CN1890085A - 具有微孔膜的合成绝缘材料 - Google Patents

具有微孔膜的合成绝缘材料 Download PDF

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CN1890085A
CN1890085A CNA2004800366934A CN200480036693A CN1890085A CN 1890085 A CN1890085 A CN 1890085A CN A2004800366934 A CNA2004800366934 A CN A2004800366934A CN 200480036693 A CN200480036693 A CN 200480036693A CN 1890085 A CN1890085 A CN 1890085A
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insulating
package body
layer
cloth
breathable
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凡妮莎·玛森
约瑟夫·鲁梅兹
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Albany International Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
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    • A—HUMAN NECESSITIES
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    • A41D31/00—Materials specially adapted for outerwear
    • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B2307/00—Properties of the layers or laminate
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Abstract

绝缘包装体及其形成方法，该绝缘包装体包括功能性布层、可透气的斥水绝缘层和具有孔隙网络的高度透气的微孔膜层。将功能性布、高度透气的绝缘层和微孔膜层相互层压从而形成防水透气的绝缘包装体。

Description

具有微孔膜的合成绝缘材料
发明背景
1.技术领域
本发明涉及防水透气的绝缘材料，特别是涉及用于户外服装和靴子的材料。
2.相关技术的描述
户外运动的爱好者不断地需要技术上先进的衣服来保护他们自己免于自然环境的伤害。这一需求导致了许多防水、透气的布结构的开发，其中通常将布层压在薄膜或膜上。几十年来，防水透气的布已经被用于功能服装中，并且被证明是优选的功能组分。对穿戴者就舒适度而言，防止水从衣服外面到达人身体和使人体产生的水汽去除都是非常重要的。然而，这些布的缺陷总在于，尽管它们被归为可透气的，但它们不能提供明显的水汽传输。此外，大多数透气布趋向于具有非常有限的绝缘性能。另外，层压到某些膜类型上的布不是非常柔软并且在使用时产生噪声。因此，尽管他们所声称，但大多数防水透气布的透气性趋向于比所期望的要低，并且仅提供有限的绝缘性能，以至于必须要将它们与某些形式的绝缘材料结合使用，同时需要使用者忍受其僵硬和有噪声的特点。
通常将绝缘材料与性能服装结合使用或将其掺入性能服装中，用以提供热防护。然而，大多数绝缘材料不能提供斥水性或者替换性地提供以热防护相应的减少为代价的斥水性。美国专利No.4,992,327和4,588,635中所述的PrimaLoft绝缘材料在合成绝缘材料界中独一无二之处在于，其除了热性能外还提供了优良的斥水性，从而显示具有微细的纤维结构，上述专利在此引入作为参考。
但是，PrimaLoft绝缘材料因其所增加的防水性优势而主要被用作天然羽绒的替代物。或者，PrimaLoft絮垫(batt)已以单个的绝缘层被引入到服饰的制造中。通常，例如通过缝制将其机械固定到织造或非织造材料的其它层上。但是，PrimaLoft绝缘材料自身不具有足够的结构完整性或者美观的外观，以同时满足作为绝缘材料和外在衣物层的需要。
许多防水透气布的另一要素为单片膜，其用于对布赋予透气的阻挡层。该单片膜通过使用亲水聚合物层而促进了蒸汽的渗透，该亲水聚合物层吸收紧靠皮肤的水并将其输送至外部环境中。
不幸的是，单片膜通常会遭遇亲水层的明显膨胀，该膨胀明显地改变了膜的蒸汽去除性能以及使用者的舒适性。此外，尽管这种类型的膜还具有非常高的、在性能布中通常有益的撕裂强度，但这也导致了服装中异常的刚度，其通常不被认为是正面的属性。
因此，对具有优良斥水性或防水性能以及优良蒸汽去除特性的防水透气绝缘材料存在需求，该材料将不会膨胀并具有足够的撕裂强度，而且对于穿着者而言不会过硬或有噪声。
发明概述
本发明的一个实施方案涉及绝缘材料包装体，其具有功能性的布层、具有孔隙网络的高度透气的微孔膜层、和可透气的斥水绝缘层，将这些层相互层压而形成防水透气的绝缘布。
在本发明的另一个实施方案中，绝缘层是内聚性纤维结构形式的透气防水绝缘层，该结构包括下述(a)和(b)的组合：
(a)70至95重量％的合成聚合微纤维(microfibers)，其具有3至12微米的直径；和
(b)5至30重量％的合成聚合粗纤维(macrofibers)，其具有12至50微米的直径。
本发明还涉及形成防水绝缘包装体的方法。该方法的步骤包括提供功能性布的第一层、微孔膜的第二层和透气斥水的绝缘材料的第三层。此外，将第一层结合至第二层，并将第二层结合至第三层。
表示本发明特性的各种新特征特别地在所附权利要求书中指出，并且构成了本公开的一部分。为了更好地理解本发明、由其使用而获得的操作优点和特定的目的，可参考所附的描述性内容，其中阐述了本发明的优选实施方案。
附图简述
参考如下说明和附图来更完全地理解本发明，在附图中：
图1是本发明的防水绝缘包装体的横截面图；和
图2是本发明另一个防水透气绝缘包装体的横截面图。
优选实施方案的详述
现在参照附图，本发明涉及通常如图1所示的绝缘包装体10，该包装体是既防水又透气的。如图1所示，绝缘包装体10由绝缘材料12、微孔膜14和功能性布16构成。优选地通过公知的层压技术，将绝缘材料12、微孔膜14和功能性布16相互结合。在优选实施方案中，层压的包装体10由作为绝缘材料12的PrimaLoft绝缘材料，和附着或层压至微孔膜14表面上、作为功能性布16的任意织造品、非织造品、羊毛或其它布结构组成，该微孔膜14本身被层压在PrimaLoft绝缘材料上。在某些情况下，期望地可将功能性布或衬里18的附加层添加到绝缘材料12的非膜侧上，如图2所示。
微孔膜14是优选的，因为它具有可操控的高度透气、互相连通的微孔网络。通过对膜的拉伸和操控，可选择性地限定微孔膜14的透气性和空气透过性。这种拉伸改变了原始的膜孔尺寸。此外，该微孔膜可使用适合于应用的层压技术。
在应用中，构造微孔膜的孔隙网络以使工作通道和孔隙的尺寸允许蒸汽的最佳传递，同时仍然抑制水的传递，但其尚未在可接受能视为防水可透气膜的程度。
微孔膜14的一个优点是它不会吸水或表现出膨胀。现有技术中的单片膜通常是聚氨酯类类的，且通过水分子在膜层中的溶解性而发挥作用。其结果，尽管其具有一般的抗撕裂性，但因其易于膨胀因而是不理想的。公知地，这种膨胀改变了单片膜的亲水性。
与此相反，微孔膜通过蒸汽穿过孔隙的扩散而发挥作用。典型的孔隙尺寸是1至8μm。由于这一孔隙的尺寸范围，使得本发明的微孔膜本身不被认为是防水的或疏水的。此外，微孔膜通常由聚四氟乙烯或其它具有低结晶性(一般小于30％)的聚合材料形成的。另外，可将聚合材料与具有0.5至5μm粒度的无机填料混合。微孔膜一般地可具有约30至50μm的厚度。重要的是，这种微孔膜不会遭遇单片膜共有的膨胀。
另外，通过将绝缘层12层压在微孔膜14上，从而大大提高了微孔膜的抗撕裂性，该抗撕裂性通常小于单片膜的抗撕裂性。此外，该组合的刚度明显地小于由绝缘材料结合至单片膜上所产生的刚度。
为了进一步提高绝缘包装体的防水性，可将功能层16用耐久性斥水处理剂或蜡光涂层进行涂覆。
根据本发明的一个方面，绝缘层12是内聚性纤维结构形式的合成纤维绝热材料，该结构包括下述(a)和(b)的组合：
(a)70至95重量％的合成聚合微纤维，其具有3至12微米的直径；和
(b)5至30重量％的合成聚合粗纤维，其具有12至50微米的直径，
其中，该纤维的至少一些在其接触点处结合，该结合使得所得结构的密度在3至16kg/m3(0.2至1.0磅/英尺3)的范围内，与未结合的组合相比，实现该结合并未导致此结构绝热性能的明显损失。
用于本发明中的微纤维和粗纤维可以由聚酯、尼龙、人造纤维、乙酸酯、丙烯酸类、改性聚丙烯腈(modacrylic)、聚烯烃、氨纶(spandex)、聚芳族酰胺(polyaramid)、聚酰亚胺、碳氟化合物、聚苯并咪唑、聚乙烯醇、聚二乙炔、聚醚酮、聚咪唑和聚苯硫醚聚合物制成，例如可以商品名RYTON购得的材料或适用于此目的任何其它材料。
结合可以在至少一些粗纤维之间实现以形成微纤维的支撑结构，或者可在粗纤维与微纤维之间于不同的接触点上实现。粗纤维可选自相同材料或多种材料，并且可以是与微纤维相同的材料或不同的材料。
在本发明一个有利的实施方案中，微纤维是由聚对苯二甲酸乙二醇酯形成的，并且粗纤维选自聚对苯二甲酸乙二醇酯或者聚芳族酰胺，例如商品名为“Kevlar”的市售品。
粗纤维可以是单纤维，也就是具有基本均匀结构的纤维，或者其可以是具有促进纤维与纤维结合的部分的多组分纤维。该纤维可以是纤维混合物，其中至少10重量％包括低熔点热塑性材料的粗纤维，以辅助纤维与纤维的结合。在本发明进一步的实施方案中，粗纤维可以是纤维混合物，其包括多组分粗纤维和能够彼此结合或者与微纤维结合的单组分粗纤维。
在本发明另一个实施方案中，粗组分纤维可以是具有不同性能的粗纤维的混合物或掺合物，例如粗纤维混合物可包括两种或多种不同的纤维、如提供所期望的结合的聚酯纤维和提供刚度的“Kevlar”纤维。可改变硬化纤维与结合纤维的比例，以提供不同的性能，从而符合粗纤维结构的可结合纤维比例足以对微纤维提供开式支撑的需要，如下文所述。
某些材料，例如聚苯硫醚纤维、商品名为“APYIEL”芳族聚酰胺类型、和例如由奥地利的Lenzing AG制造的聚酰亚胺纤维，表现出阻燃或者是不燃的性能。因此，此类材料能够对包含根据本发明材料的制造品提供改进的阻燃或防火性能。
根据本发明的一个方面，绝缘层12的纤维的结合优选主要是在粗纤维组分的纤维之间的接触点上。粗纤维与粗纤维结合的目的是形成微纤维组分的支撑结构，所述支撑结构对绝缘材料的机械性能具有明显的贡献。通过将粗纤维结合，使粗纤维保持开放的结合纤维结构，在该结构中可容留微纤维。可替换地，粗纤维和/或微纤维可在其接触点处结合。
粗纤维间的任意结合方法均可采用，例如通过加入固体、气体或液体粘合剂、或者优选地通过加热以使低温纤维组分熔融并在接触点处熔合。
绝缘层12的组分的结合方法不是关键的，只需满足的要求是结合的实施条件应使得无纤维组分失去其结构完整性。本领域技术人员可以理解的是，在结合过程中粗或微纤维中任何可以感知的变化反过来都将影响热性能；因此，需要在尽可能保持纤维组分和包装体的物理性能和尺寸下进行结合步骤。
结合的绝缘层12的绝热性能优选与类似的未结合组合的隔热性能基本相同，或者不明显低于后者的隔热性能。
在本发明一个特定的实施方案中，可在足以使纤维结合的温度下加热纤维一段时间，以实现绝缘层12内的结合。该加热时长可以是在约125℃(257)至225℃(437)的温度下进行大约1分钟至10分钟，优选在约140℃(284)至200℃(392)的温度下进行约3至7分钟；当然，该时长依纤维组分混合物的材料而定。
上述的PrimaLoft适于与本文所述的微孔膜一起层压应用。对附着至布的应用及持续性来说，该层压技术需要在绝缘材料上具有基本光滑的表面。
该光滑表面可以利用本领域中公知的方法产生，例如IR轧光、热板轧光、加热辊、树脂涂覆和/或独特的热空气烘箱处理(独特定义为温度和气流操控)。除了表面处理以外，絮垫的内部结构也需要很好地结合，目的是保持结构的完整性，以便重复使用和洗涤该层压物品时不会产生剥离。
尽管在优选的实施方案中使用了PrimaLoft绝缘层，特别是使用了由PrimaLoft形成的絮垫材料，应当可以理解的是，在不背离本发明范围的情况下，可使用其它绝缘材料，包括由天然和合成纤维或其混合物制成的织造和非织造的绝缘材料。
实验数据
根据标题为“防水性：静水压力试验(Water Resistance：HydrostaticPressure Test)”的AATCC测试方法127，绝缘包装体10具有超过2.0psi静水压力的防水性。在户外服装工业中通常接受的观点是，具有超过2.0psi静水压能力的任何纤维根据定义均被视为具有防水性。AATCC是美国纺织品化学家和染料师协会的缩写。AATCC 127是测量在静水压力下纤维防水透过性的试验方法，其适用于所有类型的布。对试样的一个表面施加经加压的水，其中的水压以恒定速率增加直到在试样的另一表面上观察到三个点的渗漏。在一个实验中，发现使用PrimaLoft絮垫作为绝缘层12的绝缘包装体10具有超过185cm-H2O或2.63psi的抗静水压力。因此，发现绝缘包装体10表现出远远超过被认为防水所必需的防水特性。
针对绝缘包装体进行的另一项试验是确定蒸汽穿透率(WVTR)。它是根据ASTME 96-00规程E进行的。WVTR是确定在给定时间内能够通过布的蒸汽量的试验。
例如，在现有技术中经常被引用作为比较和对照基础的一种公知微孔膜是CELGARD2500，已知其具有5000g/m2/24hrs的WVTR。
现有技术的可透气的外套服饰，例如在美国专利No.6,100,208的实施例1中所描述的服饰，其具有多组分纤维的第一层、多组分纤维的第二层和在二者之间由低密度聚乙烯形成的不渗水阻挡层，其已显示出具有3465g/m2/24hrs的WVTR。然而，在专利’208中所述的服饰不能提供像本发明一样的绝缘层。可以预期的是，绝缘层的增加可降低户外布的WVTR。
本发明绝缘包装体的试验在37.8℃和90％相对湿度下进行。在此试验中，正如本发明中所述的那样，层压有SUPPLEX布、微孔膜材料和PrimaLoft绝缘材料的样品达到了3521g/m2/24hrs的WVTR。这是很明显的，因为该试样提供了上述专利的两个实施例未出现的绝缘层，但仍具有比未绝缘的层压户外布更高的WVTR，同时具有几乎与微孔膜本身同样高的WVTR。如此，本发明的绝缘包装体表明，使用绝缘包装体制成的服装的穿着者尽管有明显的运动活动，仍预期能保持合理的舒适性。
因此已表明，在由前面描述明显清楚的内容中，可有效达到上面所提出的目的，并且由于在不背离本发明的主旨和范围的情况下，可以对所进行的上述方法和所提出的结构进行任何的改变，预期在上述描述中所包含的和在附图中所表示的所有内容，均应被认为是用于解释说明而非限定的意思。

Claims (20)

1.绝缘包装体，其包括
至少一层功能性布层；
具有孔隙网络的高度透气的微孔膜层；
可透气的斥水绝缘层；
其中将功能性布、微孔膜层和绝缘层相互层压而形成防水透气的绝缘布。
2.根据权利要求1的绝缘包装体，其中该至少一层功能性布层中的至少一层是耐水布。
3.根据权利要求2的绝缘包装体，其中功能性布层涂覆有蜡光涂层。
4.根据权利要求1的绝缘包装体，其进一步包括第二功能性布层。
5.根据权利要求4的绝缘包装体，其中将第二功能性布在非膜侧层压至绝缘层。
6.根据权利要求1的绝缘包装体，其中通过拉伸微孔膜来限定孔隙网络中的孔隙尺寸。
7.根据权利要求1的绝缘包装体，其中所述绝缘包装体允许蒸汽的传递并抑制水的传递。
8.根据权利要求1的绝缘包装体，其中高度透气的斥水绝缘材料是非织造的，并包括选自微纤维、粗纤维、天然纤维及其混合物的纤维。
9.根据权利要求1的绝缘包装体，其中高度透气的斥水绝缘材料是织造的，并包括选自微纤维、粗纤维、天然纤维及其混合物的纤维。
10.根据权利要求1的绝缘包装体，其中高度透气的斥水绝缘层具有内聚性纤维结构，该结构包括下述(a)和(b)的组合：
(a)70至95重量％的经纺丝及拉伸的合成聚合微纤维，其具有3至12微米的直径；和
(b)5至30重量％的合成聚合粗纤维，其具有12至50微米的直径。
11.根据权利要求1的绝缘包装体，其中可透气的防水绝缘层形成为絮垫，该絮垫具有适合于层压技术的光滑表面。
12.根据权利要求11的绝缘包装体，其中通过选自IR轧光、热板轧光、使用加热辊、树脂涂覆和热空气烘箱处理的至少一种方法形成所述的光滑表面。
13.根据权利要求1的绝缘包装体，其中功能性布选自羊毛、织造和非织造布。
14.形成防水绝缘包装体的方法，其包括以下步骤：
提供功能性布的第一层；
提供微孔膜的第二层；
提供可透气的斥水绝缘材料的第三层；
将第一层结合至所述第二层；和
将第二层结合至第三层。
15.根据权利要求14的方法，其进一步包括将第三层形成为絮垫的步骤。
16.根据权利要求15的方法，其进一步包括在所述絮垫上形成光滑表面的步骤。
17.根据权利要求14的方法，其中第一和第二层的结合是层压过程。
18.根据权利要求14的方法，其中第二和第三层的结合是层压过程。
19.根据权利要求14的方法，其进一步包括提供第二功能性布层的步骤。
20.根据权利要求17的方法，其中将第二功能性布层层压至绝缘层。
CNA2004800366934A 2003-12-09 2004-12-06 具有微孔膜的合成绝缘材料 Pending CN1890085A (zh)

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TW200523117A (en) 2005-07-16
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US20160262477A1 (en) 2016-09-15
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ATE533618T2 (de) 2011-12-15
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