CN1213284A - 用于控制进入发热元件氧气流量的复合薄膜 - Google Patents
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Abstract
用于控制进入发热元件(10)氧气流量的复合材料,包括制成盒(14)状的底板(12)。该底板不透氧气。盒中装有许多颗粒(20)。当与氧气接触时,这些颗粒发生放热反应。在盒周围的法兰处将顶板密封到底板上,以封装这些颗粒,使其不能从盒中掉出来。顶板具有能高度透氧的底基(22)。底基上涂有能透过氧气的硅氧烷基弹体(24),当顶板与氧气接触时,弹体的厚度能调节进入盒中的氧气流量。该复合材料还包括用压敏粘合剂(27)粘接到顶板上的不能透氧的隔离膜,以在身体加热器使用之前防止顶板与氧气接触。一种制造顶板材料的方法包括将硅氧烷橡胶层涂覆到光滑表面,使硅氧烷部分固化,将多孔性底基层压到硅氧烷橡胶层,最后使硅氧烷橡胶完全固化,使其与底基粘接。
Description
发明领域
本发明涉及可透氧材料，更具体地涉及可用其厚度来控制由周围空气进入发热元件(thermal cell)中氧气流量的材料。
发明背景
用于身体取暖器的发热元件，特别是使用活性铁粉和活性炭混合物的发热元件在本领域中是众所周知的。这些元件需要氧来产生受控放热反应。上述的放热反应能在几小时内提供热量。这种混合物一般装在透气袋(pocket)内。使用前，这种透气袋一直密封在不透气的外包装袋内。这种透气袋可以是非织造材料或穿孔材料。不论是哪一种情况，当挤压该装置时，混合物颗粒可能穿过孔眼或非织造材料的纤维间隙。混合物(特别是炭)偶然的渗漏可能污染使用者的衣服，并降低发热元件的性能。
在常见身体取暖器中，可能有一个以上的发热元件。使用由某些底基材料隔开的并排放置的多个较小的元件能使身体取暖器具有比单个元件更大的柔软性，以顺应体形。发热元件越小，放在元件上的非织造底基的孔眼部位和数目或密实性对于控制进入元件的氧气流量来说越重要。这种控制是必要的，以确保元件不会过热和烧伤使用者或过早用完放热潜能。
用于分离过程的透气膜已可得到。例如，92年4月7日公布的美国专利5,102,552(Callahan等)揭示了一种涂覆在平均孔隙度约为0.005-0.2微米的微孔载体上的可紫外固化的聚合物。73年8月28日公布的美国专利3,754,375(Bouchilloux等)揭示了一种“具有极好机械性能和良好透气性能的各向异性薄膜”。它包括乙烯基三有机基硅烷聚合物或共聚物，它具有平均厚度为0.01-10微米的稠密层和有20-80％开口面积的多孔层。
其它人甚至已将透气薄膜用于发热元件，但成效有限。例如，91年9月10日公开的美国专利5,046,479(Usui)揭示了一种用经“热熔融处理”的微孔薄膜来控制其氧气渗透量的方法，以限制一次性身体取暖器的氧气渗透量。含有铁粉发热剂的平袋(flat bag)具有透气的表面，每单位的透气量为5000-10000秒/100立方厘米。令人遗憾的是微孔薄膜很贵。
发明目的
本发明的一个目的是提供用于发热元件的能极好地控制氧气渗透性的廉价复合材料。
本发明的另一个目的是提供一种没有孔眼或空隙的复合材料，从而装有发热混合物(thermal mixture)的袋中不会泄漏出这种混合物的颗粒。
本发明的还有一个目的是提供可热合到装有发热混合物的不透气盒法兰处的复合材料。发热元件使用前用来密封氧气的不透气盖片易于从这种复合材料上剥离。
本发明的最后一个目的是提供制备这种用于发热元件的能极好地控制氧气渗透性的复合材料的方法。
发明概述
在本发明的实施过程中，用硅氧烷涂覆非织造或其它多孔底基，形成身体取暖器所用的发热元件的顶板。涂有硅氧烷的底基能以优选的速度透过氧气，而不会漏出装在发热元件中的颗粒材料。氧气渗透速度易于通过改变硅氧烷涂层的厚度来加以调节。底基提供结构的整体性，因为已知硅氧烷材料本身是易于撕裂的。开始渗透氧气并产生热量时除去的隔离膜可易于从硅氧烷涂层上剥离，因为硅氧烷涂层起着压敏粘合剂的剥离表面的作用。
在本发明的一个方面中，用于控制进入发热元件氧气流量的复合材料包括制成盒状的底板。所述的底板是不能透过氧气的。在所述盒中装有许多颗粒。当与氧气接触时，这些颗粒发生放热反应。在所述盒周围的法兰处将顶板密封到底板上，以封装这些颗粒，使其不能从盒中掉出来。所述的顶板具有能高度透氧的底基。底基上涂有能透过氧气的硅氧烷基弹体，当顶板与氧气接触时，弹体的厚度能调节进入盒中的氧气流量。
该复合材料还包括一种在身体取暖器使用前防止顶板与氧气接触的装置。该装置是用压敏粘合剂粘接在顶板上的不透氧隔离膜。该装置也可以是用来存放带有发热元件的身体取暖器的不透氧气的袋。
所述的许多颗粒含有活性铁混合物。所述的混合物包括活性炭、水和盐，以提高所述混合物与氧气接触时的放热反应速度。进入盒内的氧气流量较好为约1.75×105厘米3/100英寸2/天。该底基包括孔眼至少为2微米的非织造织物，该硅氧烷基弹体(silicone based elastomer)包括涂在所述底基上厚度约为0.0001英寸的聚二甲基硅氧烷。
在本发明的另一方面中，一种制备用于控制氧气流量的复合材料的方法包括如下步骤：将硅氧烷橡胶层涂覆在光滑的表面上和使硅氧烷橡胶层部分固化，以提高其从所述光滑表面上的可剥离性。其它的步骤包括将氧多孔性底基压在所述硅氧烷橡胶层上，然后使所述的硅氧烷橡胶层完全固化，使其与氧多孔性底基粘接。该方法还有一个从所述的光滑表面上剥离所述的氧多孔性底基和硅氧烷橡胶层的步骤。所述的光滑表面可以是一个转鼓，所述的氧多孔性底基包括卷绕在所述一部分转鼓上的连续薄膜。
附图简介
虽然说明书和权利要求书相结合已特别指出和明确本发明要求保护的内容，但参照附图并根据如下优选实施方式的描述可更好地理解本发明。在附图中，相同的附图标记表示相同的部件。
图1是用于控制进入本发明发热元件氧气流量的复合材料的优选实施方式的顶视图，它揭示了从复合材料法兰向上突出的倒置的圆柱形盒；
图2是沿图1中剖面线2-2所取的局部侧剖视图。它表示发热元件放在不透气袋中防止其与氧气接触时的复合材料层和该盒中的发热混合物颗粒；
图3是类似于图2的局部侧视图，但表示了一层与复合材料粘接的用来保护发热混合物免与氧气接触的不透气可剥离的隔离膜；和
图4是用于控制进入本发明发热元件中氧气流量的复合材料的制造方法的侧视图，它表示一个转鼓、加热灯、涂料辊和一对连续薄膜卷料控制辊。
发明的详细描述
现在参看附图，特别是图1、2和3。它们表明本发明的第一优选实施方式，提供至少一个发热元件10。发热元件10具有制成盒14状的底板12。底板12在围绕盒14的法兰18处与顶板密封，顶板统称为16。密封的盒14较好包含发热混合物20。顶板16是由底基22和硅橡胶层24构成的复合材料。底基22是高度透氧的。
图2表示发热元件10的剖面侧视图。在图2的实施方式中，发热元件10被封入不透氧气的袋26中。打开不透气的袋26，可使发热混合物20活化，从而使氧气透过顶板16进入发热混合物20中。
图3是类似于图2的剖面侧视图，但带有用压敏粘合剂27粘接在硅橡胶涂层24上的可剥离薄膜28。在该实施方式中，可剥离薄膜28具有剥离舌片(teartab)30。当用舌片30从硅橡胶涂层24上剥离可剥离膜28时，空气中的氧通过硅橡胶层24和底基22进入发热混合物20中。压敏粘合剂27较好粘接在可剥离薄膜28上，而不是粘接在硅橡胶涂层24上。
关于本发明身体取暖器发热元件使用上的其它细节可参见95年6月29日提交的待审申请08/496,373，题目为“具有菱形图案的弹性背覆盖物和防滑装置”，该申请已转让给本申请的受让人。该申请结合参考于本发明中。
在本发明的一个特别优选的实施方式中，底基22是Durapel0.65微米的微孔膜(购自Millipore Corporation,of Bedford,MA)。通过先按10∶0.25的质量比将粘度约为1000厘沲的以羟基为端基的聚二甲基硅氧烷(PDMS)与辛酸锡催化剂混合，将硅橡胶24涂覆在底基22上。用锋利的刀片将PDMS混合物涂覆在微孔性薄膜上，厚度约为0.0001英寸。然后将PDMS混合物在四乙氧基硅烷(TEOS)的蒸汽中暴露5-15分钟。更长的暴露时间相应于更厚的涂层。先用甲苯，后用甲醇洗掉剩余的未反应的PDMS。在TEOS中暴露5-15分钟得到的氧气渗透速度为3.5×105-1.5×105厘米3/100英寸2/天。
虽然微孔薄膜提供非常均匀的涂层表面和均匀的孔隙大小，但它们被认为是非常昂贵的。比较起来，昂贵的非织造材料一般提供相当均匀的涂层表面和相当均匀的孔隙大小。廉价的非织造材料一般提供非常粗糙的涂层表面和很大的孔隙。这使得用本领域中已知的涂布技术(如线绕棒涂覆法和凹版印刷涂覆法)非常难于在其表面上涂覆0.0001英寸厚的开始为液体的硅橡胶层。通过在光滑表面上涂覆液态硅橡胶，使非织造材料与部分固化的硅橡胶接触，然后当与非织造材料接触时将硅橡胶完全固化，会将硅橡胶从该光滑表面上转移到非织造材料上。这种方法可以在非织造材料的粗糙表面上形成硅橡胶的均匀涂层。据认为，图4中所示的优选涂覆法可以使在廉价非织造织物的不平滑表面上涂覆0.0001英寸厚硅橡胶层的操作自动化。图4中所示的方法当然也可用于昂贵的微孔薄膜。
图4中所示用于制造顶板16的方法统称为29。当转鼓26转动时，硅橡胶涂覆系统32在转鼓36上沉积约0.0001厚的未固化、液态硅橡胶。转鼓36的表面较好是抛光的光滑表面。它可以是不锈钢、镀铬的材料或其它合适的光滑表面。液态硅橡胶可以用初步固化源37部分固化。上述的初步固化源37较好是用来加热固化硅橡胶的加热装置。也可使用其它固化装置，如紫外灯。自动化方法29包括一卷穿引在引入惰轮38和转鼓36之间的底基22。底基22较好是非织造薄膜或微孔薄膜。在本方法中，液态硅橡胶34较好先沉积在底基22的表面上。当转鼓36转动时，用固化源37使液态硅橡胶34部分固化。固化源37较好是用来固化可热固化的硅橡胶的加热器。将液态硅橡胶转化成固体硅橡胶24后，用引入惰轮38将底基织物22压在硅橡胶涂层24上。底基织物22中的张力使其保持与硅橡胶涂层24接触。当辊36转动时，用固化源40使硅橡胶涂层24完全固化。固化源40较好是类似于固化源37的加热器。固化完全时，底基22与硅橡胶涂层24粘接，形成复合顶板16。然后在卸料惰轮42处从转鼓36上卸下顶板16。
在本发明的一个特别优选的实施方式中，当转鼓36的表面速度为50-750FPM时，加热器37和40在100-200下的温度下分别加热硅橡胶34和24。转鼓的直径较好为6英寸-36英寸，并具有不锈钢或镀铬的外表面。
虽然已对本发明的具体实施方式作了说明和解释，但本领域中的普通技术人员显然可以在不偏离本发明精神和范围的条件下对其作各种变化和改进。因此，所附的权利要求书试图覆盖所有这些本发明范围内的改进。
Claims (10)
1．用于控制进入发热元件氧气流量的复合材料，其特征在于：
a)制成盒状的底板，所述的底板是不能透过氧气的；
b)装在所述盒中的许多颗粒，当与氧气接触时，这些颗粒发生放热反应；
c)在所述盒周围的法兰处密封到底板上的顶板，以封装这些颗粒，使其不能从盒中掉出来，所述的顶板具有能高度透氧的底基，底基上涂有能透过氧气的硅氧烷基弹体，当顶板与氧气接触时，弹体的厚度能调节进入盒中的氧气流量。
2．用于控制氧气流量的复合材料，其特征在于：
a)氧气多孔性底基；和
b)涂覆在所述氧气多孔性底基上的可透氧硅氧的烷基弹体，其厚度能将通过所述复合材料的氧气流量控制在约1.5×105厘米3/100英寸2/天-3.5×105厘米3/100英寸2/天。
3．如权利要求1或2所述的复合材料，其特征在于所述的氧气流量约为1.75×105厘米3/100英寸2/天。
4．如权利要求1所述的复合材料，其特征在于所述的许多颗粒包含活性铁混合物，所述的混合物包括活性炭、水和盐，以提高所述混合物与氧气接触时的放热反应速度。
5．如权利要求1、2、3或4所述的复合材料，其特征在于所述的底基包括孔隙至少为2微米的非织造织物，所述的硅氧烷基弹体包括涂在所述底基上厚度约为0.0001英寸的聚二甲基硅氧烷。
6．用于控制进入发热元件氧气流量的复合材料，其特征在于：
a)制成盒状的底板、所述的底板是不能透过氧气的；
b)装在所述盒中的许多颗粒，所述的许多颗粒包含活性铁混合物，所述的混合物包括活性炭、水和盐，以提高所述混合物与氧气接触时的放热反应速度；
c)在所述盒周围的法兰处密封到底板上的顶板，以封装这些颗粒，使其不能从盒中掉出来，所述的顶片包括孔隙至少为2微米的高度透氧的非织造织物，所述的非织造织物具有一个外表面，所述外表面上涂有厚度约为0.0001英寸的聚二甲基硅氧烷，当所述顶板与氧气接触时，用于调节进入所述盒中的氧气流量。
7．如权利要求6所述的复合材料，其特征在于所述进入盒中的氧气流量约为1.75×105厘米3/100英寸2/天。
8．如权利要求6或7所述的复合材料，其特征在于防止接触的装置包括用压敏粘合剂与所述顶板粘接的不透氧隔离膜，所述的不透氧隔离膜能从所述聚二甲基硅氧烷上剥离。
9．一种制备用于控制氧气流量的复合材料的方法，其特征在于它包括如下步骤：
a)将硅氧烷橡胶层涂覆在光滑的表面上；
b)使硅氧烷橡胶层部分固化，以提高从所述光滑表面上的可剥离性；
d)将氧多孔性底基压在所述硅氧烷橡胶层上，并使所述的硅氧烷橡胶层完全固化，使其与氧多孔性底基粘接；
e)从所述的光滑表面上剥离所述的氧多孔性底基和硅氧烷橡胶层。
10．如权利要求9所述的方法，其特征在于所述的光滑表面包括一个转鼓，所述的氧多孔性底基包括卷绕在所述一部分转鼓上的连续卷料。
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101257096B (zh) * | 2002-01-15 | 2011-02-02 | 精工爱普生株式会社 | 有机el装置 |
| CN103476370A (zh) * | 2011-04-12 | 2013-12-25 | 麦考尔株式会社 | 发热体 |
| CN103476370B (zh) * | 2011-04-12 | 2015-09-30 | 麦考尔株式会社 | 发热体 |
| CN107972969A (zh) * | 2016-10-25 | 2018-05-01 | 尼托母斯股份有限公司 | 袋体构造部件、袋体以及一次性怀炉 |
Also Published As
| Publication number | Publication date |
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| NZ331755A (en) | 2000-05-26 |
| US5718955A (en) | 1998-02-17 |
| NO984201D0 (no) | 1998-09-11 |
| EP0888100A1 (en) | 1999-01-07 |
| KR19990087720A (ko) | 1999-12-27 |
| NO984201L (no) | 1998-11-09 |
| CA2248919C (en) | 2002-03-19 |
| WO1997033542A1 (en) | 1997-09-18 |
| AU2058497A (en) | 1997-10-01 |
| PE48298A1 (es) | 1998-10-02 |
| BR9707989A (pt) | 1999-07-27 |
| AU730971B2 (en) | 2001-03-22 |
| CA2248919A1 (en) | 1997-09-18 |
| KR100360950B1 (ko) | 2005-05-19 |
| JPH11513912A (ja) | 1999-11-30 |
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