Outlast Technologies GmbH has developed a technology that can directly incorporate the extraordinarily light and insulating material aerogel into viscose fibres.
This innovation has improved insulation properties without increasing weight. Initial testing by an independent institute confirmed that the fibres treated with Aersulate offered up to 35 percent better insulation performance than conventional viscose fibres.
“Weight plays a key role in sleeping comfortably. If a blanket is too heavy, it can seem uncomfortable and restrict breathability. At the same time, it often does not provide sufficient insulation if it is too light,” said Volker Schuster, Head of Research and Development at Outlast Technologies.
Until now, manufacturers have had to compromise the weight and insulating properties. However, the Outlast Technologies experts have succeeded for the first time in integrating aerogel, a notoriously tricky material to process, directly into the filling’s fibres using a patent-pending process.
“Aerogel is a silicate-based solid derived from quartz sand and has a unique insulating effect. Its outstanding insulating performance is based on its highly porous structure, 98 percent air. These special properties have made aerogel essential for NASA space missions for many years,” added Schuster.
“While conventional insulating materials such as foams, wadding or nonwovens rely on trapped air to regulate heat, aerogel binds the air inside the fibre. The result is that it retains its insulating properties even under pressure and moisture. This gives it a considerable advantage over traditional materials, which essentially lose functionality under such conditions.”
Outlast has succeeded in utilising aerogel, a very challenging material, and its outstanding properties for bedding with the new, patent-pending process. This innovation is up-and-coming in developing lightweight, sustainable, highly insulating fibres and textiles.
The company has already successfully used its patented Aersulate technology by effectively applying the material to textile webs. In contrast to stiffer composites, which are more suitable for technical applications, fibres treated with Aersulate are noticeably soft and are, therefore, ideal as filling material for bedding.
An independent, ISO-certified laboratory carried out tests to assess the Aerolite technology’s insulation performance. This involved comparing viscose wadding of two-centimetre thickness with and without aerogel content by DIN EN ISO 11092.
The results revealed that the Aersulate-treated wadding has a 35 percent better insulation performance than conventional viscose fibres.
“We have fully exploited aerogel’s benefits for the textile industry for the first time with this new technology without compromising softness or comfort. Bedding manufacturers can now develop extremely lightweight yet highly insulating products that meet the growing demands for quality and functionality. The materials are also sustainable and protect animal welfare by offering an animal-friendly alternative to down-based bedding.”
Outlast Technologies will present the new Aersulate-treated fibres for the first time at HEIMTEXTIL 2025.
