Letters From the Field: Yukon Quest to Alaska
WHY CONTINUOUS FILAMENT VERSUS CHOPPED STAPLE FIBERFILL?
All polyester fiber regardless of its end use is extruded as a continuous filament fiber product. Until the Celanese Corp ( no longer in business) developed the machinery that separated the continuous filament fiber and arranged the fibers in a configuration that created a lofty batting the fiber was cut or chopped (referred to as chopped staple) to two inch lengths. The two inch length equaled the length of the cotton fiber used for making battings. These two inch fibers are then formed into a web structure and they are joined via either a bonding process (spraying a resin on the fibers which when the resin dries holds them together) or blending two fibers; one of a low melt consistency which when placed in an over with the standard fiber liquefies and when cooled solidifies there by joining the fibers in the same manner as the bonding process. In the first process the fibers are referred to as bonded and in the second process, low melt or thermally bonded. This seems a complete waste of time and money when the end result is to have an insulating medium when finished. Why (?) because you are starting out with fully joined fibers in the first place; i.e. continuous filament fiber. When you resin bond or low melt bond you do not have any control over the amount of resin or liquefied fiber that coats the original fiber. In either of these processes the original fiber is adulterated. This adulteration adversely affects the resilience of the fiber, it diminishes the resilience dramatically. Historically all polyester batting that have been constructed in either method of manufacture lose their loft quite quickly. Because the structure is weak quilting is necessary to hold the fibers in place. Of course quilting is detrimental to insulated products since all quilt stitches are cold spots. Since the fiber thickness is compressed along the quilt lines water is easily trapped along the quilt lines. Retention of water is obviously not good. Think about this for a moment, you are starting out with continuous fiber, long unbroken strands of fiber, and then you are cutting the fiber into two inch lengths just so you can put them through a process to rejoin the cut fibers all over again. Does this make any sense (?); today no. I have researched the history of garneting cotton fiber which starts when cotton was first grow and the garneting was done by hand. In the 1700’s machinery was invented to eliminate the hand garneting. This method of combing or separating fibers has survived until today and is necessary when you work with natural fiber; cotton, wool, silk, or chopped synthetic fiber when the end product is yarn, but when it comes to making insulation from polyester fiber why go through the garneting process when we have a process that allows us to use the continuous fiber in its natural state? To stay with the garneting process in this instance is no different than continuing to make automobiles using a carburetor to feed the engine versus fuel injection. If you are interested in a very inexpensive fiberfill product to use in inexpensive bedspreads as an example it is perfect. But if the end product is a relatively expensive sleeping bag chopped staple fiber will never perform even remotely close to continuous filament fiber. Over the years companies who have endeavored to get into the business of making or rather marketing fiberfill insulations believe that utilizing finer and finer denier (thicknesses) fibers will make for a more efficient insulation. Air sticks to all surfaces for a distance of 1/8th inch, therefore if the space between the fibers is reduced or broken into an area less than 1/8th the air will stay more securely in place. While that is true the down side is the finer denier fibers are weak and therefore collapse easily from compression. The collapsing of these very fine denier fibers means that the spaces between the fibers disappears as the fibers are mashed together; a decrease in the space between the fibers means a reduction in insulation. Things do get worse; since the fibers are mashed together the rate of conductive heat loss is increased and due to the reduction of loft or thickness cold air settling on the surface of a sleeping bag will penetrate more easily. Climashield (continuous filament fiber) is made with heavier denier fibers than is used by the manufacturers using the chopped fiber, and these CF fibers are not capable of being mashed together, so loss of loft is not experienced, loss of insulation does not occur. In the final analysis chopping the fiber to glue it back together again makes no more sense than changing from fuel injection back to carburetion.
__________________________________________________________________________
A REPLACEMENT FOR DOWN
ALTERNATIVE: Stating or offering the one or the other of two things of which either maybe taken. Source: Oxford Unabridged Dictionary.
Down as we know has a wonderful heat retaining property so long as it stays dry. As all who have had down sleeping bags as well as outerwear garments know once the down starts to get wet the insulating property begins to deteriorate. The down clusters absorb moisture very quickly. Once this takes place the item, regardless if it is a sleeping bag or garment, it gains in weight and loses its loft. The loss of loft is just the start of the process of deterioration. Each day the item is used it gains more moisture, hence more weight and lower loft resulting in less insulation. The moisture that is now absorbed into the down clusters cools to the ambient air temperature and if the temperature is below the freezing point it will freeze. Initially the down material which does not ever reach body temperature continually conducts heat from the body. The moisture absorbed into the down also absorbs the heat generated from the body amplifying the speed of the heat loss. And finally when the temperature is below freezing when the moisture in the down freezes you are building an ice box around yourself, and now the cold temperature is not held at bay by the material used for insulation; it will simply conduct into the garment. In physics we learn that heat travels to cold and the cold will accommodate the heat by getting as close to it as possible. Also, in order to dry the down it must be placed in a warm environment. If it does not get dried it will not be of any value as insulation. To continue to use a moisture ridden down product is of little value. Keeping your body wrapped in a wet covering can lead to a hypothermic state. So there is good reason to find not an alternative, but a replacement for down as an insulating medium. A material that is oblivious to moisture, meaning that it is completely unaffected by the moisture; does not absorb it and therefore does not lose its loft; i.e. insulating capability.
In all of the years I have worked in the fiberfill industry I have noted that all chopped staple fiberfill battings, whether they are 2.5 denier or 6 denier or any denier in between, perform negligibly different.
It is not necessary for you to believe me, all you have to do is experience using any of the sleeping bags or outerwear in the cold conditions these items are recommended for use by the manufacturer and you will discover or learn what I have over the years.
Lamilite/Climashield (L/C) is not an alternative to down but a replacement. When you replace down with L/C you have a much improved product. L/C does not absorb any moisture of consequence, and even if it does get wet there is no appreciable reduction in loft. No moisture; no conduction of heat from the body and no deterioration of loft. By replacing down with L/C the end product is improved dramatically; i.e. it works even if wet. I have accumulated a significant number of letters that attest to the L/C’s ability to continue to perform regardless of its getting wet. I performed an experiment at my office with an equal thickness of the L/C (L-6 or 4.7 ounce per square yard) and it not only didn’t retain much water but its loft recovery time was almost instantaneous. Therefore, loss of insulation is insignificant.
__________________________________________________________________________
CLO VALUE
Clo value is an arbitrary number given to a comfort level of a man wearing a wool business suit, plus underwear, socks and shoes. This wearing attire relates to one “clo.” It does not relate to a specific temperature, say 56 degrees F. Therefore, in my educated opinion “clo” has no value.
In May 1986 shortly after I started making the Wiggy’s sleeping bags I became aware of Kansas State University’s Institute for Environmental Research and their copper man. They were doing and had for a few years been testing sleeping bags on the copper man to advise sleeping bag manufacturers how efficient the manufacturers were at temperature rating their sleeping bags. I knew about the copper man testing since I had worked with Natick Labs who had their own copper man. I had two bags tested at Natick, a Super Light rated for 0 degrees F and an Ultima Thule rated for -20 degrees F. This testing of my bags took place in May 1986, the Super Light (0 degrees) calculated to 5.18 clo and the Ultima Thule (-20 degrees) calculated to 5.94 clo. In May 1986 I sent a Wiggy bag to KSU a +20 degree F bag and its clo calculation was 4.42. In each instance I called the person conducting the test and asked what the temperature rating would be in F? The response I received in both instances was “I can not tell you that.” As I recall I naturally asked why and in both instances they refused to put an F rating to equal the clo calculation. In March 1989 I sent a bag, Ultima Thule to a company that may no longer be in business (Comfort Technology) owned by a former Natick employee. His testing showed a clo calculation of 5.51. In this report there is a temperature rating stated, +42 degrees F. That was the end of me having any of my bags tested on copper men and paid for by me. As you will see my bags have been tested at KSU, paid for by Celanese Corp., no longer in business. In September 1986 Celanese Corp. sent 11 sleeping bags to KSU for testing. Some were insulated with continuous filament fiber and some with chopped staple fiber. The one notable item is that the continuous filament fiber was superior to the chopped staple fiber.
In March of 1990 Hoechst Celanese Corp (no longer in business) purchased from me two Ultima Thule’s, one of which was vacuum packed. I was told they wanted to see the difference in insulation between the non-vacuum packed bag and the vacuum packed bag after it was removed from the blister packaging. That may have been part of the reason but the primary reason was to test it against another company’s -25 degree bag. This I was not told and only found out when they sent me a copy of the report. The end result was that the Ultima Thule’s had consistent clo calculations of 4.9 and the two other bags ranged from clo calculations of 6.5 to 6.8. Also note that the Ultima Thule is 6 pounds. Remember the first bag I sent to KSU was a 3.75 pound +20 degree bag and it had a clo calculation of 4.42. The Ultima Thule is almost twice as heavy with the bulk of the insulation added to the top of the bag, but it only increased by 0.48 in the clo calculation.
The point of this is simple; clo has no value. For years I have suggested that bags be tested for temperature performance and then see what the weight is. There is an old adage “do not put the cart in front of the horse.”
__________________________________________________________________________
Jerry,
I have attached several photos from my running in the 1000 mi 07 Yukon Quest. Feb 10th to 25th.
I wore/ used Wiggys Antarctic Parka & Bibs, Overbag, 2-Stainless Steel Water Bottles, Joe Reddington Mukluks, Sun Walkers and 60"Ground Pad.
The first week, Whitehorse --> Dawson was a piece of cake. From the mouth of the 40 mi river (7 days of travel) of travel) to Fairbanks was "COLD", it would generally warm up to -40 mid afternoon (I rested the dogs the warmest part of the day) At Circle City and Central, it felt warm to me (compared to being on the Yukon and Birch Creek) and it was -52 F. The locals thought it was -68 F on Birch Creek when I went thru. I had a small thermometer on my parka pull, the lowest marker was -30 and the merc was pegged in the bottom!!!!
I was impressed with how fast the Parka and bibs would dry out when I got in a cabin with heat. Generally twice in a 24 hr period. The water bottles would freeze up but I was able to thaw them out directly on wood stoves. The Mukluks kept my feet from any frost bite. I only used my sleeping bag & overbag once in the 2 weeks of travel and that was at the 40 mi bridge in a spartan wall tent with a small wood stove. I removed my parka to hang it up to dry. I wore bibs, mukluks, layed on one bag and the ground pad on a blue tarp on the ground. The sun walkers worked well when at cabins and doing dog chores while drying my mukluks. I slept on the ground pad generally twice per 24 hr period. Either rolled out on top of my sled or on the floor / bunk in cabins. It was the very best equipment that I have used. I could only sleep two hrs at a time most of the race.
Key to the pic's;
1- My bibs drying at Eagle after going thru overflow water at -40. 2- At the finish line, after a night of -50 F, 90 mi run in 15 hrs from Chena Hot Springs to Fairbanks. 3- The team on a afternoon break, aprox 150 miles south of Dawson.
Take Care
Bob McAlpin
__________________________________________________________________________
In the early 1960’s I experimented with the lamination of chopped staple fiberfill battings. When the batting was soft and pliable it would fall apart in laundering and general use, and if the fiberfill was made structurally strong enough to go through several laundering cycles it had no resilience. In 1968 that changed with the manufacture of continuous filament fiber, hence Lamilite. What I find interesting is the simple fact that I have not ever changed my insulation to the newest greatest. If something works and has proven itself over and over and over again that should tell you something.
TECHNICAL DATA
INSULATION: Continuous filament fiberfill with a surface treatment of silicone.
Continuous filament fiberfill treated with silicone has certain qualities not found in any other form of fiberfill used as insulation. The need to quilt the fiberfill to any sub straight is eliminated. Once the insulation is sewn in place around the perimeter to any sub straight it will not shift or be displaced with use as well as laundering.
When the quilting is eliminated as is necessary to do with any chopped staple form of fiberfill insulation there are no cold spots from any quilt or cross stitching. A uniform layer of insulation is accomplished.
The silicone treatment is a “lubricating” finish. There are several reasons why the addition of the “silicone lubricating finish” is desirable; 1- Water as a vapor or liquid will not attach to the fibers. While in a vapor state the moist vapor will rise and when it gets into the continuous filament fiberfill that is silicone treated it slides easily past the fibers without sticking. When the continuous filament fiberfill treated with silicone is exposed to water it will shed the water very easily and quickly when removed from the water, shaking will eliminate whatever is left to the extent of 90 to 95 percent, the balance of wetness will dry very quickly from exposure to sun or a breeze. 2- The treatment of silicone applied to the continuous filament fiberfill adds to its resilience. We know this to be fact since all of the sleeping bags that are vacuum packed for use as survival bags in military aircraft and Navy survival rafts are equipped with sleeping bags and other items insulated with silicone treated continuous filament fiberfill because after compression of 25 tons of pressure these bags return to full loft. 3- The silicone lubrication does not allow the fibers to tangle into each other as happens with chopped staple fiberfill so loss of loft is eliminated. 4- We also observe when the silicone treated continuous filament fiberfill is laundered the normal tumbling action of both washing machine and dryer cause the fibers to move away from each other demonstrating an on going retention of the loft. Actually we observed an increase of loft.
SHELL AND LINING FABRIC: Single ply 70 denier nylon taffeta. This was probably the first nylon fabric made. The thread count is 104 by 86 threads per square inch; the weight is two ounces per square yard.
The 70 denier yarn is the optical thickness for use in any insulated product as a lining. All synthetic fiber is temperature sensitive. When exposed to cold it will quickly reach the same temperature as what ever temperature it is exposed too. The same holds true when it is exposed to heat. All temperature should be viewed in terms of heat. While 0 degrees F is a cold temperature it should be viewed as 0 degrees of heat. The 70 denier yarn will absorb heat more rapidly than a 200 denier yarn but less rapidly than a 40 denier yarn, however it will not lose the heat that it has absorbed as quickly as a 40 denier yarn. It is irrelevant to further compare the 70 denier yarn to a 200 denier yarn since the 200 denier yarn is not suitable for use as a lining or shell fabric in sleeping bags. The process of absorbing heat should be as quick as possible at the absorption side and as slow as possible on the lose side. The 70 denier single ply taffeta offers the best performance at each side of the equation.
The 70 denier yarn is stronger than a 40 denier yarn so a lesser amount of yarns is required to weave a fabric. In order to weave a 40 denier yarn fabric many more threads are required which adversely affects the vapor permeability of the fabric. As a rule the weight of 40 denier fabric is 1.9 ounces per square yard. The thread count is normally 160 by 100 threads per square inch. The more tightly woven a fabric is the lower the vapor permeability. The 70 denier 104 by 86 thread count allows for the optimum vapor transmission otherwise known as vapor permeability. The more rapidly the nylon fabric warms to the body temperature the slower the rate of conductive heat loss. The slower the rate of conductive heat lose the slower the rate the human body metabolizes its fuel; i.e. food. The slower the rate of food consumption the longer the body stays warm. This process is further aided by the high degree of vapor transmission found in a 70 denier single ply taffeta. Moisture is very efficient at absorbing heat. Therefore, the more rapidly the moisture evacuates the interior of a sleeping bag the longer the occupant stays warm. The same material is used as the shell of the bag. It has proven durability, as well as not retaining moisture, and can with stand numerous laundering.
CONSTRUCTION: There are two methods of constructing a sleeping bag with continuous filament fiberfill insulation; 1- via lamination of the fiberfill and 2- quilting of the fiberfill. Both methods serve the same purpose; to stabilize the fiber for greater ease of cutting and sewing. When lamination is the construction method used accomplishing a uniform loft through out the entire bag is possible at a minimum cost. When the continuous filament fiberfill insulation is adhered to the lining fabric it is stabilized allowing for greater stability when used (slept in, stuffed and un-stuffed and laundered). The insulating properties are enhanced; there is no space between the continuous filament fiber and the lining material so convective heat loss is eliminated, moisture while in a vapor state does not have a chance to cool as it passes through the spaces between the yarns of the 70 denier single ply taffeta and because of the silicone treatment applied to the continuous filament fiberfill the moisture slides easily past all of the fibers till it reaches the shell fabric where it will condense on the outside of the bag.
The lack of quilt through stitching means that there is a uniform loft so heat loss is minimized.
Conversely when quilting is employed there are cold spots at the rate of 10 stitches per inch. The quilting method reduces the loft of each layer of insulation regardless if the insulation is continuous filament fiberfill or chopped staple fiberfill. Therefore, in order to compensate for the natural compression created by quilting additional layers of fiberfill must be added to off set the thin spots created. This offset quilting adds weight to the overall sleeping bag. The quilting also restricts continuous filament fiber so it atrophies; ie; loses its resilience. Also previously noted so do chopped staple fiberfill's they both lose loft when used; slept in, stuffed and un-stuffed, compressed, and laundered.
CARE: Laundering; the un-quilted constructed sleeping bag when continuous filament fiberfill is the insulation as in the case with this bag has no known limit. Bags manufactured in this manner have been laundered in the hundreds of times and dried in any dryer. They have demonstrated that the water temperature, form of detergent (liquid or powder), or type of machine is irrelevant. As noted, the laundering of the bags assures the long term maintenance of the loft of the insulation, vital to any sleeping bags long term performance.
Storage; bags manufactured in this manner are currently used and have been since 1991 in the survival kits of military air craft as well as Naval survival rafts. They are vacuum packed under 25 tons of pressure and may not be used for years. When taken out of their double blister packaging loft returns relatively quickly assuring that their insulating capacity is not compromised. Therefore, storage in a stuff sack and left on a shelf in an inventory status for long periods of time will not adversely affect the performance of each bag.
FEATURES: The snap placement has the male snaps on the lower half of the bag and the female snaps on the top half as a security measure. If there is a zipper failure the snaps can be used to effectively close the sleeping bag. In addition the snap placement on the bivi bag is the opposite if the sleeping bag therefore if needed the bivi bag can be closed around the sleeping bag.
__________________________________________________________________________
A MULTI-PURPOSE TENT AND SLEEPING BAG
The Wiggy's Inc. multi-purpose tent is also known as the Freedom Shelter. The name implies that you have the freedom of three entities; a tent, bivi bag, and poncho, all in a single item. There is also a special model sleeping bag that fits inside the shelter or poncho like a glove.
It is my belief this combination of shelter and sleeping bag is the most intelligent design for any person who is interested in traveling in the backcountry light. It is especially efficient for soldiers. About 1993 or 4 we produced only the sleeping bag part of the system to the tune of about 3000 for Force Recon, an activity of the Marine Corps.
__________________________________________________________________________
I recently returned from a trip into the Cascade mountains. I brought along my Super Light sleeping bag, which I was issued as a member of US Air Force Combat Search and Rescue. During my hike into the mountains on the first day, my CamelBack water reservoir broke inside my pack, spilling three liters of water onto the sleeping bag. When I reached camp (on five feet of snow) I discovered that the sleeping bag was covered in ice. With many other sleeping bags this would have been an emergency situation. With your product, however, the only measure I had to take was wear my Goretex clothing while inside the bag in order to keep myself dry. Despite extremely cold temeratures, I continued to stay warm inside the sleeping bag. Thank you for making such a superior product. I know that when taking one of your bags along I can be confident that I'll sleep warm, regardless of the conditions!
Sincerely,
Mike Walker
__________________________________________________________________________
WARMEST PARKA IN THE WORLD
I have always advertised that my Antarctic Parka was the warmest clothing item in the world and I believe this is an illustration of that fact.
__________________________________________________________________________
I just returned back from a guided hunt to AK for Mt. Goat, Dall Sheep, Moose, Brown Bear, Black Bear, and Wolf. The guide service we used ,"Don Alaskan Guide Service" sent us a list prior to the hunt of recommend items,. I continued to do research in that dept. and also purchased a Wiggy's Super Lite, my hunting partner purchase one also.
On Sep the 5th of 2007 we spent the night on the side of a Mountain waiting for Daylight to recover a Mt. Goat I had shot. Rick Cherry, myself, our guide, and Daniel our packer. During the night it rained and rained and rained, the next morning Rick and I were the only people out of the four to stay dry, nothing over us but the Wiggy's sleeping bag. Our guide said when we get off this Mt. I will have one of those bag's.
On Sep 8, 2007 as we were coming off the Mt. in the rain I fell and tore the ACL and MCL in my right knee. I was very wet and hypo was starting to set in, our guide put up one of the tents, took my Wiggy's bag and placed inside the tent, help me get my boots and outer clothing off, and inside the bag. In about 20 minutes my body temp was starting to rise and within 45 minutes was back to normal, I remained in the bag until we heard the noise of the Med-a-Vac they used to get me off the Mt. and into the hospital in Anchorage.
I gave my bag to Craig our guide, and have ordered another one for myself. Rick, Craig, and Daniel are today Sep 18 still in the MT's of Alaska looking for Dall Sheep while I am home waiting on surgery this Friday to my knee.
I will go back next year with Don's Alaskan Guide Service and my new Wiggy's bag, to finish the hunt of a lifetime.
Thanks again of a product that is more than what you say it is. " In Alaska it is worth it's weight in GOLD on a wet, and cold Mt."
Good Hunting
Gary W