Office Action 1: Notice of Allowance (2025-09-08)

CLAIMS:
CLAIMS

1\. Batting comprising a bonded nonwoven web, said batting having a first surface parallel to a second surface, and said bonded nonwoven web comprising a fiber mixture containing, based on the total weight of the fiber mixture:(a) 20 to 55 wt % of siliconized fibers having a denier of 1.5 to 10.0 and a length of 51 mm to 84 mm;
(b) 10 to 45 wt% of hollow conjugate fibers having a spiral crimp, and having a denier of 1.5 to 10.0 and a length of 51 to 84 mm;
(c) 10 to 45 wt % of a first population of binder fibers, said first population of binder fibers being elastomeric co-polyester binder fibers having a denier of 1.5 to 8.0, a length of 51 mm to 84 mm, and a bonding temperature of 110°C to 180°C; and
(d) 1 to 20 wt % of a second population of binder fibers different from the first population of binder fibers, said second population of binder fibers having a denier of 1.5 to 6.0, a length of 51 mm to 84 mm, and a bonding temperature of 80°C to 135°C;
wherein fibers in the fiber mixture are homogenously mixed.

2\. The batting according to claim 1, wherein said first surface and said second surface comprise a resin.

3\. The batting according to claim 2, comprising 4 to 15 wt% resin, based on the total weight of the batting.

4\. The batting according to claim 3, comprising 6 to 10 wt% resin, based on the total weight of the batting.

5\. The batting according to any one of the preceding claims, wherein the fiber mixture comprises, based on the weight of the fiber mixture:(a) 20 to 40 wt % of the siliconized fibers; and/or:
(b) 20 to 40 wt% of the hollow conjugate fibers; and/or (c) 20 to 40 wt % of the first population of binder fibers; and/or (d) 5 to 15 wt % of the second population of binder fibers.

6\. The batting according to any one of the preceding claims, wherein:(a) the siliconized fibers have a denier of 3.0 to 10.0; and/or

(b) the hollow conjugate fibers have a denier of 3.0 to 10.0; and/or (c) the first population of binder fibers have a denier of 3.0 to 8.0; and/or (d) the second population of binder fibers have a denier of 1.5 to 4.0.

7\. The batting according to any one of the preceding claims, wherein:(a) the siliconized fibers are hollow.

8\. The batting according to any one of the preceding claims, wherein:(b) the hollow conjugate fibers are dry fibers.

9\. The batting according to any one of the preceding claims, wherein:(a) the siliconized fibers are polyester fibers.

10\. The batting according to claim 9, wherein:(a) the siliconized fibers are polyester fibers comprising recycled polyester.

11\. The batting according to any one of the preceding claims, wherein:(b) the hollow conjugate fibers are polyester fibers.

12\. The batting according to claim 11, wherein:(b) the hollow conjugate fibers are polyester fibers comprising recycled polyester.

13\. The batting according to any one of the preceding claims, wherein:(c) the second population of binder fibers comprise polyester.

14\. The batting according to claim 13, wherein:(c) polyester in the second population of binder fibers comprises recycled polyester.

15\. The batting according to any one of the preceding claims, having an area weight of 25 to 60 g/m2 and a density of 11 to 15 kg/m3.

16\. The batting according to any one of the preceding claims, having an area weight of 30 to 40 g/m2 and a density of 13 to 14 kg/m328

17\. The batting according to any one of the preceding claims, having a warmth per weight thermal performance greater than 0.012 clo per g/m2 according to ISO 11092.

18\. The batting according to any one of the preceding claims, having a water uptake property of less than 150 wt%.

19\. The batting according to claim 18 having a water uptake property of less than 100 wt%.

20\. The batting according to any one of the preceding claims, having a migration resistance of less than 20 fibers when tested according to the INS-17 Fiber Migration Test.

21\. An article comprising the batting according to any one of the preceding claims.

22\. The article according to claim 21, wherein said article is selected from the group consisting of an outerwear product, clothing, a sleeping bag, and bedding.

23\. A method of making the batting according to any one of the preceding claims, said method comprising:- preparing the fiber mixture by mixing:
(a) 20 to 55 wt % of siliconized fibers having a denier of 1.5 to 10.0 and a length of 51 mm to 84 mm;
(b) 10 to 45 wt% of hollow conjugate fibers having a spiral crimp, and having a denier of 1.5 to 10.0 and a length of 51 to 84 mm;
(c) 10 to 45 wt % of a first population of binder fibers, said first population of binder fibers being elastomeric co-polyester binder fibers and having a denier of 1.5 to 8.0, a length of 51 mm to 84 mm, and a bonding temperature of 110°C to 180°C;
and (d) 1 to 20 wt % of a second population of binder fibers different from the first population of binder fibers, said second population of binder fibers having a denier of 1.5 to 6.0, a length of 51 mm to 84 mm, and a bonding temperature of 80°C to 135°C;- forming a nonwoven web from the fiber mixture;

\- providing the nonwoven web, or optionally layering the nonwoven web formed from the fiber mixture with one or more additional nonwoven webs;- heating the nonwoven web(s) to or in excess of a highest binder fiber bonding temperature, thereby forming batting or a batting intermediate comprising one or more nonwoven webs, including at least the bonded nonwoven web comprising the fiber mixture, said batting or batting intermediate having a first surface parallel to a second surface;- optionally applying a resin solution to the first and second surfaces of the batting intermediate;- optionally heating the batting intermediate to a temperature in excess of the glass transition temperature of the resin in the resin solution; and- optionally calendaring one or more surface of the batting intermediate,
thereby forming the batting.

24\. The method according to claim 23, wherein said providing the nonwoven web, or optionally layering the nonwoven web formed from the fiber mixture with one or more additional nonwoven webs forms a batting intermediate, and wherein said method comprises subjecting the batting intermediate to a needling process.

OFFICE ACTION:
EXAMINER'S AMENDMENT
An examiner’s amendment to the record appears below. Should the changes and/or additions be unacceptable to applicant, an amendment may be filed as provided by 37 CFR 1.312. To ensure consideration of such an amendment, it MUST be submitted no later than the payment of the issue fee.
Authorization for this examiner’s amendment was given in an interview with Erica Hines on August 26, 2025.
The application has been amended as follows:
Amend Claims 13 and 14 as follows:
13.  (Currently Amended)  The batting according to claim 1, wherein:
(d) the second population of binder fibers comprise polyester.
14.  (Currently Amended)  The batting according to claim 13, wherein:
(d) polyester in the second population of binder fibers comprises recycled polyester.
Allowable Subject Matter
Claims 1-15, 17, and 20-23 are allowed.
The following is an examiner’s statement of reasons for allowance: the cited art of record does not fairly disclose or suggest the combination of limitations required by Claim 1 with regard to a bonded nonwoven web comprising a fiber mixture containing the (a) siliconized fibers in the specified amounts with the specified limitations and dimensions, the (b) hollow conjugated fibers in the specified amounts with the specified limitations and dimensions, the (c) first population of binder fibers in the specified amounts with the specified limitations and dimensions, and the (d) second population of binder fibers in the specified amounts with the specified limitations and dimensions.  U.S. Patent Application Publication No. 2019/0271104 to Mason et al. (“Mason”) discloses an insulative batting comprising a blend of a plurality of fibers that includes a fiber mixture containing functional fibers and non-functional fibers.  See, e.g., Abstract, entire document.  Mason discloses that the batting can be formed of a nonwoven web, paragraph [0020], having a first surface parallel to a second surface, Figures 1-4, wherein the nonwoven web can be thermally bonded.  Paragraph [0043].  Mason provides an example of a bonded nonwoven web comprising at least 15% staple binder fibers with a length of 51 mm and a denier of 2.2, at least 20% siliconized polyester staple fiber with a length of 51 mm and a denier of 1.4, and at least 20% siliconized polyester hollow conjugate staple fiber with a length of 64 mm and a denier of 7.0.  Paragraphs [0077] to [0082].  However, Mason does not teach that the siliconized fibers have a denier of 1.5 to 10.0, nor does Mason teach the presence of a second population of binder fibers containing an elastomeric copolyester, which is different from a first population of binder fibers, nor does Mason specify the bonding temperature of the binder fibers.  U.S. Patent Application Publication No. 2017/0370037 to Mason (“Mason II”) discloses a migration resistant batting material comprising a nonwoven web migration-resistant, stretchable, bonded nonwoven web for use as batting for e.g. outerwear products, comprising 35% to 65% of a first population of synthetic polymeric fibers, which can be siliconized, having a denier of less than or equal to 1.0, 10% to 30% of a second population of spiral-crimped synthetic polymeric fibers, which can also be siliconized having a length of greater than or equal to 60 mm, 20% to 50% elastomeric fibers having a denier between 2.0 and 7.0, and 5% to 25% synthetic binder fibers having a denier of 1.5 to 4.0, wherein the binder fibers have a bonding temperature lower than the softening temperature of the synthetic polymeric fibers.  Paragraphs [0037] to [0041].  However, Mason II does not disclose that the siliconized fibers have a denier of 1.5 to 10, nor does Mason II teach that the spirally crimped fibers have a hollow, conjugate configuration, nor does Mason II disclose that the binder fibers should comprise two different populations wherein one of the populations comprise a copolyester.  U.S. Patent Application Publication No. 2019/0335830 to Stangeland et al. (“Stangeland”) discloses nonwoven insulation material in the form of a batting, see, e.g., Abstract, entire document, that contains 25% to 35% of waterfowl fibers, about 40% of two different types of hollow and crimped siliconized PET fiber, wherein each of these fibers have a different denier, and about 20% of low melting binder fiber.  Paragraph [0046].  Stangeland teaches that the bonding temperature of the binder fiber can be about 90 degrees C.  Paragraph [0059].  However, Stangeland does not disclose that the amount of conjugate fibers, when present, to be utilized, nor does Stangeland teach using an elastomeric binder fiber formed of copolyester, nor does Stangeland teach the binder fibers should comprise two different populations.  U.S. Patent No. 6,156,680 to Goettmann (“Goettmann”) relates to nonwoven composite web materials wherein the nonwoven composite material is formed with two different populations of binder fibers.  See, e.g., Abstract, entire document.  However, the utilization of different binder fibers in Goettmann relates to the processing of the nonwoven fabric in papermaking machines, where the material is subjected to different melting processes, i.e., calender bonding and exposure to papermaking machine, and such processing limitations are not relevant to the insulation batting art.
Any comments considered necessary by applicant must be submitted no later than the payment of the issue fee and, to avoid processing delays, should preferably accompany the issue fee.  Such submissions should be clearly labeled “Comments on Statement of Reasons for Allowance.”
Conclusion
The prior art made of record and not relied upon is considered pertinent to applicant's disclosure: U.S. Patent No. 4,520,066 to Athey and U.S. Patent No. 5,527,600 to Frankosky et al.



CITED REFERENCE SUMMARIES: Ref US20190271104A1: Claims:
Self-regulating insulative batting, comprising: a blend of a plurality of fibers including functional fibers and non-functional fibers, the plurality of fibers being non-woven and oriented substantially vertically along a thickness direction of the batting, wherein the functional fibers are configured to self-regulate at least one insulative quality of the batting based on changes in at least one environmental condition interacting with the batting.
a blend of a plurality of fibers including functional fibers and non-functional fibers, the plurality of fibers being non-woven and oriented substantially vertically along a thickness direction of the batting,
wherein the functional fibers are configured to self-regulate at least one insulative quality of the batting based on changes in at least one environmental condition interacting with the batting.
The self-regulating batting according to claim 1 , wherein the batting is in the form of a sheet extending along width and length directions.
The self-regulating batting according to claim 1 , wherein the functional fibers are configured to self-regulate the insulative quality of the batting with respect to heat based changes in at least one environmental condition interacting with the batting.
The self-regulating batting according to claim 1 , wherein the functional fibers are configured to self-regulate the insulative quality of the batting with respect to moisture based changes in at least one environmental condition interacting with the batting.
The self-regulating batting according to claim 1 , wherein the functional fibers are configured to self-regulate at least one insulative quality of the batting based changes in humidity of an environment interacting with the batting.
The self-regulating batting according to claim 5 , wherein the functional fibers are configured to self-regulate insulative quality of the batting with respect to at least heat based changes in humidity of the environment interacting with the batting.
The self-regulating batting according to claim 6 , wherein the functional fibers are configured to self-regulate insulative quality of the batting with respect to at least heat based changes in humidity of the environment interacting with the batting by varying the thickness of the batting.
The self-regulating batting according to claim 7 , wherein the functional fibers are configured to vary the thickness of the batting by self-varying their length along the thickness direction based changes in humidity of the environment interacting with the batting.
The self-regulating batting according to claim 8 , wherein the functional fibers self-vary their length along the thickness direction by forming a crimp therein or increasing a crimp thereof.
The self-regulating batting according to claim 7 , wherein the functional fibers are configured to decrease the insulative quality of the batting with respect to at least heat based of increases in humidity of the environment interacting with the batting by decreasing the thickness of the batting.
The self-regulating batting according to claim 10 , wherein the functional fibers are configured to decrease the insulative quality of the batting with respect to at least heat based of increases in humidity of the environment interacting with the batting above a predetermined threshold humidity level by decreasing the thickness of the batting.
The self-regulating batting according to claim 1 , wherein the plurality of fibers are vertically lapped.
The self-regulating batting according to claim 1 , wherein the plurality of fibers comprises staple fibers of a staple length within the range of 12 mm to 70 mm and a denier within the range of 0.5 D to 8 D.
The self-regulating batting according to claim 1 , functional fibers include a hygroscopic component and a non-hygroscopic component.
The self-regulating batting according to claim 1 , wherein the non-functional fibers include binder fibers.
The self-regulating batting according to claim 1 , wherein the non-functional fibers comprise synthetic fibers.
The self-regulating batting according to claim 18 , wherein the synthetic fibers comprise polyester fibers.
The self-regulating batting according to claim 18 , wherein the synthetic fibers comprise siliconized fibers.
The self-regulating batting according to claim 1 , wherein the functional fibers comprise at least 15% of the blend of fibers.
An article, comprising: the self-regulating insulative batting according to claim 1 .
the self-regulating insulative batting according to claim 1 .
The article according to claim 22 , wherein said article is selected from the group consisting of an outerwear product, clothing, a sleeping bag, and bedding.
The article according to claim 22 , wherein the article is configured to be used by a user such that a micro climate interacting with the batting is formed between the user and the self-regulating insulative batting extending along the thickness direction.
The article according to any of claims 22 , wherein the article includes at least one outer protection layer that prevents the environment exterior to the self-regulating batting from interacting with the self-regulating batting.
A method of making self-regulating batting, comprising: forming at least one nonwoven web from a blend of a plurality of fibers including functional fibers and non-functional fibers; and vertically lapping the at least one nonwoven web such that the fibers are oriented substantially vertically along a thickness direction of the batting, wherein the functional fibers are configured to self-regulate at least one insulative quality of the batting based on changes in at least one environmental condition interacting with the batting.
forming at least one nonwoven web from a blend of a plurality of fibers including functional fibers and non-functional fibers; and
vertically lapping the at least one nonwoven web such that the fibers are oriented substantially vertically along a thickness direction of the batting,
A method of making self-regulating insulative batting, comprising: obtaining a plurality of opened and blended fibers including functional fibers and non-functional fibers, the functional fibers being configured to self-regulate at least the length thereof based on changes in at least one environmental condition interacting with the fiber; parallelizing the plurality of opened and blended fibers into at least one non-woven, carded web layer; and vertically lapping the at least one non-woven, carded web layer to form a self-regulating insulative batting with the lengths of the fibers being oriented substantially vertically along thickness direction of the batting so that at least one insulative quality of the batting self-regulates based on changes in at least one environmental condition interacting with the batting.
obtaining a plurality of opened and blended fibers including functional fibers and non-functional fibers, the functional fibers being configured to self-regulate at least the length thereof based on changes in at least one environmental condition interacting with the fiber;
parallelizing the plurality of opened and blended fibers into at least one non-woven, carded web layer; and
vertically lapping the at least one non-woven, carded web layer to form a self-regulating insulative batting with the lengths of the fibers being oriented substantially vertically along thickness direction of the batting so that at least one insulative quality of the batting self-regulates based on changes in at least one environmental condition interacting with the batting.
The method according to claim 27 , wherein obtaining a plurality of opened and blended fibers comprises opening a plurality of the functional fibers and non-functional fibers and blending a plurality of the opened functional fibers and non-functional fibers.
The method according to claims 27 , further comprising positioning the self-regulating insulative batting within an article configured to be used by a user such that a micro climate interacting with the batting is formed between the user and the self-regulating insulative batting extending along the thickness direction.
The method according to claim 31 , wherein the article includes at least one outer protection layer that prevents the environment exterior to the self-regulating batting from interacting with the self-regulating batting.
Ref US4520066A: [content unavailable]
Ref US5527600A: [content unavailable]
Ref US6156680: Claims:
1. A nonwoven web comprising: 40 to 84 wt. % of polymeric staple fibers having a length in the range of 5 to 15 mm and a denier in the range of 0.2 to 3.0, said polymeric staple fibers having a melting temperature;16 to 60 wt. % of polymeric binder fibers comprising a first thermoplastic binder material having a first melting temperature less than said melting temperature of said polymeric staple fibers; and a second thermoplastic binder material having a second melting temperature less than said first melting temperature, wherein said polymeric staple fibers and said first and second thermoplastic binder fibers are substantially homogeneously mixed so that said polymeric staple fibers are bonded to form the nonwoven web by said first and second thermoplastic binder materials, and the nonwoven web has a permeability of 5 to 10 cfm, wherein said staple fibers comprise a first fraction of staple fibers having a denier greater than 0.2 but less than 1.0 and a second fraction of staple fibers having a denier greater than 1.0 but less than 3.0.
2. The nonwoven web as defined in claim 1, wherein said polymeric staple fibers are made of polyester.
3. The nonwoven web as defined in claim 1, wherein said first thermoplastic binder material is a co-polyester.
4. The nonwoven web as defined in claim 1, wherein said first thermoplastic binder material is co-polyester from a first fraction of co-polyester/polyester bicomponent fibers.
5. The nonwoven web as defined in claim 1, comprising 5 to 40 wt. % of said polyester staple fibers of said first fraction and 0 to 60 wt. % of said polyester staple fibers of said second fraction.
6. The nonwoven web as defined in claim 4, wherein said co-polyester/polyester bicomponent fibers of said first fraction have a co-polyester sheath material which melts at said first melting temperature.
7. The nonwoven web as defined in claim 6, wherein said homogeneously mixed fibers comprise 15 to 50 wt. % of said co-polyester/polyester bicomponent fibers of said first fraction and 1 to 10 wt. % of said co-polyester/polyester bicomponent fibers of a second fraction.
8. A nonwoven web made from a furnish comprising:5 to 40 wt. % of polymer staple fibers having a denier greater than 0.2 but less than 1.0; 0 to 60 wt. % of polymer staple fibers having a denier greater than 1.0 but less than 3.0; 15 to 50 wt. % of co-polymer/polymer bicomponent fibers having co-polymer sheath material which melts at a first melting temperature less than the melting temperature of said polymeric staple fibers; and 1 to 10 wt. % of co-polymer/polymer bicomponent fibers having co-polymer sheath material which melts at a second melting temperature less than the first melting temperature, wherein said polymer staple fibers and said bicomponent fibers are substantially homogeneously mixed so that said polymer staple fibers are bonded to form the nonwoven web at least in part by solidification of said co-polymer sheath material after subjecting said fibers to temperatures in excess of said first melting temperature, but not in excess of the melting temperature of said polymer staple fibers, and the thermally bonded nonwoven web has a permeability of 5 to 10 cfm.
9. The nonwoven web as defined in claim 8, wherein said polymeric staple fibers are made of polyester.
10. The nonwoven web as defined in claim 8, wherein said co-polymer sheath material is co-polyester.
11. The nonwoven web as defined in claim 8, wherein said co-polymer/polymer bicomponent fibers comprise co-polyester/polyester bicomponent fibers.
Ref US4520066: Claims:
1. A fibrefill blend comprising (a) from 90 to 50% by weight of slickened crimped hollow polyester fibre having a cavity volume of 10 to 30% and, complementally, to total 100% by weight, (b) from 10 to 50% by weight of slickened crimped conjugate fibre, the improvement being that the hollow polyester fibres and the conjugate binding fibres have substantially the same density and decitex (and so diameter) and that the conjugate fibre comprises a polyester core and a polyolefin sheath.
2. A thermally bonded batt formed from the fibrefill blend of claim 1.
Ref US5527600: Claims:
1. A bonded batt with upper and lower faces, said batt comprising polyester fiberfill of 0.2 to 10 dtex per filament, in an amount of about 75 to 98%, and bonded throughout with lower melting binder material, in an amount of about 2 to 25%, said amounts being calculated on the basis weight of the batt, said upper and lower faces of said batt being sealed with a resin having a glass transition temperature (Tg) in the range of about 0 degrees to -30 degrees Celsius, in an amount of about 10 to 30% of the total weight of the batt, whereby the sealing rating (SR, as defined) after 3 wash cycles of said faces is at least 4, said batt having a wash durability (WD, as defined) of at least 3, and a bending stiffness (B, as defined) of about 80 cN/cm2 or less.
2. A batt according to claim 1, wherein the bending stiffness is about 50 cN/cm2 or less.
3. A bonded batt with upper and lower faces, said batt comprising polyester fiberfill of 0.2 to 10 dtex per filament, in an amount of about 75 to 98%, and bonded throughout with lower melting binder material, in an amount of about 2 to 25%, said amounts being calculated on the basis weight of the batt, said batt having a wash durability (WD, as defined) of at least 3, and a bending stiffness (B, as defined) of about 80 cN/cm2 or less, wherein at least one of said faces is sealed with a rosin having a glass transition temperature (Tg) in the range of about 0 degrees to -30 degrees Celsius, in an amount of about 5 to 15% of the total weight of the batt, whereby the sealing rating (SR, as defined) after 3 wash cycles of said face is at least 4.
4. A batt according to claim 3, wherein the bending stiffness is about 50 cN/cm2 or less.
5. A bonded bait with upper and lower faces, said bait comprising polyester fiberfill of dealer per filament about 1 or less, in an amount of about 75 to 96%, and bonded throughout with lower melting binder material, in an amount of about 4 to 25%, said amounts being calculated on the basis weight of the batt, said batt having a wash durability (WD, as defined) of at least 4, and a bending stiffness (B, as defined) of about 40 cN/cm2 or less, wherein at least one of said faces is sealed with a resin having a glass transition temperature (Tg) in the range of about 0 degrees to -30 degrees Celsius, in amount about 0.02 oz/yd2 to about 0.35 oz/yd2, calculated with regard to said face of the batt, whereby the sealing rating (SR, as defined) after 3 wash cycles of said face is at least 4.
6. A batt according to claim 5, wherein the amount of resin is about 0.1 to about 0.25 oz/yd2.
7. A batt according to claim 5, wherein each of said upper and lower faces is sealed with said resin in said amount and has a sealing rating after 3 wash cycles of at least 4.
8. A batt according to claim 6, wherein each of said upper and lower faces is sealed with said resin in said amount and has a sealing rating after 3 wash cycles of at least 4.