CN106367976A - 气体阻隔织物 - Google Patents

气体阻隔织物 Download PDF

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CN106367976A
CN106367976A CN201610575830.6A CN201610575830A CN106367976A CN 106367976 A CN106367976 A CN 106367976A CN 201610575830 A CN201610575830 A CN 201610575830A CN 106367976 A CN106367976 A CN 106367976A
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barrier
fabric
nanometer sheet
layer
air
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X.方
S.A.伊斯特曼
B.圣罗克
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Goodrich Corp
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Goodrich Corp
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Abstract

公开了一种气体阻隔织物。所述阻隔织物包括织物基底。耐热涂层被安置在所述织物基底的第一侧上。包括聚合物的第一气体阻隔层(在本文中也简称为阻隔层)被安置在所述织物基底的第二侧上。第二气体阻隔层被安置在所述织物基底的所述第一空气阻隔涂层上。所述第二阻隔层具有5nm至1000nm的厚度且包括对齐的纳米片。

Description

气体阻隔织物
技术领域
本发明是关于气体阻隔织物，且更具体来说是关于用于充气式结构，诸如飞机疏散滑梯和救生筏、充气式船只、缓冲垫、陈列品、游憩结构和其他充气式结构的织物。
背景技术
充气式结构通常由织物制成。虽然织物提供了诸如强度、柔性和容易使用多片织物进行组装之类的益处，但织物往往必须经过处理以便提供必需的渗透性水平。另外，许多应用还被强加额外的要求。举例来说，飞机疏散滑梯往往必须满足由法规或客户要求所强加的额外要求。
在紧急情况下需要安全地疏散飞机乘客是众所周知的。起飞和着陆时的紧急情况通常需要从飞机中迅速转移乘客，因为可能因着火、爆炸或沉没水中而导致受伤。从飞机中快速疏散大量乘客的常规方法是提供多个应急出口，各应急出口配备有充气式疏散滑梯，它在水中疏散情况下通常兼作救生筏。这些疏散滑梯最通常是由被形成多个管形构件的空气阻隔涂层织物材料构建。当被充气时，这些管形构件形成具有滑梯表面的自支承结构，其能够承载被疏散的乘客。除了不渗透性以外，构建管形构件的织物材料必须满足TSO-C69c关于对辐射热、可燃性、污染物、真菌的耐性的FAA规范要求和其他要求。
虽然疏散滑梯允许乘客从飞机出口门的水平快速而又安全地下降到地面，但各飞机出口门配备有充气式疏散滑梯的要求意味着必然有相当大的额定载重量被用于解决多个疏散滑梯的重量。因此，业内对制造尽可能轻的充气式疏散滑梯的需要存在已久。紧急疏散滑梯系统的重量有一大部分是滑梯织物本身的重量。因此，已经多方尝试减少滑梯织物的重量。一种被接受的方法是通过增加充气压力来减小滑梯结构构件的物理尺寸。然而，增加充气压力会对滑梯织物造成更大的压力，且因此，减小物理尺寸的益处至少有一部分由于需要使用较重规格的滑梯织物以便承受较高充气压力而被抵消。技术现状滑梯织物由超高韧性尼龙纤维制成的72×72支纱线/英寸尼龙布组成。这种72×72织物本身所具有的抓握拉伸强度在经线方向上大约是380磅且在纬线方向上是320磅(如本文中所使用，抓握拉伸强度是指通过将典型地4英寸宽的织物样品抓握在一组一英寸宽的夹爪之间且拉伸至破损而测得的强度)。所述织物典型地涂有多层弹性聚合物以使其不透空气，以及耐辐射热涂层。由此获得了强却重的织物，其抓握拉伸强度在经线方向上和纬线方向上大约是390磅，但单位面积重量可能超过7.0oz/yd2。如从上文可以确定，这些涂层不会显著有助于织物强度。
已经提出将填充剂用于阻隔织物层中以便在对总织物重量具有较低贡献的情况下抑制渗透性。然而，一些填充剂可能在涂料组合物中聚集，导致可能会抑制阻隔性能和耐火性的涂层缺陷。涂料组合物中的高溶剂水平可以帮助减少聚集，但是也可能导致低涂料组合物粘度，使得所述组合物难以涂布至织物基底上。
发明内容
在本发明的一些方面，气体阻隔织物(在本文中也简称为阻隔织物)包括织物基底。耐热涂层被安置在所述织物基底的第一侧上。包括聚合物的第一气体阻隔层(在本文中也简称为阻隔层)被安置在所述织物基底的第二侧上。第二气体阻隔层被安置在所述织物基底的所述第一空气阻隔涂层上。所述第二阻隔层具有5nm至1000nm的厚度且包括对齐的纳米片。
在本发明的一些方面，充气式结构包括由所述阻隔织物形成的外壳和处于所述外壳内的充气气体源或用于从所述外壳外部引入充气气体的可闭合开口。
在本发明的一些方面，飞机滑梯包括由所述阻隔织物形成的管形构件和滑梯表面，由此在充气时形成自支承结构。
附图说明
在本说明书结尾处的权利要求书中特别指出和明确要求了被视为本发明的标的物。从结合附图进行的以下详细描述中显而易见本发明的上述和其他特征和优点，其中：
图1是如本文中所描述的阻隔织物的横截面的示意性描绘；
图2是如本文中所描述的阻隔织物的横截面的示意性描绘；
图3是如本文中所描述的阻隔织物的横截面的示意性描绘；
图4是如本文中所描述的阻隔织物的横截面的示意性描绘；
图5是如本文中所描述的飞机疏散滑梯的侧视图；且
图6是如本文中所描述的飞机疏散滑梯的底视图。
具体实施方式
织物基底或基底织物可以由任何类型的具有所期望的物理性质和可加工性的纤维形成。通常使用尼龙纤维，这至少部分是由于尼龙织物所具有的强度和强度与重量比。可以使用多种尼龙，诸如尼龙-6,6或尼龙-6，以及其他已知的尼龙聚合物。还可以使用其他聚合物纤维，诸如聚酯、其他芳香族和/或脂肪族聚酰胺、液晶聚合物等。还可以使用天然纤维，诸如蚕丝。碳纤维也是一个可行的选择，但是在大部分应用中因成本高昂而无人问津。可以选择纤维直径以实现所期望的性质，诸如纤维强度、伸长率和环境抗性以及其他属性。纱线是个别纤维的组装件，并且能够以纤维彼此平行对齐的方式组装，将其捻搓或使其旋转在一起以形成具有不同强度、伸长率、捻距、尺寸和纤度(纱线的一个特征，以每9000米纱线长度的克数来度量)的纱线。然后可以在纤维间距、每英寸纬线数、每英寸纱线数或者每码或其他类似尺寸的总织物重量方面进一步定义织物。纱线支数可以介于每英寸30×30支纱线至每英寸90×90支纱线或更高，且更具体来说每英寸40×40支纱线至每英寸75×75支纱线的范围内。需要时，纱线支数几何参数还可以是不对称的(即，每英寸40×60支纱线)。织物基底的单位面积重量可以介于0.1至大于10oz/yd2、更具体来说1至10oz/yd2且甚至更具体来说2至8oz/yd2的范围内。
可以通过向纤维本身的聚合物基质中并入纳米增强体来增加基底布的纤维强度。所述纳米增强体可以是碳纳米管、碳纳米纤维、石墨烯纳米片、石墨烯氧化物纳米片、聚合物纳米纤维、金属纳米管或纳米纤维、金属氧化物纳米管、金属氧化物纳米纤维、金属氧化物纳米颗粒、金属氧化物纳米片、无机纤维(诸如玻璃、碳化硅、氮化铝)、无机纳米片(诸如蒙脱石、其他粘土或氮化硼或其组合)或其组合。所述纳米增强体可以在合成纤维基质或将所述基质加工成纤维期间并入纤维的聚合物基质中。举例来说，可以在通过旋转或其他纤维形成工艺热加工成纤维之前将纳米增强体与纯聚合物基质组合。还可以将纳米增强体并入用于合成布匹纤维的聚合物组合物的单体前体中。
耐热(HR)涂层典型地处于织物的一侧上，这一侧将处于充气式结构的外部。HR层可以包括高温聚合物树脂粘合剂和铝颜料(例如薄片铝)。HR层可以含有至少5wt％铝颜料，更具体来说10wt％至50wt％。除了由铝颜料提供的辐射热反射性质以外，耐热层还可以包括吸热添加剂，诸如陶瓷微球体，或隔热添加剂，诸如陶瓷中空微球体。示例性制剂含有介于0.1wt％与10wt％之间的微球体。另一种示例性制剂含有介于1wt％与5wt％之间的微球体。所有重量百分比都基于所述层的总重量。HR层的厚度可以变化，例如介于0.5μm至50μm之间，更具体来说是5μm至20μm。还可以存在衔接涂层。衔接涂层是用来提供比各种功能层可能提供的基底粘附力更大的基底粘附力。举例来说，聚氨基甲酸酯-聚碳酸酯共聚物树脂可以用于直接施加至织物表面的衔接涂层中，其中，其相对较低弹性模量提供了树脂对布匹形态的良好配置，而用作阻隔层粘合剂的聚氨基甲酸酯聚合物树脂的相对较高弹性模量提供了必需的强度和柔性，从而当在充气期间经受变形和压力时能维持总体涂层完整性和不透空气性。
如以上所提到，所述阻隔织物还具有包括聚合物的第一气体阻隔层。这个层可以具有介于1μm至100μm、更具体来说5μm至50μm范围内的厚度。在一些方面，所述第一阻隔层不含纳米片，或如果其包括纳米片，则其不呈如以下所描述的对齐状态。用于耐热层还有阻隔织物上的其他含聚合物的层的聚合物可以选自多种聚合物。通常使用聚氨基甲酸酯聚合物和含聚氨基甲酸酯的共聚物，这至少有部分是由于其弹性和耐久性。众所周知的聚氨基甲酸酯化学性质允许多种芳香族和/或脂肪族聚异氰酸酯与多元醇共同反应，从而提供所期望的涂料特征，且此类涂料树脂容易得自市面。其他聚合物可以容易地与聚氨基甲酸酯共聚，通常是通过在聚异氰酸酯/多元醇反应混合物中包括羟基封端预聚物(例如，OH封端聚酯或OH封端聚碳酸酯或聚醚)。在一些实施方案中，使用了除聚氨基甲酸酯以外的聚合物，例如聚酯。涂料组合物中还可以包括一种或多种聚合物树脂(诸如以上所描述的那些)的掺合物。
用于形成阻隔织物上的所述层的涂料组合物还可以含有一种或多种交联剂。举例来说，氨基甲酸酯和聚酯树脂可以包括多官能醇(例如三羟甲基丙烷)或多官能醇反应性化合物(例如三聚氰胺衍生物，诸如六甲氧基羟甲基三聚氰胺或三聚氰胺树脂)或聚碳化二亚胺作为交联剂。聚氨基甲酸酯树酯还可以包括多官能异氰酸酯(例如，由诸如二苯甲烷二异氰酸酯(MDI)或异氟尔酮二异氰酸酯(IPDI)之类的二异氰酸酯形成的三官能异氰脲酸酯化合物)作为交联剂。聚酯还可以包括多官能酸(例如三羧酸)作为交联剂。交联剂的量可以由本领域技术人员加以调节以实现所期望的性质。除了加速固化以外，所加入的交联剂倾向于增加涂层硬度和降低弹性。涂料组合物还可以含有一种或多种挥发性液体，包括水和/或多种极性或非极性有机溶剂。此类挥发性液体在固化之前或期间被蒸发且不形成固化或修饰涂层的一部分。反应性稀释剂即在施加含聚合物树脂的涂料组合物期间充当溶剂但具有能在固化期间与聚合物反应从而使其形成固化涂层的一部分的官能基的有机化合物。
被施加在本文中所描述的织物上以形成任何涂层的涂料组合物可以包括通常并入涂料组合物中的多种添加剂。此类添加剂可以在混合所述组分以便形成组合物期间在合适的时间混合，且包括填充剂、增强剂、抗氧化剂、热稳定剂、杀生物剂、增塑剂、润滑剂、抗静电剂、着色剂、表面效应添加剂、辐射光稳定剂(包括紫外(UV)光稳定剂)、稳定剂和阻燃剂。此类添加剂能够以不同的量使用，以涂料组合物的总重量计，一般是0.01wt％至35wt％。
如以上所提到，阻隔织物还包括第二阻隔层，所述第二阻隔层具有5nm至1000nm的厚度且包括对齐的纳米片。纳米片可以制成不同的尺寸，且本文中所描述的阻隔层中所使用的那些可以具有介于最少0.3nm、更具体来说1nm且甚至更具体来说5nm至最多100nm、更具体来说50nm且甚至更具体来说15nm的范围内的厚度。可以组合这些最大和最小范围界限以产生从任何最小值至任何最大值的范围(例如0.3-100nm、5-15nm、1-50nm、1-15nm等)。纳米片可以具有介于0.1μm至50μm、更具体来说5μm至25μm的范围内的直径。如本文中所使用，术语“直径”就纳米片而言意指平均直径，其被计算为具有与占据着x-y方向上与纳米片的一个面相同的剖面的平坦(即，未包括孔隙中的表面积)表面的面积相同的面积的圆的直径。纳米片可以具有介于5:1至10,000:1、更具体来说20:1至1000:1的范围内的纵横比(径厚比)。在一些示例性实施方案中，以所述阻隔层(即，固化涂层)的总重量计，所述阻隔层包括至少30wt％纳米片，更具体来说至少40wt％纳米片，更具体来说至少60wt％纳米片，更具体来说至少85wt％纳米片。在一些示例性实施方案中，阻隔层具有99.5wt％纳米片、更具体来说90wt％纳米片且甚至更具体来说85wt％纳米片的纳米片含量上限。可以组合这些最大和最小范围界限以产生从任何最小值至任何最大值的范围(例如0.3-100nm、5-15nm、1-50nm、1-15nm等)，当然，不包括最小值将高于最大值的不可能范围值。
纳米片可以包括多种材料，包括但不限于粘土、石墨烯或石墨烯氧化物。纳米片材料的实例包括但不限于石墨烯、层状硅酸盐粘土诸如蒙脱石粘土、高岭石粘土、氮化硼、云母石。纳米片可以通过剥落块状材料而由诸如石墨、块状粘土、氮化硼、云母石之类的块状材料制得。剥落可以通过多种技术进行，诸如超声波处理、用于使块状材料膨胀以增加相邻分子层之间的间距的化学处理和用氧化剂处理，或离子插入/交换。可以施加表面处理、热或高剪切混合或机械功以促进薄片层的剥落。还可以使用特定的溶剂以达到所期望的剥落水平。
本文中所描述的多种涂料可以使用任何已知的涂布技术来施加，包括但不限于滚涂、喷涂、浸涂或刷涂。可以通过以上所提到的类似技术，以5nm至1000nm、更具体来说10nm至800nm的厚度形成含纳米片的层，所述技术包括但不限于滚涂、喷涂、浸涂或刷涂，任选地，随后用空气刀或物理刀进行加工以实现所期望的厚度。涂料溶液可以由纯可固化聚合物树脂、基于溶剂或基于水溶液的涂料系统构成。涂料溶液的浓度将取决于溶液的所需粘度、欲施加的涂层厚度和在单次涂布内欲施加的纳米片层数而变化。典型地，粘合剂和填充剂在溶剂和水性涂料系统中的浓度非常低，从而允许填充剂更好地对齐。
如以上所提到，纳米片是对齐的。如本文中所使用，纳米片的“对齐”意指纳米片的x-y维度与层表面所在的平面平行对齐。不需要纳米片完全对齐，只需要与纳米片的随机对齐相比，更多纳米片在与所述层平行的方向上更接近对齐。对齐可以通过如本领域中已知的Hermans取向参数来表征，其中值0表示颗粒随机对齐，值1表示颗粒在层方向上完全对齐，且值-1/2表示颗粒在与层垂直的方向上完全对齐。在示例性实施方案中，的范围具有大于0、更具体来说是0.1且甚至更具体来说是0.4的下水平。所述范围的上端(小于或等于其)可以是0.9，更具体来说是0.8且更具体来说是0.7。纳米片的对齐可以通过使用已知的逐层自组装技术来实现，其中纳米片经衍生化而具有带电基团，诸如羧基，所述基团将被吸引至基底上带相反电荷的基团，诸如上面施加了分散在溶剂中的纳米片的第一阻隔层上的胺基。在其他实施方案中，纳米片可以被并入可固化聚合物涂料组合物中，其中纳米片的对齐是通过在聚合物完全固化之前施加物理力来实现。物理力的实例包括固化之前的离心力、重力和/或剪切力(例如，通过将经过涂布的基底维持在垂直位置持续一段时间)。以上所描述的用于逐层自组装的衍生化技术还可以用于在聚合物涂料组合物中提供对齐。
现在转向附图，图1示意性地描绘了示例性阻隔织物的横截面。如图1中所示，气体阻隔织物100包括织物基底112。在基底112的一侧上是耐热层114。在基底12的另一侧上是第一阻隔层16。第一阻隔层116上是包括如以上所描述的对齐的纳米片的第二阻隔层118。图2描绘了类似于图1而配置的阻隔织物，其中在耐热层114上添加了包括对齐的纳米片的第三阻隔层120。图3描绘了类似于图1而配置的阻隔织物，其中在包括对齐的纳米片的阻隔层118上添加了常规聚合物阻隔层122。图4包括阻隔层120和阻隔层122。阻隔层116和122可以包括交联聚氨基甲酸酯涂层或具有热塑性氨基甲酸酯膜的交联聚氨基甲酸酯涂层。阻隔层122可以包括热塑性氨基甲酸酯膜。
关于图5和图6，疏散滑梯组装件10的主体包括多个充气式柔性构件，包括从头部桁架组装件28延伸至地面22的侧轨管24、26。包括织物膜的滑梯表面30在侧轨管24与26之间伸展以便为下机乘客提供下滑表面。右扶手32和左扶手(未图示)分别位于侧轨管24和26顶部，以便为从疏散滑梯组装件10下来的乘客提供把手。头部桁架组装件28包括多个加固管36、38、直管40、42和横管44，从而适于保持疏散滑梯组装件10的头部12以允许疏散滑梯组装件10在其向地面延伸时以受控方式打开的取向与飞机20的机身相抵。侧轨管24和26的隔开式配置由头部横管46、趾端横管48、足端横桁架52和中间横桁架54维持。借助于从趾端16开始经足端横桁架52、中间横桁架54伸展且连接疏散滑梯组装件10的近端头部12的一个或多个箍带50来增强疏散滑梯组装件10的抗弯强度。
整个充气式疏散滑梯组装件10可以由本文中所描述的阻隔织物制造。充气式疏散滑梯组装件10的不同部分可以用合适的粘合剂连在一起，由此所述结构将形成能够在操作期间维持其形状的一体式复合结构。可以形成充气式疏散滑梯组装件10的整个结构，使得构成所述结构的所有腔室都气动互连，从而可以利用单一压缩气体源，诸如压缩二氧化碳、氮气、氩气、烟火气体发生器或其组合将其展开。当然，图4和图5中描绘的是一个例子，并且可以利用其他设计。举例来说，图5和图6中描绘了圆管状结构，但可以通过已知的技术来制造其他形状，诸如充气式方形管形状。
尽管仅结合有限数目的实施方案详细描述了本发明，但应该容易理解，本发明不限于此类公开的实施方案。相反，可以对本发明加以修改以并入任何数目的迄今尚未描述但与本发明的精神和范围相当的变更、变化、替代或等效布置。另外，尽管已经描述了本发明的各种实施方案，但应理解，本发明的诸多方面可以仅包括所描述的实施方案中的一些。因此，本发明不应被看作受上文描述限制，而是仅受所附权利要求书的范围限制。

Claims (20)

1.一种气体阻隔织物，其包括：
织物基底；
耐热涂层，其处在所述织物基底的第一侧上；
第一气体阻隔层，其包括聚合物且被安置在所述织物基底的第二侧上；和
第二气体阻隔层，其处在所述织物基底的所述第一气体阻隔涂层上，具有5nm至1000nm的厚度且包括对齐的纳米片。
2.如权利要求1所述的阻隔织物，其中所述第二空气阻隔层进一步包括聚合物粘合剂。
3.如权利要求2所述的气体阻隔织物，其中以所述第二气体阻隔层的重量计，第二气体阻隔层包括30wt％至99.5wt％的所述纳米片。
4.如权利要求2所述的阻隔织物，其中所述第二阻隔层是在使所述聚合物粘合剂固化之前经受外加的力。
5.如权利要求1所述的阻隔织物，其中所述纳米片是通过自组装涂布法来沉积。
6.如权利要求5所述的阻隔织物，其中所述自组装涂布法是逐层自组装。
7.如权利要求1至6中任一项所述的阻隔织物，其中所述纳米片是选自石墨烯、石墨烯氧化物、纳米级粘土或陶瓷。
8.如权利要求7所述的阻隔织物，其中所述纳米片是选自蒙脱石、氮化硼或云母。
9.如权利要求7所述的阻隔织物，其中所述纳米片具有5:1至10,000:1的纵横比。
10.如权利要求7所述的阻隔织物，其中所述纳米片具有0.1μm至50μm的直径。
11.如权利要求1至6中任一项所述的阻隔织物，其中所述纳米片具有5:1至10,000:1的纵横比。
12.如权利要求1至6中任一项所述的阻隔织物，其中所述纳米片具有0.1μm至50μm的直径。
13.如权利要求1至6中任一项所述的阻隔织物，其中所述第一空气阻隔涂层具有1μm至100μm的厚度。
14.如权利要求1至6中任一项所述的阻隔织物，其进一步包括第三空气阻隔层，所述第三空气阻隔层包括聚合物且处在所述第二空气阻隔层上。
15.如权利要求14所述的阻隔织物，其中所述第三空气阻隔涂层具有1μm至100μm的厚度。
16.如权利要求1至6中任一项所述的阻隔织物，其进一步包括第三空气阻隔层，所述第三空气阻隔层包括对齐的纳米片且处在所述耐热层上。
17.如权利要求1至6中任一项所述的阻隔织物，其中所述耐热层包括处于聚合物基质中的陶瓷微球体、陶瓷中空微球体和/或铝。
18.一种充气式结构，其包括由如权利要求1至6中任一项所述的阻隔织物形成的外壳和处于所述外壳内的充气气体源或用于从所述外壳外部引入充气气体的可闭合开口。
19.一种充气式飞机滑梯，其包括根据权利要求18所述的充气式结构。
20.一种充气式飞机滑梯，其包括由如权利要求1至6中任一项所述的阻隔织物形成的管形构件和滑梯表面，由此在充气时形成自支承结构。
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