EP0600843A1 - Matériau isolation thermique perméable à l'air et flottant - Google Patents

Matériau isolation thermique perméable à l'air et flottant Download PDF

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Publication number
EP0600843A1
EP0600843A1 EP93850063A EP93850063A EP0600843A1 EP 0600843 A1 EP0600843 A1 EP 0600843A1 EP 93850063 A EP93850063 A EP 93850063A EP 93850063 A EP93850063 A EP 93850063A EP 0600843 A1 EP0600843 A1 EP 0600843A1
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EP
European Patent Office
Prior art keywords
water
fiber
microfibers
weight
binder
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Application number
EP93850063A
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German (de)
English (en)
Inventor
Meredith M. Schoppee
James G. Donovan
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Albany International Corp
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Albany International Corp
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Publication of EP0600843A1 publication Critical patent/EP0600843A1/fr
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43825—Composite fibres
    • D04H1/43832—Composite fibres side-by-side
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43825—Composite fibres
    • D04H1/43828—Composite fibres sheath-core
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43835—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43838—Ultrafine fibres, e.g. microfibres

Definitions

  • This invention relates to breathable, buoyant, thermally insulating material. More particularly this invention relates to breathable, buoyant, flexible, thermally efficient insulation systems which can be achieved by the use of assemblies of fine fibers.
  • a flexible, closed-cell foam material currently used to line the multi-purpose coveralls worn by submarine crew members on deck fulfills its function of providing protection against cold and windy environments without unduly restricting the wearer's motion.
  • the lining retains its thermal insulation properties and provides buoyancy because it is impermeable to water.
  • the wearer may suffer heat stress during periods of heavy work on deck because of the inability of the lining material to transfer moisture vapor and the consequent lack of evaporative cooling.
  • a moisture vapor permeable (breathable), water penetration resistant, thermal insulating liner material for the multi-purpose coverall that will provide greater comfort to active military shipboard crew members.
  • Such an insulating material would also provide benefits to others engaged in work or recreation in cold environments where there is some risk of accidental immersion in water, such as merchant marine crewmen, fishermen, yachtsmen, off-shore oil platform workers and ski-mobilers.
  • U.S. Patents Nos. 4,588,635 and 4,992,327 each describe thermal insulating materials comprising synthetic, spun and drawn, crimped microfibers and synthetic macrofiber binders, the density of the resulting batt material being less than 1.0 lb/ft3. These materials are unsuitable for the work or recreational purposes described above because of their inability to limit water absorption to acceptable levels and, as a result, to provide both buoyancy and thermal insulation value in the event of immersion.
  • It is also an object of the invention to provide a breathable, buoyant, thermal insulator material comprising an assemblage of:
  • the invention described herein provides an alternative to impermeable closed-cell foam material as a buoyant insulator that has good thermal insulating performance, both wet and dry, equal or better flexibility, and much increased permeability to water vapor.
  • This alternative insulator is comprised of either (1) all microfibers or (2) microfibers and binder fibers.
  • the microfibers may be pre-treated with a water-repellent finish or the fiber assemblage may be treated with a water-repellent finish after formation of the fiber batt.
  • the microfibers and/or binder fibers may consist of inherently water-repelling material.
  • the level of resistance to wetting that is, water-repellency
  • the fiber surfaces are hydrophilic, i.e., the contact angle between the advancing fluid meniscus and the solid surface of the fiber is less than 90°, then water will eventually wick into the assembly to fill all pores by capillary action. If, however, the surface of the fiber is hydrophobic (advancing contact angle greater than 90°), either because of its natural state or because a water-repellent finish has been applied, then positive pressure must be applied to overcome surface tension and allow water to enter the pore.
  • fibrous insulation materials are a nonhomogeneous collection of individual fibers arranged somewhat at random, they contain interfiber pores of various sizes. Although it is difficult to characterize the pore size distribution in advance, it is possible to calculate the diameter of the average pore, d ⁇ p , based on the density of the insulation, ⁇ 0, the compressive strain, ⁇ , at the applied pressure, and the diameter, d f , and density, ⁇ f , of the fibers from which the web is constructed according to the following relationship:
  • the fiber diameter required to prevent water absorption into the average pore of a polyester assembly must be in the microfiber range below 10 microns, as also illustrated in the attached Figure 1.
  • the fiber diameter required to prevent wetting is prohibitively small in terms of current manufacturing technology.
  • the insulating material of the invention can be described as an assemblage of:
  • Water-repellency can be imparted to the assemblage of the invention by (1) pre-treating the microfibers or the microfibers and binder fibers prior to assembling, (2) treating the resulting fiber assemblage, (3) choosing fiber material that is inherently water-repellent, or (4) by a combination thereof.
  • the pre-treatment or post-treatment can be effected by applying any of the known water-repelling agents.
  • Typical water-repelling agents include aqueous solutions of organopolysiloxanes, such as polydimethylsiloxane, or emulsions of fluoropolymers, such as polytetrafluoroethylene. These treatments may provide the additional advantage of inter-fiber lubrication, which serves to improve the flexibility of the resulting assemblage.
  • the resulting assemblage can be treated with a suitable water-repelling agent, such as SCOTCHBAN® FC-824, a fluorochemical sizing agent available from 3M.
  • a suitable water-repelling agent such as SCOTCHBAN® FC-824, a fluorochemical sizing agent available from 3M.
  • Such water-repelling agents may be applied to the fibers by spray or dip techniques well known in the art.
  • the resultant fiber assemblage preferably has a density of from about 3.0 to 10.0 lb/ft3.
  • This density range is characteristic of assemblages of polyester fibers or materials of similar specific gravity. It is within the scope of the invention that the density range could be as low as about 2.0 lb/ft3 and as high as about 12.0 lb/ft3 with the selection of materials of a specific gravity different from that of polyesters.
  • the resultant fiber assemblage has an apparent thermal conductivity k measured by the plate to plate method according to ASTM C518 with a heat flow down of less than about 0.3 Btu ⁇ in/hr ⁇ ft2 ⁇ °F in the dry condition, and water absorption less than 50% of its dry weight when immersed for one hour at a depth of 2 ft. in fresh water at a temperature of 70°F.
  • the resulting assemblage preferably has a buoyancy greater than 40 lb/ft3 when immersed for one hour or less at a depth of 2 ft. in fresh water at a temperature of 70°F.
  • the buoyancy can approach but cannot exceed the density of water (62.4 lb/ft3 for fresh water).
  • the assemblage will have an intrinsic moisture vapor transfer rate defined and measured as described herein, at least 100 times greater than that of the closed-cell foam according to Military Specification MIL-P-12420C, Type II, Class 6, incorporated herein by reference.
  • the invention also includes a method of forming useful thermal insulating material, which comprises the steps of
  • Microfibers and binder fibers for use in the present invention may be manufactured from polyester, nylon, rayon, acetate, acrylic, modacrylic, polyolefins, spandex, polyaramids, polyimides, fluorocarbons, polybenzimidazols, polyvinylalcohols, polydiacetylenes, polyetherketones, polyimidazols, and phenylene sulfide polymers such as those commercially available under the trade name RYTON.
  • microfibers and the binder fibers may each be all the same material or different, and the binder fibers may be either the same as the microfibers or different.
  • the microfibers and the binder fibers are formed from polyesters.
  • Component (b) may comprise single component fibers or multi-component, preferably bicomponent, fibers, where the single component or at least one component of the multicomponent binder fiber has a melting point lower than that of the microfibers of component (a), to facilitate fiber to fiber bonding.
  • Useful two-component binder fibers include Type K 54, a sheath/core polyester/polyester material available from Kanebo, Ltd., of Japan and Type TJ04S2, a side-by-side polyester/polyester material and Type TJ04C2, a sheath/core polyester/polyester material, the latter two available from Teijin Ltd., of Japan.
  • Other useful two-component fibers are available under the tradename CELBOND® from Hoescht Celanese Corp., Charlotte, N.C., U.S.A.
  • Batts according to the invention can be stabilized at an appropriate density by effecting permanent connectivity between microfibers, between binder fibers, or between binder fibers and microfibers.
  • Such connectivity, bonding, or linking can be effected by a thermal or chemical process.
  • Thermal bonding of batts according to the invention can be achieved by utilizing binder fibers that have a component with a melting temperature lower than that of the material of the microfibers. Under such circumstances the binder fibers will bond to microfibers at their contact points or, optionally, to other binder fibers at binder fiber/binder fiber contact points.
  • Bonding between fibers may be effected by use of chemical bonding agents.
  • Certain solid, gaseous, or liquid bonding agents may cause fiber bonding.
  • certain autologous bonding agents which would cause fiber bonding directly through the action of an intermediate chemical or physical agent.
  • the insulating material may be subjected to more than one procedure to cause entanglement, densification, and/or bonding between the fibers.
  • a batt comprised of microfibers and binder fibers could first be lightly needled and then the needled batt could be subjected to sufficient heating and pressure to cause the binder fiber component to bond with microfibers and other binder fibers and to cause the resultant structure to maintain its dense configuration when cooled.
  • bonding within the structure may be effected by heating the assemblage of fibers for a time and at a temperature and pressure sufficient to cause the fibers to bond.
  • Heat and pressure may be applied in a hot press or between hot calender rolls, or by means of vacuum pressure in a through-air dryer/bonder.
  • Such heating may be at, for example, a temperature of from about 260°F to 435°F for a period of from about 20 seconds to 15 minutes.
  • the material is preferably cooled under restraint to set the densified configuration.
  • the assemblage of binder fibers and microfibers may be a batt consisting of plied card-laps although other fibrous forms such as air-laid webs are equally suitable. Webs and batts of continuous filaments - whether bonded, entangled or otherwise stabilized - may be used.
  • microfibers and/or the binder fiber may optionally be crimped. Crimping techniques are well known in the art.
  • Density The volume of each insulator sample was determined by weighing samples of known areal dimensions and then measuring the thickness at approximately 0.002 lb/in2 (0.014 kPa) pressure. The weight of each sample divided by the volume thus obtained is the basis for density values reported herein.
  • Thickness was measured at approximately 0.002 lb/in2 (0.014 kPa).
  • Flexural Rigidity The flexural rigidity, or resistance to bending, was measured according to ASTM D1388, Standard Test Methods for Stiffness of Fabrics, Option A - Cantilever Test. In this test, a strip of fabric is advanced over the edge of a horizontal platform until the unsupported end touches a line extending from the edge at an angle of 41.5° to the horizontal. The flexural rigidity is calculated from the length of overhang, or bending length, and the weight of the sample.
  • Thermal Conductivity The thermal conductivities of various examples of insulation material were measured according to ASTM C518, Standard Test Method for Steady-State Heat Flux Measurements and Thermal Transmission Properties by Means of the Heat Flow Meter Apparatus. As described in this method, "The heat flow meter apparatus establishes steady state unidirectional heat flux through a test specimen between two parallel plates at constant but different temperatures.” In our case, the measurements were made by Holometrix, Inc., Bedford, Mass., on 12 in. x 12 in. specimens with heat flow down from a top plate at a temperature of 100°F to a bottom plate at 50°F.
  • Water Penetration Resistance The resistance to local penetration by water under pressure was measured as described in Federal Specification CCC-T-19lb, Method 5516.1, Water Resistance of Cloth: Water Permeability, Hydrostatic Pressure Method. According to this method, a test specimen about 7 inches in diameter is sealed against a rising column of 80°F water. When drops of water have penetrated the fabric and appear on the face of the sample opposite to the water head, the height of the column is read and converted to hydrostatic pressure. The maximum column height of the apparatus is 45 inches, which is equivalent to a water pressure of 1.6 lb/in2.
  • Water Absorption The amount of water absorbed by the materials described herein was determined by submerging samples of at least 7 in2 in fresh water at a temperature of 70°F to a depth of 2 feet. The hydrostatic pressure at this depth is 0.9 lb/in2. The samples were held at depth in weighted mesh bags or perforated metal holders for a period of 8 hours. The samples were removed from the water periodically, drained, and weighed. The water weight gain as a percentage of the original dry weight of the sample was thus determined after immersion periods of 1, 4 and 8 hours.
  • Compression Properties The compression properties of 3.0 to 5.0 inch diameter specimens of the materials were measured at 70°F by placing them between the hardened-steel compression platens of an Instron universal test machine and monitoring the load required to reduce their thickness until a pressure of 10 lb/in2 was achieved.
  • the thickness at a pressure of 0.9 lb/in2 equivalent to the hydrostatic pressure at a depth of 2 feet, was determined from the autographic record of compression load and sample thickness.
  • the thickness at 0.9 lb/in2 was converted to compressive strain ⁇ by dividing it by the original thickness of the sample measured at a pressure of approximately 0.002 lb/in2.
  • Moisture Vapor Permeability The rate of moisture vapor transmission through the materials described herein was measured by an upright-cup water method similar to that described in ASTM E96, Standard Test Methods for water Vapor Transmission of Materials, except for the following:
  • Comparative Example 1 consisted of an expanded unicellular (closed-cell) elastomeric foam prepared commercially in sheet form from a blend of chlorine bearing vinyl resin and a butadiene acrylonitrile rubber according to Military Specification MIL-P-12420C, type II, class 6. This material is specified as the buoyant interlining for submarine deck exposure coveralls (buoyancy not less than 54.0 lb/ft3) according to the Military Specification MIL-C-29109A.
  • the closed-cell nature of this material prevents the absorption of water into its interior structure, thereby providing both buoyancy and insulation value to garments in which it is incorporated should the wearer inadvertently be submerged in water.
  • the same closed-cell structure also renders the garment impermeable to the passage of moisture vapor from perspiration so that, as a result, no evaporative cooling can take place and the garment is not comfortable to wear during periods of heavy work.
  • Example 1 of the invention consisted of a blend of 62% by weight of 7 micron diameter (0.5 denier), 1.5 inch, crimped, polyester microfiber treated by the fiber manufacturer with silicone slickener and water-repelling agent (polydimethylsilo- xane), 19% by weight of 7 micron diameter (0.5 denier), 1.5 inch, crimped, polyester microfiber without slickener or water-repelling agent, and 19% by weight of 20 micron diameter (4.0 denier), 2.0 inch, thermally-activated, polyester binder fibers of the side-by-side type.
  • the fiber components were blended and carded on a full-scale, commercial carding machine.
  • the resultant web which weighed approximately 6 oz/yd2, was subjected immediately after carding to an oven exposure at 320°F for 5 minutes to create thermoplastic bonds between the microfibers and the binder fibers.
  • Four layers of the resulting heat-set material were subsequently plied by hand to a total weight of 20 to 24 oz/yd2 and a total thickness of several inches.
  • a layer of 0.5 oz/yd2 spunbonded polyester nonwoven fabric was applied to each of the two surfaces of the plied web.
  • This assembly was densified and heat-set in its final dense configuration in a continuous process on a pilot-scale through-air bonder/drier equipped with a top restraining wire (Honeycomb Systems, Inc.).
  • a roll of 24-inch wide material was processed on this machine at an air temperature of 375°F and a line speed of 7 ft/min in a 120° wrap configuration around a 36-inch diameter perforated steel cylinder.
  • a vacuum pressure of 0.9 lb/in2 and a restraining tension of 4 lb/inch were applied during this stage of processing.
  • the web was cooled under restraint on a separate cooling roll before it was rolled up.
  • the finished material was soft and flexible with a density between 8 and 9 lb/ft3 and a final thickness of 0.21 inch.
  • Example 2 The material of Example 2 consisted of a blend of 80% by weight of 7 micron diameter (0.5 denier), 1.5 inch, crimped, polyester microfibers treated by the fiber manufacturer with a silicone slickener and water-repellent (polydimethylsiloxane) and 20% by weight of 14 micron diameter (2.0 denier), 2.0 inch, thermally-activated, polyester binder fiber of the sheath/core type.
  • the fibers were blended and carded on a 12-inch wide, laboratory-scale, carding machine. Layers of web removed from the carding machine were plied by hand to a final assembly weight of 21 to 23 oz/yd2.
  • Comparative Example 2 illustrates the effect of the absence of the water-repellent fiber finish on the wettability of the microfiber insulation material.
  • the material of this comparative example consisted of a blend of 80% by weight of 7 micron diameter (0.5 denier), 1.5 inch, crimped, polyester microfibers to which no water-repellent was added and 20% by weight of 14 micron diameter (2 denier), 2.0 inch, thermally-activated, polyester binder fibers of the sheath/core type. The fibers were blended and carded, and the resulting card webs were plied, lightly needled, and consolidated by application of heat and pressure in the same way as that described above for Example 2.
  • Example 3 of the invention illustrates the advantageous effect of the application of a water-repellent to the untreated microfiber insulation material described above as Comparative Example 2.
  • the material of Example 3 consisted of the same blend of untreated microfibers and binder fibers as Comparative Example 2, but after light needling, a 5% solution of a fluorochemical, water-repelling, sizing agent (SCOTCHBAN® FC-824, available from 3M) was padded onto the fiber web under pressure between nip rolls in a laboratory-scale padder. A solids add-on of 1.2% of the dry weight of fiber was achieved. After being dried at 212°F, the treated web was consolidated by application of heat and pressure in the same manner as described for Example 2 and Comparative Example 2.
  • a fluorochemical, water-repelling, sizing agent (SCOTCHBAN® FC-824, available from 3M) was padded onto the fiber web under pressure between nip rolls in a laboratory-scale padder. A solids add-on of 1.2% of
  • Comparative Example 3 was a 0.22 inch thick, 12.4 oz/yd2, needled felt material that consisted of 14 micron diameter (2.0 denier), 3.0 inch, Type 450 NOMEX®, crimped staple fibers.
  • the felt was prepared from this fiber in a continuous process on full-scale, commercial carding, cross-lapping, and needle-punching equipment.
  • a 5% solution of a fluorochemical, water-repelling, sizing agent (SCOTCHBAN® FC-824) was padded onto 14-inch wide strips of felt in the same way as described above for Example 3. The resultant add-on of solids was 1.0% of the dry weight of the felt.
  • Comparative Example 4 was identical to Comparative Example 3 except that the felt was not treated with a water-repellent.
  • Example 4 consisted of a blend of 62% by weight of 7 micron diameter (0.5 denier), 1.5 inch, crimped, polyester microfiber treated by the fiber manufacturer with a silicone, anti-wetting and slickening agent (polydimethylsiloxane), 19% by weight of 7 micron diameter (0.5 denier), 1.5 inch, unslickened, polyester microfiber, and 19% by weight of 20 micron diameter (4.0 denier), 1.5 inch, thermally-activated, polyester binder fiber of the sheath/core type. The fiber was blended and carded, the resulting web cross-lapped, and the binder fiber activated by the application of heat in a continuous production process on commercial manufacturing equipment.
  • the heated material was partially consolidated by passing it under a compaction roll and over a copper cooling platen as it emerged from the heat-setting oven.
  • Samples of this material measuring 12 in. x 12 in. were compressed between and thermally bonded to two layers of a hydrophilic polyester breathable barrier film (SYMPATEX®) in one final consolidating step.
  • the heat bonding and final densification of the membrane/fiber assembly was accomplished by holding it for 0.5 min to a thickness of 0.25 inch between aluminum plates placed between the platens of a hot press at 400°F. The sample was air-cooled while held to thickness between the aluminum plates.
  • Comparative Example 2 prepared from non-water-repellent treated microfibers, illustrates the effect on water penetration resistance and absorption resistance of the absence of a water-repellent treatment
  • Example 3 prepared from the same blend of fibers as Comparative Example 2, shows the effect of adding such a water-repellent treatment to batts made in the same way from the same microfiber constituents.
  • Water readily penetrates untreated Comparative Example 2, which rapidly absorbs water to the point of saturation, in spite of its microfiber content and its relatively dense construction, and, as a result, it is incapable of providing either thermal insulation or buoyancy when it is submerged in water.
  • Comparative Example 3 Neither the untreated felt of Comparative Example 4 nor its water-repellent-treated counterpart, Comparative Example 3, are particularly resistant to local water penetration under pressure or to water absorption when submerged because the water-repellent treatment is not capable by itself of providing these properties in sufficient measure to a fiber assembly in which the majority of interfiber pores are too large (because of the combination of fiber diameter and web density) to resist the ingress of water under even modest pressures.
  • Example 4 of the invention illustrates the possibility of sandwiching the water-repellent-treated microfiber insulation between layers of a breathable barrier membrane to enhance its resistance to local water penetration at high pressures.
  • the penalty for this added protection is increased weight and stiffness when dry and increased weight gain when wet due to absorption of water both by the membrane itself and within the small channels which are formed between the fibrous insulation and the membrane by the localized thermoplastic bonds.
  • the higher percentage weight gain measured for Example 4 does not, however, represent increased absorption by the fibrous layer and does not, therefore, result in loss of insulation value of the assembly in water.
  • Insulating materials prepared in accordance with some of the foregoing Examples were tested to determine the effect of web density on water absorption at a pressure of 0.9 lb/in2 (depth of 2 ft in water at 70°F), over periods of 1 hour, 4 hours, and 8 hours, respectively.
  • the data points in Figs. 2 to 4 represented by the symbol "+” represent values for insulating materials prepared in accordance with the procedure of Example 4 except that there was no further consolidation of the batt after it emerged from the heat-setting oven, and no layer of breathable barrier film was added.
  • the data points represented by the symbol " ⁇ " represent values for insulating materials prepared according to Example 2, but due to certain processing variables the materials prepared here had different densities.
  • the data points having the symbol " ⁇ " represent values for insulating materials essentially prepared according to the procedure of Example 1. However, the final consolidation to different densities was accomplished by heat-setting laboratory samples between aluminum plates as described for Example 2, rather than on a through-air bonder/dryer.
  • the data points having the symbol "*" represent values for insulating materials prepared according to Example 1.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Laminated Bodies (AREA)
  • Thermal Insulation (AREA)
EP93850063A 1992-11-30 1993-03-31 Matériau isolation thermique perméable à l'air et flottant Withdrawn EP0600843A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US98509692A 1992-11-30 1992-11-30
US985096 1992-11-30

Publications (1)

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EP0600843A1 true EP0600843A1 (fr) 1994-06-08

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EP93850063A Withdrawn EP0600843A1 (fr) 1992-11-30 1993-03-31 Matériau isolation thermique perméable à l'air et flottant

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EP (1) EP0600843A1 (fr)
JP (1) JPH06228852A (fr)
AU (1) AU661550B2 (fr)
BR (1) BR9301639A (fr)
CA (1) CA2096092A1 (fr)
FI (1) FI930779A (fr)
MX (1) MX9302181A (fr)
NO (1) NO932069L (fr)
ZA (1) ZA931437B (fr)

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GB2336164A (en) * 1998-04-07 1999-10-13 Vitafibres Limited Non-woven insole for footwear
WO2006102009A1 (fr) 2005-03-16 2006-09-28 Stuart Press Materiau isolant hydrophobe
WO2007125084A2 (fr) * 2006-04-27 2007-11-08 Libeltex Procédé de fabrication d'un matelas isolant à fibres polymères pour des applications de constructions résidentielles et commerciales
WO2011011715A2 (fr) * 2009-07-24 2011-01-27 Bellwether Materials, Inc. Matériau isolant en natte souple et procédé de fabrication
EP2616579A2 (fr) * 2010-09-14 2013-07-24 SABIC Innovative Plastics IP B.V. Articles thermoplastiques renforcés, compositions pour la fabrication desdits articles, procédés de fabrication, et articles formés à partir de celles-ci
CN103882714A (zh) * 2012-12-21 2014-06-25 3M创新有限公司 制造拒水无纺保暖材料的方法及拒水无纺保暖材料

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JP5208448B2 (ja) * 2007-05-25 2013-06-12 株式会社フジコー 車両用マット材
KR20120058837A (ko) * 2010-11-30 2012-06-08 코오롱인더스트리 주식회사 물에 뜨는 섬유 및 그 제조방법

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EP0088191A2 (fr) * 1982-03-08 1983-09-14 Imperial Chemical Industries Plc Mélange de fibres de rembourrage en polyester
US4508775A (en) * 1983-10-14 1985-04-02 Pall Corporation Gas permeable composite structures

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EP0088191A2 (fr) * 1982-03-08 1983-09-14 Imperial Chemical Industries Plc Mélange de fibres de rembourrage en polyester
US4508775A (en) * 1983-10-14 1985-04-02 Pall Corporation Gas permeable composite structures

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Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2336164A (en) * 1998-04-07 1999-10-13 Vitafibres Limited Non-woven insole for footwear
CN101180180B (zh) * 2005-03-16 2011-06-08 斯图亚特·普雷斯 疏水绝缘材料
WO2006102009A1 (fr) 2005-03-16 2006-09-28 Stuart Press Materiau isolant hydrophobe
EP1868807A1 (fr) * 2005-03-16 2007-12-26 Stuart Press Materiau isolant hydrophobe
EP1868807A4 (fr) * 2005-03-16 2008-03-26 Stuart Press Materiau isolant hydrophobe
WO2007125084A2 (fr) * 2006-04-27 2007-11-08 Libeltex Procédé de fabrication d'un matelas isolant à fibres polymères pour des applications de constructions résidentielles et commerciales
WO2007125084A3 (fr) * 2006-04-27 2008-01-17 Kerrebrouck Jozef Van Procédé de fabrication d'un matelas isolant à fibres polymères pour des applications de constructions résidentielles et commerciales
WO2008012680A2 (fr) * 2006-04-27 2008-01-31 Dow Global Technologies, Inc. mottes d'isolation en fibre polymère pour applications de construction résidentielle et commerciale
WO2008012680A3 (fr) * 2006-04-27 2008-11-06 Dow Global Technologies Inc mottes d'isolation en fibre polymère pour applications de construction résidentielle et commerciale
WO2011011715A2 (fr) * 2009-07-24 2011-01-27 Bellwether Materials, Inc. Matériau isolant en natte souple et procédé de fabrication
WO2011011715A3 (fr) * 2009-07-24 2011-06-03 Bellwether Materials, Inc. Matériau isolant en natte souple et procédé de fabrication
US8945678B2 (en) 2009-07-24 2015-02-03 Priscilla Burgess Soft batt insulation material and method for making
EP2616579A2 (fr) * 2010-09-14 2013-07-24 SABIC Innovative Plastics IP B.V. Articles thermoplastiques renforcés, compositions pour la fabrication desdits articles, procédés de fabrication, et articles formés à partir de celles-ci
CN103882714A (zh) * 2012-12-21 2014-06-25 3M创新有限公司 制造拒水无纺保暖材料的方法及拒水无纺保暖材料
WO2014100178A1 (fr) * 2012-12-21 2014-06-26 3M Innovative Properties Company Procédé de fabrication d'un matériau non tissé thermo-isolant et hydrofuge, et matériau non tissé thermo-isolant et hydrofuge
CN103882714B (zh) * 2012-12-21 2016-07-13 3M创新有限公司 制造拒水无纺保暖材料的方法及拒水无纺保暖材料

Also Published As

Publication number Publication date
FI930779A (fi) 1994-05-31
CA2096092A1 (fr) 1994-05-31
AU661550B2 (en) 1995-07-27
BR9301639A (pt) 1994-06-07
JPH06228852A (ja) 1994-08-16
NO932069D0 (no) 1993-06-07
NO932069L (no) 1994-05-31
AU3313093A (en) 1994-06-16
FI930779A0 (fi) 1993-02-22
MX9302181A (es) 1994-06-30
ZA931437B (en) 1993-09-22

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