CN110603137B - 三层织物隔热材料及其制造方法和装置 - Google Patents
三层织物隔热材料及其制造方法和装置 Download PDFInfo
- Publication number
- CN110603137B CN110603137B CN201880029006.8A CN201880029006A CN110603137B CN 110603137 B CN110603137 B CN 110603137B CN 201880029006 A CN201880029006 A CN 201880029006A CN 110603137 B CN110603137 B CN 110603137B
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- Prior art keywords
- fabric layer
- layer
- fabric
- grooved
- insulation
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Abstract
本发明描述了一种三层隔热材料(10),其包括第一织物层(12)、第二织物层(14)以及在第一织物层和第二织物层(12、14)之间的第三带凹槽的中间织物层(16),带凹槽的中间织物层(16)通过纵向接缝(18a‑18n)交替地附接至第一织物层和第二织物层(12、14),形成用于隔热材料(22)的纵向通道(20a‑20n),在每个纵向通道(20a‑20n)内具有单独的隔热材料(22)束。还公开了一种用于制造该材料的方法和装置。
Description
技术领域
本公开的发明涉及一种具有波纹状中间层的三层织物隔热材料,其中多条隔热体被分别引导至多个织物长度方向延伸的波纹状束通道。隔热体不附接至织物,而是仅通过隔热件和织物壁之间的摩擦力而浮在束通道中。隔热体是专门为服装、被褥、睡袋等设计的。还公开了一种用于制造该隔热体的方法和装置。
背景技术
在US 2607104中描述了波纹状的两层和三层织物,其具有高弹性以用于侧向压缩。描述了这种织物对侧向压缩的弹性阻力,以提供与海绵橡胶相当的缓冲。三层织物包括顶部织物、底部织物和较硬的中间织物,它们在单次操作中编织。为了形成三维形状,通过热处理将顶部和底部织物收缩。未收缩中间层将形成波纹状织物层。为了打开通道以进行填充,必须在编织后完成收缩过程。因此,如果完全在工业上可行,则填充是编织和收缩织物之后用于隔热材料的单独操作。然而,在该文件中公开的材料被构造成即使在相当大的压力下也通过较硬的中间层保持波纹状通道打开。制造三层织物也是不经济的,并且如果在该过程中引入任何隔热体,则其应该在编织过程中进行,这在说明书中未找到。
可以通过用隔热纤维填充波纹状通道来提高隔热性能。US 2607104建议用可吹胀的橡胶状材料如氯乙烯条来填充线束,该材料在加热下会膨胀并填充通道;或替代地使用玻璃纤维。虽然该文件建议用隔热材料填充通道,但它没有提供如何以工业方式进行的信息,也没有暗示该材料适合用于服装制造。
GB 1390609描述了一种隔热材料,该隔热材料具有两层片材,其中两片隔热材料中的每片隔热材料通过缝合附接到形成复合隔热材料的层中的一个层上。波纹状的(例如槽状的)表面与波纹的峰耦接在一起,波纹的峰在一个部分上分散在其他部分的波纹褶皱中,因此一个部分的缝合线不会与另一部分的缝合线重叠,由此这两个部分一起提供了在材料的整个宽度上具有均匀的隔热的复合隔热材料,而没有针孔引起的冷桥。然而,隔热材料缺少第三中间织物层,第三中间织物层将两层片材耦接在一起并提供额外的空气密封层。在其最简单的形式中,隔热体只是两种普通的绗缝的隔热材料,它们背靠背放置在一起,并且仅保持自然粘合在一起并且表面不规则。
在US 2014-0250575A中公开了通过应用交替绗缝方法制造的设备。可以在层组中布置多个层,可以将每个层组的层彼此缝合,从而可以形成针脚。每个层组的各层之间的空间可以填充有隔热材料。层组可以相对于彼此偏移,以使一个层组的针脚被富含隔热材料的另一层组的区域阻挡,其目的是阻止冷空气从针孔流过交替绗缝结构。这是昂贵的解决方案,因为两个隔热层需要绗缝,并且零件必须小心地放置在彼此相关的适当位置。
US 3805720描述了一种具有特殊接缝结构的绗缝结构,即向内翻折的缝褶,其防止磨损、钩破、拉扯缝合线。该结构只能通过单独缝纫每个接缝来缝纫,而不适用于由绗缝机制造。
WO 2014/190319A1公开了如下隔热材料,其包括衬里材料层;面材料层;设置在衬里材料层与面材料层之间的至少一层连续的合成隔热体;填充物设置在衬里材料层与面之间材料层之间;一个或多个第一接缝将衬里材料层与至少一层连续的合成隔热体耦接;并且一个或多个第二接缝将面材料层与至少一层连续的合成隔热体耦接。第一接缝和第二接缝形成两个或更多个折流板,以分隔隔热材料中的填充物。该文献描述了一种连续的隔热层,其是常规的片材。面材料层通过缝合、焊接或胶合(即用粘合剂粘合)附接到隔热层。在隔热材料和面材料层以及隔热材料和衬里层之间添加了附加的第二隔热材料。例如填充物,例如在面材料层和衬里材料层之间设置羽毛气凝胶、羊毛或法兰绒。连续的隔热层可以使附加的第二隔热材料(即填充物)的定位稳定,从而减少松散的填充物的迁移。该文件没有公开如何添加附加的的第二层(例如羽绒)。传统地,将羽绒用手塞入每个隔间,一次填充一个隔间,这费时且成本高。
US 5713079A提出了一种隔热服装,其中通过缝合,第一层隔热体被缝纫到第一织物层,第二层隔热体被缝纫到第二织物层。在两个隔热层的背面上都可以有衬里层。移位隔热层,以使缝合阵列的中点覆盖配对的隔热层的针孔阵列。隔热体包括第一层上的鹅绒,并且第二层由合成材料制成。发明目的是获得两种材料的有益效果。当使用这种类型的隔热体时,服装需要被独特地构造成具有第一隔热层的中点以覆盖第二隔热层的缝合。由于使用者具有若干种不同的体型,因此服装可能会自由悬挂或可能需要轮廓以覆盖躯干形状。外层相对于内层的位置会发生很大变化,从而导致隔热体移位。
在服装制造中,有两个要素对于防寒很重要:阻止风渗透,并通过使用纤维形成一层作为隔热体的静止空气,而使温暖的空气层保持靠近人体。
空气是常用的不导电隔热体。通过增加窗玻璃并隔离窗格之间的空气层来提高窗户的隔热性。具有三个窗格的窗口比具有两个窗格的窗口具有更高的隔热性。因此,与仅具有两层织物的服装相比,在服装中具有三层织物的隔热性更好。
发明内容
本发明描述了一种具有三层织物的材料;每层的透气性都很低,防止空气穿过织物层行进到下一束通道。这阻止温暖的空气逸出隔热体,并且防止冷空气占据隔热体的内部。纤维条(例如连续的卷曲丝束)被插入以在织物层之间的束通道内自由浮动,以使各层保持分离,捕获从用户身体散发出来的温暖空气。与两层或单层织物隔热体相比,该解决方案产生了出众的隔热能力。
传统上,服装中的隔热材料作为片材引入绗缝机。指示在面层和衬里层之间进行隔热,并用一排针缝纫在一起。针孔产生冷桥,即热桥。冷桥在隔热体中形成薄弱点,导致冷空气从服装外部迁移进入服装内部。在本发明的一个实施方式中,使用激光焊接,这使得可以将两个织物层附接在一起而没有针孔。此外,激光焊接接缝提供对于阻挡颗粒、液体和气体的阻挡。仅通过互连将织物焊接在一起,因此织物的表面保持完整。
连续隔热片材的制造涉及专门设计的方法和工艺,这增加了隔热价格的费用。代替使用传统的片材作为隔热层,本发明使用连续的纤维束隔热体,即,纤维条,一股松散的、不扭曲的纤维绳,连续的、可能卷曲的丝束,作为多个连续的长丝股直接从喷丝头挤出。喷丝头有微小的孔,化学溶液通过这些孔挤出以制成连续的长丝,例如聚丙烯、尼龙或聚酯。多个纤维长丝形成连续的束状丝束。
条也可以通过梳理过程制成,其形成轻度盘绕、蓬松的纤维股,可以是纤维精梳过程的产物。该条可以直接从收集桶引入,以纵向填充织物,沿束通道纵向延伸。条仅通过摩擦力附接到束通道的内部。最终,当隔热材料被切割并缝纫成服装时,该条将从其纵向端锚固在其位置上。这种直接的方法跳过了制造过程,这从而简化了整个过程,使隔热更加经济。
用针绗缝织物是一个缓慢且劳动密集的过程,这使绗缝在世界许多地方都是不经济的。用粘合剂将层粘合是如下过程:其中两种或更多种不同的物质通过作用在接触区域中的分子力结合。该过程需要产生粘合剂的熔化和冷却,这是耗时的过程。由于有限的剥离强度,当连续弯曲和清洗时,粘合剂粘合的接缝经常分层。另一方面,激光焊接是经济的且生产高效的。与通过缝合或粘合剂粘合的传统绗缝方法相比,激光焊接可以轻松地使速度提高数倍。增产将产生显著的经济影响。
为了使用激光焊接产生高质量的接缝,需要红外吸收纺织品,以及另一种不吸收红外辐射的纺织品。激光能量渗透穿过纺织品的非红外吸收层,并被下面的红外吸收纺织品吸收。在压力辊的压力下,织物层在分子水平上熔化在一起。在激光焊接过程中,织物的外表面不受影响,仅互连的织物薄层熔化。因此,表面或织物不受影响。
可替代地,在其他实施方式中,可以使用超声缝纫,然而该方法将熔化接缝,这对于某些情况来说可能是不希望的。
激光焊接接缝在连结处不使用附加的粘合剂。与粘合剂粘合相比,激光焊接使得连结处具有更大的柔韧性和更柔软的触感。可以通过使织物本身能够吸收红外线来达到织物的红外吸收。织物也可以被染色或印刷为能够吸收红外线,或者可以在焊接之前例如通过喷射将红外吸收剂施用到接缝上。焊接需要相同的热塑特性,因此例如聚酯织物最适合与聚酯焊接;聚丙烯最适合与聚丙烯焊接;以及聚酰胺最适合与聚酰胺焊接。可以用于在织物焊接中采用的合适的激光焊接头例如由Leister Technologies AG,CH-6056Kaegiswil,Switzerland和TWI Ltd,Cambridge,United Kingdom开发。
附图说明
在下文中,参考附图更精确地讨论本发明,在附图中:
图1示出了具有波纹状中间层的三层隔热体的剖视图,
图2示出了能够制造波纹状隔热体的激光焊接机的剖视图,
图3示出了处于打开位置的激光焊接机的剖视图,
图4示出了激光焊接机的侧视图和机器中的材料流,
图5示出了激光焊接接缝的透视图,以及
图6示出了服装和设置为服装一部分的一片隔热材料。
具体实施方式
图1示出了三层织物的波纹状隔热材料10的剖视图,其中第一织物层12、第二织物层14和带凹槽的第三中间织物层16通过多个纵向焊接的接缝18a-18n纵向地连结在一起。第一织物层12和第三中间织物层16以及相应地在相反侧的第二织物层14和所述第三中间织物层16形成多个束通道20,这些束通道分别填充有隔热材料22。织物层12、14和16可以是不同类型的纺织材料,例如编织、针织、经编、毡或非编织材料。
图2示出了激光焊接机24,其能够制造隔热材料10(图1)。机器24具有上部框架26和下部框架28,所述上部框架容纳引导第一织物层12的上部织物引导件30;所述下部框架28容纳引导第二织物层14的下部织物引导件32。第三织物层16定向在上部凹槽折叠件34与下部凹槽折叠件36之间,其中上部凹槽折叠件附接到所述上部框架26,并且下部凹槽折叠件附接到所述下部框架28。多个激光源38在多个焊接站24a-24n上方附接至所述上部框架26,并且多个激光源38在多个焊接站24a-24n下方附接至所述下部框架28。
所述多个激光源38仅象征性地示出。激光焊接的功能和设计已经在关于激光透射焊接方法的各种出版物中公开,因此,其对于本领域技术人员来说是公知的,因此这里不必对其进行详细描述。因此,省略了对激光38所源自的激光源的描绘。
当第一织物层12、第二织物层14和第三织物层16被拉、卷或以其他方式向前移动时,第一织物层和所述中间层以及在相反侧的所述第二织物层和所述中间层通过激光源38沿着接缝18a-18n(图1)在分子水平上被纵向地熔化在一起。多个中空导管42安装在折叠件34和36的前面。隔热材料22在焊接的同时通过导管42被引入束通道20内。即使中空导管42是优选的实施方式,也可以使用其他手段将隔热丝束引导至腔/束通道20。可以使用如环、通道、管道和管之类的引导装置。所有这些手段在纺织工业中被广泛使用,并且是本领域技术人员的公知常识。
图3示出了处于打开位置的激光焊接机24。在此位置,机器可以被清洁和使用,并且第三织物层16可以插入上部凹槽折叠件34和下部凹槽折叠件36之间。
图4示出了焊接机40的侧视图和焊接机中的材料流。第一织物层12从辊48引入到焊接机40,第二织物层14从辊50引入到机器,并且第三中间织物层16从辊52引入到机器。电源(未示出)连接到辊46,并且拉动隔热材料10穿过机器并将隔热材料10存储在辊46上。可替代地,可以使用其他织物移动方法,包括在焊接框架后面连接到电动机或织物拉伸器的压力辊。
同时,当织物移动通过机器时,多个束通道20(图1)分别填充有隔热材料22a-22n,该隔热材料通过所述多个导管42a-42n引入。来自辊48的第一织物12和第二织物14以及来自辊52的第三织物被引入折叠件34和36之间,并且通过多个焊接站24a-24n被纵向地焊接在一起。
为了吸收红外光的最佳能量,可以在焊接织物之前将激光吸收剂54a和54b引入到连结处的织物中。吸收剂可以是例如通过喷嘴56和58喷射在织物层的可焊接部分上的。商用红外吸收剂例如是由Centex公司以Clearweld的名称制造的。可替代地,在挤出、印刷、涂覆或以其他方式施用到织物上之前,可以将红外吸收剂包含在聚合物溶液中。
在使用热粘合剂来连结织物层的实施方式中,可以将粘合剂通过喷嘴喷射或以其他方式传导至连结区域。粘合剂可以是液体形式,也可以作为连续的长丝应用。
对于本发明的替代实施方式,也可以使用不同的激光焊接方法。在激光焊接中,代替了使用多个激光头来执行多个轮廓焊接接缝,而是可以选择仅使用一个激光头同时产生所有接缝。在工业中已知三种主要技术可用于本发明:
衍射焊接
衍射光学元件(DOE)以高能效的方式成形和分离激光束。包含在激光源中的衍射分束器是将输入光束分成N个输出光束29的单个光学元件。输出光束可以指向预定位置。激光束29被分离并且同时以最小的光损失被引导到连结熔化区域18a-18n。
扫描焊接
在扫描焊接中,光束引导是通过使用包含在激光源38中的移动镜进行的。通过改变镜的角度来定向光束29。光束以非常高的速度连续扫描焊接区域18a-18n。穿过焊接区域的织物将以近似同步的方式从连结区域熔化和熔融。
掩膜焊接
掩膜焊接方法利用在整个被焊接的表面上移动的宽光束。掩膜屏蔽是不需要焊接的保护区域。预定的焊接接缝区域18a-18n将被熔化和熔融。
掩模焊接、衍射焊接和扫描焊接的功能、设计、使用和操作模式已在关于激光透射焊接方法的现有技术的各种出版物中公开,其本身是已知的,并且因此,对于本领域技术人员来说是公知常识,因此这里无需对其进行详细描述。
图5示出了激光焊接接缝,其中织物层12渗透红外辐射,并且其中施加有红外吸收性织物中间层16并吸收红外辐射29,然后被加热、熔化并通过压力25a和25b压在一起。将受控量的热量施加到织物连结处。激光能量穿过红外渗透织物层12,加热能够吸收红外线的织物层16的表面,熔化层16的表面,并在压力25下将界面区域密封在一起,从而在织物向方向27移动时形成焊接接缝18。在压力辊23(图2和图3)与凹槽折叠件34和36的峰(图2和图3)之间施加压力。
在本发明的优选实施方式中,压力可以通过不同的方法施加到织物上,诸如:
压力板
在优选实施方式中,在第一侧上的易熔织物层12和16以及在第二侧上的易熔织物层14和16穿过并压在:第一侧上的激光源和第一织物层之间的对红外线透明的压力板(未示出)与上部凹槽元件34的峰之间;以及在第二侧上激光源和第二织物层之间的对红外线透明的压力板(未示出)与下部凹槽折叠件36的峰之间。引导元件30和32位于凹槽折叠件的顶部上,并且上部引导元件和下部引导元件是相似的。激光通过激光透明压力板施加到焊接位置。
压力辊
在一个实施方式中,压力可以通过激光束透明玻璃辊施加。
压力球
在一个实施方式中,压力可以通过激光透明球体施加,该激光透明球体可以由能够无摩擦旋转的空气轴承支撑。
采用辊或球体代替板的优点是摩擦力较小,因此当织物移动通过焊接站时,压力装置和织物之间的热量较小。
焊接站的压力可以通过机械方式产生,或者可替代地,通过静液压或气动方式产生,既可以吹正压力也可以通过吸力产生,以确保焊接区域内的织物的粘合与连接。
压力成型的功能、设计、使用和操作模式已经在关于激光透射焊接方法的现有技术的各种出版物中公开,其本身是已知的,并且因此,对于本领域技术人员来说是公知常识,因此这里无需对其进行详细描述。
例如在Leister Technologies AG的美国专利申请US 2014/0363636A1中描述了在激光焊接的情况下的不同压力源。
图6示出了服装60,以及设置为服装的一部分的一片隔热材料。隔热材料22未附接地浮在织物层12、14或16中的任一者上。当该片服装被缝纫到另一片服装上时,例如在将前部连接到后部的肩缝62中,隔热材料将在服装制造过程中由服装制造者固定在其位置上。
在一个实施方式中,材料可以从阻燃材料组中选择。阻燃隔热体可用于潜在的具有火灾危险的区域应用。
在以上这些实施方式中,描述了激光焊接接缝的使用。也可以使用通过缝合制成的常规接缝。接缝也可以是超声波焊接接缝或粘合剂粘合的接缝。
尽管已经针对某些优选实施方式示出和描述了本发明,但是很明显,对本领域的其他技术人员来说,在阅读和理解这些规范之后可以进行等同和修改。本发明包括所有这些等同和修改,并且仅由所附权利要求的范围限制。
附图标记
10 隔热材料
12 第一织物层
14 第二织物层
16 第三中间织物层
18a-18n 焊接接缝(纵向连接)
20a-20n 束通道
22 隔热材料
23 压力辊
24a-24n 焊接站
25a、25b 压力
26 机器的上部框架
27 焊接方向
28 下部框架
29 激光束
30 上部引导元件
32 下部引导元件
34 上部凹槽折叠件
36 下部凹槽折叠件
38 激光源
40 焊接机
42a-42n 多个导管
44 有意的空白
46 新制隔热材料存储辊
48 织物存储辊
50 织物存储辊
52 中间织物存储辊
54 激光吸收剂
56 喷嘴
58 喷嘴
60 服装
62 服装的肩缝
Claims (5)
1.一种三层隔热材料(10),所述三层隔热材料包括第一织物层(12)、第二织物层(14)以及位于所述第一织物层(12)和所述第二织物层(14)之间的带凹槽的第三中间织物层(16),带凹槽的所述第三中间织物层(16)通过纵向接缝(18a-18n)交替地附接至所述第一织物层(12)和所述第二织物层(14),形成用于隔热材料(22)的纵向束通道(20a-20n),并且在每个纵向束通道(20a-20n)内形成单独的隔热材料(22)束,其特征在于,所述纵向接缝(18a-18n)是激光焊接接缝,并且所述第一织物层(12)和所述第二织物层(14)是对红外线透明的织物,且带凹槽的所述第三中间织物层(16)是具有红外吸收性的。
2.根据权利要求1所述的三层隔热材料,其特征在于,带凹槽的所述第三中间织物层(16)是通过对表面施用红外吸收剂而被制成为能够吸收红外线的。
3.一种用于制造三层隔热材料(10)的方法,所述方法包括以下步骤:
-引入第一织物层(12)、第二织物层(14)和带凹槽的第三中间织物层(16),以及
-将带凹槽的所述第三中间织物层(16)交替地附接至所述第一织物层(12)和所述第二织物层(14)以形成多个纵向束通道(20a-20n),
其特征在于,
-同时形成所述纵向束通道(20a-20n),每个纵向束通道(20a-20n)填充有单独的隔热材料(22)束,
-所述第一织物层(12)和所述第二织物层(14)是通过激光焊接而附接至带凹槽的所述第三中间织物层(16)的,以及
-所述第一织物层(12)和所述第二织物层(14)被选择为对红外线透明的织物,并且带凹槽的所述第三中间织物层(16)被选择为具有红外吸收性的织物。
4.根据权利要求3所述的用于制造三层隔热材料(10)的方法,其特征在于,带凹槽的所述第三中间织物层(16)是通过对表面施用红外吸收剂而制成为能够吸收红外线的。
5.一种用于制造三层隔热材料(10)的装置,所述装置包括:用于第一织物层(12)的上部引导元件(30);用于第二织物层(14)的下部引导元件(32);以及如下装置(34、36):该装置用于将第三中间织物层(16)引导至通过附接装置附接所述第一织物层(12)和所述第二织物层(14)的附接位置处并在所述附接位置处对所述第三中间织物层(16)制作凹槽,其中所述第一织物层(12)附接至带凹槽的所述第三中间织物层(16)的第一侧,并且所述第二织物层(14)附接至带凹槽的所述第三中间织物层(16)的第二侧,从而形成纵向束通道(20a-20n),其中,安装有多个引导装置以用于将隔热材料(22)分别引入到每个纵向束通道(20a-20n),并且所述附接装置既位于所述三层隔热材料(10)的上侧也位于所述三层隔热材料(10)的下侧,其特征在于,所述多个引导装置安装在附接位置处,所述附接装置是激光焊接装置(40),所述第一织物层(12)和所述第二织物层(14)是通过激光焊接而附接至带凹槽的所述第三中间织物层(16)的,所述第一织物层(12)和所述第二织物层(14)被选择为对红外线透明的织物,并且带凹槽的所述第三中间织物层(16)被选择为具有红外吸收性的织物。
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2018
- 2018-05-02 CN CN201880029006.8A patent/CN110603137B/zh active Active
- 2018-05-02 CA CA3062259A patent/CA3062259A1/en active Pending
- 2018-05-02 PL PL18725574T patent/PL3619028T3/pl unknown
- 2018-05-02 DK DK18725574.0T patent/DK3619028T3/da active
- 2018-05-02 EP EP18725574.0A patent/EP3619028B1/en active Active
- 2018-05-02 US US16/608,216 patent/US11267222B2/en active Active
- 2018-05-02 JP JP2020512089A patent/JP7265273B2/ja active Active
- 2018-05-02 WO PCT/FI2018/050319 patent/WO2018130751A2/en unknown
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2022
- 2022-01-27 US US17/586,315 patent/US11850838B2/en active Active
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WO2018130751A2 (en) | 2018-07-19 |
US11267222B2 (en) | 2022-03-08 |
FI20175390L (fi) | 2018-05-03 |
US20220143953A1 (en) | 2022-05-12 |
WO2018130751A3 (en) | 2018-08-23 |
FI128366B (en) | 2020-04-15 |
CN110603137A (zh) | 2019-12-20 |
EP3619028A2 (en) | 2020-03-11 |
US20200164619A1 (en) | 2020-05-28 |
DK3619028T3 (da) | 2022-01-31 |
CA3062259A1 (en) | 2018-07-19 |
JP7265273B2 (ja) | 2023-04-26 |
EP3619028B1 (en) | 2021-10-27 |
JP2020520420A (ja) | 2020-07-09 |
PL3619028T3 (pl) | 2022-02-28 |
US11850838B2 (en) | 2023-12-26 |
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