CN1950195A - 耐热耐火防护板 - Google Patents

耐热耐火防护板 Download PDF

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Publication number
CN1950195A
CN1950195A CNA2005800146144A CN200580014614A CN1950195A CN 1950195 A CN1950195 A CN 1950195A CN A2005800146144 A CNA2005800146144 A CN A2005800146144A CN 200580014614 A CN200580014614 A CN 200580014614A CN 1950195 A CN1950195 A CN 1950195A
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heat
flame
fiber
texturized
protective materials
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CN100528546C (zh
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D·E·文斯特鲁普
G·J·汤普森
J·G·查
T·G·道森
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Milliken and Co
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Milliken and Co
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    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
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Abstract

本发明提供一种由耐热耐火纤维和大体积的膨化纤维所形成的耐热耐火平面整体防护板。该防护材料具有以耐热耐火纤维为主的耐热耐火区和以大量膨化纤维为主的大体积膨胀区。纤维以如下方式分布在整个防护材料中：耐热耐火纤维聚集在靠近具有耐热耐火区的防护材料的外表面处，并且大体积的膨化纤维聚集在靠近具有大体积膨胀区的防护材料的外表面处。

Description

耐热耐火防护板
相关申请的交叉引用
本申请是2004年5月7日提出的在先共同未决美国申请10/841,148的部分继续，在这里将其全文引入作为参考。
技术领域
本发明一般涉及用作防热和/或防火的材料，特别是可以用于诸如汽车的引擎罩衬垫、发动机舱衬垫、基床构造、室内装潢、墙填料等的防热和/或防火材料。
背景技术
众多的行业都需要如下的材料，它们不仅能提供耐热耐火性能，而且还可以在成本低的单一基材中提供体积、遮光性、可模压性以及其它性能。而这些屏蔽性能经常需要通过使用产生高性能的特种材料才能获得最佳，但是，这也大大增加了基材的成本。特别是在体积大的基材(Z方向厚度大)中，即使将这些特种材料以少量百分比加入到防护材料中，就可以使整个基材的成本显著提高。由于这个原因，经常使用具有特殊表面层的复合材料以得到上述防护性能。具有特殊表面层的复合材料的一个实例就是对体积大的较低成本的材料进行表面层压。虽然这个方法有效地降低了高成本原材料的价格，但是这个方法有一些缺点，例如额外的处理步骤以及表面层可能的剥离。
发明内容
本发明提供了一种替代现有技术的方法，通过使用具有不同区的整体隔热材料使材料具有各种的理想性能。
附图说明
通过参照以下说明、所附权利要求和附图可以更好地理解本发明的这些和其它特征、方面和优点：
图1显示了本发明的一个实施方式的放大的横截面；
图2显示了本发明的另一个实施方式的放大的横截面视图；
图3显示了用来加工形成本发明的平面耐热耐火防护材料的机械装置图；
图4为根据图1所示的实施方式中防护材料的放大的横截面视图；
图5显示了利用本发明防护材料的床垫的透视图；且
图6显示了图5中的床垫壁的部分放大视图，且防护材料结合在其中。
具体实施方式
现在参考这些附图，特别是图1，显示本发明的一个实施方式的放大的横截面图，图示说明了平面耐热耐火防护材料100。防护材料100可以以现有的薄片形式，在诸如焊接、高温制造或类似加工过程中用作保护层或者防护板。防护材料100还可以形成诸如汽车的引擎罩衬垫、发动机舱罩等的部件。另外，该防护材料100可以与其它材料结合和/或结合成一种结构，使材料和该结构具有附加的耐热耐火性能。例如，防护材料100可以与床垫、室内装璜、墙填充物、以及其它结构的外部材料混合，使这些结构具有附加的耐热耐火性。由于与防护材料100相结合的大体积，将防护材料100混合到这些结构中也可以通过在结构中替代任何填充材料而具有成本效益。
如图所示，平面防护材料100通常包括耐热耐火纤维101和膨化纤维102。耐热耐火纤维101和膨化纤维102是短纤维，它们结合在一起形成防护材料100。这里使用的耐热耐火纤维是指具有极限氧指数(LOI)值20.95或者更高的纤维，该值是通过ISO 4589-1测定的。耐热耐火纤维的类型包括但不限于抑燃纤维和阻燃纤维。抑燃纤维是指通过趋于抑制热源的方式耗尽来满足LOI的纤维。在一种抑制火焰的方法中，抑燃纤维在消耗过程中排出气体产物，如卤化气体。抑燃纤维的实例包括改性聚丙烯腈、PVC、用卤代物局部处理的纤维等。阻燃纤维是指受热时通过抵抗消耗来满足LOI的纤维。阻燃纤维的实例包括浸渍二氧化硅的人造丝(例如以商品名VISIL销售的人造丝)、部分氧化的聚丙烯腈、芳香族聚酰胺、对位芳香族聚酰胺、碳、间位芳香族聚酰胺、三聚氰胺和类似物。膨化纤维是为热防护材料提供体积的纤维。膨化纤维的实例包括具有高纤度/单丝的纤维(每根单丝1旦或更大)、高卷曲纤维、空心填充纤维、和类似物。
在一个实施方式中，耐热耐火纤维101和膨化纤维102通过粘合纤维105气流成网。粘合纤维是与其它纤维形成某种类型的粘附或者粘合的纤维。粘合纤维可以包括热活性纤维。在防护材料100中使用粘合纤维105的一个额外的优点就是热活化，也就是防护材料100可以随后塑造成用于引擎罩衬垫、发动机舱罩等的部分形状。热活性粘合纤维的实例是可以在较低温度下熔融的纤维，如低熔融纤维、具有较低皮层溶解温度的皮芯纤维、和类似物。在一个实施方式中，粘合纤维为具有低皮层溶解温度的聚酯皮芯纤维。
还是参考图1，耐热耐火纤维101在平面防护材料100的耐热耐火区110处聚集，并且膨化纤维102在平面防护材料100的大体积膨胀区120处聚集。耐热耐火区110使防护材料100具有主要的耐热耐火性能。大体积膨胀区120使防护材料100具有理想的Z方向厚度，该厚度使防护材料100的平面维度水平地延伸。在图1所示的实施方式中，耐热耐火区110在Z方向上比大体积膨胀区120小。
继续参考图1，耐热耐火区110具有位于防护材料100外表面的外边界111，和邻近大体积膨胀区120的内边界112。大体积膨胀区120具有位于防护材料100外表面的外边界121，和邻近耐热耐火区110的内边界122。防护材料100是单一材料，且两个区的边界不代表对层的界定，而是单一材料内的范围。由于防护材料100是单一材料，而且耐热耐火区110和大体积膨胀区120都不是结合在一起的离散的分离层，不同的单个纤维将在耐热耐火区110和大体积膨胀区120中均有出现。尽管图1显示了耐热耐火区110的厚度比大体积膨胀区120的厚度小，但两个区的相对厚度可能与图示的有显著的不同。
继续参考图1，耐热耐火区110包含耐热耐火纤维101和膨化纤维102。然而，耐热耐火区110主要包含耐热耐火纤维101。另外，纤维在耐热耐火区110中的分布，使耐热耐火纤维101在耐热耐火区110外边界111的含量比其在该区内边界112的含量更多。而且，如图所示，优选沿着从耐热耐火区110的外边界111到该区内边界112的Z轴，耐热耐火纤维101的含量以梯度降低。
继续参考图1，大体积膨胀区120包含耐热耐火纤维101和膨化纤维102。然而，大体积膨胀区120主要包含膨化纤维102。另外，该纤维在大体积膨胀区120中的分布，使膨化纤维102在大体积膨胀区120外边界121的含量比其在该区内边界122的含量更多。而且，如图所示，优选沿着从大体积膨胀区120的外边界121到该区内边界122的Z轴，膨化纤维102的含量以梯度降低。
现参考图2，该图显示了本发明的另一个实施方式的放大的横截面视图，图示说明了防热防火材料200。如图所示，防护材料200通常包括耐热耐火纤维201和膨化纤维202。耐热耐火纤维201和膨化纤维202是短纤维，它们结合在一起形成了防护材料200。在一个实施方式中，耐热耐火纤维201和膨化纤维202通过粘合纤维205气流成网。当粘合纤维205是热活性纤维时，纤维的结合体受热使粘合纤维205活化，从而使得防护材料200的纤维粘合在一起。在防护材料200中使用热活化粘合纤维作为粘合纤维205的额外优点在于，防护材料200可以随后塑造成用于引擎罩衬垫、发动机舱罩等的部分形状。
还是参考图2，耐热耐火纤维201在防护材料200的耐热耐火区210处聚集，并且膨化纤维202在防护材料200的大体积膨胀区220处聚集。耐热耐火区210使防护材料200具有主要的耐热耐火性能。大体积膨胀区220使防护材料200具有理想的Z方向厚度。在图2所示的实施方式中，耐热耐火区210在Z方向上比大体积膨胀区220小。
继续参考图2，耐热耐火区210具有位于防护材料200外表面的外边界211，和邻近大体积膨胀区220的内边界212。大体积膨胀区220具有位于防护材料200外表面的外边界221，和邻近耐热耐火区210的内边界222。防护材料200是单一材料，且两个区的边界不代表对层的界定，而是单一材料内的区域。由于防护材料200是单一材料，而且耐热耐火区210和大体积膨胀区220不是结合在一起的离散的分离层，不同的单个纤维将在耐热耐火区210和大体积膨胀区220中均有出现。尽管图2显示了耐热耐火区210的厚度比大体积膨胀区220的厚度小，但两个区的相对厚度可与图示的有显著的不同。
继续参考图2，耐热耐火区210包含耐热耐火纤维201和膨化纤维202。然而，耐热耐火区210主要包含耐热耐火纤维201。另外，纤维在耐热耐火区210中的分布，使耐热耐火纤维201在耐热耐火区210外边界211的含量比其在该区内边界212的含量更多。而且，如图所示，优选沿着从耐热耐火区210的外边界211到该区内边界212的Z轴，耐热耐火纤维201的含量以梯度降低。
继续参考图2，防护材料200的膨化纤维202包括第一膨化纤维203和第二膨化纤维204。在一个实施方式中，第一膨化纤维与耐热耐火纤维201相比，具有更高的纤度/单丝、和/或质量/纤维，并且第二膨化纤维204与第一膨化纤维203和耐热耐火纤维201相比，具有更高的纤度/单丝、和/或质量/纤维。同样，大体积膨胀区220分为第一膨胀区230和第二膨胀区240。第一膨胀区230具有邻近耐热耐火区210的外边界231和邻近第二膨胀区240的内边界232。第二膨胀区240具有邻近防护材料200外表面的外边界241和邻近第一膨胀区230的内边界242。如前所述，防护材料200是单一材料，同样地，两个膨胀区的边界不代表对层的界定，而是单一材料内的范围。由于防护材料200是单一材料，而且第一膨胀区230和第二膨胀区240不是结合在一起的离散的分离层，不同的单个膨化纤维将在第一膨胀区和第二膨胀区240中均有出现。尽管图2显示了耐热耐火区210的厚度比大体积膨胀区220的厚度小，但两个区的相对厚度可与图示的有显著的不同。
继续参考图2，第一膨胀区230包含第一膨化纤维203和第二膨化纤维204。然而，第一膨胀区230将含有比第二膨化纤维204更多的第一膨化纤维203。纤维在第一膨胀区230中的分布，使第一膨化纤维203沿着从第一膨胀区230的外边界231到位于第一膨胀区的内边界232和外边界之间的第一膨化纤维集中平面235的Z轴，其含量以梯度增加。而且，如图所示，优选沿着从第一膨化纤维集中平面235到该区内边界232的Z轴，第一膨化纤维203的含量以梯度降低。
参考图2，第二膨胀区240包含第一膨化纤维203和第二膨化纤维204。然而，第二膨胀区240将含有比第一膨化纤维203更多的第二膨化纤维204。纤维在第二膨胀区230中的分布，使第二膨化纤维204在第二膨胀区240的外边界241处的含量比其在该区内边界242处的含量更高。而且，如图所示，优选沿着从第二膨胀区240的外边界241到该区内边界242的Z轴，第二膨化纤维204的含量以梯度降低。
仍参考图2，第一膨胀区230也将包含耐热耐火纤维201。但是，第一膨胀区230将含有比耐热耐火纤维201更多的第一膨化纤维203。耐热耐火区210可具有若干量的第二膨化纤维204；但是第二膨化纤维204在耐热耐火区210中的量明显低于第一膨化纤维203。第二膨胀区240也可具有若干量的耐热耐火纤维201；但是，耐热耐火纤维201在第二膨胀区240中的量，即便有的话，也明显低于第一膨化纤维203。使用两个不同的膨化纤维203/204(图2)比使用单一的膨化纤维102(图1)的优点在于，对于同样重量的耐热耐火纤维101/201和大体积膨化纤维102/202，含有两种类型膨化纤维203和204的防护材料200比仅含一种类型膨化纤维102的防护材料100，在大体积膨胀区120/220处将有较少的耐热耐火纤维201。
参考图1和2，可考虑到防护材料100/200中可包括附加纤维，形成从膨胀区120/220向外延伸的附加区。在这样的实施方式中，膨胀区120/220的外边界121/221/241将不会邻近防护材料100/200的外部，而将排列在防护材料100/200的内部。与防护材料200中第一膨化纤维203到第二膨化纤维204的过渡类似，附加区也将具有从膨化纤维102/204的集中处到附加纤维的集中处的过渡区。多样的附加纤维可以产生多个附加区，从而形成很多附加区。与图1和2所示的膨化纤维102和204相似，在最外面的附加区内，产生最外面附加区的纤维将集中在防护材料100/200的外部。
现参考图3，该图显示了用以加工形成图1和2中的平面整体耐热耐火防护板的特定装置300。现已发现适合在该方法中形成本发明的市售装置，该装置为“K-12 HIGH-LOFT RANDOM CARD”，由奥地利Fehrer AG Linz生产。耐热耐火纤维101/201和大体积的膨化纤维102/202被打开并以适当的比例混合，然后进入气室310。在使用粘合纤维105/205的实施方式中，在进入气室310之前，将粘合纤维105/205打开并与耐热耐火纤维101/201和膨化纤维102/202混合。在含有多种类型膨化纤维203/204的大体积膨化纤维202的实施方式中，那些多种类型的膨化纤维203/204在进入气室310前，也被打开并以适当的比例与其它纤维混合。气室310令混合的纤维悬浮在空气中，然后排出以传送到使用圆筒320的气流成网装置。圆筒320旋转并将混合的纤维投向收集带330。圆筒320的自旋转将较重的纤维沿着收集带330投向比较轻纤维更远的距离。结果，收集在收集带330上的纤维垫将在邻近收集带330处有较多含量的轻纤维，而在远离收集带330处具有较多含量的重纤维。通常，纤维之间的旦数差异越大，纤维分布的梯度也就越大。
在图1所示的防护板100的实施方式中，耐热耐火纤维101比大体积的膨化纤维102轻。因此，在图3所示的工艺中，耐热耐火纤维101在靠近收集带330处以较高含量聚集，而大体积的膨化纤维102在远离收集带330处以较高含量聚集。正是由装置300得到的这种分布产生了平面整体防护材料100的耐热耐火区110和大体积膨胀区120。
在图2所示的防护板200的实施方式中，耐热耐火纤维201比大体积的膨化纤维202轻。因此，在图3所示的工艺中，耐热耐火纤维201在靠近收集带330处以较高含量聚集，而大体积的膨化纤维202在远离收集带330处以较高含量聚集。正是由装置300得到的这种分布产生了平面整体防护材料200的耐热耐火区210和大体积膨胀区220。另外，大体积的膨化纤维220中的第一膨化纤维203比第二膨化纤维204轻。因此，在图3所示的工艺中，第一膨化纤维203在靠近收集带330处比第二膨化纤维204以更高含量聚集。正是这种分布产生了平面整体防护材料200的大体积膨胀区220的第一膨胀区230和第二膨胀区240。
在防护材料100/200的形成中，耐热耐火纤维的混合百分比范围大约在总重量的10％到90％。膨化纤维在防护材料100/200中的混合百分比范围大约在总重量的80％到5％。粘合纤维在防护材料100/200中的最佳量范围大约在总重量的10％到40％。现已发现高度膨松的防护材料是一种理想产品，可以与其它材料一起缝制以用于诸如床垫边和板条的应用。在本工艺中，膨化纤维与耐热耐火纤维的结合通过减少步骤降低了成本，并且具有比将该材料的两个单独层组合在一起更好的性能，例如分层的标准。另外，防护材料的性能似乎在同样成本下具有更好的阻燃性能，并在相似性能条件下成本更低。
在本发明的第一个实施例中，平面整体耐热耐火防护材料是由下列四种纤维的混合形成的：
(1)4wt％的耐热耐火纤维，该纤维为2dpf的部分氧化的聚丙烯腈；
(2)25wt％的第一膨化纤维，该纤维为6dpf的聚酯；
(3)41wt％的第二膨化纤维，该纤维为15dpf的聚酯；和
(4)30wt％的低熔点粘合纤维，该纤维为4dpf的具有较低熔点皮层的皮芯聚酯。
这些纤维被打开、混合然后使用Fehrer AG生产的“K-12HIGH-LOFT RANDOM CARD”形成防护材料。该防护板的重量大约为16～32盎司/码2，其厚度大约在12～37mm之间。在获得的防护材料中，耐热耐火区中包括至少占该区总纤维的70％的耐热耐火纤维，而且大体积膨胀区中的耐热耐火纤维要少于该区总纤维的大约2％。
在本发明的第二个实施例中，平面整体耐热耐火防护材料是由下列四种纤维的混合形成的：
(1)40wt％的耐热耐火纤维，该纤维为约3.2dpf的Visil；
(2)20wt％的约2dpf的改性聚丙烯腈(KanecaronTM)；
(3)20wt％的膨化纤维，该纤维为15dpf的聚酯；和
(4)20wt％的低熔点粘合纤维，该纤维为4dpf的具有较低熔点皮层的皮芯聚酯。
这些纤维被打开、混合然后使用Fehrer AG生产的“K-12HIGH-LOFT RANDOM CARD”形成防护材料。该防护板的重量大约为8盎司/码2，其厚度大约为25mm。在获得的防护材料中，耐热耐火区中至少包括占该区总纤维60％的耐热耐火纤维，而且大体积膨胀区中的耐热耐火纤维要少于该区总纤维的大约40％。在第二个实施例的另一个可替换的形式中，低熔点粘合纤维为10dpf的具有较低熔点皮层的皮芯聚酯。
在本发明的第三个实施例中，平面整体耐热耐火防护材料是由下列四种纤维的混合形成的：
(1)30wt％的耐热耐火纤维，该纤维为约3.2dpf的Visil；
(2)30wt％的约2dpf的改性聚丙烯腈(KanecaronTM)；
(3)20wt％的膨化纤维，该纤维为15dpf的聚酯；和
(4)20wt％的低熔点粘合纤维，该纤维为4dpf的具有较低熔点皮层的皮芯聚酯。
这些纤维被打开、混合然后使用Fehrer AG生产的“K-12HIGH-LOFT RANDOM CARD”形成防护材料。该防护板的重量大约为8盎司/码2，其厚度大约为25mm。在获得的防护材料中，耐热耐火区中至少包括占该区总纤维60％的耐热耐火纤维，而且大体积膨胀区中的耐热耐火纤维要少于该区总纤维的大约40％。
在本发明的第四个实施例中，平面整体耐热耐火防护材料是由下列四种纤维的混合形成的：
(1)40wt％的耐热耐火纤维，该纤维为约3.2dpf的Visil；
(2)40wt％的约2dpf的改性聚丙烯腈(KanecaronTM)；
(3)15wt％的膨化纤维，该纤维为15dpf的聚酯；和
(4)5wt％的低熔点粘合纤维，该纤维为4dpf的具有较低熔点皮层的皮芯聚酯。
这些纤维被打开、混合然后使用Fehrer AG生产的“K-12HIGH-LOFT RANDOM CARD”形成防护材料。该防护板的重量大约为10盎司/码2，其厚度大约为25mm。在获得的防护材料中，耐热耐火区中至少包括占该区总纤维60％的耐热耐火纤维，而且大体积膨胀区中的耐热耐火纤维要少于该区总纤维的大约40％。
在本发明的第五个实施例中，平面整体耐热耐火防护材料是由下列四种纤维的混合形成的：
(1)50wt％的耐热耐火纤维，该纤维为2dpf的Panox；
(2)30wt％的膨化纤维，该纤维为15dpf的聚酯；和
(4)20wt％的低熔点粘合纤维，该纤维为4dpf的具有较低熔点皮层的皮芯聚酯。
这些纤维被打开、混合然后使用Fehrer AG生产的“K-12HIGH-LOFT RANDOM CARD”形成防护材料。该防护材料的重量大约为6盎司/码2，其厚度大约为25mm。在获得的防护材料中，耐热耐火区中至少包括占该区总纤维60％的耐热耐火纤维，而且大体积膨胀区中的耐热耐火纤维要少于该区总纤维的大约40％。
现参考图4，该图显示了图1所示防护材料100的实施方式的放大横截面视图，该防护材料是根据图3所公开的方法形成的。图4显示了耐热耐火区在膨胀区之上。可以看到，纤维具有取向，其角度模式大约为30°，该取向在膨胀区最为明显。纤维的角度是加工工艺造成的，并且使防护材料具有硬度和弹性。纤维角度模式可以是不同的，其范围为从防护材料100的平面维度到水平Z方向呈大约5～80°。
现参考图5，该图显示的为引入了防护材料100/200的床垫。床垫500包括第一面511、相对的第二面512、以及至少一个侧壁与第一面511和第二面512相连的侧壁521、522、523和524。图6显示的为用作图5中床垫500的面511、512、或壁521、522、523和524的壁600的部分剖面图。如图所示，壁600包括外床垫套材料610、防护材料620，支撑材料630、以及背衬材料640。图1-4所示的防护材料100/200可以用作壁600中的防护材料620，并且优选在最靠近外床垫套材料610的耐热耐火区取向。支撑材料630是弹性材料，如泡沫、非织造布、或类似物。背衬材料640是柔性材料，如机织物、针织物、或者非织造织物。
尽管本发明已经对某些优选的形式进行了相当详细地说明，但其它形式也是可能的。例如，材料的附加层，例如非织造布，可以添加到本发明的外表面或者内表面以达到额外的效果。因此，所附权利要求的主旨和范围不应当局限于对本文优选形式的描述。

Claims (45)

1.一种耐热耐火整体平面防护材料，包括：
大量耐热耐火纤维和大量膨化纤维，
所述整体平面防护材料包括：
从耐热耐火外边界延伸至耐热耐火内边界的耐热耐火区，和
从膨胀区外边界延伸至邻近耐热耐火内边界的膨胀区内边界
的膨胀区，
其中，所述耐热耐火区包括部分膨化纤维和部分耐热耐火纤维，而耐热耐火纤维的比例高于膨化纤维，其中耐热耐火纤维在靠近耐热耐火外边界处的含量比耐热耐火内边界处的含量更高，
其中，所述膨胀区包括部分膨化纤维和部分耐热耐火纤维，而大体积的膨化纤维的比例更高，其中膨化纤维在膨胀区外边界的含量比膨胀区内边界的含量更高。
2.根据权利要求1所述的耐热耐火整体平面防护材料，其特征在于，所述耐热耐火纤维比所述膨化纤维的纤度小。
3.根据权利要求1所述的耐热耐火整体平面防护材料，其特征在于，沿着从耐热耐火外边界到耐热耐火内边界的Z轴，所述耐热耐火纤维的含量以梯度降低。
4.根据权利要求1所述的耐热耐火整体平面防护材料，其特征在于，沿着从膨胀区外边界到膨胀区内边界的Z轴，所述膨化纤维的含量以梯度降低。
5.根据权利要求3所述的耐热耐火整体平面防护材料，其特征在于，沿着从耐热耐火外边界到耐热耐火内边界的Z轴，所述耐热耐火纤维的含量以梯度降低。
6.根据权利要求1所述的耐热耐火整体平面防护材料，其特征在于，进一步包括排列在其中的粘合纤维。
7.根据权利要求6所述的耐热耐火整体平面防护材料，其特征在于，所述粘合纤维包括热活化的粘合纤维。
8.根据权利要求7所述的耐热耐火整体平面防护材料，其特征在于，所述热活化的粘合纤维包括皮层熔融温度比芯层低的皮芯纤维。
9.根据权利要求1所述的耐热耐火整体平面防护材料，其特征在于，所述耐热耐火纤维包括阻燃纤维。
10.根据权利要求9所述的耐热耐火整体平面防护材料，其特征在于，所述阻燃纤维包括浸渍二氧化硅的人造丝。
11.根据权利要求1所述的耐热耐火整体平面防护材料，其特征在于，所述耐热耐火纤维进一步包括抑燃纤维。
12.根据权利要求11所述的耐热耐火整体平面防护材料，其特征在于，所述耐热耐火纤维进一步包括阻燃纤维。
13.根据权利要求12所述的耐热耐火整体平面防护材料，其特征在于，所述阻燃纤维包括浸渍二氧化硅的人造丝。
14.一种耐热耐火整体平面防护材料，包括：
大量耐热耐火纤维、包括第一膨化纤维和第二膨化纤维的大量膨化纤维；
所述整体平面防护材料包括：
从耐热耐火外边界延伸至耐热耐火内边界的耐热耐火区，和
从膨胀区外边界延伸至邻近耐热耐火内边界的膨胀区内边界的膨胀区，所述膨胀区具有第一膨胀区和第二膨胀区，所述第一膨胀区从膨胀区内边界延伸至第一膨胀区内边界，并且在两者之间具有第一膨化纤维集中表面，而所述第二膨胀区从膨胀区外边界延伸至邻近第一膨胀区内边界的第二膨胀区内边界；
其中，所述耐热耐火区包括部分第一膨化纤维和部分耐热耐火纤维，而耐热耐火纤维的比例高于第一膨化纤维，其中耐热耐火纤维在靠近耐热耐火外边界处的含量比耐热耐火内边界处的含量更高；且
其中，所述第一膨胀区包括部分第一膨化纤维、部分第二膨化纤维、和部分耐热耐火纤维，而第一膨化纤维的比例更高，其中从膨胀区内边界到第一膨化纤维集中平面，第一膨化纤维的含量增加，而从第一膨化纤维集中平面到第一膨胀区内边界，第一膨化纤维的含量降低；且
其中，所述第二膨胀区包括部分第一膨化纤维和部分第二膨化纤维，而第二膨化纤维的比例更高，其中第二膨化纤维在靠近膨胀区外边界处的含量比第二膨胀区内边界处的含量更高。
15.根据权利要求14所述的耐热耐火整体平面防护材料，其特征在于，所述耐热耐火纤维比所述膨化纤维的纤度小。
16.根据权利要求14所述的耐热耐火整体平面防护材料，其特征在于，所述第一膨化纤维比所述第二膨化纤维的纤度小。
17.根据权利要求14所述的耐热耐火整体平面防护材料，其特征在于，沿着从耐热耐火外边界到耐热耐火内边界的Z轴，所述耐热耐火纤维的含量以梯度降低。
18.根据权利要求14所述的耐热耐火整体平面防护材料，其特征在于，沿着从第一膨化纤维集中平面到第一膨胀区内边界的Z轴，所述第一膨化纤维的含量以梯度降低。
19.根据权利要求14所述的耐热耐火整体平面防护材料，其特征在于，沿着从膨胀区外边界到第二膨胀区内边界的Z轴，所述第二膨化纤维的含量以梯度降低。
20.根据权利要求19所述的耐热耐火整体平面防护材料，其特征在于，沿着从第一膨化纤维集中平面到第一膨胀区内边界的Z轴，所述第一膨化纤维的含量以梯度降低。
21.根据权利要求20所述的耐热耐火整体平面防护材料，其特征在于，沿着从耐热耐火外边界到耐热耐火内边界的Z轴，所述耐热耐火纤维的含量以梯度降低。
22.根据权利要求14所述的耐热耐火整体平面防护材料，进一步包括排列在其中的粘合纤维。
23.根据权利要求22所述的耐热耐火整体平面防护材料，其特征在于，所述粘合纤维包括热活化的粘合纤维。
24.根据权利要求23所述的耐热耐火整体平面防护材料，其特征在于，所述热活化的粘合纤维包括皮层熔融温度比芯层低的皮芯纤维。
25.根据权利要求14所述的耐热耐火整体平面防护材料，其特征在于，所述耐热耐火纤维包括阻燃纤维。
26.根据权利要求25所述的耐热耐火整体平面防护材料，其特征在于，所述阻燃纤维包括浸渍二氧化硅的人造丝。
27.根据权利要求14所述的耐热耐火整体平面挡防护材料，其特征在于，所述耐热耐火纤维进一步包括抑燃纤维。
28.根据权利要求27所述的耐热耐火整体平面防护材料，其特征在于，所述耐热耐火纤维进一步包括阻燃纤维。
29.根据权利要求28所述的耐热耐火整体平面防护材料，其特征在于，所述阻燃纤维包括浸渍二氧化硅的人造丝。
30.一种形成防护材料的方法，包括以下步骤：将大量具有第一纤度的耐热耐火纤维与大量具有比耐热耐火纤维的第一纤度更大的第二纤度的膨化纤维混合，然后将混合的耐热耐火纤维和膨化纤维沿着传送带投出，使得在传送带上形成具有耐热耐火区和膨胀区的整体非织造材料，由此所述耐热耐火区包括比膨化纤维更高百分比的耐热耐火纤维，而所述膨胀区包括比耐热耐火纤维更高百分比的膨化纤维。
31.根据权利要求30所述的方法，其特征在于，所述纤维混合的步骤包括将粘合纤维与耐热耐火纤维和膨化纤维混合。
32.根据权利要求30所述的方法，其特征在于，所述纤维混合的步骤包括含有第一膨化纤维和第二粘合纤维的膨化纤维，所述第二粘合纤维比所述第二粘合纤维的纤度小。
33.根据权利要求32所述的方法，其特征在于，所述纤维混合的步骤包括将粘合纤维与耐热耐火纤维和膨化纤维混合。
34.一种床垫，包括由至少一个侧壁连接的第一面和相对的第二面，其中所述第一面包括外床垫套材料和防护材料，非织造布的所述防护材料包括耐热耐火纤维和膨化纤维，以及具有比膨化纤维更大百分比的耐热耐火纤维的耐热耐火区、和具有比耐热耐火纤维更大百分比的膨化纤维的膨胀区，由此所述防护材料以耐热耐火区朝向所述外床垫套材料的方式安置。
35.根据权利要求34所述的床垫，其特征在于，沿着最靠近所述外床垫套材料的耐热耐火外边界到最靠近所述膨胀区的耐热耐火内边界的轴向，所述耐热耐火纤维的含量以梯度降低。
36.根据权利要求34所述的床垫，其特征在于，沿着离所述外床垫套材料最远的膨胀区外边界到最靠近所述外床垫套材料的膨胀区内边界的轴向，所述膨化纤维的含量以梯度降低。
37.根据权利要求36所述的床垫，其特征在于，沿着最靠近所述外床垫套材料的耐热耐火外边界到最靠近所述膨胀区的耐热耐火内边界的轴向，所述耐热耐火纤维的含量以梯度降低。
38.根据权利要求34所述的床垫，进一步包括排列在其中的粘合纤维。
39.根据权利要求38所述的床垫，其特征在于，所述粘合纤维包括热活化的粘合纤维。
40.根据权利要求39所述的床垫，其特征在于，所述热活化的粘合纤维包括皮层熔融温度比芯层低的皮芯纤维。
41.根据权利要求34所述的床垫，其特征在于，所述耐热耐火纤维包括阻燃纤维。
42.根据权利要求42所述的床垫，其特征在于，所述阻燃纤维包括浸渍二氧化硅的人造丝。
43.据权利要求34所述的床垫，其特征在于，所述耐热耐火纤维进一步包括抑燃纤维。
44.据权利要求43所述的床垫，其特征在于，所述耐热耐火纤维进一步包括阻燃纤维。
45.根据权利要求44所述的床垫，其特征在于，所述阻燃纤维包括浸渍二氧化硅的人造丝。
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US7446065B2 (en) 2008-11-04
US7454817B2 (en) 2008-11-25
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WO2005110733A3 (en) 2006-04-13
US20080060137A1 (en) 2008-03-13
EP1742787A4 (en) 2010-05-05
CN100528546C (zh) 2009-08-19
WO2005110733A2 (en) 2005-11-24
US20090159860A1 (en) 2009-06-25
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EP1742787A2 (en) 2007-01-17
CA2565543A1 (en) 2005-11-24

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