TWI406768B - 具有微孔膜之合成絕緣材料 - Google Patents

具有微孔膜之合成絕緣材料 Download PDF

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TWI406768B
TWI406768B TW93137906A TW93137906A TWI406768B TW I406768 B TWI406768 B TW I406768B TW 93137906 A TW93137906 A TW 93137906A TW 93137906 A TW93137906 A TW 93137906A TW I406768 B TWI406768 B TW I406768B
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TW200523117A (en
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Vanessa Mason
Joseph Rumiesz
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Primaloft Inc
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Description

具有微孔膜之合成絕緣材料 發明領域
本發明係關於一種防水可透氣的絕緣材料，此材料特別可使用在戶外服飾及靴子中。
 發明背景
戶外運動愛好者已不斷要求工藝先進的裝備來保護其本身免受惡劣天氣影響。此要求產生一些防水可透氣織物架構之發展，其中典型會將該織物積層至一薄膜或膜。防水可透氣織物已使用在性能衣物(performance garments)上數十年，且已証明其為較佳的性能組分。對穿戴者就舒服性來說，防止水從織物外部到達身體及排出由身體所產生之蒸氣二者非常重要。但是，此類織物的缺點總是為雖然它們被歸類為可透氣的，但它們不提供明顯的水蒸氣傳輸。再者，大部分可透氣的織物趨向於具有非常有限的絕緣性質。仍然再者，已積層至某些膜型式的織物趨向於不是非常有彈性且當在使用時會產生嘈雜的聲音。此外，雖然他們有所聲稱，但大部分防水可透氣織物其透氣性趨向於比想要的還低且僅提供有限的絕緣性質，此使其必需與相關的一些絕緣材料形式一起使用，且需要使用者忍受其僵硬及嘈雜的本質。
絕緣材料經常與相關的性能衣物一起使用或會將其摻入性能衣物，以提供熱保護。但是，大部分的絕緣材料不 提供斥水性或可選擇性地減少相當的熱保護代價來提供斥水性。普利馬羅浮特(Primaloft)®絕緣體(如描述在美國專利案號4,992,327及4,588,635中，其以參考之方式併於本文)在合成絕緣體界中獨一無二，其除了微及細纖維架構的熱性能象徵外尚可提供優秀的斥水性。
但是，普利馬羅浮特®絕緣體因其所加入的防水性優勢，其已主要使用作為天然羽絨的替代物。此外，普利馬羅浮特®棉絮已以一個別的絕緣層摻入服飾製造中。其經常例如透過縫製來機械穩固至織物或不織物材料的其它層。但是，普利馬羅浮特®絕緣體其自身不具有足夠的結構完整性或美觀的外觀，以足夠作為絕緣材料及外在的織物層二者。
許多防水可透氣織物之另一種元素為單片薄膜，其使用來對該織物授予一可透氣阻障。該單片薄膜透過使用能吸收貼近皮膚的水及將其傳送至外部環境之親水性聚合物層來促進水蒸氣滲透。
不幸的是，該單片薄膜典型會遭遇到該親水層會明顯膨潤，此將明顯改變該薄膜之蒸氣排出特徵及使用者之舒服性。再者，雖然此薄膜型式亦具有非常高的撕裂強度(其通常適合於性能織物)，但其亦會在服飾中造成異常僵硬，此通常不視為一正屬性。
因此，已對能提供優良的斥水性或防水特徵且結合優良的蒸氣排出特徵之防水可透氣絕緣材料有所需求，其將不會膨潤且具有足夠的撕裂強度，但是對穿戴者來說其不會過硬或嘈雜。
 發明概要
本發明的一個具體實施例係關於一種絕緣包封體，其具有一機能織物層、一具有孔洞網絡之高度透氣的微孔膜層及一可透氣的排水絕緣層，該些層彼此積層以形成一防水可透氣的絕緣織物。
在另一個具體實施例中，本發明之絕緣層為一內聚性纖維結構形式之可透氣的排水絕緣層，其結構包括下列之組合：(a)70至95重量百分比的合成聚合微纖維，其直徑從3至12微米；及(b)5至30重量百分比的合成聚合長纖維，其直徑從12至50微米。
本發明亦針對一種形成一防水絕緣包封體的方法。該步驟包括提供一機能織物的第一層、一微孔膜的第二層及一可透氣的排水絕緣體之第三層。再者，將該第一層黏合至該第二層，且將該第二層黏合至第三層。
已在所附加的申請專利範圍中詳細指出本發明之多種構形的新穎特徵且其形成此公告的一部分。為了較好地了解本發明、藉由使用其而獲得的操作優點及特定目標，可參考用來闡明本發明的較佳具體實施例之伴隨的闡明事件。
圖式簡單說明
可參考下列說明及伴隨的圖形來更完全地了解本發明，其中： 第1圖為根據本發明之一防水絕緣包封體的截面圖；及第2圖為根據本發明之另一種防水可透氣的絕緣包封體之截面圖。
 較佳實施例之詳細說明
現在轉移至圖形，本發明針對一般顯示在第1圖之絕緣包封體10，其具有防水性及可透氣性二者。如第1圖所顯示，一絕緣包封體10由一絕緣材料12、一微孔膜14及一機能織物16所組成。該絕緣材料12、該微孔膜14及該機能織物16較佳透過熟知的積層技術彼此黏合。在較佳的具體實施例中，該經積層的包封體10由普利馬羅浮特®絕緣體(作為絕緣材料12)及任何織物、不織物、絨頭織物或其它織物結構(作為機能織物16)所組成，後者已黏附或積層至該微孔膜14表面，而該微孔膜14其自身已積層至該普利馬羅浮特®絕緣體。在某些狀況中，想要將一額外的機能織物層或襯墊18加入至該絕緣材料12的非薄膜邊，如第2圖所顯示。
微孔膜14較佳，因為其具有一高度可透氣、可經操控之互相連接的微孔洞網絡。可透過拉伸及操控該薄膜來選擇性地限定該微孔膜14之透氣性及空氣滲透性質。此拉伸可改變原始的薄膜孔洞尺寸。再者，該微孔膜可使用適合於應用的積層技術。
在應用上，可建構一微孔膜的孔洞網絡，以便該孔洞的有效路徑及尺寸能准許最理想的水蒸氣傳遞同時仍然可抑制水傳遞，然而其尚未在可接受能視為防水可透氣薄膜 的程度。
該微孔膜14的優點之一為其不吸水或不會膨潤。先述技藝的單片薄膜典型為以聚胺基甲酸酯為基礎，及在該薄膜層中透過水分子可溶性來作用。結果，雖然其具有一般的抗撕裂性，它們較不想要具有膨潤傾向。此膨潤已熟知會改變該單片薄膜的親水性質。
比較上，該微孔膜可透過水蒸氣擴散過該些孔洞而作用。典型的孔洞尺寸例如在1至8微米間。因為此孔洞的尺寸範圍，本發明之微孔膜其自身不視為防水或疏水。再者，該微孔膜典型由聚四氟乙烯或其它具有低結晶性(通常少於30%)的聚合材料形成。此外，該聚合材料可與一顆粒尺寸為0.5-5微米之無機充填劑混合。該微孔膜之厚度通常在大約30至50微米間。重要的是，此微孔膜不會歷經普通單片薄膜之膨潤。
再者，可藉由將該絕緣層12積層至該微孔膜14，來大大增加該微孔膜的抗撕裂性(其通常低於該單片薄膜)。此外，此組合之硬度明顯比藉由將一絕緣材料黏合至一單片薄膜所產生的還小。
為了進一步提高該絕緣包封體的防水本質，該機能層16可經一耐用的排水處理或蠟塗層塗佈。
根據本發明的一個觀點，該絕緣層12為一內聚性纖維結構形式之合成纖維熱絕緣材料，其結構包括下列組合：(a)70至95重量百分比的合成聚合微纖維，其直徑從3至12微米；及 (b)5至30重量百分比的合成聚合長纖維，其直徑從12至50微米，其中該些纖維至少有某些在其接觸點處黏合，此黏合可讓所產生的結構密度範圍在3至16公斤/立方公尺(0.2至1.0磅/立方呎)內，可在沒有明顯減低此結構的熱絕緣性質(與未黏合的組合比較)下達成此黏合。
可使用於本發明之微纖維及長纖維能從聚酯、耐綸、嫘螢、醋酸酯、丙烯酸、副丙烯腈、聚烯烴、氨綸、聚芳族醯胺、聚醯亞胺類、碳氟化合物、聚苯并咪唑類、聚乙烯醇類、聚二乙炔類、聚醚酮、聚咪唑類及苯撐硫醚聚合物來製造，其諸如可在商業上以萊同(RYTON)之商品名稱購得或其可為任何其它合適於此目的之材料。
可在至少某些長纖維間或可在長纖維與微纖維二者間於不同的接觸點處達成該黏合，以形成該些微纖維的支撐結構。該長纖維可選自於相同材料或可選自於多種材料，且可為與該微纖維相同或不同的材料。
在本發明的一個優良具體實施例中，該微纖維可從聚對苯二甲酸乙酯形成及該長纖維可選自於聚對苯二甲酸乙酯或聚芳族醯胺，諸如例如在商業上可以商標"凱芙勒(Kevlar)"購得。
該長纖維可為單纖維(即，具有實質上均勻結構的纖維)，或它們可為一具有一部分能促進纖維對纖維黏合的多組分纖維。該纖維可為一纖維混合物，其中至少10重量%包含一較低熔點的熱塑性材料之長纖維，以幫助該纖維對纖 維之黏合。在本發明的進一步具體實施例中，該長纖維可為一包含多組分長纖維之纖維混合物，及一能彼此黏合及/或與微纖維黏合的單組分長纖維。
在本發明的另一個具體實施例中，該長組分纖維可為一具有不同性質之長纖維混合物或摻合物，例如，一長纖維混合物可包含二種或更多種不同纖維，諸如聚酯纖維(以提供想要的黏合)與"凱芙勒"纖維(以提供硬性)。可改變硬化纖維與黏合纖維之比例，以提供具有不同性質能符合需求之標的物，該可鍵結纖維的比例足以對該微纖維提供一稀鬆支撐物，如將於此之後描述。
某些材料(諸如例如，聚苯撐硫醚纖維、商業上可以"阿皮爾(APYIEL)"之商品名購得的芳香族聚醯胺型式及聚醯亞胺纖維(諸如由奧地利(Austria)的蘭精(Lenzing)AG所製造的那些))具有阻燃或不燃性質。因此，此材料可在製造包含根據本發明之材料的產物上授予經改良的耐火焰或火性質。
根據本發明的一個觀點，該絕緣層12之纖維的黏合較佳主要在該長纖維組分之纖維間且於其接觸點處。該長纖維與長纖維黏合之目的為形成一微纖維組分的支撐結構，該支撐結構可對該絕緣材料明顯貢獻出機械性質。藉由黏合該些長纖維，該些長纖維可維持一稀鬆經黏合的纖維結構(在其中可裝入微纖維)。此外，該長纖維及/或微纖維可在其接觸點處黏合。
可在長纖維間使用任何黏合方法，諸如例如藉由加入 固體、氣體或液體黏合劑或較佳地透過施加熱，以使該較低溫度的纖維組分熔化及在接觸點處熔合。
黏合該絕緣層12組分之方法非為關鍵，目標僅需應該在並無纖維組分失去其結構完整性之條件下進行該黏合。需由熟知此技藝之人士了解，在黏合期間於該長或微纖維中之任何明顯的改變將相反地影響熱性質；因此，需要在儘可能維持該纖維組分及組合的物理性質及尺寸下進行該黏合步驟。
該經黏合的絕緣層12之熱絕緣性質實質上與類似之未黏合的組合之熱絕緣性質相同或不明顯少於者較佳。
在本發明的特別具體實施例中，可藉由在足以造成該纖維黏合之溫度下加熱該纖維一段時間來達成於絕緣層12內之黏合。此加熱期間可為在溫度約125℃(257℉)至225℃(437℉)下時間級數1分鐘至10分鐘，較佳在溫度約140℃(284℉)至200℃(392℉)下時間約3至7分鐘；當然，這些時間會依該纖維組分混合物之材料而定。
如上所述之普利馬羅浮特®合適於與如描述於本文之微孔膜一起積層應用。對黏附至織物的應用及持續性來說，該積層技術需要在該絕緣體上具有一實質上平滑的表面。
此平滑表面可透過在技藝中熟知的方法來產生，諸如IR壓光、加熱板壓光、經加熱的滾筒、樹脂塗佈及/或獨特的熱空氣烘箱處理(獨特定義為溫度及空氣流操控)。除了表面處理外，需要良好地黏合該棉絮的內部結構以維持該結構的完整性，以便重覆使用及洗滌該積層物體時沒有剝離。
雖然在較佳的具體實施例中使用普利馬羅浮特®絕緣體及特別是由普利馬羅浮特®所形成之羽絨材料，應該了解的是，可使用其它絕緣材料而沒有離開本發明之範圍，包括從天然及合成纖維或其混合物所形成之織物及不織物絕緣材料。
實驗資料
根據AATCC試驗方法127，標題"抗水性：靜水壓力試驗"，此絕緣包封體10可提供大於2.0磅/平方英寸的靜水壓力之防水性。在戶外織物工業中，典型將任何具有靜水壓力能力大於2.0磅/平方英寸之織物認可視為防水的定義。AATCC為美國紡織品化學家及顏料師公會之縮寫。AATCC 127為一種試驗方法，其可測量織物在靜水壓力下的抗水滲透性且可應用至全部型式的織物。將該試驗樣品的一個表面接受經加壓的水，其中以固定速率增加壓力直到在該樣品的另外一邊觀察到三個漏水點。在一個實驗中，已發現使用普利馬羅浮特®羽絨作為絕緣層12之絕緣包封體10具有超過185公分-H2 O或2.63磅/平方英寸之抗靜水壓力。此外，已發現該絕緣包封體10具有遠超過視為防水之需求的抗水特徵。
另一個在絕緣包封體上所進行的試驗為測量水蒸氣的穿透速率(WVTR)。此可根據ASTME 96-00程序E來進行。該WVTR為一在一段所提供的時期內來測量能通過該織物之水蒸氣量的試驗。
例如，在先述技藝之實驗中經常引用已熟知作為比較 及對照基礎的西爾加得(Celgard)®2500微孔膜，其已知具有5000克/平方公尺/24小時的WVTR。
先述技藝之可透氣的外套服飾已顯示出具有3465克/平方公尺/24小時的WVTR，其諸如描述在美國專利案號6,100,208之實例1中，其具有一多組分纖維之第一層、一多組分纖維之第二層及一在其之間由低密度聚乙烯所形成的不透水阻障物。但是，描述在'208專利中之織物不像本發明般有提供一絕緣層。預計加入一絕緣層將減少該戶外織物的WVTR。
在37.8℃及90%相對溼度下對本發明之絕緣包封體進行試驗。在此試驗中，如描述在本發明中般，一積層有沙普雷斯(SUPPLEX)織物、微孔膜材料及普利馬羅浮特®絕緣體的樣品，其可獲得3521克/平方公尺/24小時的WVTR。此明顯因為該試驗樣品提供一絕緣層(其不存在於上述描述的二個實例中)，且其WVTR比無絕緣積層物的戶外織物大，及其WVTR幾乎與該微孔膜其自身一般大。就其本身而論，本發明之絕緣包封體闡明穿戴使用該絕緣包封體所建構的織物之穿戴者僅管有明顯的運動活動，亦應該預計會存在有一合理的舒服性。
因此，在明顯從前述描述所製得的那些當中，已顯示出可有效率地達成上述提出的目標，因為可在進行上述方法中及在所提出的架構中製得一些改變而沒有離開本發明之精神及範圍；而且想要的是，包含在上述說明及顯示在伴隨的圖形中之全部事件應該解釋為闡明用且無限制的意 思。
10‧‧‧絕緣包封體
12‧‧‧絕緣材料
14‧‧‧微孔膜
16‧‧‧機能織物
18‧‧‧襯墊
第1圖為根據本發明之一防水絕緣包封體的截面圖；及第2圖為根據本發明之另一種防水可透氣的絕緣包封體之截面圖。
10‧‧‧絕緣包封體
12‧‧‧絕緣材料
14‧‧‧微孔膜
16‧‧‧機能織物

Claims (20)

  1. 一種絕緣包封體，其包含：至少一機能織物層，其係在該絕緣包封體之外側；一可透氣的排水絕緣層，其係在該絕緣包封體之內側；及一具有孔洞網絡之高度可透氣、空氣可滲透的微孔膜層，其係在該至少一機能織物層與該可透氣的排水絕緣層之間；其中該機能織物、微孔膜層及絕緣層通過整體絕緣包封體彼此積層，以形成一防水可透氣的絕緣織物。
  2. 如申請專利範圍第1項之絕緣包封體，其中該至少一機能織物層的至少一層為一防水織物。
  3. 如申請專利範圍第2項之絕緣包封體，其中以一蠟塗層來塗佈該機能織物層。
  4. 如申請專利範圍第1項之絕緣包封體，更包含一第二機能織物層。
  5. 如申請專利範圍第4項之絕緣包封體，其中該第二機能織物積層至該絕緣層的非薄膜邊上。
  6. 如申請專利範圍第1項之絕緣包封體，其中可藉由拉伸該微孔膜來限定該孔洞網絡中的孔洞尺寸。
  7. 如申請專利範圍第1項之絕緣包封體，其中該絕緣包封體准許傳遞蒸氣及抑制傳遞水。
  8. 如申請專利範圍第1項之絕緣包封體，其中該可透氣的排水絕緣層為一不織物且包含選自於由微纖維、長纖維 、天然纖維及其混合物所組成之群的纖維。
  9. 如申請專利範圍第1項之絕緣包封體，其中該可透氣的排水絕緣層為一織物且包含選自於由微纖維、長纖維、天然纖維及其混合物所組成之群的纖維。
  10. 如申請專利範圍第1項之絕緣包封體，其中該可透氣的排水絕緣層具有一內聚性纖維結構，其包含下列組合：(a)70至95重量百分比之經紡織及抽拉的合成聚合微纖維，其直徑從3至12微米；及(b)5至30重量百分比的合成聚合長纖維，其直徑12至50微米。
  11. 如申請專利範圍第1項之絕緣包封體，其中該可透氣的排水絕緣層可形成如為一羽絨，而具有一與積層技術一致的平滑表面。
  12. 如申請專利範圍第11項之絕緣包封體，其中該平滑表面可藉由至少一種選自於由下列所組成之群的方法來形成：紅外線(IR)壓光、加熱板壓光、使用經加熱的滾筒、樹脂塗佈及熱空氣烘箱處理。
  13. 如申請專利範圍第1項之絕緣包封體，其中該機能織物選自於由絨頭織物、織物及不織織物所組成之群。
  14. 一種形成如申請專利範圍第1至13項中任一項之絕緣包封體的方法，該方法包含以下步驟：提供一機能織物的第一層在該絕緣包封體之外側；提供一第三可透氣的排水絕緣層在該絕緣包封體之內側； 提供一微孔膜的第二層在至少一機能織物層與該可透氣的排水絕緣層之間；將該第一層黏合至該第二層；及將該第二層黏合至該第三層。
  15. 如申請專利範圍第14項之方法，更包括一將該第三層形成為羽絨的步驟。
  16. 如申請專利範圍第15項之方法，更包括一在該羽絨上形成一平滑表面之步驟。
  17. 如申請專利範圍第14項之方法，其中該第一層與該第二層之黏合為一積層製程。
  18. 如申請專利範圍第14項之方法，其中該第二層與該第三層之黏合為一積層製程。
  19. 如申請專利範圍第14項之方法，更包括提供一第二機能織物層的步驟。
  20. 如申請專利範圍第19項之方法，其中將該第二機能織物層積層至該可透氣的排水絕緣層。
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US9185941B2 (en) 2015-11-17
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ES2375620T3 (es) 2012-03-02
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ATE533618T2 (de) 2011-12-15
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