt% (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, 99.1, 99.2, 99.3, 99.4, 99.5, 99.6, 99.7, 99.8, 99.9, or 100 wt%), including any and all ranges and subranges therein, of the said plurality of fibers having a diameter of less than or equal to 10 pm.

[0048] In some embodiments, the nonwoven polymeric web of the first outer pliable layer and/or the second outer pliable layer is a sheet of material having a structure of individual fibers or threads which are laid in, but not in a regular manner as would be the case for web formed by a knitting or weaving process. [0049] In some embodiments, the nonwoven polymeric web makes up (i.e., accounts for) 80 to 100 wt% (e.g., 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 99.1,

99.2, 99.3, 99.4, 99.5, 99.6, 99.7, 99.8, 99.9, or 100 wt%), of the first outer pliable layer and/or the second outer pliable layer. Where the nonwoven web accounts for less than 100 wt% of a layer, additives and/or other desired materials may be included as well.

[0050] The first outer pliable layer and/or the second outer pliable layer are pliable, meaning that they can be folded without cracking or breaking the layer.

[0051] In some embodiments, the first outer pliable layer and/or the second outer pliable layer has good drape (i.e., the layer hangs under its own weight). In some embodiments, the insulation has a drape of 1.5 cm to 10.0 cm (e.g., 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, or 10.0 cm) including any and all ranges and subranges therein, as measured in accordance with Method ASTM D1388.

[0052] In some embodiments, the first outer pliable layer and/or the second outer pliable layer has a basis weight range of 8-35 grams per square meter (gsm) (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, or 35 gsm) including any and all ranges and subranges therein (e.g., 20 to 30 gsm, 23-27 gsm, etc.).

[0053] The first and/or second outer pliable layers may be made by any technique capable of making the layer(s) as described herein. For example, in some embodiments, the first and/or second outer pliable layers comprise a nonwoven web formed via a meltblown process, electrospun process, forcespun, or bonded card web process. Thus, in some embodiments, the first and/or second outer pliable layer comprises a nonwoven web selected from a meltblown web, an electrospun web, a forcespun web, and a bonded carded web. As would be readily appreciated by a person having ordinary skill in the art, a meltblown web comprises meltblown fibers, an electrospun web comprises electrospun fibers, a forcespun web comprises forcespun fibers, a bonded carded web comprises bonded barded fibers (typically staple fibers, i.e., fibers having a standardized length, as opposed to filaments, which are continuous fibers that can be of indefinite length). [0054] Meltblown fibers are fibers formed via a meltblown process, which typically involves extruding a molten thermoplastic material through a plurality of fine, usually circular die capillaries (or spinnerets) as molten threads or filaments into a high velocity gas (e.g., air) stream containing the filaments of the melt fused thermoplastic material to reduce its diameter. After the fibers are formed, the meltblown fibers are carried by the gas stream at high speed and deposited on a collecting surface to form a web of randomly dispensed meltblown fibers.

[0055] Where the first and/or second outer pliable layer comprises a meltblown web or other type of nonwoven polymeric web formed by collection of discrete fibers in a web on a collection surface, the web will typically have a first face (also known as a “back side”, which is the face formed adjacent to the collecting surface, on which a pattern from the collecting surface can in some embodiments be seen) and a second face (also known as a “face side”, which is the face formed facing away from the collection surface, for which randomly oriented fibers are typically most visible). FIGS. 5A and 5B are enlarged photographs (at magnification 6x and 60x, respectively) of the first face of a portion of a polypropylene meltblown web that can be used as the first and/or second outer pliable layer. FIG. 5C is a photograph (at 60x magnification) of the second face of a portion of a polypropylene meltblown web that can be used as the first and/or second outer pliable layer.

[0056] In some embodiments of the air-permeable multi-layer insulative construct, the first outer pliable layer and/or the second outer pliable layer comprises a nonwoven polymeric web having a first face and a second face, wherein, for one or both of the layers, the second face is adjacent to the inner insulation material layer.

[0057] In some embodiments of the air-permeable multi-layer insulative construct, the first outer pliable layer and/or the second outer pliable layer comprises a nonwoven polymeric web having a first face and a second face, wherein, for one or both of the layers, the first face is adjacent to the inner insulation material layer.

[0058] In some embodiments, the first outer pliable layer and/or the second outer pliable layer comprises a plurality of randomly discontinuous polymeric fibers that form the nonwoven polymeric web.

[0059] In some embodiments, the first outer pliable layer and/or the second outer pliable layer has a thickness of 100 to 1000 pm (e.g., 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, 500, or 1000 pm), including any and all ranges and subranges therein.

[0060] Unless otherwise indicated, the chemical nature/composition of the fibers in the first and second outer pliable layers are not intended to be limited, provided that one or both layers is otherwise as described herein.

[0061] In some embodiments, the first outer pliable layer and/or the second outer pliable layer comprises fiber that can be processed in a meltblown process, electrospun process, forcespun, or bonded card web process.

[0062] In some embodiments, the first outer pliable layer and/or the second outer pliable layer allows water to pass therethrough. In some embodiments, the first outer pliable layer and/or the second outer pliable layer are not substantially liquid impervious as described in U.S. Patent No. 7,118,558. [0063] In some embodiments, the first outer pliable layer and/or the second outer pliable layer comprises polymeric fiber.

[0064] In some embodiments, nonexclusive polymers that may be used in polymeric fiber of the first outer pliable layer and/or the second outer pliable layer (or of the inner insulation material layer) 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-coval erate) (PHBV)), and combinations thereof. For example, in some embodiments, the fiber comprises polyester selected from polyethylene terephthalate) (PET), poly(hexahydro-p-xylylene terephthalate), poly(butylene terephthalate) (PBT), poly- 1,4- cyclohexelyne dimethylene (PCDT), polytrimethylene terephthalate (PTT), and terephthalate copolyesters in which at least 85 mole percent of the ester units are ethylene terephthalate or hexahydro-p-xylylene terephthalate units. In some embodiments, the fibers comprise polypropylene or polyester, e.g., polyethylene terephthalate (PET). In some embodiments, the fibers comprise virgin polymer material. In some embodiments, the fibers comprise recycled polymer material, such as post-consumer recycled (PCR) polymer material.

[0065] In some embodiments, the polymer(s) used in the first outer pliable layer and/or second outer pliable layer and/or inner insulation material layer of the air-permeable multi-layer insulative construct does not have covalently bonded pendant substituents derived from cyclodextrin, as described for example in U.S. Patent No. 8,129,450.

[0066] In some embodiments, the first and/or second outer pliable layers comprises a web containing fibers having a length of 0.5 to 85 mm (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, 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, 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, or 85 mm), including any and all ranges and subranges therein (e.g., 0.5 mm - 15 mm, 2 mm - 10 mm, 2 mm to 85 mm, etc.).

[0067] In some embodiments, the first and/or second outer pliable layers have a water uptake of less than or equal to 150 wt% based on the weight of the pliable layer when dry. For example, in some embodiments, the first and/or second outer pliable layers have a water uptake of 50 to 150 wt% (e.g., 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, or 150 wt%).

[0068] In the inventive air-permeable multi-layer insulative construct, the inner insulation material layer is disposed between the first outer pliable layer and the second outer pliable layer. The inner insulation material layer has a thermal performance warmth to weight ratio of at least 0.50 CLO/oz/sq yd (e.g., at least 0.5, 0.6, 0.7, or 0.8 CLO) according to ISO 11092.

[0069] Clo (clo/oz/yd2) is a unit used to measure the thermal resistance of clothing. A value of 1.0 clo is defined as the amount of insulation that allows a person at rest to maintain thermal equilibrium in an environment at 21°C (70°F) in a normally ventilated room (0.1 m/s air movement). Typically, above this temperature the person so dressed will sweat, whereas below this temperature the person will feel cold. Articles such as clothing and/or its components (e.g., insulative constructs) can be assigned a clo value. Higher clo indicates an article is warmer than another article with a comparatively lower clo.

[0070] In some embodiments, the air-permeable multi-layer insulative construct has a CLO of 0.5 to 1.8 CLO (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, or 1.8 CO), according to ISO 11092, including any and all ranges and subranges therein.

[0071] The inner insulation material layer has a thickness greater than 2 mm. As would be readily appreciated by a person having ordinary skill in the art, different insulation material layer thicknesses are conducive to different textile articles. For example, in some embodiments, it is desirable for a bed comforter to comprise inner insulation material layer that would be significantly thicker than a light-weight jacket. It is within the purview of a person having ordinary skill in the art to select any desired thickness for the inner insulation material layer, provided that it is greater than 2 mm. In some embodiments, the inner insulation material layer has a thickness or average thickness of at least 3 mm (e.g., at least 3.0, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, or 4 mm). In some embodiments, the inner insulation material layer has a thickness or average thickness of 3 mm to 310 mm (e.g., 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, 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, or 310 mm), including any and all range and subranges therein (e.g., 3 to 250 mm, 3.5 to 200 mm, 3.5 to 150 mm, etc.).

[0072] The inner insulation material layer can comprise any desirable insulation material suitable for use in textiles, which is a matter within the purview of a person having ordinary skill in the art.

[0073] In some embodiments, the inner insulation material is loose insulation material, which includes blowable insulation. “Blowable” is a term that is commonly used in the textile industry, and persons having ordinary skill in the art readily understand what is meant by blowable insulation. As is appreciated in the textile field, 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 insulative construct and/or an article (e.g., sacks, pockets, channels, or baffles etc. of pillows, clothing, bedding, sleeping bags, etc.). For example, the light, discrete structure of down makes it very amenable for blowing using conventional equipment. 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. Some non-limiting conventional blowing equipment is described, for example, in U.S. Patent No. 6,329,051.

[0074] In some embodiments, the inner insulation material layer comprises blowable floccules as described in U.S. Patent No. 10,633,244.

[0075] In some embodiments, the inner insulation material layer comprises batting, which is also well known within the textile field. A non-limiting example of batting conducive for use in embodiments of the inventive air-permeable multi-layer insulative construct is described in U.S. Publication No. 2017-0370037.

[0076] Denier is a unit of measure defined as the weight in grams of 9000 meters of a fiber or yarn. It is a common way to specify the weight (or size) of the fiber or yarn. For example, polyester fibers that are 1.0 denier typically have a diameter of approximately 10 micrometers. [0077] In some embodiments, the inner insulation material layer comprises, based on the total weight of the inner insulation material layer:

- 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 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);

- 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 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); and/or

- 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%) natural fibers, which include, for example, one or more members selected from wool, cotton, tencel, kapok (cotton-like fluff obtained from seeds of a Kapok tree, which may optionally be further processed before use), flax, animal hair, silk, and down (e.g., duck or goose down).

[0078] In some embodiments, the inner insulation material layer comprises 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%) polymeric fibers having a diameter of 5 to 100 pm (e.g., 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.

[0079] In some embodiments where the inner insulation material layer comprises polymeric fibers, whether microdenier or macrodenier, 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 the polymeric fibers are 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.).

[0080] In some embodiments, the inner insulation material layer comprises 0-25 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, or 25 wt%) binder fibers. 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 that may be present in the inner insulation material layer. In some embodiments of the air-permeable multilayer insulative construct wherein the inner insulation material layer comprises binder fibers, the inner insulation material layer has been heat treated so as melt all or a portion of the binder fibers (e.g., to form a bonded web-type batting). Persons having ordinary skill in the art will understand that, in such embodiments, although "binder fibers" may be wholly or partially melted fibers, as opposed to binder fibers in their original, pre-heat treatment form.

[0081] In some embodiments, 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%) of any polymeric fibers used are siliconized.

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 poly siloxane, 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. [0082] Fibers used in the inventive air-permeable multi-layer insulative construct may be crimped or uncrimped. Various crimps, including spiral and standard crimp, are known in the art.

[0083] In some embodiments, the first outer pliable layer and/or the second outer pliable layer is elastic. In some embodiments, the first outer pliable layer and/or the second outer pliable layer is inelastic. The term "elastic" is used herein to mean any material which, upon application of a biasing force, is stretchable, that is, elongatable, to a stretched, biased length which is at least about 150 percent of its relaxed unbiased length, and which will recover at least 50 percent of its elongation upon release of the stretching, elongating force in less than one minute. A hypothetical example would be a one (1) inch sample of a material which is elongatable to at least 1.50 inches and which, upon being elongated to 1.50 inches and released, will recover to a length of not more than 1.25 inches in less than one minute. Many elastic materials may be stretched by much more than 50 percent of their relaxed length, for example, 80 percent or more, and many of these will recover to substantially their original relaxed length, for example, to within 105 percent of their original relaxed length, upon release of the stretching force. The term “inelastic” refers to materials that do not fall within the definition of "elastic" above.

[0084] In some embodiments, the inner insulation material layer does not comprise one or more super absorbent polymers (SAP’s) or other materials that are intended to retain liquid, as in personal care items such as diapers, sanitary napkins/pads, etc.

[0085] In some embodiments, the inner insulation material layer is not laminated to the first outer pliable layer and/or the second outer pliable layer.

[0086] In some embodiments, the air-permeable multi-layer insulative construct additionally comprising a first fabric layer and a second fabric layer, wherein the first outer pliable layer, the second outer pliable layer, and the inner insulation material layer are disposed between said first fabric layer and said second fabric layer. In some embodiments, the first fabric layer and/or the second fabric layer is a woven or knit fabric layer.

[0087] One test method for determining a construct’s migration resistance is the IDFL (International Down and Feather Testing Laboratory) Downproofness - International Rotation Box standard test method. In accordance with that method, a 45.5 cm plastic box tumbler with a door on one side is used. A motor rotates the box at a speed of 48 +/- 2 revolutions per minute. Twenty -four No. 6.5 solid silicone stoppers are used in the box. A clean sample article is placed in the box, and the box is rotated for 30 minutes. All fibers and clusters are collected from the surface of the article, tumbler box and silicone stoppers. Collection material is evaluated and counted, and a numerical rating of 1 (significant fiber migration) to 5 (little or no fiber migration) is assigned, as shown in Table I, based on the amount of fibers (only fibers > 4 mm are counted) that escape or protrude through the fabric of the article after the 30 minute tumbling period.

Table I: Fiber Migration Ratings

Rating Fibers (> 4 mm)

5 <5

4 6 ™ 10

3 I I 20

2 21 - 30

1 >31

[0088] In some embodiments, the inventive air-permeable multi-layer insulative construct has a fiber migration rating of 5 in accordance with the IDFL Downproofness - International Rotation Box standard test method.

[0089] Applicant has developed a migration resistance test standard (the “INS-17 Fiber Migration Test”) that is even more strenuous and exacting than the IDFL Downproofness - International Rotation Box standard test method.

[0090] The INS-17 Fiber Migration Test determines the potential for migration of fibers through various types of fabric and utilizes the following equipment:

[0091] 5.1. 12”xl2” template

[0092] 5.2. Scissors

[0093] 5.3. Residential washer and dryer

[0094] 5.4. Sewing machine

[0095] 5.5. Yard stick (preferably in cm, otherwise results will have to be converted)

[0096] 5.6. Permanent market [0097] 5.7. Packing tape

[0098] 5.8. 21 Rubber stoppers (such as Herco Black Rubber One-Hole Stoppers, Part Number ST1H-04-BK sold by Hecht Rubber Corporation).

[0099] Samples are prepared as follows:

[00100] 6.1. Pick recommended fabric. Make sure coat side fabric is facing out.

[00101] 6.2. Fold fabric in half (making a 12” x 1” pillow) with three sides open.

[00102] 6.3. Sew 2 sides of the pillow (approximately i inch from the edge).

Leave the side across from the fold unsewn.

[00103] 6.4. Using the template, cut a 12” x 12” piece of insulation. (The insulation should be just small enough to fit in the fabric pillow without bunching).

[00104] 6.5. Place the insulation over the fabric pillow and carefully turn inside out such as the insulation and sewn edges are now on the inside of the pillow (The noncoated fabric side should now be external.)

[00105] 6.6. Sew the last end shut.

[00106] 6.7. Sew approximately *4” around the entire outside of the pillow to prevent the insulation from shifting.

[00107] 6.8. Sew a piece of fabric on the pillow to mark sides, A or B.

[00108] The testing procedure entails:

[00109] 7.1. After the pillow has been constructed, it should be placed in a dryer for 45 minutes, no heat with 21 rubber stoppers. This is cycle 1.

[00110] 7.2. Closely observe both sides of the pillow for fibers migrating through the fabric. The pillow should be observed using a dark background and appropriate lighting. Tape should be utilized to thoroughly scan the surface of the pillow.

[00111] 7.3. Using the residential washer, wash the pillow on the following settings (Cycles 2-4): 7.3.1.1. Regular wash cycle

[00112] 7.3.I.2. Cold water rinse

[00113] 7.3.I.3. Small wash load

[00114] 7.3.1.4. Two tablespoons of Tide or equivalent (used for first wash cycle only)

[00115] 7.4. After the wash cycle is complete, remove from washer and put pillow in dryer on low heat with the 21 rubber stoppers until completely dry. [00116] 7.5. Closely observe both sides of the pillow for fibers migrating through the fabric. The pillow should be observed using a dark background and appropriate lighting. Packing tape should be utilized to thoroughly scan the surface of the pillow.

[00117] 7.6. Repeat steps 7.3 to 7.5 two more times (3 total)

[00118] Recording and Recommendations are made as follows:

[00119] 8.1. Count and record the number of fibers migrating through the fabric after each cycle for both sides of pillow.

[00120] 8.2. The fabrics are graded as follows:

[00121] 8.2.1.1. 0 fibers counted - Migration Resistant

[00122] 8.2.I.2. Less than 3 fibers counted - Acceptable Migration

[00123] 8.2.I.3. Less than 10 fibers counted - Mild Migration

[00124] 8.2.1.4. Less than 20 fibers counted - Moderate Migration

[00125] 8.2.1.5. More than 20 fibers counted - Severe Migration

[00126] In some embodiments, the inventive air-permeable multi-layer insulative construct has a migration resistance of “Migration Resistant” (i.e., 0 fibers counted) or “Acceptable Migration” (i.e., less than 3 fibers counted) according to the INS-17 Fiber Migration Test.

[00127] In a second aspect, the invention provides an article comprising the air-permeable multi-layer construct according to the first aspect of invention.

[00128] In some embodiments, the article is a garment, sleeping bag, sleeping pad, or footwear. [00129] In some embodiments, the article is a garment selected from a coat, jacket, vest, glove, mitten, and headwear.

[00130] In some embodiments, the article is a home furnishing item (e.g., bedding, such as a comforter or quilt, pillow, cushion, upholstered chair, etc.).

[00131] In some embodiments, the article has an air permeability of 1 CFM to 500 CFM.

[00132] In a third aspect, the invention provides a method of making the air-permeable multilayer construct according to the first aspect of invention or the article according to the second aspect of the invention.

EXAMPLES

[00133] The invention will now be illustrated, but not limited, by reference to the specific embodiments described in the following examples. [00134] Three pillows were prepared. Each contained the same outer pillow fabric (109 CFM) and the same inner insulation material layer - a loose fill mixture, which consisted of 80 wt% goose down and 20 wt% 1.2 denier siliconized PET fiber. Pillow 1 consistent of only the loose fill and outer pillow fabric. Pillow 2 was identical to Pillow 1, but included a commercially available spunbond polypropylene scrim layer on each side of the fill mixture, the scrim layer having a basis weight of 28 gsm, a thickness of 0.4 mm, and an air permeability 744 CFM. Pillow 3 was identical to Pillow 2, but in place of the scrim layers, included pliable layers according to embodiments of the invention that were meltblown non-woven webs having a basis weight of 27 gsm, a thickness of 0.4 mm, and an air permeability 42.8 CFM.

[00135] Fiber migration testing was performed according to the INS-17 Fiber Migration Test. Results of migration testing on Pillows 1-3 are as follows:

[00136]

[00137] As is readily apparent, Pillow 3 enclosing an embodiment of the inventive air- permeable multi-layer insulative construct significantly outperformed Pillows 1 and 2 from a fiber migration perspective. Despite the rigorous fiber migration test procedure and having a first outer pliable layer and second outer pliable layer with an air permeability of 42.8 CFM, Pillow 3 demonstrated downproofness. The ability to achieve this level of reduced/prevented fiber migration without the need for downproof fabric (<1 CFM) allows for articles having severely reduced and/or prevented fiber migration, whilst offering breathability and comfort unparalleled by state-of-the-art and competing technologies. [00138] 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.

[00139] As used herein, the terms “comprising,” "has," “including,” "containing," and other grammatical variants thereof encompass the terms “consisting of’ and “consisting essentially of.”

[00140] 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. [00141] 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.

[00142] Subject matter incorporated by reference is not considered to be an alternative to any claim limitations, unless otherwise explicitly indicated.

[00143] 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.

[00144] 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.