I could say we get asked often about the insulation in the popular light-weight down-alternative type jackets so popular today, but that would be a lie. I just thought you might want to know.
The two primary synthetic insulation materials we see in the jackets sold in the promotional products industry (they are popular with many retail brands also) are PrimaLoft and Thinsulate. These are both referred to as “short-staple” fabrics.
Short-staple insulation consists of a huge collection of short synthetic fibers, each usually less than 2 inches long, that interlock with each other to create a layer of insulation. In contrast, continuous filament insulation consists of a single, long fiber that weaves around and interlocks with itself. Continuous filament insulation is more durable and retains loft longer than short-staple. It also tends not to shift.
The fibers in short-staple insulation are often smaller in diameter than those used in continuous filament. This, coupled with the fact that the fibers are able to move more or less independently, makes short-staple insulation more compressible than continuous filament.
The fibers are also more tightly packed together, creating more dead air spaces—and thus more warmth for the weight. The short length of the fiber creates a much puffier, down-like feel; most garments stuffed with short-staple insulation will be very soft and flexible, draping closely against your body.
The downside? Short-staple insulation can move around over time and use, creating lumps and cold spots—especially after months of repeatedly cramming it into a stuff sack. It also tends to lose loft (and thus warmth) faster than continuous filament.
Here are more complete definitions of each material:
· Primaloft® is an ultra-fine microfiber blend that is incredibly soft, lightweight, and water-repellent. It also has a down-like softness that adds comfort. In addition to sleeping bags and outerwear, Primaloft® is also used to make winter footwear. Primaloft® One has the highest warmth-to-weight ratio of any synthetic insulation currently on the market. It’s soft, durable, high-loft and made from 100% polyester microfiber. It’s also lightweight, compressible, fast-drying and water-resistant. It can be a little harder to work with so Thinsulate is seen more often.
- Thinsulate® was introduced as the original "warmth without bulk" synthetic insulation. Even wet, it is still quite warm. The breathable, ultra-fine microfibers trap warm air more efficiently than larger, generic synthetic fibers. Thinsulate® comes in 40, 70, 100, and 150 gram weights. The higher the gram weight, the warmer the insulation. Thin, warm, light and breathable insulation. It is made of 50% recycled material, consisting of polyester and olefin.
We have found, by testing the coats we sell, that either works very well.