CN114103322A - Component with metal coating and microfiber sandwich and method of making same - Google Patents

Component with metal coating and microfiber sandwich and method of making same Download PDF

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Publication number
CN114103322A
CN114103322A CN202010882753.5A CN202010882753A CN114103322A CN 114103322 A CN114103322 A CN 114103322A CN 202010882753 A CN202010882753 A CN 202010882753A CN 114103322 A CN114103322 A CN 114103322A
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CN
China
Prior art keywords
microfiber
cover layer
sandwich
assembly
layer
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Pending
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CN202010882753.5A
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Chinese (zh)
Inventor
范金土
玛纳斯·库马尔·萨卡
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Hong Kong Polytechnic University HKPU
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Hong Kong Polytechnic University HKPU
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Priority to CN202010882753.5A priority Critical patent/CN114103322A/en
Publication of CN114103322A publication Critical patent/CN114103322A/en
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
    • B32B2037/243—Coating
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    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
    • B32B2037/246—Vapour deposition
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
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    • B32B2255/00—Coating on the layer surface
    • B32B2255/20—Inorganic coating
    • B32B2255/205—Metallic coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0223—Vinyl resin fibres
    • B32B2262/0238—Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
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    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
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    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
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    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/00—Properties of the layers or laminate
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    • B32B2307/724—Permeability to gases, adsorption
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Abstract

The invention discloses an assembly having a metal coating and a microfiber sandwich and a method of making the same. The assembly includes: a first cover layer having an upper surface and a lower surface; a second cover layer having an upper surface and a lower surface; a microfiber sandwich having a porous structure, the microfiber sandwich being sandwiched between a lower surface of the first cover layer and an upper surface of the second cover layer; and a first metal coating covering an upper surface of the first cover layer. The module has excellent air permeability and heat insulation, and is simple and light in structure.

Description

Component with metal coating and microfiber sandwich and method of making same
Technical Field
The present invention relates generally to textile materials, and more particularly to components having a metal coating and a microfiber sandwich and methods of making the same.
Background
One of the important functions of a garment is to protect the human body from extreme weather conditions and to provide maximum comfort. The main purpose of summer clothing is to enhance the perspiration of the human body in order to dissipate the heat of the human body into the atmosphere. In contrast, winter clothing has the main purpose of retaining body heat in the clothing, but at the same time, sweat from the wearer should also be emitted into the atmosphere, which is a great challenge to existing textile technology.
To meet the requirements of winter clothing, many different types of fabrics have been developed, but these fabrics are either too heavy or not sufficiently protective against cold weather. In addition, these fabrics also do not adequately dissipate perspiration to the atmosphere, and as a result, create a highly humid environment inside the garment, which results in discomfort to the wearer. Us patent US10,130,129B2 discloses an insulating composite fabric using a fleece material. Although it can protect the human body from the air in winter, the fabric is too heavy. In addition, some prior art techniques spray staple sheets directly onto the nonwoven fabric, but are not durable because the fibrous sheets are not properly protected on the outer layer.
Chinese utility model patent CN202228854U discloses a thermal insulation structure comprising at least one layer of ultra fine fibrous web coated with an infrared radiation reflective coating or a fibrous web formed of a fabric and one layer of coarse fibers. The material prevents thermal radiation without affecting the moisture transfer within the fibrous insulation system, thereby improving the insulation performance without compromising the weight of the system. However, the thermal insulation structure has the following problems: 1) the wear resistance of the surface of the superfine fiber is poor; 2) the surface of the superfine fiber is not smooth, and the reflectivity of the infrared reflection coating is seriously influenced; 3) the infrared reflective coating is susceptible to damage and peeling due to the weakness on the surface of the microfiber.
Therefore, there is a need in the art for a new material for thermal insulation and ventilation that solves the above-mentioned problems of the prior art.
Disclosure of Invention
The invention discloses an assembly having a metal coating and a microfiber sandwich, the assembly comprising: a first cover layer having an upper surface and a lower surface; a second cover layer having an upper surface and a lower surface; a microfiber sandwich having a porous structure, the microfiber sandwich being sandwiched between a lower surface of the first cover layer and an upper surface of the second cover layer; and a first metal coating covering an upper surface of the first cover layer.
According to some embodiments, the first cover layer is a first nonwoven or a first foam layer and the second cover layer is a second nonwoven or a second foam layer.
According to some embodiments, the first cover layer is a first nonwoven fabric and the second cover layer is a second nonwoven fabric.
According to some embodiments, each of the first nonwoven fabric and the second nonwoven fabric comprises polypropylene, polyethylene terephthalate, polyamide resin, high density polyethylene, or polyvinyl chloride.
According to some embodiments, the first nonwoven fabric, the second nonwoven fabric and the microfiber sandwich layer comprise the same polymer.
According to some embodiments, the first cover layer is a first foam layer and the second cover layer is a second foam layer.
According to certain embodiments, each of the first foam layer and the second foam layer comprises a polymer foam.
According to certain embodiments, the first foam layer, the second foam layer, and the microfiber sandwich comprise the same polymer.
According to certain embodiments, the microfiber sandwich comprises electrospun fibers produced by electrospinning.
According to certain embodiments, the microfiber sandwich comprises polyvinyl chloride microfiber, nylon microfiber, polyacrylonitrile microfiber, or polyvinylidene fluoride microfiber.
According to some embodiments, the microfiber sandwich comprises microfiber having a diameter between 50nm and 1 μm, the porous structure comprising a pore size between 30nm and 80 μm and a porosity between 60% and 90%.
According to certain embodiments, the microfiber sandwich further comprises a functional additive or a thermal bonding resin.
According to certain embodiments, the first metal coating comprises aluminum, zinc, copper, combinations thereof, or oxides thereof.
According to some embodiments, the assembly further comprises a second metal coating covering a lower surface of the second cover layer.
The present invention also discloses a method for manufacturing an assembly having a metal coating and an ultrafine fibrous interlayer, comprising: coating the superfine fibers on the surface of the first covering layer to generate a superfine fiber interlayer; overlaying a second cover layer on a surface of the microfiber sandwich to sandwich the microfiber sandwich between the first cover layer and the second cover layer, thereby creating a subassembly; hot pressing the subassembly; and applying a first metal to one surface of the subassembly to produce a first metal coating, thereby producing the assembly.
According to some embodiments, the first cover layer is a first nonwoven or a first foam layer and the second cover layer is a second nonwoven or a second foam layer.
According to some embodiments, coating the ultrafine fibers on the surface of the first cover layer includes coating the ultrafine fibers on the surface of the first cover layer by electrospinning.
According to certain embodiments, hot pressing the subassembly comprises a hot pressing temperature between 110 ℃ and 150 ℃ and a hot pressing speed between 1 meter/minute and 3 meters/minute.
According to some embodiments, coating the first metal on one surface of the subassembly comprises coating the first metal on the surface of the subassembly by metal vapor deposition, thermal evaporation, sputtering, or ion exchange.
According to some embodiments, the method further comprises coating a second metal on another surface of the subassembly to produce a second metal coating.
Drawings
The invention will be described in further detail below with reference to the following figures and examples, wherein:
FIG. 1 shows a schematic view of an assembly having a metal coating and a microfiber sandwich according to certain embodiments of the present invention;
FIG. 2 illustrates a flow diagram of a method for manufacturing an assembly having a metal coating and a microfiber sandwich in accordance with certain embodiments of the present invention;
FIG. 3 illustrates a schematic flow diagram for manufacturing an assembly having a metal coating and a microfiber sandwich in accordance with certain embodiments of the present invention;
FIG. 4 illustrates a schematic flow diagram for manufacturing an assembly having a metal coating and a microfiber sandwich in accordance with certain embodiments of the present invention;
FIG. 5A shows direct infrared reflectance of a nonwoven fabric without a metal coating and with a different metal coating;
FIG. 5B shows the temperature rise of a nonwoven fabric without a metal coating and with a different metal coating; and
fig. 5C shows the total infrared transmittance of the nonwoven fabric without and with the aluminum coating.
Detailed Description
The term "microfiber sandwich" as used in this disclosure refers to a sandwich consisting essentially of microfibers. The term "ultrafine fibers" as used in this disclosure refers to fibers having a diameter between 50nm and 1 μm.
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
The invention discloses an assembly with a metal coating and a superfine fiber interlayer, which comprises two light cover layers for clamping the superfine fiber interlayer with high air permeability, and at least one cover layer is coated with metal or metal oxide on the surface to preserve human body heat.
FIG. 1 illustrates an assembly 100 having a metal coating and a microfiber sandwich in accordance with certain embodiments of the present invention. The assembly 100 includes a first cover layer 110, a second cover layer 120, a microfiber sandwich 130, and a metal coating 140. The first cover layer 110 has an upper surface 111 and a lower surface 112. The second cover layer 120 has an upper surface 121 and a lower surface 122. The microfiber sandwich 130 has a porous structure, and the microfiber sandwich 130 is sandwiched between the lower surface 112 of the first cover layer 110 and the upper surface 121 of the second cover layer 120. The metal coating 140 covers the upper surface 111 of the first cover layer 110. The porous structure of the microfiber sandwich 130 has excellent air permeability, which helps to disperse sweat of the human body. Since the microfiber sandwich 130 is sandwiched between the first cover layer 110 and the second cover layer 120, it does not fall off after repeated abrasion and washing. The metal coating 140 has a high infrared reflectivity, which helps preserve the thermal radiation of the human body, thereby improving the thermal insulation and heat retention of the assembly 100.
According to some embodiments, the first cover layer is a first nonwoven or a first foam layer and the second cover layer is a second nonwoven or a second foam layer. According to some embodiments, the first cover layer is a first nonwoven and the second cover layer is a second nonwoven. According to some embodiments, the first cover layer is a first foam layer and the second cover layer is a second foam layer.
According to certain embodiments, the first and second nonwoven comprise a lightweight nonwoven having a weight of between 5gsm (grams per square meter) and 8gsm, between 8gsm and 12gsm, or between 12gsm and 15 gsm. The material of the light non-woven fabric can be spun-bonded polypropylene or melt-blown polypropylene.
According to some embodiments, the first nonwoven fabric and the second nonwoven fabric comprise polypropylene, polyethylene terephthalate, polyamide resin, high density polyethylene, or polyvinyl chloride.
According to certain embodiments, the first foam layer and the second foam layer comprise a polymer foam. The polymer foam may comprise polyethylene or polyurethane.
According to certain embodiments, the microfiber sandwich comprises electrospun fibers generated by electrospinning.
According to certain embodiments, the microfiber sandwich comprises polyvinyl chloride fibers, nylon fibers, polyacrylonitrile fibers, or polyvinylidene fluoride fibers having a diameter between 50nm and 1 μm. According to certain embodiments, the porous structure has a pore size between 30nm and 80 μm and a porosity between 60% and 90%. According to certain embodiments, the microfiber sandwich has a weight between 0.1gsm and 0.5gsm, between 0.5gsm and 1.0gsm, or between 1.0gsm and 3.0 gsm.
According to some embodiments, the microfiber sandwich layer further comprises a thermal bonding resin for increasing the bonding degree of the microfiber sandwich layer to the cover layer. According to certain embodiments, the microfiber sandwich further comprises a functional additive. The functional additive may be an antimicrobial agent (e.g., silver ions) or a uv light blocker (e.g., zinc oxide).
According to some embodiments, the first nonwoven fabric, the second nonwoven fabric and the microfiber interlayer comprise the same polymer to improve the adhesion thereof. According to certain embodiments, the first foam layer, the second foam layer, and the microfiber sandwich layer comprise the same polymer to improve their adhesion.
According to some embodiments, the assembly further comprises a further metal coating covering the lower surface of the second cover layer.
According to certain embodiments, the metal coating comprises aluminum, zinc, copper, combinations thereof, or oxides thereof.
FIG. 2 illustrates a flow diagram of a method for manufacturing an assembly having a metal coating and a microfiber sandwich in accordance with certain embodiments of the present invention. Step S21: the microfiber is coated on the surface of the first cover layer to create a microfiber sandwich. Step S22: a second cover layer is overlaid on a surface of the microfiber sandwich layer to sandwich the microfiber sandwich layer between the first cover layer and the second cover layer, thereby creating a subassembly. Step S23: the subassembly is hot pressed which helps to bond the microfiber sandwich layer more firmly to the first cover layer and the second cover layer. Step S24: coating a metal on one surface of the subassembly to produce a metal coating to produce the assembly. Step S25: optionally, a metal is coated on the other surface of the subassembly to produce another metal coating.
According to some embodiments, the first cover layer is a first nonwoven or a first foam layer and the second cover layer is a second nonwoven or a second foam layer. According to some embodiments, the first cover layer is a first nonwoven and the second cover layer is a second nonwoven. According to some embodiments, the first cover layer is a first foam layer and the second cover layer is a second foam layer.
According to some embodiments, coating the ultrafine fibers on the surface of the first cover layer includes coating the ultrafine fibers on the surface of the first cover layer by electrospinning. Electrostatic spinning is carried out by carrying out spinning jet on a polymer solution in a strong electric field. The polymer solution may include polyvinyl chloride, nylon, polyacrylonitrile, or polyvinylidene fluoride. According to certain embodiments, the polymer solution further includes a thermal bonding resin to more securely bond the fibrous material and the cover layer material together during the hot pressing step. According to certain embodiments, the polymer solution further comprises a functional additive, such as an antimicrobial agent (e.g., silver ions) or a UV blocker (e.g., zinc oxide).
According to some embodiments, hot pressing the subassembly comprises hot pressing the subassembly with an adhesive or a hot press. According to some embodiments, hot pressing the subassembly comprises a hot pressing temperature between 110 ℃ and 150 ℃ and a hot pressing speed between 1 meter/minute and 3 meters/minute.
According to certain embodiments, to further improve the thermal insulation of the assembly, a lightweight (e.g., 10gsm) polyethylene foam or polyurethane foam may be used as the material of the cover layer. When using foam, the bonding is preferably performed by spot welding using a pattern calender roll heated.
According to some embodiments, coating the metal on the one surface of the subassembly comprises coating the metal on the one surface of the subassembly by metal vapor deposition, thermal evaporation, sputtering, or ion exchange. According to some embodiments, coating the metal on the other surface of the subassembly comprises coating the metal on the other surface of the subassembly by metal vapor deposition, thermal evaporation, sputtering, or ion exchange.
FIG. 3 illustrates a schematic flow diagram for manufacturing an assembly 30 having a metal coating and a microfiber sandwich, according to some embodiments of the present invention. First, the nonwoven fabric 31 is provided. Then, the nanofibers are coated on the surface of the non-woven fabric 31 to produce the air-permeable nano microfiber sandwich 32. Subsequently, the non-woven fabric 33 is covered on the surface of the air-permeable nano microfiber sandwich 32 to sandwich the air-permeable nano microfiber sandwich 32 between the non-woven fabric 31 and the non-woven fabric 33, and the non-woven fabric 31, the air-permeable nano microfiber sandwich 32 and the non-woven fabric 33 are hot pressed by a lamination method. Finally, a metal is coated on the surface of the nonwoven fabric 33 to produce a metal coating 34, thereby producing the assembly 30.
Fig. 4 illustrates a schematic flow diagram for manufacturing an assembly 400 having a metal coating and a microfiber sandwich in accordance with certain embodiments of the present invention. Nanofibers 422 are sprayed onto the surface of the non-woven fabric 410 through an electrospinning machine 420 filled with a polymer solution 421 to generate a breathable nano microfiber sandwich 423. A non-woven fabric 430 is coated on the surface of the air-permeable nano-microfiber sandwich 423 to create a fiber subassembly 440. The fiber subassembly 440 is hot pressed by a bonder 450. The assembly 400 is produced by placing the hot pressed fiber subassembly 440 in a thermal evaporation deposition machine 460, and evaporating metal 462 through a heat generator 461 to coat the metal 462 on the surface of the fiber subassembly 440 to produce a metal coating 463.
Fig. 5A shows the direct infrared reflectance of a nonwoven fabric without a metal coating and with a different metal coating. As can be seen from fig. 5A, the nonwoven fabric without the metal coating has only a 10% infrared reflectance. In contrast, the infrared reflectance of the non-woven fabric having different metal coatings (including a zinc coating, a copper coating, an aluminum coating, and a copper-aluminum double coating) was between 18% and 51%. Wherein, the infrared reflectivity of the non-woven fabric with the copper-aluminum double coating can reach 51%.
Accordingly, fig. 5B shows the temperature rise of the nonwoven fabric without the metal coating and with a different metal coating. As can be seen from fig. 5B, the temperature of the nonwoven fabric with the metal coating layer increases compared to the temperature of the nonwoven fabric without the metal coating layer. Wherein, the temperature rise of the non-woven fabric with the copper-aluminum double coating can reach 7.9 ℃, which is much higher than that of the non-woven fabric without the metal coating (3.4 ℃). Therefore, the non-woven fabric with the metal coating can provide better heat insulation and heat preservation effects.
Fig. 5C shows the total light transmittance at different wavelengths for the non-woven fabric without coating and with aluminum coating. As can be seen from fig. 5C, the nonwoven fabric with the aluminum coating has a lower infrared transmittance due to increased reflection of infrared radiation in different wavelengths, which leads to an improved thermal insulation of the nonwoven fabric assembly. In certain embodiments, the thermal insulation performance of the nonwoven fabric assembly is improved by as much as 45%.
Compared with the prior art, the assembly with the metal coating and the superfine fiber interlayer disclosed by the invention has excellent heat insulation and air permeability, and is simple and light in structure. The porous structure of the microfiber sandwich has excellent air permeability, which helps to disperse sweat from the human body. Because the superfine fiber interlayer is clamped between the non-woven fabrics (or foam layers), the superfine fiber interlayer can not fall off after repeated abrasion and washing. The heat and pressure treatment also helps to bond the microfiber sandwich layer and the cover layer more firmly. The metal coating has a high infrared reflectivity, which helps preserve the thermal radiation of the human body, thereby improving the thermal insulation and heat retention of the assembly. The metal coating can be firmly adhered to the non-woven fabric or the foam, and the metal coating is not easy to fall off from the surface even after repeated abrasion or washing. The assembly preferably uses a lightweight nonwoven fabric and foam, which helps to reduce the weight of the assembly. The invention requires low material and manufacturing costs. The assembly of the present invention may be used in garments, building insulation, or other applications where breathable thermal insulation is desired.
While the invention has been described with reference to specific embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.

Claims (20)

1. An assembly having a metal coating and a microfiber sandwich, comprising:
a first cover layer having an upper surface and a lower surface;
a second cover layer having an upper surface and a lower surface;
a microfiber sandwich having a porous structure, the microfiber sandwich being sandwiched between a lower surface of the first cover layer and an upper surface of the second cover layer; and
a first metal coating covering an upper surface of the first cladding layer.
2. The assembly of claim 1, wherein the first cover layer is a first nonwoven or a first foam layer and the second cover layer is a second nonwoven or a second foam layer.
3. The assembly of claim 1, wherein the first cover layer is a first nonwoven and the second cover layer is a second nonwoven.
4. The assembly of claim 3, wherein each of the first and second nonwoven fabrics comprises polypropylene, polyethylene terephthalate, polyamide resin, high density polyethylene, or polyvinyl chloride.
5. The assembly of claim 3, wherein the first nonwoven fabric, the second nonwoven fabric and the microfiber sandwich layer comprise the same polymer.
6. The assembly of claim 1, wherein the first cover layer is a first foam layer and the second cover layer is a second foam layer.
7. The assembly of claim 6, wherein each of the first and second foam layers comprises a polymer foam.
8. The assembly of claim 6, wherein the first foam layer, the second foam layer, and the microfiber sandwich comprise the same polymer.
9. The assembly of claim 1, wherein the microfiber sandwich comprises electrospun fibers produced by electrospinning.
10. The assembly of claim 1, wherein the microfiber sandwich comprises polyvinyl chloride microfiber, nylon microfiber, polyacrylonitrile microfiber, or polyvinylidene fluoride microfiber.
11. The assembly according to claim 1, wherein the microfiber sandwich comprises microfibers having a diameter between 50nm and 1 μ ι η, the porous structure comprising pore sizes between 30nm and 80 μ ι η and a porosity between 60% and 90%.
12. The assembly of claim 1, wherein the microfiber sandwich further comprises a functional additive or a thermal bonding resin.
13. The assembly of claim 1, wherein the first metal coating comprises aluminum, zinc, copper, combinations thereof, or oxides thereof.
14. The assembly of claim 1, further comprising a second metal coating covering a lower surface of the second cover layer.
15. A method for manufacturing an assembly having a metal coating and a microfiber sandwich, comprising:
coating the superfine fibers on the surface of the first covering layer to generate a superfine fiber interlayer;
overlaying a second cover layer on a surface of the microfiber sandwich to sandwich the microfiber sandwich between the first cover layer and the second cover layer, thereby creating a subassembly;
hot pressing the subassembly; and
the assembly is produced by applying a first metal to one surface of the subassembly to produce a first metal coating.
16. The method of claim 15, wherein the first cover layer is a first nonwoven or a first foam layer and the second cover layer is a second nonwoven or a second foam layer.
17. The method of claim 15, wherein coating the ultrafine fibers on the surface of the first cover layer comprises coating the ultrafine fibers on the surface of the first cover layer by electrospinning.
18. The method of claim 15, wherein hot pressing the subassembly comprises a hot pressing temperature between 110 ℃ and 150 ℃ and a hot pressing speed between 1 meter/minute and 3 meters/minute.
19. The method of claim 15, wherein coating the first metal on one surface of the subassembly comprises coating the first metal on the surface of the subassembly by metal vapor deposition, thermal evaporation, sputtering, or ion exchange.
20. The method of claim 15, further comprising coating a second metal on another surface of the subassembly to produce a second metal coating.
CN202010882753.5A 2020-08-28 2020-08-28 Component with metal coating and microfiber sandwich and method of making same Pending CN114103322A (en)

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CN103552318A (en) * 2013-11-05 2014-02-05 中航复合材料有限责任公司 Nonwoven fabric containing metal coating as well as product thereof
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CN101628491A (en) * 2008-07-07 2010-01-20 香港理工大学 Three-tier reflective nanofibrous structure and fabricating method thereof
JP2011088349A (en) * 2009-10-22 2011-05-06 Teijin Techno Products Ltd Multilayer fiber structure and filter medium comprising the same
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