CN1678778A - 蓬松、可拉伸的绝热体 - Google Patents

蓬松、可拉伸的绝热体 Download PDF

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CN1678778A
CN1678778A CNA03820004XA CN03820004A CN1678778A CN 1678778 A CN1678778 A CN 1678778A CN A03820004X A CNA03820004X A CN A03820004XA CN 03820004 A CN03820004 A CN 03820004A CN 1678778 A CN1678778 A CN 1678778A
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tpu
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J·G·达诺万
A·J·贾格罗斯基
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Abstract

本发明披露一种绝缘材料，其是由微纤维及长纤维组成，其可作为绝热材料，同时也具有拉伸性。

Description

蓬松、可拉伸的绝热体
发明领域
本发明着重于绝缘材料，特别是不仅具有绝缘特性亦为可拉伸的材料。
发明背景
已尝试非常多的努力来产生合成的绝缘材料，其为天然材料的取代物。举例而言，羽绒长久已来已为珍贵的天然绝缘材料。其替代物无数。作为羽绒替代物的特别有效的材料是描述于美国专利第4,992,327号中，发明名称为“合成羽绒”的材料，该专利公开的内容被引入本说明书作为参考。在此专利文献中，已揭露纤维条形式的合成纤维绝热材料。此粘结纤维结构包含不同尺寸及不同重量百分比的微纤维及长纤维的混合物。所得的材料具有优异的绝热特性，以及已达到广布的商业上成功。目前销售的为Albany International Corp.以商标Primaloft销售的产品。
人们希望这种绝热材料具有供特殊应用的额外特性。举例而言，此类材料为可拉伸的，以供使用于例如可拉伸的运动服装及手套是理想的。
可拉伸纤维已为人所熟知且包括Dupont公司以商标Lycra销售的弹性纤维。弹性纤维一般在大部分拉伸上衣中提供弹性。
因此，人们在希望拥有具有描述于上述专利文献中的特性的绝热材料的同时，希望此类材料不仅为可拉伸的，同时亦具有蓬松本质。
发明概要
因此，本发明的主要目的为提供一种绝热材料，其为可拉伸的纤维条或织物形式。
本发明的另一目的为提供一种粘结绝缘材料，其可利用现有的纤维化学来提供拉伸性。
本发明的又一目的为提供这样的材料，其具有优异的绝缘特性，同时可由合成纤维制得。
本发明的另一目的为提供这样的材料，其在含有使得纤维条或织物具有可拉伸性的纤维的同时，还含有所希望的微纤维及长纤维。
本发明的另一目的为提供一种粘结绝缘材料，其中蓬松程度可藉由微纤维及长纤维的比例来调整。
本发明可达到这些及其他目的及优点。在此方面，本发明着重于具有所希望百分比的微纤维及长纤维的绝缘材料。这种纤维较佳为合成纤维，但也可为合成纤维与例如棉或羊毛等天然纤维的混合物。为了提供此材料的拉伸性，在此混合物中掺合弹性纤维型的纤维。弹性纤维包含具有弹性纤维核心及粘合剂外鞘，且可用于取代揭露于前述专利中的常规粘合纤维或连同其一起使用。与粘合剂外鞘相比，弹性纤维核心具有显著较高的熔化温度。粘合剂/弹性纤维外鞘/核心纤维将使绝缘材料的纤维条或织物具有所希望的面内(in-plane)弹性拉伸性。
该纤维将提供纤维条或织物中大部分纤维之间的机械连结。可藉由粘合纤维本身，使所需的额外结合达到所需程度并不减损所希望拉伸性的程度。
此外，如果需要增加蓬松及维持高度的面内弹性拉伸性，可藉由调整长纤相对于微纤维的量及性能来达到。
附图说明
通过结合附图对本发明的描述，可以了解其目的及优点，其中：
图1为体现本发明教导的纤维条形式的可拉伸绝缘材料的侧截面图；
图2A-2E为体现本发明教导的具有可拉伸核心及由粘合剂材料形成的涂层或外鞘的纤维的侧截面图；以及
图3为体现本发明教导的制造双组分纤维的流程图。
优选实施方案的详细说明
现在将特别就附图来进行说明，图1大致显示了本发明的绝缘材料，其为纤维条或织物10的形式。纤维条10是由微纤维及长纤维制成，其在某种程度上可为描述于前述美国专利第4,992,327号中的形式。在该专利中，已提及可提供具有优异绝缘特性的产品的纤维直径/重量百分比的建议及实施例。举例而言，绝缘材料可为70至95重量百分比的直径为3至12微米的纺制和拉制的合成聚合微纤维，与5至30重量百分比的直径为12至50微米的合成长纤维的混合。如同本申请说明书所讨论的，本发明是对此类参数采取调整或改良。再者，本发明的绝缘材料可与如所述专利中所揭露的绝缘材料混合，以获得具有拉伸性同时亦提供绝热作用的产品。
在此方面，如上述专利所述，使用太高比例的长纤维将倾向于降低整体绝热特性。然而，具有高百分比的微纤维的问题为纤维条的机械安定性，尤其是湿润时。因此，存在着一个平衡；即，虽然为了增加绝缘特性而有必要具有较高百分比的微纤维，但机械安定性及回复特性减小。较大直径的纤维增加安定性及回复性，但降低了绝缘效果。
因此，在本发明中，可理想地增加长纤维的百分比以增加纤维条的蓬松度同时增加面内弹性拉伸性的程度。其原因在于长纤维提供材料的拉伸性。长纤维的使用量愈多，蓬松度愈大及拉伸性愈高。这将为材料的绝缘特性的一种平衡。然而，这种比例可被调整以达到蓬松度、绝缘性及拉伸性上的所希望效果。
接着说明双组分可拉伸粘合纤维的组成物，在此方面，适宜首先做出某些说明。一般而言，可注意到的是，虽然复合丝为已知(例如参见美国专利第4,159,618号)，本发明的纤维意图具有弹性纤维核心。一般而言，藉由弹性纤维制造商生产的最低纤度(denier)为约10旦(denier)。利用现有的干式纺丝技术，生产低纤度产品(低于20旦)并不具有经济吸引力。
传统地，干式纺丝的弹性纤维是用聚酯或尼龙纤维覆盖的，其是经由将另一纤维机械缠绕在伸长的弹性纤维四周，或籍由将人造短纤维空气缠绕在伸长的弹性纤维四周。已证实热塑性聚氨酯(TPU)可熔融纺制成双组分纤维，作为具有尼龙外鞘的核心材料。商业上可取得的弹性纤维为组合的聚氨酯-聚脲，以及商业化的TPUs为接近100％聚氨酯组合物。
商业上可取得的弹性纤维及TPU熔融纺制弹性纤维中，商业上的弹性纤维材料已显示为较佳的弹性体。弹性纤维的机械性质，伸长率、韧度、滞后作用及定形(set)(纤维回复)显著优于TPU。弹性得到改良的原因是添加了聚脲成分，其使得聚氨酯分子的硬片段及软片段可以更好地进行相分离，造成较佳的回复及韧度特性。在熔融纺丝期间，可对TPU进行组成上的改良，以产生物理性质改良的效果，例如在熔融挤出时，添加交联剂至TPU中。该工艺技术显著地改良TPU的性质，以供使用于所选择的织物市场。
人们正在开发对于精细纤度TPU产品的显著熔融纺丝操作。虽然与例如杜邦的Lycra的弹性纤维的传统干式纺丝相比，熔融纺丝技术尚未成熟，但它是理想的，因为与干式纺丝相比，TPU的熔融纺丝产生的投资成本较低。
较高纤度范围的弹性纤维的商业来源，是由聚醚基材料而非聚酯基材料组成的。后者与聚对苯二甲酸亚乙酯(PET)的相容性较高。再者商业上的弹性纤维含有局部硅酮涂饰剂，以利于包装安定性及后续的纤维加工。此涂饰剂一般是在纤维建构后去除。因此，在无洗涤程序和使用增粘剂的情况下，无法预期有非常好的粘附作用。
如可预见的掺合至绝缘形式所要求的，非常精细的弹性纤维可利用如上所述的习用弹性纤维覆盖操作来覆盖，虽然此方法无法与短纤维纱的制造及加工兼容。
然而，达到上述操作的一个方法为双组分熔融纺丝。此方法是可行的，原因是经熔融挤出的TPU核心符合使用于可拉伸绝缘产品的弹性要求。而目前使用于商业上熔融纺制纤维的TPU、或经改质以最优化机械特性的TPU可使用于弹性核心。
制造双组分纤维的另一方法为线缆涂覆。线缆涂覆为应用于电子工业供制造电导体的技术，其涉及利用绝缘体(聚乙烯)包覆电导体(铜导线)。此加工技术大致如下：a)牵引商业来源的弹性纤维通过线缆涂覆模，b)当弹性纤维离开模时，将低熔点的PET粘合剂施用至弹性纤维表面，以及c)将所得的双组分纤维在浴中冷却并卷绕在线轴上。
类似的方法记载于授予Sokatis的美国专利第4,159,618号中，其揭露的内容被引入本文中以供参考。虽然此专利文献涉及可用于制造供高温应用的编织(woven)及针织(knitted)织物的抗高温复合丝，但此技术可经改良及修改以生产所述用于绝热材料的有用的发明性纤维/纤维丝。
生产双组分纤维的另一方法将在2图A-2E中说明。双组分纤维可由包埋至一U形低熔点热塑性聚酯(PET)纤维丝中的弹性纤维核心来制造。在此方面，PET纤维丝20经挤出而具有一条或多条的U形沟槽22。PET纤维丝可具有不同的形状及尺寸，包括正方形、矩形、椭圆形或其它适合于所希望目的的形状。物理地插入U形沟槽22的是弹性纤维核心纤维24。若有需要的话，在将双组分纤维26掺合入制成绝缘材料的纤维条之前，可接着将双组分纤维26一起热定形(heatset)至必需的程度。这是可做到的，因为弹性纤维核心24的熔点为约450°F，而PET纤维丝22的榕点为约230°F。
关于上述的方法描述于图3中。在此方法中，方框32解释说明挤出具有一条或多条U形沟槽的低熔点聚酯(例如PET)纤维丝的步骤。若有需要的话，下一步骤34为确保纤维丝是适当地定位(被拉伸)的。若使用多于一条的U形沟槽时，弹性纤维核心是插入(38)沟槽的。若没有充分的承载力或摩擦力以使核心维持于沟槽中，接着，若有需要，双组分纤维可部分地加热(40)，以使弹性纤维及外鞘之间产生结合。所形成的纤维现在可收集(42)，以及于切割及卷起等(43)后，最后籍由梳理(carding)及热定形掺合入纤维条10中，藉此产生粘结可拉伸的绝缘产品。
虽然在核心底外鞘之间在弹性上有配合失当，一相对较薄的外鞘有可能使困难降至最低，这使得外鞘上可以产生破裂以顺应核心的较大伸长率。外鞘破裂应不影响纤维条的品质达有害的程度。
需注意的是，虽然具有弹性纤维核心及粘合剂外鞘的双组分纤维可有效地作为经改良的蓬松且可拉伸的绝缘材料的成分，可想象到各种不同的变化。举例而言，微纤维、巨弹性纤维、粘合纤维，及/或如美国专利第4,992,327号所述的纤维在适当比例下的混合物，可提供具有理想特性的产品。再者，在本说明书，虽然通常提到弹性纤维核心，但可利用TPU核心取代弹性纤维核心，或其它适合此目的的弹性材料的核心亦可使用。再者，虽然本发明着重于具有弹性纤维或TPU核心的长纤维，应可想像到其在某些方面亦可应用于微纤维。
因此，藉由本发明的说明，已确知其目的和优点。虽然在本说明书中已揭露及说明较佳具体实施方案，但本发明的保护范围及目的不受此等实施例的限制，本发明的保护范围应由后附的权利要求来决定。

Claims (18)

1.一种粘结结构物形式的纤维绝缘材料，其包含下述的组合：
具有第一组成物的纤维；
具有第二组成物的纤维；
所述组成物中至少之一具弹性；以及
将该纤维粘合在一起以形成粘结结构物的工具，该结构物作为绝热材料且同时具有拉伸性。
2.如权利要求1的绝缘材料，其中所述材料包含微纤维及长纤维。
3.如权利要求2的绝缘材料，其中该长纤维是由弹性纤维或TPU构成。
4.如权利要求3的绝缘材料，其中该长纤维为具有核心及外鞘的双组分纤维，其中核心是由弹性纤维或TPU构成，并且外鞘是由粘合剂构成。
5.如权利要求1的绝缘材料，其中该纤维中至少之一为长纤维，其具有核心及外鞘，其中核心是由弹性纤维或TPU组成，并且外鞘是由粘合剂组成，其中利用该弹性纤维或TPU提供拉伸性及利用该粘合剂将该纤维粘合在一起。
6.如权利要求4的绝缘材料，其中所述核心是机械地插入所述外鞘中并与该外鞘结合。
7.如权利要求5的绝缘材料，其中所述核心是机械地插入所述外鞘中并与该外鞘结合。
8.一种粘结结构物形式的合成纤维绝热材料，其包含下述的组合：
约70至95重量百分比的纺制及拉制的合成聚合微纤维，其直径为3至12微米；以及
约5至30重量百分比的合成聚合长纤维，其直径为12至50微米，与下述成分形成混合物：
双组分纤维，具有核心及外鞘，其中核心是由弹性纤维或TPU构成，并且外鞘是由粘合剂构成。
9.如权利要求8的绝缘材料，其中所述弹性纤维或TPU提供拉伸性及该粘合剂将该纤维粘合在一起。
10.如权利要求9的绝缘材料，其中所述核心是机械地插入所述外鞘中并与该外鞘结合。
11.一种制造具有拉伸性的双组分纤维的方法，该方法包含下述步骤：
提供线缆涂覆模器件；
提供由弹性纤维或TPU制成的材料；
牵引该弹性纤维或TPU通过线缆涂覆模；
当该弹性纤维或TPU离开该模时，于该弹性纤维或TPU表面施用PET粘合剂；以及涂覆所得的双组分纤维。
12.一种制造粘结结构物形式的绝缘材料的方法，该方法包含下述步骤：
将如权利要求11所述的双组分纤维与其它纤维组合，以形成一纤维条材料。
13.如权利要求12的方法，其包括提供所述其它纤维的步骤，其中所述其它纤维包括约70至95重量百分比的纺制及拉制的合成聚合微纤维，其直径为3至12微米；以及约5至30重量百分比的合成聚合长纤维，其直径为12至50微米。
14.一种制造可拉伸双组分纤维的方法，该方法包含下述步骤：
挤出低熔点的聚酯纤维丝，该纤维丝带有沿着该纤维丝的长度延伸的“U”形沟槽；
视需要使该经挤出的纤维丝定位；
将弹性纤维或TPU核心插入该″U″形沟槽以产生双组分纤维；以及
加热该双组分纤维以使该弹性纤维或TPU核心与该纤维丝结合。
15.一种制造粘结纤维结构物形式的绝缘材料的方法，该方法包含下述步骤：
将如权利要求14所述的双组分纤维与其它纤维组合，以形成纤维条材料。
16.如权利要求15方法，其包括提供所述其它纤维的步骤，其中所述其它纤维包括约70至95重量百分比的纺制及拉制的合成聚合微纤维，其直径为3至12微米；以及约5至30重量百分比的合成聚合长纤维，其直径为12至50微米。
17.如权利要求14的方法，其包括下述步骤：藉由熔融纺丝形成该TPU核心。
18.一种制造可拉伸双组分纤维的方法，该方法包括下述步骤：
提供一聚酯材料；
提供TPU；以及
熔融纺丝该聚酯材料及该TPU以形成该双组分纤维。
CNA03820004XA 2002-08-28 2003-08-21 蓬松、可拉伸的绝热体 Pending CN1678778A (zh)

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