JP2008505008A - Isolation method - Google Patents

Abstract

  A method for isolating a vehicle includes providing an isolation system (e.g., an automobile, truck, train, boat, ship or aircraft, preferably an aircraft) with an isolation system that includes at least one isolation article that includes a plurality of separate vacuum-containing cells. including.

Description

This application claims priority to US Provisional Application No. 60 / 584,588, filed July 1, 2004, the entire contents of which are hereby incorporated by reference. .

  The present invention relates to a method of providing thermal insulation and / or sound insulation for a transport vehicle such as, for example, an aircraft.

  Blankets that provide thermal insulation and / or sound insulation are used in aircraft and other vehicles to isolate passengers from engine and aerodynamic noise and extreme temperatures. One problem with such blankets is moisture absorption. This problem is particularly important in aircraft where the increase in weight due to water uptake in the blanket is dramatic.

  At cruising altitude, commercial aircraft experience outside temperatures significantly below freezing, often as low as -40 ° C. Aircraft passengers and crew generate a large amount of water vapor in the fuselage, either inside the interior cabin wall, in the space separator between the interior cabin wall and the aircraft outer shell, or inside the outer shell. There is a tendency to condense on the cold surface present.

  Condensation of the internal cabin is undesirable in terms of passenger comfort. Condensation within the separator is undesirable because it reduces the isolation efficiency and increases the operating cost of the aircraft due to the increased weight due to condensed water and reduces its charged load volume. Condensation inside the outer shell causes corrosion of the shell and the various structural members attached to it, reduces the life of various components, and requires periodic inspection for inspection, repair or replacement of the corroded components. Become. Such an inspection requires that the isolation system be easily removable.

  This condensation problem can be largely eliminated if an optimized isolation system can be used. The most common isolation system used today includes a fiberglass vat surrounded by an impermeable membrane. The membrane has several small holes to prevent the problem of expansion in the walls due to the inevitable pressure changes that occur when the aircraft changes altitude. These fiberglass blankets must be made to order for each aircraft type, while eliminating the space between the inner cabin and outer shell, also with the various structures and other assemblies in this space. For efficient isolation, many distinct and different patterns must be used for each type. Thus, these thermal blankets are expensive and difficult to install and maintain.

  The fiberglass blanket works well during initial installation. However, water enters the blanket due to the holes required in the outer membrane. This water is estimated to increase the weight of the thermal blanket by a factor of 3 over a typical aircraft use period of 3 years. Another drawback of fiberglass blankets is that they do not efficiently deal with low frequency sounds (eg, frequencies below about 500 Hertz).

  The industry has sought an alternative isolation system that overcomes the aforementioned shortcomings and disadvantages of conventional fiberglass blankets. While such alternative systems (eg, foam isolation) have improved moisture absorption and retention compared to fiberglass blankets, many systems are still expensive and / or difficult to install and / or remove. Furthermore, such systems do not completely eliminate the moisture problem and often require additional relatively heavy components that can cope with low frequency sound.

  Thus, vehicle isolation processes (especially aircraft isolation processes) utilize isolation articles that are easy to manufacture and install, and provide efficient thermal insulation and / or sound insulation without significant moisture absorption and / or moisturization. And can be easily removed from the vehicle (e.g., to allow repair or replacement of items and / or maintenance or repair of the vehicle).

  Briefly stated, in one aspect, the present invention provides a method for providing a vehicle with an isolation system that includes at least one isolation article that includes a plurality of separate vacuum-containing cells. The vehicle is, for example, an automobile, truck, train, boat, ship or aircraft (preferably an aircraft, more preferably a commercial aircraft, most preferably a commercial jet with at least about 100 passenger capacity).

  As used herein, “separate” means that the cells of the article are not in communication with each other and there are a plurality (ie, at least two) independent vacuums. The article preferably comprises a matrix material (more preferably a flexible or semi-rigid matrix material, most preferably a polymer film). The cell of the article can be integrated with the article (i.e., formed by a matrix material), but the vacuum element can be used with a second material that can be surrounded by or attached to the matrix material, for example. Preferably formed.

  It has been found that by using vacuum isolation, the water condensation problem can be addressed and substantially eliminated. From a sound and thermal point of view (because sound containing low frequency sound is not transmitted in a vacuum and thermal energy is not transmitted through conduction or convection), not only the final isolation material is vacuum, but also for vacuum system isolation. Also, no perforations or vents are required to avoid expansion problems associated with pressure / altitude changes.

  The isolation article used in the method of the present invention provides efficient thermal insulation and sound insulation with little or no moisture absorption and / or moisture retention. Because the article relies on a number of independent vacuums for efficiency, even if some of the article's vacuum is lost (eg, due to puncture or tearing), the isolation properties of the entire article are not necessarily destroyed. Thus, such articles are more durable (and more robust during installation and removal) than articles that contain a single vacuum. At least some embodiments of the method of the present invention meet the need for a method that provides efficient thermal insulation and / or sound insulation without causing significant moisture absorption and / or moisturization problems.

Isolation Article An isolation article useful for carrying out the method of the present invention is such that it includes a plurality of separate vacuum-containing cells. The article can hold a vacuum (eg, about 0.5 atmospheres (380 torr) or less) (preferably over at least about one year) and breaks under vacuum with the aid of the original rigid or support structure (or spacer) Without including at least one material that can be either separated or integrated (eg, a microstructure created in the material itself). The article preferably comprises a relatively lightweight material, more preferably at least some of the material is flexible and inherently provides at least a somewhat flexible article. Many useful configurations are possible.

  For example, in one embodiment of the method of the present invention, an isolation article comprising a vacuum-containing sphere (“spherical vacuum element”) made of a rigid material (eg, glass microsphere) can be utilized. Such an article may be in the form of a panel containing a sphere (eg, a foam panel), or the article may optionally be one or more protective layers or even a protective case or bag (eg, substantially or completely surrounding the sphere). A polymer film). The layers and / or bags can be either flexible, semi-rigid or rigid. Microspheres are preferred for their durability, resistance to damage from impact and vibration, but larger spheres can also be used. If desired, the sphere can be attached to a protective layer or bag and / or a binder can be applied to the sphere to increase the stiffness of the article and prevent or reduce movement of the sphere.

  In other embodiments of the method of the present invention, a slightly different isolation article can be utilized. A rigid material (e.g., glass, metal or rigid polymer) can be used to form a number of vacuum elements other than spheres, each including a vacuum-containing cell. These vacuum elements can be placed (and / or attached) in a protective bag (eg, including a polymer film), eg, supported, attached and / or wrapped in one or more protective layers of the polymer film. A vacuum-containing sheet somewhat close to a bubble wrap can be formed. The resulting isolation article can be flexible while still maintaining a vacuum (eg, due to the flexibility of the film extending between the vacuum elements).

  In yet another embodiment of the method of the present invention, an isolation article that includes multiple flexible vacuum elements can be utilized. A flexible film (eg, a low gas permeable polymer film, a metallized polymer film, a multilayer film, or combinations thereof) can be used to form a flexible vacuum element. The element can be in the form of a sheet that can be stacked or laminated to produce an isolated article. A spacer (eg, a gas-containing or vacuum-containing microsphere, a rigid lightweight nonwoven skeleton structure, or a film microstructure such as a plurality of micropins) is used as a film support to form a vacuum-containing cell of a vacuum element. Can do. Optionally, the article can further include one or more protective layers or protective cases or bags (eg, including a polymer film) that substantially or completely surround the flexible vacuum element. The protective layer and / or bag can be either flexible, semi-rigid or rigid, and the flexible vacuum element can optionally be attached to it.

  If desired, spherical, non-spherical or flexible vacuum elements can be arranged alternately in layers so that sound and / or heat is transmitted through at least one vacuum element (between vacuum elements) (Rather than a space or a joint).

  Other useful isolation articles are contemplated and can include one or more vacuum-containing layers. In addition, other materials and layers, such as those typically used for isolation blankets, can be included. For example, the article may include one or more high temperature resistant materials (eg, including materials that are resistant to fire spread and / or flame penetration), one or more adhesive compositions or films, one or more scrims (eg, polymer). Woven fabric), one or more water repellent coatings, one or more swelling additives or coatings, one or more reflective films (eg to control radiant energy) and one or more polymer films (optionally metallized). As well as flame retardants, antistatic agents, fungicides, and the like.

  The isolation articles described above can be manufactured by known methods and can include one or more additional attachment devices used to attach the articles to each other and / or the vehicle. Useful attachment devices include adhesives (eg, pressure sensitive or non-stick adhesives), reclosable fasteners (eg, hook and loop fasteners or dual lock fasteners), mechanical interlocks (eg, tongs) And grooves, buttons and button holes, snaps, molded “puzzle-like” ends or structures), clips, pins, etc., and combinations thereof. The attachment device is preferably an integrated part of the article, but a separate attachment device can be used if desired.

  The article can be any shape and size that facilitates covering the vehicle surface. If desired, the shape can be designed to the shape of the vehicle surface (eg, to form a custom molded article) and can be provided with one or more cuts or holes to match the surface protrusions. it can. Representative examples of useful shaped articles include spherical articles, “two-dimensional” panels or sheets, or, for example, square (6 faces), rectangle (6 faces), triangle (5 faces), hexagon (8 faces) And thicker versions (three-dimensional “solid”), such as octagonal (10 faces), donut, etc. The particular shape and size of the article selected to carry out the method of the invention will vary depending on, for example, the size of the vehicle and its surface configuration.

Isolation System and Method A vehicle can be provided with an isolation article in any desired manner (eg, by applying the article to the vehicle or one or more of its components, eg, by installation, application, or attachment). In this way, the isolation articles can be attached to the vehicle and / or each other to form an isolation system, for example. This can be done with a mounting device that can be used with materials and vehicle surfaces including isolation articles.

  For example, the isolation article can be coated with a first adhesive that only bonds to itself and peels off when pulled. Such adhesives usually cannot actively bind dust and other contaminants. With the second adhesive, the isolation article can be attached to the vehicle surface. Alternatively, the articles can be attached to each other using a mechanical fastening system and the articles can be attached to the vehicle surface using an adhesive.

  When the isolated article is in the form of a panel or a sheet, it can be laid so as to overlap in the same manner as a roof plate. Such overlap reduces heat and sound leakage at the joint between the isolated items and increases the isolation characteristics of the system. This approach facilitates installation in confined spaces and allows desirable thermal and sound characteristics to be obtained in such spaces. For such systems, an adhesive can be used on one side of the panel or sheet for attachment to both the vehicle surface and other panels or sheets. A mechanical fastener can be used to hold each sheet underneath.

  In addition to the methods described above, many other possible ways of applying an article to a vehicle can be envisioned by those skilled in the art. The isolation method of the present invention provides an isolation system between (i) the inner surface of the aircraft shell and (ii) the outer surface of the aircraft interior (including the underside of the cabin floor) or the area containing them. (E.g., applying or attaching) is particularly useful for aircraft isolation. If desired, at least one inner panel of the vehicle (eg, an aircraft interior panel) can include an isolation article (eg, can be attached to the panel or an integral part of the panel). The isolation article can be designed to be soft enough to push the irregular shape of the aircraft surface, simply placed so that the wire can penetrate, and so on. In order to isolate an aircraft substrate, the isolation article can be designed to be resilient so that it can remain in place on the substrate while being sufficiently rigid. Such an isolation article isolates the substrate and also provides an attachment site for the remainder of the isolation system.

  Objects and advantages of the present invention are further illustrated by the following examples, which are not intended to unduly limit the present invention to the specific materials and amounts, other conditions and details listed in these examples.

Example 1
Vehicle Isolation Process Using Isolation Articles Containing Glass Bubbles First available from Orcofilm® AN-54W Cover Film (Orcon Corporation, Union City, California, California) The heat-sealable metallized polyvinyl fluoride) is cut into two 1 m ² pieces to form an isolation article. Four pieces of wood having a length of 1 meter and 5 mm × 25 mm are cut and joined with wood glue to produce a wood frame of 1 m ² and a thickness of 25 mm. A piece of cover film placed on a wood frame and reinforced, metal available from Orcotape® OT-54W tape (Orcon Corporation, Union City, California, California) Pressure sensitive polyvinyl fluoride tape) and seal one of the two open faces of the frame. The frame is made of 3M® Scotchlite® K1 glass bubbles (hollow glass microspheres with an internal pressure in the range of 1/3 of atmospheric pressure, 3M Company, St. Paul, Minnesota). , Available from Minnesota) to a depth of just over 25 mm. Shake the frame with glass bubbles by hand to harden the filling volume. A straight ruler in the form of 1 metric is applied to the exposed surface of the glass bubble and they are flattened to a depth of 25 mm. A second piece of cover film is placed on the exposed glass bubble and the remaining open face of the frame and taped in place as described above to provide the isolation article. A 3M® adhesive transfer tape 468MP (available from 3M Company, St. Paul, Minnesota), including acrylic type adhesive, is attached to the vehicle.

Example 2
Vehicle Isolation Process Using Isolation Articles Containing Glass Bubbles 3M (R) Scotchlite (R) K1 Glass Bubble (hollow glass microsphere with internal pressure in the range of 1/3 of atmospheric pressure, St. Paul, Minnesota) The 3M Company (available from 3M Company, St. Paul, Minnesota) is heat treated by vacuuming to further reduce its internal pressure. This is done by placing a glass bubble in an ultra high vacuum chamber model number LVC1220-HU (available from LACO Technology Incorporated, Salt Lake City, Utah) and at least chamber pressure. This is done by reducing the temperature to ^1x10-9 torr and increasing the temperature to 900 ° C. After one week under these conditions, the glass bubble is slowly cooled to room temperature and then returned to atmospheric pressure in order to promote pressure equalization. An isolated article is constructed using the resulting reduced pressure glass bubble and attached to the vehicle as described in Example 1.

Example 3
Vehicle Isolation Process Using Flexible Isolation Articles Containing Non-spherical Glass Vacuum Elements Separate non-spherical glass vacuum elements approximately 50 mm long x 30 mm wide x 10 mm thick with an internal vacuum of 1 x ^10-7 torr Made by glass technology. A wall thickness of 0.2-2.0 mm is selected to provide durability without excessive weight. Isolation article is available from 3M Super 77® Spray Adhesive (3M Company, St. Paul, Minnesota) Aerosol Spray Adhesive The Mylar® SBL heat-sealable film (multi-layer polyester-based film with metallized coating and heat-sealable layer, DuPont Teijin Films®, Hopewell, Va.) (Dupont Teijin Films, Hopewell, Virginia)). The thickness of the heat-sealable film is in the range of 25.4 micrometers to 127 micrometers. The spacing between each element is approximately 2-10 mm, which is sufficient to make the resulting isolation article comprising 10 mm thick elements conformal. Again, the second sheet of Mylar® SBL heat-sealable film was removed from the vacuum element and film using 3M® Super 77® spray adhesive (Spray Adhesive). Join to the first sheet. The resulting structure is heated around its ends and between the rows and columns of vacuum elements using a standard heat sealer available from Packco Incorporated, Rocky Mount, Missouri, Missouri. Seal and provide an isolation article. A 3M® adhesive transfer tape 468MP (available from 3M Company, St. Paul, Minnesota), including acrylic type adhesive, is attached to the vehicle.

Example 4
VEHICLE ISOLATION PROCESS USING FLEXIBLE ISOLATION ARTICLE INCLUDING A FILM VACUUM ELEMENT HAVING FOAM CORE , Midland, Michigan) microcellular open-cell polyester foam) core with Mylar® SBL barrier film (multilayer polyester-based film with metallized coating and heat-sealable layer, Hopewell, VA) Separate vacuum elements are created by vacuum sealing in DuPont Teijin Films (Dupont Teijin Films, Hopewell, Virginia). A vacuum chamber of about 0.05 Torr is obtained using a vacuum chamber equipped with thermal sealing means. Each desiccant is incorporated into a separate vacuum element. Aerosol spray available from 3M Company, St. Paul, Minnesota, 3M® Super 77® Spray Adhesive (3M Company, St. Paul, Minnesota) Place the Mylar (R) SBL barrier film with an adhesive to hold the element in place. The spacing between each element is about 2-10 mm, which is sufficient to make the resulting isolation article comprising 10 mm thick elements conformal. Using 3M® Super 77® Spray Adhesive, place a second sheet of Mylar® SBL barrier film in multiple elements and place it in place. Hold on. The resulting structure is heat sealed around its ends and between the rows and columns of vacuum elements to provide an isolation article. A 3M® adhesive transfer tape 468MP (available from 3M Company, St. Paul, Minnesota), including acrylic type adhesive, is attached to the vehicle.

Example 5
Vehicle Isolation Process Using Multilayer Flexible Isolation Article A flexible multi-layer isolation article is constructed by placing two flexible isolation articles described in Example 4 on top of each other. In order to improve the isolation performance, the width is offset by 10 mm and the length by 25 mm so that the articles overlap. The two layers are aerosols available from 3M® Super 77® Spray Adhesive (3M Company, St. Paul, Minnesota, St. Paul, Minnesota). Bond with spray adhesive. The resulting two-layer structure is a Mylar® SBL barrier film (a multilayer polyester-based film having a metallized coating and a heat-sealable layer, DuPont Teijin Films®, Hopewell, VA). Films, Hopewell, Virginia)) and is held in place on the barrier film using 3M® Super 77® spray adhesive (Spray Adhesive). A second equivalent sized piece of barrier film is joined to the upper layer of the two-layer structure in a similar manner. The two pieces of barrier film end are heat sealed to provide a multilayer flexible isolation article. A 3M® adhesive transfer tape 468MP (available from 3M Company, St. Paul, Minnesota), including acrylic type adhesive, is attached to the vehicle.

Example 6
Vehicle Isolation Process Using Isolation Articles Containing Honeycomb Core 25 mm thick Plascore® PN2 Nomex® Honeycomb Core (DuPont Nomex® made of paper An isolated article is constructed by cutting an aramid fiber honeycomb coated or impregnated with a heat resistant phenolic resin, available from Plascore, Zeland, Michigan, Michigan, into 1 m ² pieces. Approximately 1 m ² of Mylar® PET (polyester-based film, Dupont Teijin Films®, Hopewell, Virginia) (Dupont Teijin Films, Hopewell, Virginia) 0.5 mm thick sheet 3M® Super 77® Spray Adhesive (aerosol spray adhesive available from 3M Company, St. Paul, Minnesota, St. Paul, Minnesota) To each main surface of the core. A small amount of desiccant is added to the core cell. The resulting structure is a 1 meter square panel with a plurality of separate seal cells.

  An opening or aperture with a diameter of about 0.5 mm is made in each cell that penetrates the polyester sheet. (Alternatively, a plurality of perforations are provided in one of the polyester sheets before joining to the core.) The resulting film cover core is used in a vacuum chamber with thermal sealing means to obtain a vacuum of about 0.05 Torr. Mylar® SBL barrier film (multi-layer polyester-based film with metallized coating and heat-sealable layer, DuPont Teijin Films®, Hopewell, Virginia (Dupont Teijin Films, Hopewell, Virginia) )) Vacuum seal inside. A barrier film seals each cell to provide an isolation article comprising a plurality of separate vacuum containing cells. A 3M® adhesive transfer tape 468MP (available from 3M Company, St. Paul, Minnesota) containing an acrylic type adhesive is attached to the vehicle.

  The references described in the patents, patent applications, patent documents, and literature cited herein are incorporated by reference in their entirety so that each is incorporated by reference. Various unexpected modifications and changes of the invention will be apparent to those skilled in the art without departing from the scope and spirit of the invention. The present invention is not unduly limited by the illustrative embodiments and examples described herein, which are given for illustration only and the scope of the invention is not limited. It is considered limited only by the scope of the claims.

Claims (17)

  Providing the vehicle with an isolation system comprising at least one isolation article comprising a plurality of separate vacuum-containing cells.   The method of claim 1, wherein the vehicle is selected from the group consisting of automobiles, trucks, trains, boats, ships and aircraft.   The method of claim 1, wherein the vehicle is an aircraft.   The method of claim 1, wherein the isolation article comprises a plurality of spherical vacuum elements.   The method of claim 4, wherein the spherical vacuum element is a glass microsphere.   The method of claim 4, wherein the isolation article further comprises one or more protective layers or a protective bag that substantially or completely surrounds the spherical vacuum element.   The method of claim 1, wherein the isolation article comprises a plurality of non-spherical vacuum elements.   The method of claim 7, wherein the non-spherical vacuum element comprises a material selected from the group consisting of glass, metal and polymer.   8. The method of claim 7, wherein the isolation article further comprises one or more protective layers or a protective bag that substantially or completely surrounds the non-spherical vacuum element.   The method of claim 1, wherein the isolation article comprises a plurality of flexible vacuum elements.   The method of claim 10, wherein the flexible vacuum element comprises a material selected from a polymer film, a metallized polymer film, a multilayer film, and combinations thereof.   11. The method of claim 10, wherein the isolation article further comprises one or more protective layers or a protective bag that substantially or completely surrounds the flexible vacuum element.   The vacuum elements are arranged in a layer offset from each other so that sound and / or heat always strikes at least one vacuum element as it attempts to pass through the isolation article. 10. The method according to 10.   Providing the aircraft with an isolation system comprising at least one isolation article comprising a flexible or semi-rigid matrix material and a plurality of discrete rigid non-spherical vacuum elements formed from a second material. Including methods.   The method of claim 14, wherein the matrix material is semi-rigid and at least one inner panel of the aircraft includes the isolation article.   The method of claim 14, wherein the aircraft is a commercial aircraft.   The method of claim 16, wherein the commercial aircraft is a commercial jet with a passenger capacity of at least about 100 people.