CN112976721A - 贴面的纤维绝缘体 - Google Patents

贴面的纤维绝缘体 Download PDF

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CN112976721A
CN112976721A CN201911282740.8A CN201911282740A CN112976721A CN 112976721 A CN112976721 A CN 112976721A CN 201911282740 A CN201911282740 A CN 201911282740A CN 112976721 A CN112976721 A CN 112976721A
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fibrous insulation
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李云芳
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Abstract

提供一种贴面的纤维绝缘体(10)，其在纤维绝缘材料的一个或多个表面上具有贴面(12)。该贴面提供改进的表面质量、高的和受控的粘合性，并且容易制造。本发明的贴面包括预施加的粘合剂(22、24)，其被热活化以提供对纤维绝缘体的粘合性。该贴面可以被输入到纤维绝缘体生产线的玻璃纤维形成区段中。可选地，该贴面可以被施加到固化之前的未固化的衬料(64)上或被施加到固化的纤维绝缘体上。作为另一个可选方案，防潮层(14)可以附着在绝缘体的与所述贴面相对的表面上。

Description

贴面的纤维绝缘体
本发明专利申请为申请日2005年5月24日，申请号200580049533.8，发明名称“贴面的纤维绝缘体”的专利申请的分案申请。
本发明的技术领域和工业实用性
本发明涉及贴面的纤维绝缘体。本发明的贴面的绝缘体提供改进的热学、声学性能以及在住宅绝缘体的安装过程中提供改进的操作性。本发明的贴面的绝缘体还为包封的绝缘体提供改进的表面质量，而且在安装过程中提供改进的贴面粘合性质量。
发明背景
贴面的纤维绝缘体被应用于各种热学、声学和住宅应用。常规的绝缘体通常包括粘附于纤维绝缘体层的贴面层。贴面层可用于防止或至少限制可能由直接穿过绝缘体层的空气流动引起的任何空气侵蚀破坏。
包封的绝缘体用来使通常由框架构件限定的建筑空腔绝缘，所述框架构件例如墙壁和顶楼中的立筋、搁栅或椽木。绝缘体通常为低密度玻璃纤维绝缘体。包封的绝缘体可以通过将横向法兰钉入框架构件或者通过在框架构件之间“摩擦安装(friction-fit)”或“压接安装(press-fit)”尺寸过大的绝缘体而固定就位。一种此类包封的绝缘体在US专利5,277,955中示出，其公开了使用直接施加到玻璃纤维绝缘体上的加热的聚乙烯薄膜，并且公开了也可以使用非织造材料，比如非织造材料的层。
公开包封的绝缘体的另一个专利为US专利5,848,509，其中使用恰在施加贴面之前才施加到粘面或绝缘体上的热熔粘合剂将非织造覆盖物固定到玻璃纤维绝缘体上。
US专利5,981,037公开了一种绝缘体组合件，包括纤维绝缘材料的伸长垫，其具有通过使用一系列以一定距离间隔的粘合带固定到其主表面上的贴面。
其它贴面的绝缘体产品用于HVAC设备、管道板和其它工业绝缘体的绝缘应用。常规贴面的纤维绝缘体产品的一个实例在US专利6,444,289中公开。US专利6,444,289公开了使用通过粘合剂粘附于纤维绝缘体上的无孔铝箔、金属箔加固纸、foilscrimpaper或聚合物材料。在贴面层和绝缘体层相连接并且粘合剂硬化或固化之后，在贴面层中形成开孔。
US专利5,783,268和6,270,865公开了用于管道板的贴面的纤维绝缘体提供了空气流量增加和湍流减少的空气流表面。该贴面的纤维绝缘体还提供了降低污物和灰尘积聚的光滑表面。另外，US专利5,783,268和6,270,865公开了使用一英寸或一又二分之一英寸厚的压缩玻璃纤维中间层，其具有密度为约0.01磅/平方英尺、纵向方向中的最小拉伸强度为7磅/英寸、横向方向中的最小拉伸强度为5磅/英寸的聚酯/玻璃贴面。该纤维绝缘体由Owens Corning研发的工业标准旋转纤维工艺形成，其中熔融玻璃通过穿孔纺丝机纺成纤维并由高温气体吹塑以将各根纤维拉长。纤维然后用苯酚-甲醛粘合剂喷涂以形成玻璃纤维的未固化衬料(pack)。然后将贴面施加于该玻璃纤维衬料，使得当衬料和贴面固化时，贴面仅通过衬料中的未固化粘合剂粘附于玻璃纤维。
′268和′865专利还公开了在管道板外部边缘形成搭叠边缘以帮助制造玻璃纤维管道。但是，由于控制表面上的粘合剂量的固有难度，这种方法倾向于导致毡片贴面对纤维绝缘体的粘合性差。该方法还倾向于增加制造成本，因为必须使纤维绝缘体的固化工艺最佳化，以在毡片贴面和玻璃纤维之间提供适合的粘合，而不是进行最佳化以改进纤维衬料中的粘合剂的固化效率。
除了′268和′865专利中公开的方法之外，本领域中还已知的是通过在将贴面施加到未固化的纤维衬料上之前，将粘合剂直接喷涂到贴面上并且随后固化衬料中和贴面上的粘合剂从而制造贴面的绝缘体。例如，US专利5,041,178公开了将粘合剂喷涂到其中贴面接触未固化衬料的上表面和下表面的界面上。这种方法倾向于使成品板(finishedboard)表面上的纤维饱和，在纤维绝缘体上由于通过表面处的大量粘合剂固定就位的纤维末端而产生易碎表面。毡片上的大量粘合剂还可能引起毡片贴面变色，在纤维绝缘体上产生斑点状或斑纹状表面。
贴面的纤维绝缘体也可以通过将聚合物直接施加于固化的玻璃纤维衬料表面而形成。US专利5,900,298公开了使用一排螺旋形喷涂挤出头以1.2到3.5g/ft2的量将乙烯乙酸乙烯酯(EVA)纤维直接挤出到固化的纤维衬料上。US专利5,487,412公开一种管道板，包括板表面的干燥固体含量为10-20g/ft2的丙烯酸类泡沫涂料的施涂层。该涂料还包括无机杀生物剂，例如硝酸银。
发明概述
本发明在纤维绝缘材料的一个或多个表面上提供贴面。该贴面提供改进的表面质量、高的和受控的粘合性、并且容易制造。本发明的贴面包括热活化的预施加的粘合剂。该贴面可以输入到纤维绝缘体生产线的玻璃纤维形成区段中。可选地，该贴面可以施加到固化之前的未固化的衬料上或施加到固化的纤维绝缘体上。该贴面可以施加于绝缘体的一个或多个表面，并且可以结合标准防潮层贴面，例如牛皮纸沥青贴面一起施加。本发明的一个目的是在纤维绝缘材料的一个或多个表面上提供贴面，以提供改进的表面质量、高的和受控的粘合性，并且容易加工。本发明的另一个目的是提供一种贴面的纤维绝缘体，其可以经由多种工艺参数可靠地制造，不会不利地影响表面质量或贴面对纤维绝缘体的粘合性。
附图简述
图1为在单侧上具有贴面的本发明贴面的纤维绝缘体(部分被切掉)的透视图。
图2为在相对两侧上具有贴面的本发明贴面的纤维绝缘体(部分被切掉)的透视图。
图3为其上施加有粘合剂的根据本发明的贴面的纤维绝缘体细部结构的横截面视图。
图3A为说明贴面上的玻璃纤维与粘合剂的相互作用的图3的详细横截面视图。
图3B为说明贴面上的玻璃纤维与纤维状粘合剂的相互作用的与图3A相似的详细横截面视图。
图4为生产本发明贴面的纤维绝缘体的生产线的平面图，其中贴面被输入到玻璃纤维形成区段，且未固化的衬料沉积在贴面上，并且该图显示在固化之后贴面的纤维绝缘体被卷起。
图5为生产贴面的纤维绝缘体的生产线的详细平面图，其中在衬料离开玻璃纤维形成区段之后，贴面被施加于未固化的衬料的上表面和下表面，并且该图显示在固化之后双贴面的纤维绝缘体被平分并卷成两个辊。
图6为生产贴面的纤维绝缘体的生产线的详细平面图，其中在衬料离开玻璃纤维形成区段之后，贴面被施加于未固化的衬料的上表面，并且该图显示贴面的纤维绝缘体被横切以形成板，所述板被堆叠。
图7A为使用加热的压板将贴面粘附到纤维绝缘体，在后固化炉或离线工序中形成贴面的纤维绝缘体的可选方法的平面图。
图7B为使用加热的辊将贴面粘附到纤维绝缘体，在后固化炉或离线工序中形成贴面的纤维绝缘体的可选方法的平面图。
图7C为使用加热的履带将贴面粘附到纤维绝缘体，在后固化炉或离线工序中形成贴面的纤维绝缘体的可选方法的平面图。
本发明的详细说明和优选实施方案
本发明的贴面包括预施加的粘合剂，其被热活化以提供对纤维绝缘体的粘合性。该贴面可以被输入到纤维绝缘体生产线的玻璃纤维形成区段，或者可以施加于固化之前的未固化的衬料，或施加于固化的纤维绝缘体，或者在又一个可选方案中可以在后固化炉或离线工序中施加。贴面可以施加于绝缘体的一个或多个表面。贴面也可以施加在绝缘体的主表面上，在绝缘体的另一个表面上具有常规贴面，例如牛皮纸/沥青、牛皮纸/聚合物或箔/纱布(scrim)/牛皮纸贴面。
本发明贴面的纤维绝缘体产品包括至少一层的例如玻璃纤维、矿物棉、石毛或聚合物纤维的纤维绝缘体，和至少一层的贴面。本发明贴面的绝缘体产品包括具有单层纤维绝缘体和施加于一个表面的贴面的产品；具有单层纤维绝缘体和施加于相对主表面的贴面的产品；具有单层纤维绝缘体和施加于相对主表面的贴面的产品，其中贴面的至少一层比主表面宽，使得纤维绝缘体的一个或多个次表面可以被贴面，并且贴面被施加于绝缘体的一个主表面而防潮层被施加于相对的主表面。
在图1所示的实施方案中，贴面的纤维绝缘体10包括通常为玻璃纤维，但是任选为矿物棉、石毛或聚合物纤维的纤维绝缘体16的层，和包括贴面12的至少一层。贴面12可以由任何适合的纤维绝缘体形成，例如但不限于玻璃纤维、矿物棉、石毛或聚合物或天然纤维。纤维可以具有任何适合的长度和直径，其能够由本领域技术人员容易地确定。纤维长度高度依赖于加工工艺，并且可以为小于1英寸(2.5cm)到大于7英寸(17.5cm)。纤维直径通常以HT(hundred thous andths ofan inch)计量。纤维绝缘体16可以具有任何适合的粘合剂量。粘合剂含量用固化之后粘结的纤维的重量百分比来表示，按重量百分比计。纤维的长度和直径，以及施加于纤维绝缘体16的粘合剂量取决于产品的最终用途。例如，住宅绝缘体可以具有20-35HT的纤维直径和3-15％的粘合剂含量。管道板通常为更加刚性的产品，并且可以具有12-22HT的纤维直径和2-10％的粘合剂含量。轻密度绝缘体可以具有20-35HT的纤维直径和3-15％的粘合剂含量。用于这些产品的未固化纤维绝缘体在足以固化粘合剂的时间和温度下固化。固化时间由产品中的粘合剂量、产品厚度和产品密度决定，并且受烘炉长度和生产线运行速率的控制，但是可以为小于1分钟到大于5分钟。控制固化炉的温度以蒸发粘合剂中使用的水，固化粘合剂，以及控制可能产生非所需的反应产物的任何化学反应。
图2示出一个可选实施方案，其中贴面的纤维绝缘体10包括位于一个主表面上的贴面12和位于第二主表面上的贴面或防潮层14。在相关实施方案中，可以将贴面12施加于纤维绝缘体16的一个表面，其中贴面12比纤维绝缘体16宽并且遮盖在边缘上以将纤维绝缘体16的一个或多个次表面贴面。
图3示出贴面的纤维绝缘体10的横截面视图，详细说明其上施加有粘合剂的贴面12。贴面12包括纤维网20，其通常为有机纤维，例如人造丝(rayon)、聚乙烯、聚丙烯、尼龙、聚酯或其共混物，其可以由已知方法加工以包括任何合适的粘合剂，例如丙烯酸，任何合适的阻燃剂，例如卤素、氧化锑或硼酸盐，和/或任何合适的颜料，例如炭黑或有机染料。形成网20的一个优选方法为常规的干法成网工艺，采用丙烯酸乳液粘合剂的浸流和提取(floodand extract)施用。其它合适的粘合剂包括胶乳和苯乙烯-丁二烯橡胶。当该网优选为干法成网非织造网时，可以使用其它材料，例如点粘结、织造和其它非织造材料，例如针刺、纺粘或熔喷法网。
非织造网20可以由任何合适的纤维，例如聚乙烯、聚丙烯、聚酯、人造丝、尼龙和所述纤维的共混物形成。纤维可以为短纤维或连续长丝。另外，纤维可以为双组分以促进粘合。例如，可以使用具有壳和芯(壳和芯为不同聚合物，例如聚乙烯(PE)和聚丙烯(PP))的纤维，或者可以使用PE和PP纤维的混合物。非织造网20可以任选地用任何合适的杀真菌剂进行处理。杀真菌剂在非织造领域是公知的。一种特别合适的杀真菌剂为二碘甲基-对甲苯基砜，购自Angus ChemicalCompany of Buffalo Grove(纽约，美国)，商品名为AMICALFLOWABLE。但是，可以使用本领域技术人员确定的其它合适的杀真菌剂。非织造网20可以在制造过程中或在后制造工序中用杀真菌剂进行处理。
如图3A所示，粘合剂22的颗粒分布在非织造网20的表面上，并被加热到高于粘合剂22熔点的温度以将粘合剂粉末22粘附到非织造网20上。合适的粘合剂22包括热塑性粘合剂，例如聚乙烯、聚丙烯、乙烯-乙酸乙烯酯和其它聚合物粘合剂。合适的热固性粘合剂22包括聚酰胺粘合剂、环氧树脂、聚氨酯、三聚氰胺、酚醛树脂粉末，例如苯酚甲醛、脲甲醛，并且热固性粘合剂是适用的。
如图3B所示，粘合剂24的纤维状颗粒也可以分布在非织造网20的表面上，并被加热到高于粘合剂纤维24熔点的温度以将粘合剂纤维24粘附到非织造网20上。用于粘合剂纤维24的合适的材料包括热塑性粘合剂，例如聚乙烯、聚丙烯、乙烯-乙酸乙烯酯和其它聚合物粘合剂。合适的热固性粘合剂24包括聚酰胺粘合剂、环氧树脂、聚氨酯、三聚氰胺、酚醛树脂纤维，例如苯酚甲醛、脲甲醛，并且热固性粘合剂是适用的。对于本申请的目的，术语“颗粒”或“颗粒状”旨在包括任何颗粒形状，包括但不限于球状、粒状、棒状、纤维状、薄片状或允许粘合剂被充分加热以活化粘合剂并将贴面12、14粘合到纤维绝缘体16上的任何其它形状和尺寸。
非织造网包括丙烯酸粘合剂、卤素氧化锑阻燃剂、炭黑、有机染料和二碘甲基-对甲苯基砜。该网20也可以包括有色纤维、染料或有色填料，例如炭黑，为贴面提供任何所需颜色。
如图4所示，玻璃纤维生产线包括纤维形成区段58、固化炉70和卷取机构82。如图4所示，形成区段58包括多个被供给熔融玻璃料流(未示出)的成纤纺丝机50。成纤纺丝机50以高速旋转，并且熔融玻璃被强制穿过纺丝机50的圆周侧壁中的孔洞以形成纤维。
鼓风机52以基本上向下的方向引导气流冲击纤维，使它们向下，使初级纤维变细以形成幕帘60。粘合剂喷雾器54将粘合剂喷涂到幕帘60上，幕帘60沉积在贴面12上，贴面12放置在收集链62上，其中幕帘60中的纤维被收集在未固化的衬料64中。
未固化的衬料64和贴面12在引出辊66下离开形成区段58并进入固化炉70。未固化的衬料64和贴面12在上部固化炉链72和下部固化炉链74之间被压缩。加热的空气由风扇76强制经过下部链72、衬料64和上部链74，以固化衬料64中的粘合剂并将贴面12粘附到衬料上以形成贴面的纤维绝缘体10。加热的空气经由排气区段78离开固化炉70。
贴面的纤维绝缘体10然后离开固化炉并由卷取机构82卷起以用于存储和运输。
贴面的纤维绝缘体10随后可以被切割或模压以形成纤维绝缘体部件。
在图5中所绘第二个实施方案中，未固化的衬料64离开形成区段，并且贴面12由辊90施加于未固化衬料64的一个表面，并且贴面或防潮层14被施加于未固化衬料64的另一个表面。合适的防潮层包括但不限于牛皮纸/沥青、牛皮纸/聚合物、聚合物和箔/纱布/牛皮纸层。贴面层12、14和未固化的衬料64然后进入固化炉70。未固化的衬料64和贴面层12、14在上部固化炉链72和下部固化炉链74之间被压缩，加热的空气被强制通过链72、74和衬料64，使衬料64中的粘合剂固化并将贴面层12、14粘附到衬料上以形成贴面的纤维绝缘体10。
当贴面的纤维绝缘体10离开固化炉时，其被平分锯80平分并由下部卷取机构82和上部卷取机构84卷成两个辊以用于存储和运输。同样考虑平分的材料可以在单个卷取机构上卷起以形成双层单一辊。同样考虑贴面的纤维绝缘体将不被平分，并且将作为如图2所示的双贴面的绝缘体产品提供。同样考虑贴面14可以提供给如图4所示的形成区段中的衬料64。进一步考虑双贴面的产品可以如图6所示的板形式提供。
另一个实施方案在图6中示出。在图6中可以看到，一旦未固化的衬料64离开形成区段，贴面12就由辊90施加于未固化的衬料64的一个表面上。贴面层12和未固化的衬料64然后进入固化炉70。未固化的衬料64和贴面层12在上部固化炉链72和下部固化炉链74之间被压缩，加热的空气被强制通过链72、74和未固化的衬料64，使衬料64中的粘合剂固化并将贴面层12粘附到衬料上以形成贴面的纤维绝缘体10。
贴面的纤维绝缘体10离开固化炉并被刀片86切割为一定长度以形成贴面的纤维绝缘体的板88，该板然后可以由包装设备92堆叠或装袋。同样考虑贴面的纤维绝缘体10的板88将作为如图2所示的双贴面的产品提供。进一步考虑贴面14可以提供给如图4所示的形成区段中的衬料64。
图7A示出使用加热的压板100将来自辊90的贴面12粘附到纤维绝缘体16，在后固化炉或离线工序中形成贴面的纤维绝缘体10的可选方法。
图7B为使用加热的辊102将来自辊90的贴面12粘附到纤维绝缘体16，在后固化炉或离线工序中形成贴面的纤维绝缘体10的可选方法的平面图。
图7C为使用加热的履带110在后固化炉或离线工序中形成贴面的纤维绝缘体10的可选方法的平面图，该加热的履带110具有加热的上部皮带112，其围绕第一上部皮带轮114和第二上部皮带轮116旋转以将纤维绝缘体抵靠着围绕第一下部皮带轮122和第二下部皮带轮124旋转的加热的下部皮带120压缩，持续足以加热粘合剂22、24从而将贴面12粘附到纤维绝缘体16的第一表面上并将防潮层14粘附到纤维绝缘体产品16的第二表面上的时间。
本发明贴面的纤维绝缘体包括至少一层的例如玻璃纤维、矿物棉、石毛或聚合物纤维的纤维绝缘体，和至少一层的贴面。本领域技术人员将认识到根据本文中的教导可以制造出许多种产品构造，包括具有施加于一个表面的单层贴面的单层纤维绝缘体，具有施加于相对主表面的贴面的单层纤维绝缘体，具有施加于相对主表面的贴面的单层纤维绝缘体，其中贴面的至少一层比主表面宽，使得纤维绝缘体的一个或多个次表面可以被贴面。同样可以施加具有贴面的多层纤维绝缘体，在其间具有施加的上述贴面中的任何一种。同样可以在上述产品中提供防潮层材料来代替至少一个贴面。
本申请的发明已经在以上概括地和根据特定实施方案加以描述。虽然本发明已经以据信是优选实施方案的形式加以阐明，但是可以在一般公开范围内选择本领域技术人员已知的多种可选方案。除了以下阐明的权利要求的叙述之外，本发明并不另外受到限制。

Claims (8)

1.一种制造贴面的纤维绝缘体产品的方法，包括以下步骤：
形成在其上具有未固化粘合剂的纤维衬料(64)；
将贴面(12)施加于所述纤维衬料的第一表面，所述贴面包括贴面层、熔结到所述贴面层上的颗粒状粘合剂；和
固化纤维衬料以形成纤维绝缘体产品，
其中贴面在所述固化步骤期间被粘附到纤维衬料上。
2.权利要求1的方法，进一步包括在所述固化步骤之前将第二贴面施加于所述纤维衬料的第二表面的步骤。
3.权利要求1的方法，进一步包括在所述固化步骤之后将第二贴面施加于所述贴面的纤维绝缘体的第二表面的步骤。
4.权利要求1的方法，进一步包括将防潮层(14)施加于所述贴面的纤维绝缘体的第二表面的步骤。
5.权利要求1的方法，其中颗粒状粘合剂选自聚乙烯、聚丙烯、乙烯-乙酸乙烯酯、聚酰胺、环氧树脂、脲甲醛、三聚氰胺、聚氨酯、酚醛树脂及其结合物。
6.权利要求1的方法，其中颗粒状粘合剂为粉末状粘合剂。
7.权利要求1的方法，其中颗粒状粘合剂为纤维状粘合剂。
8.权利要求1的方法，其中贴面层由选自聚乙烯、聚丙烯、聚酯、人造丝、尼龙及其共混物的纤维形成。
CN201911282740.8A 2019-12-13 2019-12-13 贴面的纤维绝缘体 Withdrawn CN112976721A (zh)

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