CN1237217C - 可吹制的绝缘材料 - Google Patents

可吹制的绝缘材料 Download PDF

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CN1237217C
CN1237217C CNB00808968XA CN00808968A CN1237217C CN 1237217 C CN1237217 C CN 1237217C CN B00808968X A CNB00808968X A CN B00808968XA CN 00808968 A CN00808968 A CN 00808968A CN 1237217 C CN1237217 C CN 1237217C
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fiber
silk
blowable
batt
mixture
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CN1355865A (zh
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齐威勒·M·格罗
维克托·P·拉斯克斯基
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Albany International Corp
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Abstract

一种可吹制的绝缘材料，其包括切碎成为可吹制丝团的毛层。在多个优选实施例中，丝团包括经过抗水剂或润滑剂处理的纤维，和/或干燥纤维，和/或粘合纤维，其可以是丝团和包括天然材料的混合物，所述天然材料包括羽绒、蚕丝、丝、毛、棉花或者具有绝缘性质的任何天然材料，或者是它们的结合物，还包括开松的合成纤维。

Description

可吹制的绝缘材料
技术领域
本发明涉及一种羽绒状绝缘丝团(clusters)和混合物，以及制造这种材料的方法。
背景技术
专业人员已经付出了许多努力，试图获得具有类似羽绒质量的绝缘材料，以便将这种材料用于绝缘物品，例如服装、睡袋、暖被或类似物。经过在先的努力，已经提出了可以使用的材料，其中生产的大部分这种材料相对于羽绒状物品具有过大的重量和过大的密度，而且，很难通过常规的设备来吹制。
在授予Babbitt等人的No.专利5,624,742中，描述了一种吹制的绝缘材料，这种绝缘材料包括由第一种和第二种具有绝缘作用的玻璃纤维材料的混合物。多种纤维之一种具有较小尺寸，以便填充在一大堆纤维之间的空隙。
在授予Miller的专利No.3,892,919中，描述了一种填充材料，其采用比较大的圆柱形或球形纤维体，以及由羽毛状物体，根据要填充的空间，将纤维体与羽毛状物体相互混合。
在授予Aldrich的专利No.4,167,604中，描述了一种经过改进的热绝缘材料，这种材料是羽绒和合成短纤维的混合物，所说合成短纤维由空心的聚酯长丝构成，后者采用硅树脂对其进行处理，并且形成经过梳理的网状物。
在授予Liebmann的专利No.4,248,927中，描述了一种绝缘材料，其中包括由天然羽毛和羽绒，以及合成聚酯的结合物形成的网状物。
在授予Smith的专利No.4,468,336中，描述了松散填充的绝缘材料，将其吹入空间中。绝缘材料包括松散填充的纤维素绝缘材料与短纤维混合的混合物。
在授予Muncrief的专利No.5,057,168中，描述了一种由粘合纤维与绝缘纤维混合形成的绝缘材料。绝缘纤维选自合成纤维和天然纤维形成的毛层(batt)，可以将毛层切割成任何需要的形状。
在授予Hernandez等人的专利No.5,458,971中，描述了一种纤维混合物，将其用于服装的纤维填充物。纤维填充混合物包括卷曲的空心聚酯纤维和卷曲的粘合纤维。
在授予Cooper等人的专利No.4,040,371中，描述了一种聚酯纤维填充材料，其包括聚酯短纤维与有机短纤维的混合物。
在授予Frank的专利No.5,492,580中，描述了一种将第一种热塑性、热固性、无机或有机纤维的混合物和第二种热塑性纤维混合的材料。
在授予Donovan的专利No.4,588,635中，公开了一种优良的合成羽绒，并且，具有特殊的重量轻的热绝缘系统，通过使用低密度组合的纤细纤维可以获得所述的热绝缘系统，并且描述了纤维混合物的范围，当将其用于制造绝缘毛层时，其具有的优点是具有羽绒状物品的质量，例如，具有比较高的热-重量比，柔软的手感，以及良好的压缩恢复能力。这种材料可以接近或者在某些情况下甚至可以超过天然羽绒的热绝缘性能。但是，从机械的观点出发，非常纤细的纤维具有刚性和强度缺陷，使其很难生产、制造和使用。这种合成绝缘材料的恢复性能可以通过加大纤维直径来加强，但是，较大纤维成分的增加将严重地降低整个材料的热绝缘性能。在潮湿条件下，纤细纤维组合物的机械稳定性下降，这是由于和毛细管水相关的表面张力大大高于由于地心引力或者其他正常使用的负载产生的表面张力，其对于材料结构具有相当大的不良影响。与水禽的羽绒不同，其中描述的公开的纤维结合物具有优良的抗水性能。
在Donovan等人的美国专利US-4,992,327中，其中描述了采用粘合纤维成分改善绝缘物品的整体性能，其中不存在需要考虑的妥协因素。特别是，其中公开了涉及的合成纤维热绝缘材料，这种材料具有粘合的纤维结构形式，这种纤维结构包括下述组合：a)70-95％重量的合成聚合物微细纤维，这种微细纤维的直径是3-12微米；b)5-30％重量的合成聚合物大纤维，这种大纤维的直径是12-50微米，其特征是，至少有部分纤维在其接触点相互结合，这种结合使得结构材料的密度范围是3-60kg/m2，结合的组合物的热绝缘性能等于或者基本上不会差于相当的没有结合的组合物的热绝缘性能。在其文件中还描述了羽绒状的丝团形式的良好的纤维混合物。在这篇专利中还公开了比毛层更好的区别性能优点。
但是，在现有技术中，通常采用手工制造丝团，其生产过程慢，时间长，不便于批量生产。此外，在现有技术中的材料不容易形成可吹制材料，其不便采用常规的制造设备。因此，需要提供一种可吹制的材料，其可以部分或者全部代替羽绒，并且便于制造，而且由常规的设备吹制。
发明内容
本发明的主要目的是克服上述材料中存在的缺陷。
本发明的另一个目的是提供一种可吹制的材料，以便用于部分代替或者完全代替羽绒或其它可吹制的天然绝缘材料。
本发明公开了由切碎的100％合成毛层制造的丝团。这种毛层可以是热固化的毛层，其最好包括经过抗水剂或润滑剂处理的纤维，和/或干燥纤维，和/或粘合纤维。然后，将毛层机械切碎成为小丝团，以便通过常规的设备对其进行吹制。在某种程度上，呈随机形状的丝团在相当均匀的填充过程中，可以形成良好的包装。在另一个优选的实施例中，丝团与天然材料相结合，所述天然材料包括羽绒、丝、毛、棉和其他具有绝缘性能的适合于满足上述目的的天然材料。在另一个实施例中，对于由经过抗水剂和/或润滑剂处理的合成纤维和干燥合成纤维组成的材料进行开松处理，然后，与具有前面所述的天然材料的丝团混合。所有这些实施例的目的是提供一种可吹制的材料，其具有蓬松性质、良好的压缩性能、改善的手感、优越的混合性、均匀性和外观。
根据本发明，还提供了一种可吹制的绝缘材料，包括与可吹制的丝团混合的可吹制的天然材料，所述可吹制的丝团通过以下步骤由切碎的毛层制成，(a)梳理由粘合纤维混合物制成的毛层；(b)加热所述梳理的毛层，其加热时间和温度足以使所述粘合纤维与其它纤维粘合在一起；(c)切碎热固化的毛层；和(d)与可吹制的天然材料混合。
附图说明
图1a是本发明丝团的优选实施例的主视图。
图1b是图1a所示本发明由SEM放大的主视图。
图2a是表示丝团和天然材料，例如羽绒的第二优选实施例的主视图。
图2b是图2a所示本发明由SEM放大的主视图。
图3是材料浸湿之后，回弹(loft)的比较曲线。
图4是材料浸湿之后，回弹的比较图像。
具体实施方式
本发明的材料包括由切碎的100％的合成毛层制成的丝团。根据毛层的组成成分，这种毛层可以是热固化的毛层，或者不是。这种毛层最好包括经过抗水剂处理或润滑剂处理的纤维和/或干燥纤维和/或粘合纤维。然后，毛层被机械切碎一到几倍小的丝团，后者可以被吹制，而具有羽绒状的质量。可以考虑采用网状物(通常是单独的一层状材料)和毛层(通常是多层材料)，或者其部分可以用于制造本发明的丝团。通过下面的实例来描述本发明的制造丝团的方法。
丝团可以由重量轻的粗梳条子制成，所述粗梳条子由合适的合成的粘合纤维的混纺纱制成。纤维混纺纱最好是授予Donovan等人的美国专利US-4,992,327中公开的纤维混纺纱，其中公开的内容在本文中作为参考。其他利用纤维混纺纱的优选实施例包括经过抗水剂处理、或经过润滑剂处理的纤维和/或干燥纤维和/或粘合纤维。首先，使条子在梳理机的外侧的通常用于此目的的条筒中汇集，并且，直接通过加热管，由加热管加热结合粘合纤维混合物。在完成结合步骤的过程中，蓬松的粗梳条子不收缩和密度不加大是非常重要的。各条子端部下降通过竖直管，同时由导向环使其位于中心，随着加热空气通过管件向上吹，结合形成蓬松的、线形的纤维组合物。从加热管出来，条子被拉到切割机型短纤维切割机的入口一侧。进行单纯切割，在切割过程中，不产生纤维熔化导致密度增加的效果。这种方法产生汇聚在一起的非常蓬松的纤维丝团。
在如上所述的试验方法中，采用长而薄的7/8英寸，4盎司/码2的PRIMALOFT毛层(PRIMALOFTONE)薄片对上述方法进行试验，而不是粗梳条子，PRIMALOFT毛层具有交叉叠合、结合的结构，其由Donovan等人的美国专利中公开的那种纤维混纺纱构成，如上所述，并且可以通过商业购买。毛层的带条大约为7/8英寸宽，沿着机器横向(CD)进行切割，获得的纤维取向基本上平行于毛层带条的长度方向，在这一方面正像粗梳条子。由PRIMALOFT毛层制成的带条预先结合，因此具有足够的整体性，以便容易供给进入切割机。可以相信，在切割之前进行结合还改善了切割质量。采用的短纤切割机(staple cutter)类型是由日本ACE MACHINERY CO.公司制造的实验设备，其设计型号为NO.C-75，以间隔7/8英寸处进行切割。单纯地切割PRIMALOFT毛层的供给原料，成为汇集的丝团状立方体，后者每个的尺寸大约为7/8×7/8×7/8英寸。显示出来的丝团汇集物的密度大大小于0.5lb/ft3，将其制成羽绒状，并且具有单位重量足够有效的绝热物。作为供给原料的PRIMALOFT毛层具有公称密度0.5lb/ft3，并且在切割过程中，实际上没有增加密度的现象发生。
丝团汇集物的密度大大小于单独丝团的密度。如果本发明的丝团直接由粗梳条子制成，而不是由毛层制成，由此产生的丝团在某种程度上呈圆柱形，而不是立方体或矩形形状。
这种优选方法采用的毛层由叠置的粗梳毛卷(plied card-laps)组成，但是，其他类型的纤维也同样适用。最好，由粗梳毛卷或网状物形成毛层，其具有的密度和羽绒的密度相当。粗梳毛卷或网状物最好由0.5-0.6旦尼尔的粘合纤维和/或干燥纤维和/或抗水纤维制备。在此优选的方法中，粗梳毛卷或网状物包括40％粘合纤维，30％1.4旦尼尔干燥纤维，30％1.4旦尼尔抗水纤维。最好，借助具有固定盖板的、单独的圆柱形金属梳理机，将这些选择的纤维梳理成为3oz./sq.yd.的组合物。这些梳理机可以通过南加利佛尼亚HOLLINGSWORTHSACO LOWELL OF GREENVILLE获得。被送出的梳理机的输出物，通过热的电子和/或气体点火源，加热固化粘合纤维。将毛层加热经过一段时间，并且达到一定温度，足以引起纤维结合。在这种情况下，采用的温度在300-400°F之间。然后，切碎热固化的毛层，最好经过RANDO开松混合机两次(这种设备由NY的RANDO MACHINECOMPANY OF MACEDON)制造，以便制成本发明的丝团。附图1a和1b是丝团的主视图，其中丝团经过两次切碎。
其它变化包括：
1.增加短纤维的长度，达到能够梳理的极限，以便于改善丝团的整体性和耐久性；
2.改变粘合纤维含量使之能够良好地调节(“fine tune”)丝团的切碎性能、可切割性能、凝聚力，以及工作特性；
3.改变丝团的尺寸、形状和各方比例；
4.根据目的需要采用超声波结合装置；
5.切碎丝团一次以上；
6.采用未经过热固化的毛层；
7.仅仅部分切碎毛层或网状物。
显而易见，经过两次切碎的丝团光滑，而且，比仅仅切碎一次的丝团更容易混和。而且，能够制成热固化毛层的带条或条子，其可以被切开，然后，将这些部分通过标准的切碎加工过程，从而形成丝团。
通过上表面所述的实例，在不脱离本发明范围的条件下，根据需要可以获得多种变化的形式。
图2a和2b中描绘了另一个实施例，其中丝团与天然材料，即，羽绒相互混合。对于这些实施例中材料的回弹和压缩性能进行评估，并且用其填充织物中的空隙(fill for channels in fabric)进行试验。已经发现，这些混合材料具有比仅包含单一品种的材料具有更优越的性能。应当理解，根据需要，本发明可以使用其他天然材料，例如、丝、毛、棉和其他合适的天然绝缘材料，或者是它们的结合，与丝团混合。当然，为了满足需要，这些材料可以通过加工处理，从而构成具有可吹制性能的混合物。而且，本发明还提供了另一种实施例，其中包括含有开松纤维的丝团、天然材料和合成材料的混合物。用于混合物中的开松纤维可以是任何一种0.5-6.0旦尼尔纤维、经过防水剂处理和润滑剂处理纤维的混合物。
试验1
丝团的性能
25英磅的经过两次切碎的毛层丝团包括30％经过抗水剂或润滑剂处理的纤维、30％干燥纤维和40％粘合纤维，将其装入吹制站的混合桶中。一旦打手在桶中转动，切碎的毛层丝团很容易地单独被开松，并且，通过测量和吹制系统，不产生任何问题。
试验2
丝团和天然材料，即，羽绒混合的性能
随后，基本上是将25英磅羽绒加入试验1中的桶中。在五分钟内进行混合，显示产品混合相当均匀，并且呈羽绒状。产品能吹制得极好。将产品放入内衣中以便用手进行评估。这种产品伸展性能非常好。这种混合物比单独的羽绒更容易加工。
试验3
天然材料，即羽绒和添加丝团的性能
将25英磅羽绒装入吹制站的混合桶中。接着加入25英磅切碎的毛层。虽然花费比试验2中的方法更长的时间，其组成成分显示出良好的混合效果。此外，获得的产品从外观上看，均匀性稍有欠缺。这种产品能吹制得极好。将产品放入内衣中以便用手进行评估。产品的伸展性能比试验2中的产品稍差。但是，这种混合物比单独的羽绒具有更容易的加工性能。
重复上述加工过程若干次，保证上述加工过程是可重复的。制造试验2中的一批50英磅产品，填充12件内衣。非常容易混合，其均匀程度与前面的试验一样好，而且，这种产品的吹制性能与羽绒中的性能相同。但是，代替丝团和羽绒的比例50/50，将丝团/羽绒的这种比例改变为65/35。其吹制性能不如比例为50/50的材料好，而且不均匀。
试验4
重复试验2的过程。但是，将丝团与羽绒的比例50/50替换为丝团/羽绒是75/25。这种产品的吹制性能和均匀性都不如50/50产品好。
简而言之，采用高百分比例的丝团与天然材料，即，羽绒相互混合而成的混合物，其羽绒状的感觉比50/50比例的混合物稍差。这种混合物也很难进行精确计量。进行吹制的喷嘴尺寸可以对此进行补偿。在某些情况下，用手进行混合，也可以加强混合物的性能。
在抗吸水性方面，丝团具有比羽绒优越的性能。在干燥和经过浸湿水分不同次数之后，对于合成物混纺纱和羽绒/合成物类型的绝缘材料和羽绒进行实验，测量其回弹、吸水性和密度。
试验5
在最终使用中，绝缘材料被用于服装或睡袋。为了表示实际的湿度条件，在浸水之前，将试验材料放入织物枕套中。这些枕套的尺寸是8”×9”，用3oz./sq.yd.防破裂尼龙织品制造，缝纫三个边缘。第四个边缘采用安全别针钉合。
被试验的材料是天然材料，即，羽绒、50/50的羽绒/切碎毛层丝团、单独的切碎毛层丝团，带抗静电处理剂的切碎的毛层丝团。将12克绝缘材料放入各枕套中，各种类型的材料填充三个同样制品。测量各样品最初的回弹和重量，并且进行记录。
首先，将各样品半浸入70°F水中10秒，然后，保持在水中漂浮20分钟。在此时，将各样品送入工业压榨机，经过一次压制，测量其回弹度。然后，将各样品剧烈摇动10秒钟，再测量记录其回弹度。然后，再将样品半浸入水中10秒，重复上述过程，以便测量在总浸水暴露(soakiny exposure)1、2和4小时后的数值。图3表示通过浸水暴露后，产品回弹效果的比较曲线。图4是一幅图片，其表示在通过浸水暴露后，回弹度的区别，其中(A)表示经过浸水、压榨和摇动四小时后的羽绒；(B)表示经过浸水、压榨和摇动四小时后的50/50的羽绒/切碎毛层；(C)表示干燥羽绒。
当清洗丝团/羽绒混合物时，这种混合物变得更蓬松。通常，在含水环境条件下，羽绒不像其干燥时那样蓬松。羽绒变得扁平，其结果是变薄。单独的丝团和其与羽绒的混合物表现出具有优良的抗水性能，并且，通过清洗性能加强，不会导致单独填充羽绒时常见的结块现象。
众所周知，使用丝团(和开松纤维)可以导致在产品中出现一定程度的静电，这种情况可以得到解决，即，采用织物软化片材和/或静电去除喷雾剂。在某些时候，需要在切碎之前，采用静电去除处理剂处理毛层。
因此，通过上面的详细描述，公开了本发明的优选实施例，可以理解本发明的优点。本发明的范围并不限于上述实施例，而是由本发明的权利要求书来限定。

Claims (5)

1.一种可吹制的绝缘材料，其包括一种或多种材料，所述材料选自由粘合毛层、粘合网状物、部分粘合毛层和部分粘合网状物构成的组，所述材料经过一次或多次切碎，制成为随机形状的可吹制的丝团，所述可吹制的丝团由在纤维之间的许多接触点处粘合在一起的随机纤维构成，并与可吹制的天然绝缘材料混合形成一种混合物，所述天然材料包括一种或多种由羽绒、丝、毛、棉组成的组中选出的材料。
2.按照权利要求1所述的可吹制的绝缘材料，其特征是：所述丝团不超过所述混合物的50％。
3.按照权利要求1所述的可吹制的绝缘材料，其特征是：所述丝团按重量计不超过所述混合物的40～75％。
4.按照权利要求1所述的可吹制的绝缘材料，其特征是：还包括一种或多种从由经过开松的、经过抗水剂处理的合成纤维、经过润滑剂处理的合成纤维和干燥的合成纤维构成的组中选出的材料。
5.按照权利要求4所述的可吹制的绝缘材料，其特征是：干燥纤维是干燥聚酯纤维，经过抗水剂或润滑剂处理的纤维是硅化聚酯纤维。
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CN1355865A (zh) 2002-06-26
EP1190133A1 (en) 2002-03-27
NO20016084L (no) 2001-12-13
AU5332900A (en) 2001-01-02
ES2337015T3 (es) 2010-04-20
HK1045719A1 (en) 2002-12-06
CA2374799A1 (en) 2000-12-21
PT1190133E (pt) 2010-02-23
EP1190133B1 (en) 2009-12-23
DE60043583D1 (de) 2010-02-04
NO20016084D0 (no) 2001-12-13
WO2000077287A1 (en) 2000-12-21
NZ515828A (en) 2002-11-26
HK1045719B (zh) 2010-04-16
BR0011633B1 (pt) 2010-11-30
JP2003502516A (ja) 2003-01-21
CA2374799C (en) 2007-03-13
AU760007B2 (en) 2003-05-08
US6329052B1 (en) 2001-12-11
BR0011633A (pt) 2002-03-19

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