CN1428205A - 加热元件 - Google Patents

加热元件 Download PDF

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CN1428205A
CN1428205A CN02142010A CN02142010A CN1428205A CN 1428205 A CN1428205 A CN 1428205A CN 02142010 A CN02142010 A CN 02142010A CN 02142010 A CN02142010 A CN 02142010A CN 1428205 A CN1428205 A CN 1428205A
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speckle
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CN1230256C (zh
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P·W·汉米尔顿
K·S·麦克圭尔
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Hui Shi
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Procter and Gamble Co
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Abstract

一种加热元件，它包括a)带有一个袋的底片，所述的底片不能透过氧气；b)装在所述袋中的许多颗粒，当与氧气接触时，这些颗粒发生放热反应；c)在所述袋周围的法兰处密封到底片上的顶片，以封装这些颗粒，使其不能从袋中掉出来，所述的顶片具有多孔的基片，所述的基片涂有用不透氧材料制成的斑点图案，所述的不透氧材料均匀地覆盖95％以上的所述多孔基片表面，使得在0.21大气压扩散驱动力下扩散性氧气渗透速度为0.5×105厘米3/645厘米2/天至2×105厘米3/645厘米2/天。

Description

加热元件
本申请是国际申请号为PCT/US98/14676，国际申请日为1998年7月15日的PCT国际申请进入中国阶段后的国家申请号为98807344.7的中国专利申请的分案申请。
发明的领域
本发明涉及透气材料的制造方法，具体涉及将不透气材料施涂在透气基片上并改变透气面积的方法。更具体地说，本发明涉及将热熔粘合剂涂覆在非织造卷材上，将氧气渗透性面积限制在约占非织造织物面积的1％的方法，用于控制流入产生热量的发热单元的氧气量。
发明的背景
用于身体取暖器的发热单元，尤其是使用反应性铁粉和活性碳混合物的发热单元是本领域已知的。这种发热单元需要氧气产生受控的放热反应，在数小时内产生热量。通常，将该混合物包装在一个可渗透空气的口袋中，并在使用前将该口袋密封在不透气的外包装中。透气口袋可由非织造织物制成。在0.21大气压的压力下难以使非织造材料的扩散氧气渗透速度处于约0.5×105cm3/645厘米2/天至约其四倍的范围内。因为要达到该范围必须覆盖大于约95％但小于100％的非织造织物表面。这种透气性范围是他人所不使用的。液体和空气过滤过程需要更高的渗透性范围(通常约50％敞开面积)，气体分离隔膜具有较低的渗透性范围(0％敞开面积)。
透气隔膜已用于分离过程。例如，1992年4月7日授予Callaban等的美国专利5,102,552公开了一种可紫外光固化的聚合物，它涂覆在平均孔径约为0.005-0.2微米的微孔载片上。1973年8月28日授予Bouchilloux等的美国专利3,754,375公开了一种各向异性的隔膜，它具有优良的渗透性能和良好的渗透特性。它包括乙烯基三有机基硅烷聚合物或共聚物，具有平均厚度0.01-10微米的致密层和20-80％敞开面积的多孔层。
其它人还尝试将透气性隔膜应用于发热单元，但是成效不大。例如，1991年9月10日授予Usui的美国专利5,046,479公开了一种控制氧气透过微孔薄膜的方法，其中对微孔薄膜进行热熔处理以限制氧气渗透至一次性渗透取暖器中。一个装有铁粉发热剂的扁平口袋的透气表面的单位面积透气性为5000-10,000sec/100cc。但是这种微孔薄膜非常昂贵。
其它人用针在不透气的薄膜上戳一些小孔以使发热单元具有所需的氧气渗透性。实践中这种方法限制在相对较稀并且较大的孔的图案。由于该限制，要求发热单元的尺寸较大。较大发热单元的缺点在于其是非挠性的，不能根据其施用的身体表面轮廓进行弯曲。用形成具有相同透气性的更细微图案的方法制得的较小的“针孔”能制成较小的但具有更好表面贴合性的发热单元。同样，较小的针孔能更好地防止发热单元的粒状化学品渗出。在用针处理薄膜使之具有透气性的方法中，难以控制透气性的轻微变化。同样，在针刺加工时薄膜的张力会撕裂或以其它形式扩大针孔；因此当卷材张力变化时难以控制针孔的尺寸。
其它人将粘合剂涂覆在多孔卷材上。其例子有1996年11月26日授予Ahr等的美国专利5,558,344，它报道了使用圆周上带网格的印辊将树脂材料施加至基片卷材上。该印辊的表面速度比基片卷材的表面速度至少大100％。表面速度差产生的涂抹过程导致树脂材料渗入基片，使基片具有水不渗透性。Ahr等未试图提供小于100％的覆盖率，并未建议使用这种方法将基片的氧气渗透性控制在一个窄的范围内。
本发明的一个目的是提供一种氧气渗透性材料的价廉的制造方法，这种材料的渗透性在控制发热单元中产生的热量所需的窄范围内。
本发明另一个目的是提供一种透气材料的制造方法，在含发热混合物的不透气口袋边缘可直接密封该材料，无需热密封。
本发明再一个目的是提供一种透气材料的制造方法，其中一个简单的步骤变化就能在所需的窄范围内轻微地改变材料的氧气渗透性。
发明概述
在本发明的一个方面，一种在0.21大气压驱动力下扩散性气体渗透速度为0.5×105厘米3/645厘米2(100英寸2)/天至2×105厘米3/645厘米2/天的透气材料的制造方法包括如下步骤：首先把不透气材料的斑点图案涂布在多孔基片上；然后放大上述的斑点图案，以覆盖约95％(较好约99％)以上的多孔基片，使得上述的扩散气体渗透性仅存在于上述斑点图案之间的敞口(opening)处。上述的扩散气体渗透速度较好是扩散性氧气渗透速度，但它也可包括二氧化碳和其它气体。上述的不透气材料较好是热熔粘合剂，且上述的多孔基片较好是非织造织物。
上述斑点图案的放大步骤包括当把上述斑点图案印刷在上述多孔基片上时把基本上圆形的斑点拖抹成椭圆形的斑点。上述的基本上圆形的斑点较好排列成使得上述的拖抹可令椭圆形的斑点部分重叠。上述的拖抹是通过操作旋转印刷丝网，使其表面速度大于上述多孔基片的牵引速度来实现的。
或者，上述的斑点图案放大步骤可包括涂覆斑点图案后通过固定的间隙压延上述的多孔基片。上述间隙的尺寸小于上述多孔基片和上述斑点图案的总厚度，使得压延后上述斑点图案的每个斑点放大成与其它斑点部分重叠。较好放大上述的斑点图案，使放大后的各个斑点与至少另两个放大的等距离斑点部分重叠，在所有等距离斑点之间形成大小和形状基本上均匀的敞口。
在本发明的另一个方面，加热元件包括具有不透氧袋的底片、装在上述袋中且当与氧气接触时发生放热反应的许多颗粒以及在上述袋周围的法兰处密封到底片上用于封装这些颗粒使其不能从袋中掉出来的顶片。上述的顶片具有多孔的基片，该基片涂有用不透氧材料制成的斑点图案，上述的不透氧材料均匀地覆盖95％以上的上述多孔基片表面，使得在0.21大气压的驱动力下扩散性氧气渗透速度为0.5×105厘米3/645厘米2/天至2×105厘米3/645厘米2/天。
上述的不透氧材料较好是热熔粘合剂，上述的多孔基片较好是非织造织物。上述的热熔粘合剂较好在上述多孔基片面向袋的一侧上，使该热熔粘合剂也可用于将上述的顶片密封到上述的底片上。
附图简介
虽然说明书和后附的权利要求书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是本发明发热元件的优选实施方式的顶视图，它揭示了用透氧顶片覆盖的基本上圆形的元件。
图2表示沿图1中剖面线2-2所取的局部正剖视图。它表示由不透氧底片制成的袋、袋中的发热材料颗粒和覆盖该袋的顶片。该顶片包括多孔基片以及位于顶片和底片之间的不透氧材料的图案层。
图3是制造本发明顶片的方法的侧透视图。它揭示一个印刷胶辊，该胶辊以比基片牵引速度更快的表面速度在多孔基片上涂覆不透气材料的基本上圆形斑点，从而使这些斑点在多孔基片上拖抹成椭圆形。
图4是制造本发明顶片的另一方法的侧透视图。它揭示在多孔基片上辊涂不透气材料的基本上圆形的斑点，然后进行压延步骤，使斑点扩大重叠。
图5是扩散氧气渗透速度与另一种印刷斑点热熔拖抹方法中印刷胶辊速度对多孔基片膜速度之比的关系。
发明的详细描述
现在参照附图，更具体地参照图1和2，它表示本发明的第一优选的实施方式。该方法提供一个发热元件，总括地表示为10。加热元件10有一个形成在不透气底片14(如0.025毫米厚的低密度聚乙烯薄膜)上的袋12。加热元件10也有一个透气的顶片16。该顶片较好是涂有闭塞材料(occluding material)的非织造织物，以限制非织造织物扩散氧气渗透速度。顶片16较好用密度为14克/米2的聚丙烯非织造织物制成。闭塞材料18较好是热熔粘合剂，如Century International ofColumbus，OH制造的CA-X-105-A3。更优选的是压敏粘合剂，因为当它涂布在顶片16面向底片14的一侧上时，它是理想的闭塞材料，而且该两个片材不用热合就可结合。
袋12较好是直径约为12.5毫米和深度约为6.5毫米的圆形。加入袋12内的是化学发热材料20。它较好是铁粉颗粒、粉末状活性炭、水和盐。这些化学材料需要氧气以引发放热反应。当控制进入袋内的氧气速度时，就可控制发热的温度和时间。因此，氧气通过顶片16进入袋中的渗透速度是重要的。关于发热元件12的进一步细节可参见1995年6月29日提出的题目为“发热元件”的待审申请08/496,694，该申请已转让给本发明的申请人。该申请的内容参考结合在本申请中。
当用0.21大气分压驱动时，加热元件12所需的透氧率约为0.5×105厘米3/645厘米2/天至2×105厘米3/645厘米2/天。0.21大气压驱动力是指基片一侧的氧气分压高于另一侧。这就是说，基片的一侧与另一侧没有总压差，仅有氧气浓度差。以这种仅由顶片16提供的透氧率，发热可持续8小时左右，温度约为40-43℃。
当顶片16是涂有热熔粘合剂18且覆盖95％以上表面的非织造织物，化学发热材料颗粒有效地保持在袋12中，且在搬动加热元件10时，化学发热材料颗粒不会掉出。
本发明的优选实施方式表示在图3和4中。图3是总括地表示为30的辊涂法。该图中，辊32的表面上涂有基本上圆形的闭塞材料斑点34。使透气顶片材料的卷材36以表面速度38在辊32下通过，表面速度38低于辊32的表面速度40。当斑点从辊32转印到卷材36时，表面速度差使基本上圆形的斑点34在卷材36上纵向拖抹，在顶片卷材36上形成椭圆形闭塞材料斑点42。斑点34在辊32上的位置，较好是使得当在卷材36上拖抹时，除其纵向末端外各斑点42部分重叠。经拖抹的斑点42的纵向末端之间有一个敞口。这些敞口提供气体渗透进顶片卷材36的通道。
在一个优选的实施方式中，辊32的直径约为220毫米，表面速度40为0.21米/秒。顶片卷材36较好是表面速度38约为0.13米/秒的非织造织物。表面速度之比为1.61。基本上圆形的斑点34较好是用常规丝网印刷法(未画出)挤出在辊32表面上的热熔压敏粘合剂。上述的丝网较好有#40标准目，且由Stork Screens ofAmerica，Inc.of Charlotte，NC制造。印刷温度约为260°F，涂布在顶片卷材36上的涂布重量约为47克/米2。在卷材36上拖抹斑点34后，形成的斑点部分重叠，非织造顶片卷材36的透气率较好约为0.5×105厘米3/645厘米2/天至2×105厘米3/645厘米2/天。
方法30可涂布热熔粘合剂以外的闭塞材料和非织造卷材。例如，可将热塑性塑料、热固性塑料和/或高粘度流体冷却在微孔性薄膜、纸和细的丝网上。斑点34也可以是基本上圆形以外的图形。例如，它可以是横向长度大于纵向长度的椭圆形。形成的拖抹可以在卷材上产生基本上圆形的斑点。也可以在卷材36上转印和拖抹多边形，以便将经拖抹斑点间的敞口制成任何所需的形状。
图5表明改变丝网印刷机的旋转丝网与被印刷多孔基片卷材的表面速度之比对通过基片卷材的扩散性氧气渗透速度的影响。卷材速度保持不变的0.13米/秒，而丝网表面速度在0.19-0.26米/秒范围内调节。如图5所示，当增加丝网速度对卷材速度之比时，扩散性氧气渗透速度减小。扩散性氧气渗透速度减小是热熔粘合剂斑点被拖抹到更大程度的结果，从而闭塞更大百分数的多孔基片开口区域。
图4表明本发明的另一优选方法，总括地表示为50。方法50是两步斑点转印和压延法。第一根辊52类似于图3中的辊32，辊52上置有基本上圆形的闭塞材料斑点54。透气顶片材料卷材6从辊52下通过，斑点54从辊52转印到卷材56上，形成转印斑点58。方法50包括第二根或第二对辊60-61。这对辊较好具有小于卷材56和斑点58的总厚度的固定间隙B。因此，辊60-61把斑点58压延成更大的斑点62。斑点62相互重叠，在它们之间有基本上长方形的敞口。敞口64提供气体渗透入顶片卷材56的通道。在本实施方式中，不需要不同的表面速度，但也可有不同的表面速度，以在压延前部分放大斑点58。基本上圆形的斑点54较好是用常规丝网印刷法(未画出)放置在辊52表面上的热熔粘合剂。在方法50的这一步中，这些斑点较好不重叠，但稍有重叠是允许的。在卷材56上压延斑点58后，形成的斑点62较好部分重叠，压延后非织造顶片卷材56的扩散性氧气渗透速度较好约为0.5×105厘米3/645厘米2/天至2×105厘米3/645厘米2/天。
方法50可涂布热熔粘合剂以外的闭塞材料和非织造卷材。例如，可将热塑性塑料、热固性塑料和/或高粘度流体冷却在微孔性薄膜、纸和细的丝网上。斑点54也可以是基本上圆形以外的图形。例如，它可以是横向长度大于纵向长度的椭圆形。也可以在卷材56上转印多边形，以便将放大斑点间的敞口制成任何所需的形状。
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，所附的权利要求书应覆盖所有这些本发明范围内的改进。

Claims (2)

1.一种加热元件，其特征在于：
a)带有一个袋的底片，所述的底片不能透过氧气；
b)装在所述袋中的许多颗粒，当与氧气接触时，这些颗粒发生放热反应；
c)在所述袋周围的法兰处密封到底片上的顶片，以封装这些颗粒，使其不能从袋中掉出来，所述的顶片具有多孔的基片，所述的基片涂有用不透氧材料制成的斑点图案，所述的不透氧材料均匀地覆盖95％以上的所述多孔基片表面，使得在0.21大气压扩散驱动力下扩散性氧气渗透速度为0.5×105厘米3/645厘米2/天至2×105厘米3/645厘米2/天。
2.如权利要求1所述的加热元件，其特征在于所述的不透氧材料是热熔粘合剂，所述的多孔基片是非织造织物，所述的热熔粘合剂放在所述多孔基片面向袋的一侧上，使所述的热熔粘合剂也可用于将所述的顶片密封到所述的底片上。
CNB021420106A 1997-07-18 1998-07-15 加热元件 Expired - Lifetime CN1230256C (zh)

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NO20000220L (no) 2000-03-17
EP1003929A1 (en) 2000-05-31
JP2010005415A (ja) 2010-01-14
EP1003929B1 (en) 2003-02-12
KR100338854B1 (ko) 2002-05-30
KR20010022002A (ko) 2001-03-15
CN1230256C (zh) 2005-12-07
DK1003929T3 (da) 2003-04-22
DE69811372T2 (de) 2003-11-27

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