Method of making blowable floccule insulation

Abstract

The disclosure provides blowable insulation or filling material, and apparatus and methods for making same. The blowable insulation or filling material includes a plurality of discrete elongate floccules each formed of a plurality of fibers. The floccules include a relatively open enlarged medial portion. The floccules also include relatively condensed twisted tail portions extending from opposing ends of the medial portion. The floccules can be utilized by existing garment fill blowing machines without clogging thereof, and include a superior soft hand feel, thermal resistance and launderability. The floccules may be formed by forcing staple fibers through apertures of a rotating hollow drum to partially form the floccule structure within the drum. The partially formed floccules may be retained within the rotating drum for a dwell time to finalize the floccule structure.

Dependencies are inferred from the claim text.