CN1607912A - 能量吸收材料 - Google Patents
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Abstract
提供了一种自支撑的能量吸收复合材料,其包括:i)固体发泡的合成聚合物基体;ii)不同于i)的聚合物基胀流型体,其分布基体中并在i)的制备期间结合在其中;和iii)流体,它分布于基体中,基体、胀流型体和流体的结合是这样的,以使复合材料为弹性可压缩的。还提供了一种自支撑的能量吸收复合材料,其包括:iv)固体的闭孔的泡沫基体;v)不同于i)的聚合物基胀流型体,其分布基体中并在i)的制备期间结合在其中;和vi)流体,它分布于基体中,基体、胀流型体和流体的结合是这样的,以使该复合材料为弹性可压缩的。
Description
本发明涉及能量吸收材料,例如那种设计用于保护人、动物或物体不受冲击伤害的系统所采用的能量吸收材料;以下称之为冲击保护系统。
通常,冲击保护系统采用弹性体泡沫或相似的相对软的弹性可压缩的材料作为能量吸收材料。然而,只达到了有限的保护。在某些系统中,采用了将此能量吸收材料与刚性的构件相结合,其目的是将冲击力遍布于较大的面积上,因此而降低其作用。但是,如果这种系统与人体接触,它往往不易弯曲和不舒服的。身体的需要保护的大多数脆弱区域,如肘和膝,都会经受显著的几何形状的变化,因此针对刚性的传播负荷的形状的任何匹配的努力通常会失败。一种解决方案是向刚性元件中引入铰链,但这会损害性能并且增加成本。
最近,在冲击吸收系统中提出了使用剪切增稠的硅氧烷腻子材料,即所知道的有机硅胀流型体,用于或用作能量吸收材料的建议。就剪切增稠的材料或胀流型体来说,我们指的是这样一种材料,它在低的形变速率下粘性地流动,但在升高的形变速率下,它随着形变变化的速率而经历根本的粘度增加。在非常高的形变速率如由冲击所诱导的速率下,该材料变为基本上竖硬的或刚性的。例如,US-A-5599290描述了一种防止骨折的服装,其采用了固体颗粒在粘性流体中的分散体作为胀流型体或剪切增稠的材料。GB-A-2349798描述了一种包括腻子状的胀流型体的吸收能量垫。但是,在两种情形下,需将此胀流型体包含在封套中,原因在于它的非自支撑的特性。因此,所得到的产品往往缺乏柔韧性,并且将需要相对复杂和昂贵的制备方法。
JP 6-220242公开了一种震动吸收材料,它是由挠性的、三维的筛孔或泡沫体所组成的,在其内部有相互连接的中空空间,并且它的表面涂覆有硅氧烷弹性腻子。
本发明提供一种能量吸收材料,它适宜用于或用作冲击吸收系统,并且它是自支撑的。
根据本发明的一个方面,提供了一种自支撑的能量吸收复合材料,其包括:
i)适宜地为弹性的、优选地为弹性体的固体发泡的合成聚合物基体;
ii)不同于i)的聚合物基胀流型体,在i)的制备期间它分布于基体中并结合在其中;和
iii)流体,它分布于基体中,基体、胀流型体和流体的结合是这样的,以使此复合材料为弹性可压缩的,还优选为挠性的。
就弹性可压缩的来说,我们指的是耐压缩形变性。
就固体基体来说,我们指的是不需要容器就能保持其边界的基质材料。通常,所述基体为弹性的。
根据本发明的第二个方面,提供了一种自支撑的能量吸收复合材料,其包括:
i)固体的、闭孔的泡沫基体;
ii)不同于i)的聚合物基胀流型体,,它分布于基体中;和
iii)分布于基体中的流体,所述基体、胀流型体和流体的结合是这样的,以使此复合材料是弹性可压缩的。
本发明的复合材料除了是自支撑的之外,还提供一定程度的冲击保护,这可以潜在地超越现有的刚性系统,而且,在其中复合材料是挠性的又弹性可压缩的优选实施方案中,它具备适应于几何形状的能力,该几何形状被设计为通过在相对大的几何改变下保持密切的接触来保护的。这是设计保护性部件的关键特征,因为导致的损害是源于冲击的最大力除以该力分布的面积的函数。本发明的复合材料能够既减少力并且增加力作用或反作用的面积,由此对于给定的冲击能量显著地减少所导致的压力或所传输的应力。就耐磨性而言,它还提供了展示与冲击源的某些一致性的能力,由此而产生额外的力吸收以及有利的几何形状。与使用通过其自身使用的相同质量的胀流型体相比,借助于本发明还可以达到改进的性能。
尽管可以理解的是其它的固体材料可以适宜用作基体,但在本发明的一个优选的实施方案中,基体选自弹性体。虽然也可以使用天然的弹性体,例如胶乳橡胶,但是我们优选的是合成的弹性体,包括合成的热塑性弹性体。一类优选的合成弹性体是弹性体聚氨酯,但希望其它如硅橡胶和EP橡胶,例如EPDM橡胶也是适宜的。
一般而言,复合材料的可弹性压缩性将由分散于基体中的流体来提供。通常,该流体会基本上均匀地分散于基体中,但在某些确定的情形下也需要不均匀的分散。可弹性压缩性可以是起因于流体在基体内的再分布和/或(在优选的情形下,其中流体包含气体)流体的压缩。这样,例如,基体和流体的组合可以有利地是发泡的弹性体,如发泡的聚氨酯弹性体,泡沫可以是开孔的、闭孔的或部分开孔、部分闭孔的。所述泡沫的一个重要性质是它经受压缩后的复原速度。优选地,复原在几秒钟内例如5秒钟或更少,更优选为2秒钟或更少,是完全的或基本上完全的。但是,较慢的复原速度可以实际上优选用于某些应用。
可以使用任何可以向所选择的基体中引入的聚合物基胀流型体。就“聚合物基胀流型体”来说,它是指这样一种材料,其中胀流性是单独由聚合物或由聚合物以及一种或多种组分如细碎的颗粒材料、粘性流体、增塑剂、填充剂或其混合物的组合所提供的,并且其中此聚合物为主要的组分。在一个优选的实施方案中,胀流型体选自表现出胀流型体特征的硅氧烷聚合物基材料。优选此硅氧烷聚合物选自含硼(borated)的硅氧烷聚合物。胀流型体可以与除提供胀流性的组分之外的其它组分如填料、增塑剂、着色剂、润滑剂和稀释剂相结合。填料可以是颗粒的(包括微球体)或纤维状的,或颗粒与纤维状的混合物。一类特别优选的胀流型体包含由DowCorning以商品目录号3179出售的含硼硅氧烷基材料,其中聚硼二甲基硅氧烷(PBDMS)构成基础聚合物。
也包括其它聚合物基胀流型体材料,其具有相似的胀流性特征,如在低的应变速率下具有相似的模量和相似的模量对应变速率的曲线。
可以通过下面的方法形成本发明的复合材料:使固体基体、聚合物基胀流型体和流体的结合,由此该胀流型体和流体通常基本上均匀地分布于基体中,从而产生弹性可压缩的材料。其中基体选自合成的弹性体,一种适宜的方法包含将聚合物基胀流型体引入发泡的合成弹性体中。该胀流型体可以在泡沫的形成过程中引入。例如,可以在胀流型体的溶液或分散体的存在下使形成泡沫的组分反应以形成泡沫。但是,无论使用何种方法,虽然可以将胀流型体引入泡沫的泡孔中,但重要的是不完全地从孔中排出流体。
本发明的复合材料可以包括除胀流型体和流体外的组分,例如纤维状的和/或粒状的填料、增塑剂、润滑剂、填充剂、颜料、染料等。如果需要的话,可以将本发明的复合材料加入到可以是刚性的或挠性的封套中,但这并不是必需的。同样,可以将其与刚性的部件相结合,但这对于该复合材料的使用不是必需的,且这可以甚至损害它的某些性能。
如果需要的话,可以向所述复合材料涂布涂层。
所述复合材料的实际构成将会受到预期的应用的影响。应用涵盖了大范围的用途,并且包括对物体、动物和人的冲击保护。潜在的应用延伸至任何动态的情形,其中此物体可能已经接触了表面,并且物体与表面的结合可以经受剧烈的加速和/或减速,例如如包装中的精密设备或在汽车座位上的人体。这样,弹性可压缩的主体的特性、例如根据主体的密度来表示的主体中流体的量,和对主体中胀流型体的选择和负载的程度将由其中即将采用该复合材料的保护系统的要求来决定。一般而言,胀流型体将构成5至80%,优选10至50%,更优选20至40%(如15至35%)的复合材料,并且流体的量(在优选的情形下,它是气体)将会是这样的,按体积计,优选复合材料的流体含量为约30至90%(如20至90%),更优选为约45至90%(如30至80%),再更优选为约55至85%(如40至70%)。应当注意的是,这些性能不包括任何填料或另外的组分的应用。
本发明的能量吸收复合材料可以应用于在各种各样的领域中:例如用于人和动物的保护垫或服装,用于或用作人或动物可能会与之猛烈地接触的车辆和其它物体中的能量吸收区域;和用于或用作精密物件或机器的包装。应用的具体实例是头部遮盖物和头盔;用于肘、膝、臀和胫骨的保护性服装或保护垫;一般的身体保护,例如用于在其中飞行的或降落的物体是一种危害的环境中、车辆的仪表板、悬挂的衬套、车内装饰及座位。其它潜在的用途是例如在运动或娱乐中保护撞击物体的身体部分的外衣或垫子;例如跑鞋鞋底、足球靴、拳击手套以及用于玩墙手球的手套。不意味着此名单是排它性的,并且读者会想到其它潜在的用途。
下面的实施例举例说明本发明,其中在基体的制备期间将胀流型体材料加入固体发泡的合成聚合物基体中。
实施例1
此实施例详述了纯的聚硼二甲基硅氧烷(PBDMS)胀流型体在聚氨酯(PU)泡沫的制备中的混入。
基础PU系统是由Jacobson Chemicals Ltd.,Farnham,Surrey出售的。产品是模型的泡沫参比J-Foam 7087。此为两部分的系统,它要求A部分和B部分两个组分按3比1的比率分别混合。然后,可以将混合物浇铸到敞开的或闭合的模具中,以制备成型的泡沫组分。在A部分和B部分的反应过程中,散发出了一种气体(相信包括二氧化碳),使得在PU软泡沫中产生了闭孔结构。
在室温下,在聚乙烯杯中,用手在木勺的帮助下,将由ChemicalInstitute,Warsaw,Poland提供的PBDMS与J-Foam的A部分预混合大约15分钟,直到该混合物均匀为止。试验了各种PBDMS与A部分的比率,并且详述如下:
试验1-15g PBDMS+40g A部分
试验2-15g PBDMS+30g A部分
试验3-39g PBDMS+50g A部分
然后,用相同的混合方法将以上预混合物的每一种与B部分混合,并保持A部分与B部分的比率为3比1,而与PBDMS的量无关。混合时间典型地为大约10秒钟。下一步将这三种组分的混合物浇铸入平底敞口的聚乙烯容器中,使其自由膨胀,以制备泡沫。
由于PBDMS具有比A部分或B部分高得多的粘度,所以增加PBDMS的比例会使所得到的泡沫的密度降低。此三种组分的混合物增加了的粘度(熔体强度)限制了该混合物在反应和固化阶段的膨胀。为了确定通过加热此预混合物来降低PBDMS/A部分预混合物粘度的效果,进行了另一批的试验3:在与B部分混合之前加热预混合物至65℃。按照以前试样的相同方法混合,但是同时将模具预加热至65℃之后就立即浇铸样品。制备泡沫,其所得到的密度为:
试验1-400kg/m3
试验2-500kg/m3
试验3(65℃预加热)-380kg/m3
密度是通过简单地称重样品和测量其线性的外形尺寸来确定其总体积,并用样品的重量除以它而测得的。
实施例2
将如实施例1中所示的相同技术应用到含Dow Corning 3179硅氧烷胀流型体的PU泡沫的制备中。胀流型体为填充的PBDMS,其中PBDMS的重量百分比为65%。这使得3179比纯的PBDMS更硬更坚固。作为这些填料存在的结果是,即使借助于电动食物搅合器的协助,3179也不会与J-Foam的A部分混合。使用电动食物搅合器使50g的3179溶解于作为溶剂的异丙醇(IPA)中,然后再与大约100g的J-Foam的A部分混合。这样产生了一种乳油状的乳液。为了使IPA存在的量在其与J-Foam的B部分的随后反应过程中减少到最小,保持搅合器处于接通的状态,其中将3179、IPA及J-Foam的A部分的混合物置于通风橱中以促进IPA的蒸发。将此情形保持1小时。在这一段时间内IPA的蒸发导致3179胀流型体从溶液中出来,并在混合物中形成胀流型体的固体小球。因此重复该过程,但在蒸发阶段以10分钟的间隔停止搅合器,用视觉观察混合物的性质。40分钟后悬浮的3179胀流型体的微小颗粒为仅用肉眼可见,在此阶段用手将B部分引入混合物中,且如以前一样浇铸到敞口的容器中,还是保持A部分与B部分的比率为3比1。所得到的泡沫的测量密度为290kg/m3,它具有大的闭孔结构(泡孔直径大致是0.7至1.2mm)。
为了提高这种泡沫的密度,重复该过程,其中在3179胀流型体、IPA及J-Foam的部分A的混合过程中,加入35g的PBDMS,以提高混合物的粘度。所得到的泡沫具有小得多的泡孔尺寸(泡孔直径大致是0.1至0.4mm)和更高的密度-640kg/m3。
Claims (16)
1.一种自支撑的能量吸收复合材料,其包括:
i)固体发泡的合成聚合物基体;
ii)不同于i)的聚合物基胀流型体,其分布基体中并在i)的制备期间结合在其中;和
iii)流体,它分布于基体中,基体、胀流型体和流体的结合是这样的,以使所述的复合材料为弹性可压缩的。
2.权利要求1所述的能量吸收复合材料,其中所述的基体是弹性的。
3.权利要求1或2所述的能量吸收复合材料,其中所述的基体选自合成弹性体。
4.权利要求3所述的能量吸收复合材料,其中所述的合成弹性体选自弹性体聚氨酯。
5.上述权利要求之任何一项所述的能量吸收复合材料,其中所述的聚合物胀流型体选自表现出胀流型体特性的硅氧烷聚合物。
6.权利要求5所述的能量吸收复合材料,其中所述的硅氧烷聚合物选自含硼酸的硅氧烷聚合物。
7.上述权利要求之任何一项所述的能量吸收复合材料,其中所述的流体是气体。
8.上述权利要求之任何一项所述的能量吸收复合材料,其包含在所述的泡沫的泡孔内的聚合物胀流型体。
9.一种形成自支撑的能量吸收复合材料的方法,该方法包含混合:
i)固体发泡的合成聚合物基体;
ii)不同于i)的聚合物基胀流型体,和
iii)流体,由此通过在所述基体的制备过程中将胀流型体合并到发泡的合成聚合物中,而将所述的胀流型体分布于基体中,并且所述的流体基本上均匀地分布于基体中,以制备弹性可压缩的材料。
10.权利要求9所述的方法,其中所述的基体是根据权利要求2至4中的任何一项所述的。
11.权利要求9或10所述的方法,其中所述的聚合物胀流型体是根据权利要求5、6或8所述的胀流型体。
12.权利要求9至11中任何一项所述的方法,其中所述的流体包含气体。
13.一种自支撑的能量吸收复合材料,其包含:
i)固体的、闭孔的泡沫基体;
ii)不同于i)的聚合物基胀流型体,它分布于基体中;和
iii)它分布于基体中的流体,所述基体、胀流型体和流体的结合是这样的,以使所述的复合材料为弹性可压缩的。
14.权利要求13所述的能量吸收复合材料,其中所述的基体是合成弹性体、和/或根据权利要求2或3或4中所述的基体,和/或所述的聚合物胀流型体是根据权利要求5或6或8中所述的聚合物胀流型体,和/或所述的流体包含气体。
15.一种由权利要求9至12之任何一项所述的方法得到的能量吸收复合材料。
16.一种冲击保护系统,该系统包含权利要求1至8或13至15之任何一项所述的能量吸收复合材料。
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