CN1063246C - 含有双组分纤维的纤维网/气凝胶复合材料及其生产工艺和使用 - Google Patents

含有双组分纤维的纤维网/气凝胶复合材料及其生产工艺和使用 Download PDF

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CN1063246C
CN1063246C CN95196918A CN95196918A CN1063246C CN 1063246 C CN1063246 C CN 1063246C CN 95196918 A CN95196918 A CN 95196918A CN 95196918 A CN95196918 A CN 95196918A CN 1063246 C CN1063246 C CN 1063246C
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composite
fiber
aeroge
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CN1170445A (zh
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D·弗兰克
F·索尼森
A·齐默曼
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Cabot Corp
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Abstract

本发明是一种至少具有一层纤维网和气凝胶粒子的复合材料,其中纤维网至少包括一种双组分纤维材料,此双组分纤维材料具有低和高熔融区域,且纤维网不仅与气凝胶粒子、而且互相间通过纤维材料的低熔融区域粘合;本发明还包括其生产工艺及其使用。

Description

含有双组分纤维的纤维网/气凝胶复合材料及其生产工艺和使用
本发明涉及一种具有至少一层纤维网和气凝胶粒子的复合材料以及其生产工艺和使用。
气凝胶,特别是孔隙率大于60%、密度小于0.4g/cm3的气凝胶,具有很低密度、高孔隙率和小孔径因而热传导率极低,因此用作热绝缘材料,例如EP-A-0171722所述。
但是,高孔隙率不但使(干燥后得到气凝胶的)凝胶、而且使干燥后的气凝胶本身的机械稳定性降低。
在较广意义上,即“以空气为分散介质的凝胶”的意义上,气凝胶用干燥适当的凝胶生产。在此意义上,术语“气凝胶”包含狭义的气凝胶,干凝胶和冻干胶。干凝胶是一种狭义的气凝胶,是大于临界温度时,从大于临界压力开始将凝胶的液体除去而得的气凝胶。反之,如果在亚临界状态下除去凝胶的液体,例如通过生成液-汽边界相,所得的凝胶称作干凝胶。应该注意到,本发明的凝胶是气凝胶,是以空气作为分散介质意义上的凝胶。
气凝胶的成型是在溶胶-凝胶转化期间完成的。一旦固体凝胶结构生成,则只能通过粉碎(例如研磨)改变其外形,此时材料太脆,不能用其它方式加工。
然而许多应用需要使用具有某种成型体结构形式的气凝胶。原则上,在凝胶期间生产成型体是可能的。但是,在生产期间一般需要的由扩散支配的溶剂交换过程(见例如US-A4610863、EP-A0396076关于气凝胶;见例如WO93/06044关于气凝胶复合材料)和相似的扩散支配的干燥过程会使生产时间长而不经济。因此,在生成气凝胶以后,亦即干燥后进行任何成型是合理的,此时不会使气凝胶内部结构发生任何明显的取决于应用的变化。
有许多应用例如弯曲或不规则形状的绝热件要求含有绝热材料的柔性板和垫。
DE-A3346180描述了含有由压制结构组成的抗弯板,压制结构以火成硅石气凝胶为基础,由长矿物纤维增强。但火成硅石气凝胶非上述意义上的气凝胶,因为它不通过干燥凝胶生产,因而具有完全不同的孔结构;因此它在机械上更稳定,并能在不破坏其微结构下受压,但其导热率高于上述意义的典型气凝胶。这种压制结构的表面是非常敏感的,因此必需加以硬化,例如通过在表面上使用粘合剂或必需用薄膜层压保护。另外,所得的压制结构是不可压缩的。
而且,德国专利申请P4418843.9描述了一种由纤维增强干凝胶组成的垫。此垫的导热率很低,因为其气凝胶的含量很高,但其生产时间由于上述扩散问题而相对较长。尤其是较厚垫的生产只有通过将多个薄垫结合到一起才可能是切合实际的,因而需要附加费用。
本发明的一个目的是提供一种粒状气凝胶复合材料,其热导率低、机械上稳定,易于生产垫或板。
此目的通过具有至少一层纤维网和气凝胶粒子的复合材料而达到,其中纤维网包含至少一种双组分纤维材料,双组分纤维材料具有较低的和较高的熔融区域,且网的纤维通过纤维材料的低熔融区域不仅与气凝胶粒子结合,还彼此结合。双组分纤维的热固着作用使其低熔融各部分相粘合,从而保证了网的稳定。同时,双组分纤维的低熔融部分将气凝胶的粒子与纤维粘合。
双组分纤维是由两种互相牢固粘结的聚合物组成的化学纤维,两种聚合物具有不同的化学和/或物理结构以及不同的熔点区域,也就是较低和较高的熔融区域。较低和较高熔融区域的熔点最好相差至少10℃。双组分纤维最好具有芯-皮结构。纤维的芯是一种聚合物,较好为一种热塑聚合物,其熔点高于形成皮层的热塑聚合物的熔点。双组分纤维较好为聚酯/共聚酯双组分纤维。可以进一步使用由聚酯/聚烯烃组成的双组分纤维变体,例如聚酯/聚乙烯或聚酯/共聚烯烃,或具有一种弹性皮层聚合物的双组分纤维。但是也可用并排的双组分纤维。
纤维网可进一步包含至少一种单一纤维材料,此材料在热固着过程中与双组分纤维的低熔融区相粘合。
单一纤维是有机聚合物纤维,例如聚酯、聚烯烃和/或聚酰胺纤维,较好为聚酯纤维。纤维的横截面可以是圆的、三叶状的、五叶状的、八叶状的、带状的、像圣诞树的、哑铃状的或星形的。同样,可用空心纤维。这些单一纤维的熔点应高于双组分纤维低熔融区的熔点。
为了减少辐射对热传导的影响,双组分纤维,即高和/或低熔融组分,和可选地单一纤维可用红外遮光剂使其变暗,例如碳黑、二氧化钛、氧化铁或二氧化锆或其混合物。
为了着色,双组分纤维和可选地较单一的纤维也可染色。
用于复合物的纤维的直径较好应小于气凝胶粒子的平均直径,以确保纤维网中大部分的气凝胶的粘合。很细的纤维直径使生产柔性大的垫成为可能,而较粗的纤维则具有较大的抗弯刚度,导致垫体积膨大刚性好。
单一纤维的纤度较好应为0.8-40dtex,而双组分纤维的纤度较好应为2-20dtex。
亦可使用由不同材料组成的双组分纤维和单一纤维的混合物,它们具有不同的横截面和/或不同的纤度。
为了在一方面确保网的优良固着作用和在另一方面确保气凝胶颗粒的粘附作用,双组分纤维基于总纤维含量的重量比例应为10-100%(重量)较好为40-100%(重量)。
在复合材料中的气凝胶体积比例应尽可能高,至少为40%,较好为高于60%。但是,为了确保复合物具有一定的机械稳定性,比例应不高于95%,较好为不高于90%。
用作本发明组份的适合的气凝胶为基于适于溶胶-凝胶技术(C.J.Brinker,G.W.Scherer,Sol-Gel-Science,1990二、三章)的金属氧化物的气凝胶,例如硅或铝的化合物或基于适于溶胶-凝胶技术的有机物质的气凝胶,例如三聚氰胺-甲醛缩合物(US-A-5086085)或间苯二酚-甲醛缩合物(US-A-4873218)。它们也可是基于上述材料的混合物。可选择使用含有硅化合物的气凝胶,特别是SiO2气凝胶,最好为SiO2干凝胶。为了减少辐射对热传导的影响,气凝胶可含有红外遮光剂,例如碳黑、二氧化钛、氧化铁、二氧化锆或其混合物。
此外,气凝胶的导热率随着孔隙率的增加和密度的减少而减少。因此气凝胶的孔隙率较好为大于60%而其密度较好为小于0.4g/cm3。气凝胶颗粒的导热率应小于40mW/mK,较好为小于25mW/mK。
在一较好的实施方案中,气凝胶颗粒具有疏水表面基团。这是因为-若需避免由于孔中湿气凝结引起气凝胶后来的破裂-气凝胶的内表面具有在水的作用下不会脱离的共价结合的疏水基是有利的。用于持久的疏水作用的较好的基为三取代的甲硅烷基,其通式为-Si(R)3,最好为三烷基-和/或三芳基甲硅烷基,其中每一个R独立地是非活性的有机基,例如C1-C18-烷基或C6-C14-芳基,较好为C1-C6-烷基或苯基,特别是甲基、乙基、环己基或苯基,它们亦可用其它的官能基另外取代。三甲基甲硅烷基特别有利于使气凝胶得到持久的疏水作用。这些基可如WO94/25149所述的那样引入或通过气凝胶与例如一种活性的三烷基硅烷衍生物,如氯三烷基硅烷或六烷基二硅氮烷间的气相反应引入,(比较R.IIer,硅石化学(TheChemistryofSilica),Wiley&Sons,1979)。
颗粒的大小取决于材料的用途。但是,为了粘合大部分的气凝胶颗粒,粒子应大于纤维直径,较好为大于30μm。为了得到高稳定性,颗粒不应太大,较好应小于2cm。
为了达到气凝胶的高体积比例,可较好地使用双模态粒度分布的颗粒。亦可使用其它适合的粒度分布。
复合材料的防火等级取决于气凝胶和纤维的防火等级。为了得到复合材料的最佳防火等级,应使用低可燃性的纤维类型,例如TREVIRA CS
如果复合材料只由含有气凝胶粒子的纤维网组成,在复合材料上的机械应力可引起气凝胶颗粒破裂或与纤维脱离,以致碎片从网上脱出。
因而,对于某些应用,将纤维网的一面或两面上至少加上一层覆盖层是有利的,覆盖层是相同或不同的。覆盖层可以在热固着过程中经双组分纤维的低熔融组分粘合,也可通过其它黏合剂粘合。覆盖层可以例如是塑料膜,较好为金属箔或镀金属的塑料膜。此外,每一覆盖层本身可由多层组成。
纤维网/气凝胶复合材料优选为垫或板的形式,它具有含有气凝胶的纤维网作为中间层,并在两面各有覆盖层,至少一层覆盖层包含细单一纤维和细双组分纤维组成的网层,且各个纤维层可内部或层间热固着。
对于覆盖层的双组分纤维和单一纤维的选择的要点与保持有气凝胶粒子的纤维网的纤维的选择相同。
但是为得到尽可能密的覆盖层,单一纤维和双组分纤维的直径都应小于30μm,较好为小于15μm。
为了得到表面层更大的稳定性或密度,覆盖层的网层可以是针刺的。
本发明的又一目的是提供生产本发明复合材料的工艺。
本发明的复合材料可通过例如下列工艺生产:
为了生产纤维网,短纤维使用商业上可得到的盖板梳理或罗拉梳理的形式。网是按照熟练此技术者所熟悉的工艺敷设的,而颗粒状气凝胶是喷入的。将气凝胶颗粒加至纤维复合物中应是非常均匀的。商业上可用的喷淋器能确保此要求。
当使用覆盖层时,纤维网可在喷入气凝胶时敷设到一个覆盖层上,而在完成此操作后敷设上部覆盖层。
如果使用由较细纤维材料组成的覆盖层,首先下部网层由细纤维和/或双组分纤维按已知工艺敷设,且可选针刺的。如上所述,将含有气凝胶的纤维复合物敷设于上部。对于下一步骤的上覆盖层,可如同下部网层方式进行,并由细的纤维和/或双组分纤维敷设一层,并可选择将其针刺。
所得的纤维复合物在皮层材料的熔融温度和单一纤维材料和双组分纤维的高熔融组分的两个熔融温度中的较低的温度之间,在使用或不使用压力下进行热固着。压力取大气压和所用气凝胶的压缩强度之间的压力。
整个工艺可较好地由熟练技术者在所熟知的设备上连续地施行。
本发明的板和垫由于其导热率低而被用作绝热材料。
另外,本发明的板和垫可直接用作消声材料或以共振吸收器的形式使用,因为它们的声速低,且与单片气凝胶相比具有较高的阻尼声音的能力。这是因为,除了由气凝胶材料所提供的阻尼以外,另外的阻尼由于网材料中孔间的空气摩擦而发生,这取决于纤维网的穿透能力。纤维网的穿透能力可随纤维直径、网的密度和气凝胶粒子的粒度的变化而变化。若此网包括另外的覆盖层,这些覆盖层应允许声音进入网中,并不会导致声音的显著的反射。
本发明的板和垫,由于网的孔隙率(特别是高孔隙率)和气凝胶的比表面积,亦可用作液体、蒸汽和气体的吸收材料。通过改进气凝胶的表面,可达到特殊的吸收。
现将用实施例更具体地描述本发明。
实施例1:
重量含量为50%的Trevira290,0.8dtex/38mmhm和重量含量为50%的Trevira254,2.2dtex/50mmhm型的聚酯/共聚酯双组分纤维被用于敷设具有基底重量为100g/m2的纤维网。在敷设期间,喷入颗粒状的疏水气凝胶,气凝胶基于TEOS,其密度为150kg/m3,导热率为23mW/mK,粒子的直径为1-2mm。
所得的网复合材料在160℃下热固着5min,并压缩至1.4cm的厚度。
在所固结的垫中的气凝胶的体积比例为51%。所得的垫具有1.2kg/m2的基底重量。它易于弯曲,亦可压缩。其导热率为28mW/mK,按照DIN52612第一部分用平板法测定。
实施例2:
重量含量为50%的Trevira120短纤维,其纤度为1.7dtex、长38mm、纺丝-染黑以及重量含量为50%的Trevira254,2.2dtex/50mmhm型的聚酯/共聚酯双组分纤维首先将两者用于敷设用作下部覆盖层的网。此覆盖层的基底重为100g/m2。在其上,作为中间层,敷设一纤维网,其基底重为100g/m2,由重量含量为50%的Trevira292,40dtex/60mmhm和重量含量为50%的Trevira254,4.4dtex/50mmhm型的聚酯/共聚酯双组分纤维所组成。在敷设期间,喷入颗粒状的疏水气凝胶,气凝胶基于TEOS,其密度为150kg/m3,导热率为23mW/mK,粒子的直径为2-4mm。此含有气凝胶的纤维网,用覆盖层覆盖,覆盖层的结构与下部覆盖层相同。
所得的复合材料在160℃下热固着5min,并压缩至1.5cm的厚度。在所固着的垫中的气凝胶的体积比例为51%。
所得的垫具有1.4kg/m2的基底重量。其导热率为27mW/mK,按照DIN52612第一部分用平板法测定。
此垫易于弯曲和压缩。甚至在弯曲后,此垫亦不脱落任何气凝胶的颗粒。

Claims (14)

1.一种至少具有一层纤维网和气凝胶粒子的复合材料,纤维网至少包括一种双组分纤维材料,双组分纤维材料具有低和高熔融区域,其中网上的纤维不仅与气凝胶粒子、而且互相间通过纤维材料的低熔融区域粘合并且气凝胶粒子的孔隙率大于60%、密度小于0.4g%/cm3以及导热率小于40mW/mK。
2.权利要求1的复合材料,其中双组分纤维材料具有芯-皮结构。
3.权利要求1或2的复合材料,其中纤维网还包括至少一种单一纤维材料。
4.权利要求3的复合材料,其中双组分纤维材料的纤度范围为2-20dtex,而单一纤维的纤度范围为0.8-40dtex。
5.权利要求1的复合材料,其中气凝胶粒子在复合材料中的体积比例至少为40%。
6.权利要求1的复合材料,其中气凝胶是一种SiO2气凝胶。
7.权利要求1的复合材料,其中双组分纤维材料、单一纤维材料和/或气凝胶粒子至少包括一种红外遮光剂。
8.权利要求1的复合材料,其中气凝胶粒子的导热率小于25mW/mK。
9.权利要求1的复合材料,其中气凝胶粒子具有疏水表面基。
10.权利要求1的复合材料,其中纤维网在一面或两面上至少各设有一层覆盖层,覆盖层可以是相同的或不同的。
11.权利要求10中的复合材料,其中覆盖层含有塑料膜、金属箔、镀金属的塑料膜,或较好为含有由细的单一纤维和/或细的双组分纤维组成的网层。
12.权利要求1的复合材料,其形式为板或垫。
13.权利要求1中的复合材料的生产工艺,包括将孔隙率大于60%、密度小于0.4g%/cm3以及导热率小于40mW/mK的气凝胶粒子喷淋至至少含有一种具有低和高熔融区域的双组分纤维材料的纤维网中,并将所得的纤维复合材料在高于低熔融温度和低于高熔融温度下、使用或不使用压力下热固着。
14.权利要求1至12中至少一项的复合材料用于绝热、消声和/或作为气体、蒸汽和液体的吸收材料的用途。
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