Synthetic wadding: use continuous nature and make ripstip, dispensing with dead weight of shell

[al b]

As so far synthetic insulation manufacturers do not seem to be matching downs durability / compressability / warmth to weight by simply copying its structure, why not compete by avoiding down's disadvantage: the need to be enclosed in a shell:

ie make rip-stop wadding which doesn't need a shell (or very open close-looped hollow fibre "fleece"/"pile" made from very fine polyester/polypropylene.

eg RAB microlight down vest weighs 248g of which 90g is the down insulation!! 180g of shellless synthetic insulation (50% weight to warmth) would still be lighter!!

Chris Knapton (in the UK): used such an idea to make a cheap lunch stop insulation: cut square of cheap polyester wadding from market/standard fabric shop, cut hole for head, and wear under windshirt.

[Dale Wambaugh]

I had brought this up some time ago, envisioning something like a belay jacket with no outer shell, perhaps a light mesh overlay to keep the insulation in place, and offered with a mating windshirt for the outer layer. It may be helpful to secure the batting to the inner layer in the same way traditional quilts are ticked at regular intervals. Ryan Jordan had replied that BPL experimented with the same, but it wasn't as warm. I think it could be successful with the right drawstrings and a bit of Velcro.

I think it is a waste to haul several layers of cloth that have identical function.

Fleece does exactly that, but it is heavy for the loft provided and doesn't compress/stow as well. Perhaps what is needed is a "balloon" fleece.

[James holden]

needs a shell as youd be wearing it over all yr layers

[Eric Blumensaadt]

I'll stick with the shell construction for its protection from wind, light misting/fog, bushes & branches and light snow.

Also shells hsve pockets both inside and out.

What REALLY needs to be studied by the synthetic fiber industry is making a very fuzzy hollow core fiber that has great compactability combiuned with down-like loft retention after repeated stuffings.

Likely the fuzzy fibers (or puffs) would need to be siliconized to avoid clumping. This is the synthetic equivalent of the natural oils on down plumules that keep the down resiliant. Waterfowl constantly preen their feathers & down with oils from their tail glands to refresh the oils and thus the waterproofing of their feathers/down so they can stay afloat.

Perhaps there is a new lighter and stronger, more water resistant shell fabric waiting in the wings. Technology marches on…

BTW, any continuous filament insulating fiber would have to be resin coated to hang together with a heavier application than is presently used for some synthetic insulations. And any such coating would likely be at least as heavy as a light ripstop shell.

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