CN109234909A - 绝热可伸缩羽绒片材及其制造方法 - Google Patents

绝热可伸缩羽绒片材及其制造方法 Download PDF

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CN109234909A
CN109234909A CN201811018171.1A CN201811018171A CN109234909A CN 109234909 A CN109234909 A CN 109234909A CN 201811018171 A CN201811018171 A CN 201811018171A CN 109234909 A CN109234909 A CN 109234909A
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sheet material
natural feather
scalable
insulation
core
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CN109234909B (zh
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罗尼·鲁本
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7513194
Canadian Ltd
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Canadian Ltd
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    • A47G9/00—Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows
    • A47G9/02—Bed linen; Blankets; Counterpanes
    • A47G9/0207—Blankets; Duvets
    • A47G9/0223—Blankets
    • A—HUMAN NECESSITIES
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    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
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Abstract

本发明公开了一种绝热可伸缩羽绒片材及其制造方法。片材芯包括与呈现弹性的粘合剂混合的羽绒。所述芯夹在具有多方向伸缩性的顶部和底部可伸缩弹性片之间。芯羽绒和粘合剂及弹性片通过热处理限制在一起，以提供在不折断所述片材的情况下在所有方向可伸缩的绝热羽绒片材。

Description

绝热可伸缩羽绒片材及其制造方法
本申请是申请号为201480005584X，申请日为2014年11月19日，发明名称为“绝热可伸缩羽绒片材及其制造方法”的中国发明专利申请的分案申请。
技术领域
本发明涉及绝热羽绒片材，尤其涉及具有多方向伸缩性的羽绒片材及其制造方法。
背景技术
在本申请人的专利号为6,025,041的美国专利中，描述了第一代羽绒片材，其中的羽绒由化学粘合剂或刚性纤维均匀地保持，且其中的羽绒在片材的各侧裸露。那种羽绒片材的主要目的是提供用作服装制造业的服装高级绝热的羽绒片材。这样的羽绒片材提供稳定的羽绒分布，从而防止绝热中的冷点扩展。因为羽绒在羽绒片材的各外侧裸露，所以必须格外小心，以防止羽绒从片材的表面脱落，或图案从片材切断。
需要开发一种用于许多其他用途的羽绒片材，以提供改善的绝热性能，如，在车辆的制造中，在热或冷的天气条件下受气候控制的乘客围护结构需要良好地绝热。存在人们能够想到的数不胜数的其他应用。然而，用于这样的商业用途和在服饰用品的制造中一样，需要将羽绒保持在片材或图案上，并使羽绒片材可伸缩(有弹性)，由此在安装或使用期间需要伸缩时可被伸缩。
最近，这种羽绒片材已被限制在附着于片材相对的顶面和底面的无纺纤维片材之间，并由与羽绒接合处的粘合胶保持在那里。虽然那种解决方式防止一些羽绒逃逸，但这种材料不能提供用作其他工业制造用途。这是因为这种材料尽管具有柔性，但不供片材伸缩，以将其连接到柔性和刚性形状的物体和需要片材伸缩的受限空间。另外，当用在服装上需要移动的区域时，如服装的腋下区域或膝盖区域，当刚性的羽绒绝热片材伸缩时，会撕裂形成绝热块，绝热块集中在特定区域且肉眼可见，形成服装冷点。因此，该改进未克服这些现存的问题以扩展这种羽绒片材的用途。
发明概述
本发明的一个特征是提供一种透气的、柔软的、重量轻的和可伸缩的羽绒片材，同时大致防止羽绒从羽绒片材的相对面逃逸。
本发明的另一个特征是提供一种羽绒片材，其中的羽绒由呈现弹性的粘合剂保持在一起，至少一个具有多方向伸缩性的可伸缩的弹性片连接到所述羽绒片材顶面或底面的外部之一。
本发明的另一个特征是提供一种羽绒片材，所述羽绒片材通过由弹性胶/聚合物弹力丝约束的羽绒形成，所述弹性胶/聚合物弹力丝也约束外部弹性片。
本发明的另一个特征是提供一种制造绝热可伸缩羽绒片材的方法，所述羽绒片材具有上面提及的特征，并能满足上面提及的要求。
根据以上特征，从一方面概括，本发明提供一种绝热可伸缩羽绒片材，所述羽绒片材包括羽绒和呈现弹性并且以预定的比例与羽绒混合在一起的粘合剂的混合物，以形成可伸缩的羽绒芯。至少一个具有多方向伸缩性的可伸缩的弹性片连接到所述羽绒片材的上表面或下表面。
根据本发明另一概括的方面，具有多方向伸缩性的可伸缩的弹性片通过与羽绒和上述可伸缩弹性片中的聚合物成分相混合的粘合剂而连接到所述可伸缩羽绒芯的相对的顶面或底面。
根据本发明又一概括的方面，提供一种制造绝热可伸缩羽绒片材的方法，所述方法包括以下步骤：当在粘合剂的软化点以上进行热处理时，在混合室中将预定量的羽绒与预定量的具有粘性及弹性的干粘合剂混合。弹性片在混合室的沉积出口下方被移动，其中大体均匀的与所述粘合剂混合的羽绒层沉积在所述弹性片的顶面。具有大体均匀的与所述粘合剂混合的羽绒层的所述可伸缩的弹性片接着被送往热处理室进行热处理，以将所述羽绒和粘合剂限制及粘合在一起，并且将所述羽绒和粘合剂限制及粘合到所述弹性片，以形成绝热可伸缩羽绒片材，接着所述绝热可伸缩羽绒片材被送出所述热处理室，成为连续粘合的可伸缩羽绒片材。
附图说明
本发明的优选实施例现在将参考附图描述，其中：
图1a是根据本发明构建的绝热可伸缩羽绒片材局部透视图，示出了两种外部弹性片和不同类型的粘合工艺；
图1b是羽绒芯的截面放大图，由弹性胶和弹力丝将羽绒和粘合剂限制及粘合在一起，以形成可伸缩的羽绒芯；
图2示出了制造绝热可伸缩羽绒片材方法的示意图，使用具有弹性的与羽绒混合的粘合剂并被固定控制在具有多方向伸缩性的相对的弹性片之间；
图3示出了图2的改进示意图，在羽绒片材和外部弹性片之间应用增粘粘合剂涂层；
图4是放大和局部剖视图，示出绝热可伸缩羽绒片材的应用，所述片材伸缩并固定到不规则形构件。
优选实施例的详细描述
现在参考附图，具体参考图1a，示出了根据本发明构建的绝热可伸缩羽绒片材10。羽绒片材10包括可伸缩的羽绒芯11，羽绒芯11夹在顶部可伸缩弹性片12和底部可伸缩弹性片13之间，并分别与顶部可伸缩弹性片12和底部可伸缩弹性片13粘合。芯11包括以预定比例与粘合剂15混合的羽绒14。粘合剂15为热处理时可以粘合的弹性胶或可伸缩聚酯纤维，由此形成具有弹性的均匀芯，允许它在对芯没有或仅有最少的折断的情况下通过弹性片伸展。
此处使用的词语“弹性材料的”意指有弹性的或可伸缩的，其中片材或纤维在伸展或变形之后能大体恢复到它原来的自由形状。而且，片状、膜状、网状、无纺布状、纤维状和线状等形式的弹性物体基本是各向同性的，在二维平面的所有方向基本呈现相同的性质。本发明中使用的这种弹性物体，如聚氨酯树脂，加热时能够熔化以粘合。一些聚合物弹力丝15′形成于苯乙烯绞合线(styrene strands)，其中一些呈现至少200％的断裂伸长率，且当从伸展状态释放时退回到它原始长度的125％。许多这种纤维或长丝和无纺布目前市场有销售。由此制成的网状物提供优秀的伸缩性、透气性、柔软性、轻量性和耐气候性。
弹性片12和13也可为网状形式，如图1a中标号12′所指示的，包括由挤出流制成的聚合物长丝，形成纬向和经向可伸缩长丝的规则阵列，长丝在它们的交叉点粘合在一起，形成具有多方向伸缩性的网。如，这样的网由尼龙6和聚丙烯制造。这样的网在美国专利4,636,419中公开，此处引入该公开专利用于参考。美国专利4,241,123也公开了众所周知的现有技术，其中无纺布网由第一组熔化的挤压模成型的单丝形成，第二组单丝或人造丝被交叉、按压和热焊，以形成能在热处理下软化的塑料网，粘合到芯粘合剂，并能在所有方向伸缩。
图1b是放大图，示出了羽绒与由弹性胶颗粒15及聚合物弹力丝15′的混合物构成的粘合剂的混合物。如能看到的，如从标号17可辨认的，一些熔化的胶水颗粒与羽绒14及聚合物弹力丝15′两者粘合，从而提供改善的构件粘合性和羽绒留滞性，防止羽绒从片材10的侧边逃逸。同样，由标号18指示的，长丝15′在它们的交叉点彼此粘合，并与羽绒粘合，在所有方向延伸。长丝彼此或通过羽绒的互联形成跨越芯的桥，保持混合物均匀。
现在参考图2，描述了本发明制造绝热可伸缩羽绒片材10的方法。如此处示出的，机器20包括传送装置21，传送装置21具有环形皮带22，环形皮带22由不粘的材料制成并能耐受至少150℃的热。尽管传送装置可由两个或更多彼此同步的从动传送带组成，但如此处示出的，皮带延伸过机器长度。皮带由连接到传动滚筒或链轮24的电机23驱动，其速度由控制电路25控制，由此控制放置在皮带上的羽绒芯11的厚度或密度。机器的不同操作参数被编程进控制器并可被调节。
在传送装置21的入口端支撑有滚筒26，滚筒26包含可伸缩弹性片13的供给，弹性片13在输送带的顶面22′上以与输送带22同步的速度分配。空气混合室27支撑在传送装置顶面22′上方，优选地，虽不是唯一地，通过构建的透明塑料观察具有粘合胶颗粒和/或可伸缩纤维的羽绒14的空气湍流混合作用在其中的操作。空气混合流28由吹风机29在混合室27内部以向上的角度注入，其空气速度可由控制器的设置调节。羽绒14由进料槽30以一定控制速率送进混合室27。干弹性胶颗粒15和/或弹力丝15′也以预定量由槽31送到混合室27。弹性胶颗粒被以与羽绒的混合物的6％-20％的量释放，优选地为6％-12％。同样地，当粘合剂是可伸缩弹力丝15′时，由分离槽32送到混合室27。可伸缩弹力丝包括羽绒混合物的6％-30％，优选地为6％-12％。粘合剂也可由弹性胶颗粒15和可伸缩或弹力丝15′以上面的胶水比例混合而成。如本文所期望的，弹性胶水粘合剂具有80℃以上的软化点，而低分子量聚合物弹力丝可具有稍低于80℃的软化点。当羽绒和粘合剂在混合室的上部混合时，混合物开始向下沉积到混合室的下部27′，在此处分配转子33转动，以通过混合室27的底部沉积出口34以恒定量将混合物分配到弹性片13上。通过控制输送带的速度来控制沉积混合物的厚度，其通过控制器25中传送装置的速度设置来实现。
混合室的下游支撑有第二滚筒35，其包含可伸缩弹性片12的供给，弹性片12被施加在羽绒芯片材11的顶面，从混合室27下方退出通道。可选地，羽绒芯片材限制器36可横跨输送带22支撑，以通过可调导板侧壁37限制其相对侧的羽绒混合物，可调导板侧壁37支撑在输送带22顶面上方并靠近输送带22顶面，以防止羽绒从其侧边逃逸。弹性片12限制羽绒混合物的顶面。此外，顶部压缩板38可在羽绒混合物上方跨越输送带，以在需要时于进入热处理室39之前逐步压缩混合物。如果需要，仅在底部弹性片上支撑羽绒与粘合剂的混合物，则弹性片的第二滚筒35不是必需的。然而，为将羽绒混合物保持在适当位置，顶部压缩板38要充当羽绒与粘合剂混合物顶面正上方的覆盖物。
热处理室39具有预设长度，并提供加热装置40，加热装置40能在热处理室内产生范围大约在80℃-160℃之间的受控热量，以熔化弹性胶15和/或弹力丝15′。在热处理室的出口41排出本发明的绝热可伸缩羽绒片材10，且它可沿着传送装置21的冷却端部42输送，以冷却片材10。或者，冷却风机43可安装在传送装置出口端部42的上方，以对片材10提供快速冷却。分切机装置44接着将片材切割成段，或可安装图案切割机，如激光切割机，在片材10充分冷却后从片材10切割图案。这样的分切和图案切割也可在远程位置执行。而且，排出热处理室的片材可采用卷状或片状收集用来输送。
现在参考图3，示出了机器20的进一步改进。如此处示出的，增粘剂或增塑剂涂抹器50和50′可分别毗邻混合室27的入口端和出口端设置，由此在可伸缩弹性片13的顶面13′和羽绒与粘合剂混合物的顶面释放少量的增粘剂，用作附加的可伸缩粘性材料。增粘剂可由弹性胶颗粒或弹性粘合丝构成，由此增强可伸缩弹性片12和13与羽绒芯11交界面处的粘合性。如果弹性片由网状物构成将是特别有益的，将改善透气性，附加的增粘剂进一步防止羽绒通过网状物的空隙释放。
如图4所示，由于本发明的绝热羽绒片材10是可伸缩的，相应地可被用于许多隔热用途。如此处示出的，片材通过紧固件固定在刚性弧形本体55上，此处示出了一个紧固件56，在本体55的弧形区域57被拉伸，其中片材10被拉伸，从而在由箭头58确定的区域拉伸和压缩芯材料11，由于片材的可伸缩性而不会折断片材。类似地，当片材10分布于服饰用品时，在服装的特定区域产生同样的拉伸，那里具有拉伸绝热材料的运动，如在夹克的腋窝区域等提供的通风孔中。当设于特定服饰用品的通风孔区域或需要这种透气性特征的任何区域时，可伸缩绝热羽绒片材10的透气性也提供湿气和气流的通道。可伸缩绝热羽绒片材可通过多种固定方式固定到各种构件，如胶合、缝合和热粘合等。
上述优选实施例旨在涵盖落入所附权利要求的范围内的所述具体实施例的等同实施例。

Claims (25)

1.一种绝热可伸缩片材，包括：芯，其由以预定的比例混合在一起的羽绒和呈现弹性的粘合剂的混合物构成，所述粘合剂由热熔性可伸缩胶颗粒和热熔性弹性粘合长丝构成；
可伸缩的第一片和第二片，其具有能够在所有方向伸缩的多方向伸缩性，分别地连接到所述芯的上表面和下表面；
所述芯和所述可伸缩的第一片和第二片具有形状恢复特性，其中所述绝热可伸缩羽绒片材在伸缩或变形后能够大致恢复到其原来的自由形状。
2.根据权利要求1所述的绝热可伸缩片材，其中每个所述可伸缩弹性片材是热熔性材料，其分别与所述芯的所述上表面和下表面热熔合。
3.根据权利要求1所述的绝热可伸缩片材，其中所述芯由6％-20％量的热熔性干胶颗粒与羽绒一起制成。
4.根据权利要求1所述的绝热可伸缩片材，其中所述芯由6％-12％量的热熔性干胶颗粒与羽绒一起制成。
5.根据权利要求1所述的绝热可伸缩片材，其中所述芯由6％-30％量的热熔性弹性粘合长丝与羽绒一起制成。
6.根据权利要求1所述的绝热可伸缩片材，其中所述芯包括由6％-12％量的热熔性弹性粘合长丝与羽绒一起制成。
7.根据权利要求1所述的绝热可伸缩片材，其中所述粘合剂具有80℃以上的软化粘合点，并能承受80℃至150℃之间的热处理。
8.根据权利要求1所述的绝热可伸缩片材，其中所述弹性粘合长丝是具有低于80℃软化点的低分子量聚合物长丝。
9.根据权利要求2所述的绝热可伸缩片材，其中所述可伸缩片材是弹性网，由在聚合物长丝之间的交叉点处熔合在一起的纬向和经向聚合物长丝构成，该弹性网呈现优良的伸缩性、粘性和透气性。
10.根据权利要求9所述的绝热可伸缩片材，其中所述聚合物长丝是苯乙烯绞合线或其混合物。
11.根据权利要求1所述的绝热可伸缩片材，其中所述可伸缩片材是弹性片材。
12.一种制造绝热可伸缩羽绒片材的方法，包括以下步骤：
(i)当在粘合剂的软化点以上进行热处理时，在混合室中将预定量的羽绒与预定量的呈现粘性及弹性的干粘合剂混合物混合，所述干粘合剂混合物由热熔性可伸缩胶颗粒和热熔性弹性粘合长丝构成；
(ii)在所述混合室的沉积出口下方移动具有多方向可伸缩性的弹性片材，将与所述干粘合剂混合物混合的所述羽绒的大体均匀层沉积在所述弹性片材的顶面，以形成绝热芯；
(iii)将具有多方向可伸缩性的第二弹性片材设置在与所述干粘合剂混合物混合的所述羽绒的所述大体均匀层上；
(iv)将所述可伸缩弹性片材与其之间的所述绝热芯一起送入热处理室进行同样的所述热处理，以将所述干粘合剂混合物与所述羽绒一起热熔，以形成所述绝热可伸缩羽绒片材，所述绝热可伸缩羽绒片材在伸缩或变形之后能够大致恢复到其原来的自由形状。
13.根据权利要求12所述的方法，其中还包括以下步骤：将所述绝热可伸缩羽绒片材送出所述热处理室，成为连续可伸缩羽绒片材。
14.根据权利要求12所述的方法，其中还包括以下步骤：将所述弹性片材两者分别同与所述干粘合剂混合物混合的所述羽绒的所述大体均匀层的底面和顶面粘合。
15.根据权利要求14所述的方法，其中在所述步骤(iv)之后还包括以下步骤：使所述绝热可伸缩羽绒片材经受冷却气流。
16.根据权利要求13所述的方法，其中在所述步骤(iv)之后还包括以下步骤：在所述羽绒片材充分冷却后，将所述绝热可伸缩羽绒片材输送至分切机以切割所述片材。
17.根据权利要求12所述的方法，其中在所述步骤(iii)之后还包括以下步骤：在所述羽绒传送过所述混合室的所述沉积出口后，限制与所述干粘合剂混合物混合的所述羽绒的至少相对侧边。
18.根据权利要求12所述的方法，其中在所述步骤(i)之后和所述步骤(ii)之前还包括以下步骤：在所述弹性片材的顶面上以预定量喷射热熔性粘合剂；并且其中在所述步骤(ii)之后和所述步骤(iii)之前还包括以下步骤：在与所述干粘合剂混合物混合的所述羽绒的所述大体均匀层的顶面上以预定量喷射所述热熔性粘合剂，以在与所述弹性片材的交界面处增强所述羽绒与所述干粘合剂混合物的交界面处的粘合性。
19.根据权利要求12所述的方法，其中所述步骤(iv)包括对所述羽绒片材中的所述干粘合剂混合物进行80℃至150℃之间的热处理。
20.一种绝热可伸缩羽绒片材，包括：芯，其由羽绒和呈现弹性的粘合剂混合物的混合物构成，所述粘合剂由热熔性可伸缩胶颗粒和热熔性弹性粘合长丝构成；所述粘合剂与所述羽绒以2％至30％量的所述可伸缩胶颗粒和2％至30％量的所述热熔性弹性粘合长丝进行混合；
可伸缩的第一片和第二片，其具有能够在所有方向伸缩的多方向伸缩性，分别地连接到所述芯的上表面和下表面；
所述芯和所述可伸缩的第一片和第二片具有形状恢复特性，其中所述绝热可伸缩羽绒片材在伸缩或变形后能够大致恢复到其原来的自由形状。
21.根据权利要求20所述的绝热可伸缩羽绒片材，其中所述可伸缩片材均为弹性片材。
22.根据权利要求20所述的绝热可伸缩羽绒片材，其中所述芯由6％-15％量的热熔性可伸缩胶颗粒与羽绒一起制成。
23.根据权利要求20所述的绝热可伸缩羽绒片材，其中所述芯由10％-25％量的弹性粘合长丝与羽绒一起制成。
24.根据权利要求20所述的绝热可伸缩羽绒片材，其中所述芯由6％-80％量的所述粘合剂混合物制成，形成的所述绝热可伸缩羽绒片材具有宽范围的期望特性和成分。
25.根据权利要求20所述的绝热可伸缩片材，其中所述弹性长丝是苯乙烯绞合线或其混合物，所述弹性长丝是具有低于80℃的软化点，所述热熔性胶颗粒具有约80℃的软化点。
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