WO2020211115A1 - 一种被服气凝胶填充结构及其应用 - Google Patents

一种被服气凝胶填充结构及其应用 Download PDF

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Publication number
WO2020211115A1
WO2020211115A1 PCT/CN2019/084609 CN2019084609W WO2020211115A1 WO 2020211115 A1 WO2020211115 A1 WO 2020211115A1 CN 2019084609 W CN2019084609 W CN 2019084609W WO 2020211115 A1 WO2020211115 A1 WO 2020211115A1
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aerogel
vapor
small
permeable
particle
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PCT/CN2019/084609
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English (en)
French (fr)
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翁文灏
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翁文灏
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B68—SADDLERY; UPHOLSTERY
    • B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G1/00—Loose filling materials for upholstery

Definitions

  • the invention belongs to the field of filling materials for clothing and bedding, and relates to a powder-proof and vapor-permeable aerogel filling structure and clothing and bedding prepared therefrom, in particular to ultra-thin clothing, quilts, sleeping bags, hats and gloves containing aerogel .
  • Aerogels are currently known solids with the best thermal insulation performance and the lowest density. It can lock a large amount of still air in a small space, has extremely low thermal conductivity, and is extremely light, and has excellent performance as a thermal insulation material.
  • aerogel is a brittle material and cannot be directly applied to clothing and bedding products that need to be bent repeatedly during use and/or storage; therefore, the aerogel must be made into particles or powder beforehand. Make it adhere to or be wrapped in other substrates for use.
  • the dropped aerogel powder will not only affect the appearance, but also cause allergies, coughing, sputum, sneezing, itching, faint eyes, chest tightness, difficulty breathing, dermatitis, rhinitis and/or other diseases, long-term use of such powder Aerogel products can even cause serious diseases such as pneumoconiosis/silicosis, so they cannot meet the basic safety requirements and aesthetic requirements of clothing and bedding; moreover, the reduction of aerogel content after powder drop will also reduce the thermal insulation performance of the product , Affect product quality.
  • the aerogel interlayer of these clothing products will produce a large number of sub-millimeter or even millimeter-level penetrating needle thread holes during the sewing process, and the aerogel particles in the interlayer are not restrained, and the aerogel powder will be like a down jacket.
  • the velvet runaway phenomenon escapes and drops powder at these needle thread holes.
  • the movement of human limbs will inevitably cause these aerogel interlayers to be repeatedly squeezed and decompressed, and the aerogel powder in these interlayers will continue to escape from the needle hole with the repeated squeezing out of steam. Drop powder.
  • the aerogel powder is sealed with plastic film, aluminum film or other airtight materials into flat membrane capsules of different sizes and shapes, and then fixed to some positions of the clothing like armor or plaster .
  • Extremely thin textile materials or interlayers are not ideal for eliminating or reducing free air in such concave-convex curved structures due to their own extremely thin characteristics; but if such extremely thin textile materials or interlayers are replaced with A certain thickness of the filling structure, because the filling has a certain degree of bulkiness, polishing and expansion capacity, the free space in this kind of concave-convex curved structure or free drooping structure will be squeezed by the filling or the continuous cloth pressed against it , It can reduce or even eliminate the free air layer, inhibit or even eliminate the mutual exchange of hot and cold air and the convection and conduction inside the hot air, which can greatly improve the heat preservation and heat insulation performance of the final bedding product.
  • the research and development of a kind of aerogel can not only use the extremely excellent thermal insulation performance, but also prevent the aerogel powder from falling or seeping out of the product, but also permeable vapor, and can eliminate or reduce the existing aerogel clothing
  • the aerogel filling structure of the free air layer at the fabric and/or the interlayer and the clothing and bedding made therefrom are technical problems that need to be solved urgently by those skilled in the art.
  • the purpose of the present invention is to develop a kind of aerogel that can not only use the extremely excellent thermal insulation performance of aerogel, but also can permeate steam, can reduce or eliminate the free air layer in the clothing, and can prevent the aerogel powder from getting out of the product.
  • An aerogel filling structure for clothing comprising: a vapor-permeable fabric and/or a vapor-permeable membrane and a large aerogel particle monomer and/or aerogel small particle aggregate;
  • the aerogel macroparticle monomer includes aerogel macroparticles and a coating layer wrapped around the aerogel macroparticles;
  • the small aerogel particle aggregates are small aerogel particles which are connected by one or more mixtures including adhesives, adhesives, structural glues, curing agents, crosslinking agents, and coupling agents. to make;
  • the vapor-permeable fabric and/or vapor-permeable membrane completely wraps a plurality of large aerogel monomers and/or small aerogel particle aggregates, and the large aerogel monomers and/or aerogels
  • the size of the aggregates of small rubber particles is larger than the size of the vapor-permeable fabric and/or vapor-permeable membrane vapor-permeable gaps and needle holes;
  • the aerogel particles are large aerogel particles with a coating layer, or the small aerogel particles in the aggregation of the small aerogel particles are tightly bonded together to form a whole. Will not disperse easily; the moisture emitted by the human body can easily pass through the vapor-permeable gaps on the above-mentioned vapor-permeable fabrics and/or vapor-permeable membranes, as well as the gaps between fiber filaments and/or fiber bundles, and large aerogel particles
  • the vapor permeable space between the monomers and/or small aerogel particle aggregates is discharged, and the minimum size of the above-mentioned large aerogel monomers and/or small aerogel particle aggregates is larger than the above-mentioned vapor-permeable fabric And/or the size of the vapor-permeable gaps and needle holes (if any) on the vapor-permeable membrane, the aerogel powder particles cannot leak from the vapor-permeable fabrics and/or the vapor-perme
  • the large aerogel particles are provided with a wrapping layer outside the monomer, and the small aerogel particles are tightly connected to each other through the binder to form an aggregate of small aerogel particles that will not easily disperse. Therefore, these aerogels
  • the product is not easily crushed during repeated folding.
  • the aerogel particles that constitute the aerogel particles aggregates are firmly bound/fixed together by the binder and will not be further crushed (for example, a special grinding process is required to obtain nano-scale aerogel particles. After being bonded into silk or millimeter-sized aerogel particle aggregates, the deformation range of the aerogel particle aggregates under pressure is thousands, tens of thousands, or even hundreds of thousands of nano-sized particles.
  • these aerogel particles can also be stably attached or confined in conventional filling materials, and the gas can be made through a multi-level fixed structure.
  • the gel powder can be very firmly bonded or sealed in the modified filling material, and it is not easy to fall or fall, and there will be no powder falling phenomenon.
  • the large aerogel particles 1 are crushed in a long-term process, the large aerogel particles are provided with a coating layer outside the monomer can still continue these crushed small aerogel particles (powder) Enclosed in the coating layer, it becomes another form of aerogel small particle aggregates that will not easily disperse (that is: this kind of crushed aerogel small particle aggregation is that the small particles in the coating layer are not It is completely fixed and can move relative to the inside of the coating layer but cannot be dispersed.
  • the small particles in the aforementioned small particle aggregates are fixed by adhesives, etc. and will not be dispersed, and even after being fixed, the coating layer can be set outside the aggregate.
  • the above preferred 0.6-1 mm aerogel particles properly coated or bonded have a size smaller than or close to the sewing needle diameter. During the sewing process, such particles with a size smaller than or close to the diameter of the sewing needle will be pushed around by the needle, and it is difficult for the needle to hit the center and break. despite this:
  • aerogel small particle aggregates are concerned, because you can choose an adhesive with high bonding strength, even if a small amount of aggregates are cracked by the sewing needle, it is only the aggregates cracked, the aggregates after cracking Either part of the adhesion is continued, or the size of the lobes after cracking is still larger than the size of the fabric's air-permeable voids and needle thread holes, and the powder will not fall off. Even the extremely small amount of lobes is smaller than the size of the needle thread hole, because these extremely small amount of lobes are still on the micron-sized particles fixed and aggregated by the binder and/or other filler fibers.
  • the nano-sized aerogel powder is not It will not fly easily in the air but directly fall to the ground. Therefore, not only are these possible leaks far from exceeding the safety standard in quantity, but also in weight, they can be controlled to fall vertically to the ground instead of flying in the air and being inhaled by consumers, posing a health threat.
  • aerogel filling structure for clothing further includes: fibers, foamed materials, glass beads and/or functional materials;
  • the above-mentioned fiber is one or a mixture of cotton, wool, cashmere, hemp, polyester staple fiber, polyester filament, spandex yarn, and aramid fiber.
  • the large aerogel particle monomer and/or the small aerogel particle aggregate is an aqueous silica aerogel, an aqueous titanium dioxide aerogel, an aqueous carbon aerogel or an aqueous polyimide aerogel .
  • the vapor-permeable fabric or vapor-permeable membrane includes two layers, and the first layer of vapor-permeable fabric or membrane completely wraps a plurality of large aerogel monomers and/or small aerogel particle aggregates. It is made into a layered or group structure, and a second layer of vapor permeable fabric or film is wrapped on the surface of the layer or group structure;
  • a wrapping layer is further provided on the surface of the layered or mass structure and/or the vapor-permeable membrane or the vapor-permeable fabric.
  • the above-mentioned aerogel filling structure for clothing further includes:
  • High heat reflectance material or far-infrared material and the surface of the layered or group structure is wrapped with high heat reflectance material or far-infrared material.
  • the wrapping layer is an organic wrapping layer and/or an inorganic wrapping layer
  • the organic coating layer material is one or a mixture of structural adhesives, adhesives/adhesives, curing agents, crosslinking agents, and coupling agents;
  • the inorganic coating layer material is one or a mixture of silicon dioxide membranes, ceramic membranes, metal membranes, zeolite membranes, glass membranes and/or molecular sieve composite membranes.
  • the above-mentioned adhesive is any one or more of water-based pure acrylic emulsion, water-based vinegar-acrylic emulsion, water-based styrene-acrylic emulsion, water-based acrylate emulsion, water-based polyurethane emulsion, water-based epoxy resin emulsion, and water-based silicone emulsion. mixture.
  • the functional material is a high heat reflectivity material, and/or a far-infrared material, and/or a moisture-absorbing heat-generating material, and/or a phase change material.
  • the beneficial effect of adopting the above-mentioned preferred technical solution is that the overall heat preservation performance of the final product can be further improved, the moisture-absorbing and heat-generating material can absorb the moisture emitted by the human skin to generate heat, and the human body wrapped in it can obtain an additional heat source, making the human body better Get more calories faster.
  • the high heat reflectance material is aluminum powder or aluminum film
  • the far infrared material is far infrared fiber.
  • the beneficial effect of adopting the above-mentioned preferred technical solution is that the overall thermal insulation performance of the final product can be further improved, and the high heat reflective material is arranged in the above-mentioned filling material to reflect the heat emitted by the human body back to the skin surface, reducing heat loss; far-infrared material It is more conducive to lock the heat, and can also reduce heat loss.
  • the above-mentioned aerogel clothing and bedding further includes: an electric heating device, a temperature sensor and/or a temperature control device.
  • An electric heating device, a temperature sensor and/or a temperature control device are arranged on the inside or outside of the fabric of the aerogel clothing bedding.
  • the beneficial effect of adopting the above-mentioned further technical solution is that an electric heating device is arranged inside or outside the fabric of the aerogel clothing and bedding, which greatly improves the thermal insulation performance, and also obtains an additional heat source other than the body temperature, which can make The human body wrapped in it gets more and faster heating and less temperature loss, which is especially suitable for applications in extreme environments such as polar regions and mountains.
  • the temperature sensor and temperature control device can be used to accurately control the temperature in the filling material like the battery heating suit that is now popular.
  • the large aerogel particle monomer and the small aerogel particle are any one or a mixture of particles, flakes, short rods, fibers, and flocs. As long as the minimum size of these particles, small flakes, short rods, fibers, flocculent aerogel particles or aggregates is larger than the size of the fabric voids or needle thread holes (if any), the phenomenon of aerogel powder falling can be avoided . Even if the small aerogel particle aggregates are directly made into fibrous or flocculent aerogel aggregates with a coating layer, they can be directly used as fillers, reducing the manufacturing process.
  • the bedding and clothing aerogel filling structure of the present invention can be used in the preparation of clothing, quilts, sleeping bags, hats and/or gloves.
  • the deformation range of the aggregate under pressure is thousands, tens of thousands, or even hundreds of thousands of times that of nano-sized particles; it is dispersed within such a large deformation range
  • the pressure on the nano-sized particles is not enough to crush it, but only a certain overall deformation of the small particle aggregates, and these deformations are recoverable or have no substantial effect on the macro-scale finished product).
  • these aerogel particles can be stably attached or confined in conventional filling materials, and the aerogel powder can be very firmly bonded or sealed in the modified filling material through the multi-stage fixing structure.
  • the reduction effect is not ideal; but in the present invention, after replacing such extremely thin textile materials or interlayers with a filling structure with a certain thickness, since the filling naturally has a certain bulkiness, polishing degree and expansion ability, this type of The free space in the concave-convex curved structure or the free drooping structure will be squeezed by the filler or the continuous cloth pressed against it, which can reduce or even eliminate the free air layer, inhibit or even eliminate the mutual exchange of cold and hot air and the internal hot air Convection and conduction can greatly improve the thermal insulation performance of the final quilt.
  • the large aerogel monomers and/or small aerogel particle aggregates due to the aggregation between the filled substrates, the large aerogel monomers and/or small aerogel particle aggregates, the aggregation of the substrate and the large aerogel monomers and/or the small aerogel particles There are a large number of through-type voids between the bodies, so the vapor permeability of the aerogel apparel bedding will be very good. This point has obvious advantages over the various technical solutions that make aerogel into a vapor-impermeable interlayer on the market, and it can overcome the low aerogel content and poor thermal insulation effect in these technical solutions. problem.
  • the main process is a simple physical mixing or adhesion process of the aerogel Compared with the complex chemical process of wrapping the aerogel powder into the closed-cell foam structure, the manufacturing cost and process difficulty will be much lower, and it is more suitable for commercialization and large-scale promotion. Taking a step back, regardless of the manufacturing cost and the aerogel content, even considering the existing aerogel-containing vapor-impermeable interlayers on the market can be cut or broken into a particle size larger than the fiber gaps and needle holes of the cloth.
  • the granular or sheet-like filler is filled into the filling bag made of fabric to achieve vapor transmission (because the impermeable interlayer is cut or broken into many granular or sheet-like fillers, these A large number of vapor-permeable voids can be generated between the particles or flakes) and no powder is lost (because the aerogel powder of these products is limited in the closed-cell foam structure).
  • the technical solution of the present invention that directly mixes the aerogel particles that will not drop powder into the traditional filler fiber is obviously more reasonable, cheaper, and more feasible. more reliable.
  • the aerogel particles are placed in the internal voids of the aerogel clothing and bedding, it is compared with conventional non-woven fabrics, cotton, hemp and other natural fibers, polyester, aramid, spandex and other chemical fibers and/or blended fibers of these materials themselves.
  • the heat preservation and heat insulation capacity will be much larger, so its heat preservation and heat insulation performance can be greatly improved.
  • the maximum spacing can reach several millimeters or even centimeters, so aerogel powder particles can be placed in these substrates in large quantities and easily. Therefore, the weight ratio of aerogel in the above-mentioned aerogel apparel and bedding with stable and reliable performance can easily exceed 1%, and even 99%. That is to say, the above-mentioned conventional filling substrate can even be mainly used as a maintenance insulation
  • the layer maintains its shape and is used as a supporting base material, not as a heat insulating material.
  • the filler as the substrate plays a secondary or even negligible thermal insulation role, so it can be used with lower bulkiness, lower porosity, and relatively poor quality
  • the filling material to obtain the same or even far more thermal insulation performance. Therefore, relatively inferior filling can be used to obtain the same or even more thermal insulation capacity, which can reduce costs and expand the source of raw materials.
  • FIG. 2 is a schematic diagram of the filling structure of the large aerogel particles in FIG. 1 after being partially crushed during use;
  • FIG. 3 is a schematic diagram of the filling structure of aerogel small particle aggregates in the present invention.
  • Figure 4 is a schematic diagram of a filling structure formed by aerogel small particle aggregates and fiber materials in the present invention.
  • Fig. 6 is a schematic diagram of the filling structure formed by the aggregates of small aerogel particles, large aerogel particles, ceramic or glass beads, and phase change material beads in the present invention.
  • the small aerogel particle aggregate 10 can be made by firmly bonding the small aerogel particles 8 through the adhesive 9; As shown in FIG. 1, the large aerogel particle monomer can be dried or solidified to form the coating layer 2 by uniformly spraying the coating liquid outside the large aerogel particle 1. Then, these small aerogel particle aggregates 10 or large aerogel particles 1 are made or sieved into aerogel particles of a certain size (preferably 0.6-1 mm).
  • the above fully mixed and homogeneous mixture can be further made into a layered or agglomerated structure, and then the adhesive 9, fixing agent or adhesion wrapping layer 2 can be sprayed on the surface of the layered or agglomerated structure to achieve the Further and multi-level fixation or limitation of aerogel particles, the multi-stage fixed aerogel filling material of the present invention is prepared, and then the aerogel filling material of the present invention is filled into the vapor-permeable fabric and/or vapor-permeable membrane 3
  • the manufactured bag may be further cut into interlayer and then sewn into various clothing and bedding.
  • the sealed or semi-sealed space into which the large aerogel particle monomer or the small aerogel particle aggregate 10 is blown may include a cotton thinner, a spray cotton production line, a down box/hair separator, a stacker and/or
  • the existing machinery and equipment, including the down filling machine, have reliable performance, easy operation and good availability.
  • the needle number 6 makes the size of the needle hole formed during the sewing process smaller than the particle size of the aerogel powder monomer.
  • the large aerogel particles sprayed with the coating layer and/or other fillers are filled into the sewn quilt to obtain a powder-proof and vapor-permeable aerogel quilt.
  • these small aerogel particle aggregates are solidified or dried, they are first blown vigorously or blown to a state of violent boiling to collide with each other many times to peel off those small aerogel particles with insufficient binding fastness, and then move by wind And/or vibrating sieve to sieve the aerogel small particle aggregates of the specified size, the above sieve is used as the aerogel filling in the present invention, and the under sieve can be returned to the droplet dropping process and the newly added air
  • the small gel particles continue to participate in the formation process of small particle aggregates until the particle size formed is large enough to become an oversieve.
  • the cloth with the gap between the cloth fibers smaller than the aerogel powder aggregate is selected and sewn together with the flat layered filling interlayer to form a cold-proof quilt product.
  • the slurry is mixed with a curing agent evenly, dried, and solidified into a block. Then use a pulverizer or mixer to pulverize the dried and solidified block. After pulverization, the aerogel particles with insufficient binding fastness are peeled off by violent blowing or blowing to violent boiling. Then the air of the specified size is sieved through the wind and/or vibrating screen.
  • Example 2 100% of the filling material of the clothing product is the above-mentioned above-mentioned Example 2 or Example 3 (aerogel powder aggregate), and its aerogel content is high, and its thermal insulation ability is extremely strong, and it can make various A kind of ultra-thin and/or ultra-light thermal insulation bedding products.
  • aerogels purchased from other aerogel material suppliers (such as Shenzhen Zhongning Technology Co., Ltd., Suzhou Tongxuan New Material Co., Ltd., Guangdong Alison High-tech Co., Ltd. and other domestic and foreign aerogel material manufacturers)
  • the particles are added to the needle punched non-woven fabric production process, the tightly combined aerogel particles are squeezed into the non-woven fabric fibers, and then needle punched into felt.
  • Figure 5 shows a kind of aerogel large particle 1 monomer and ceramic or glass microbeads 12 together in the vapor-permeable fabric and/or vapor-permeable membrane 3 to form a thermal insulation filling structure.
  • the size of the ceramic or glass microbeads 12 shown in the figure is also preferably larger than the vapor permeable gap 4 on the vapor permeable fabric and/or vapor permeable membrane to avoid leakage. If the size of these ceramic or glass microspheres 12 is smaller than the vapor-permeable voids 4 on the vapor-permeable fabric and/or vapor-permeable membrane in some special cases, they only need to be used as widely used in the paint industry. It is sufficient that the ceramic or glass microbeads 12 adhere to each other and/or to the large aerogel particles 1 alone.
  • Figure 6 shows a large aerogel particle 1 monomer, small aerogel particle aggregates 10, fibers 11, ceramic or glass beads 12 and phase change material beads 13 together in a vapor-permeable fabric and/or permeable material.
  • the vapor film 3 constitutes a bedding with a thermal insulation filling structure.
  • Large aerogel particles 1 monomer, small aerogel particle aggregates 10, fibers 11, ceramic or glass microbeads 12 are jointly arranged on the side exposed to the outside air to obtain an excellent thermal insulation effect;
  • the phase change material beads 13 are arranged on the side close to human skin or underwear.
  • the structure composed of large aerogel particles 1 monomer, small aerogel particle aggregates 10, fibers 11, ceramic or glass microbeads 12 together has a super strong heat insulation performance, resulting in microscopic phase change materials.
  • the phase change heat in the beads 13 can only be released to or absorbed from the skin side, but is difficult to be released to the external environment side or absorbed from the external environment side. These materials cooperate with each other to obtain quilt products with stronger functionality and better use effect.

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Abstract

一种气凝胶填充结构，包括：透汽面料和/或透汽膜与气凝胶大颗粒单体和/或气凝胶小颗粒聚集体；气凝胶大颗粒单体包括气凝胶大颗粒及包裹在气凝胶大颗粒外的包裹层；透汽面料和/或透汽膜完全包裹住多个气凝胶大颗粒单体和/或气凝胶小颗粒聚集体，气凝胶大颗粒单体和/或气凝胶小颗粒聚集体的尺寸大于透汽面料和/或透汽膜透汽空隙和针线孔的尺寸。将该气凝胶填充材料制成服饰寝具不但保温隔热性能极好、人体贴合度高，减少甚至消除服饰内部自由空气层进一步提高保温性能，不会出现气凝胶掉粉现象，不会对使用者造成健康危害，也不会由于掉粉导致的气凝胶减少使保温隔热性能变差，而且还透汽、不闷热，使用舒适度高。

Description

一种被服气凝胶填充结构及其应用 技术领域
本发明属于服饰寝具填充材料领域，涉及一种不掉粉且透汽的气凝胶填充结构及其制得的服饰寝具,尤其涉及含气凝胶的超薄服饰、被子、睡袋、帽子和手套。
背景技术
气凝胶为目前已知的保温隔热性能最好、密度最低的固体。它能大量锁定微小空间内的静止空气、热导率极低、重量极轻，作为保温隔热材料性能极优。但气凝胶为脆性材料，无法直接整块/整体地应用到服饰寝具这类在使用和/或收纳时需要反复弯折的产品上；因此必须先将气凝胶制成颗粒或粉末状再使其附着或被包裹到其他基材中使用。
目前已有大量公司将气凝胶粉末简单地夹杂到玻璃纤维毡、无纺布、开孔发泡材料或塑料膜等基材内进行应用。此类将气凝胶粉末夹在纤维束、开孔发泡结构或膜结构基材之间的方案，虽已在无需反复弯折的墙体/管道用气凝胶保温隔热材料等产品上获得广泛的商业应用，但将其直接搬用到需要反复弯折和/或清洗的服饰、被子、睡袋、垫子等穿着坐卧用具上时，就会出现严重的气凝胶掉粉现象。掉落的气凝胶粉末不但影响美观，而且会导致人体过敏、咳嗽、咳痰、喷嚏、发痒、迷眼、胸闷、呼吸困难、皮炎、鼻炎和/或其他疾病、长期使用此类掉粉气凝胶产品甚至会导致尘肺/硅肺等严重疾病，因此根本无法满足服饰寝具所需的基本安全要求和美观要求；而且，掉粉后气凝胶含量减少也会导致产品保温隔热性能降低，影响产品质量。
此类简单夹杂复合气凝胶产品产生掉粉现象的主要原因在于气凝胶粉末颗粒与基材只是简单混合，二者之间并无稳定的连接，一旦受到外力或汽流冲击，质轻粒细的气凝胶粉末颗粒就会在基材之间自由运动。此时，如果包裹此类复 合材料的面料纤维之间的空隙尺寸大于这些自由运动的气凝胶粉末颗粒，这些气凝胶粉末颗粒就会从这些面料纤维之间的空隙之中逸出，导致掉粉现象。而且，这些被服产品的气凝胶夹层在缝制过程中会产生大量的亚毫米甚至毫米级贯穿性针线孔，而夹层内的气凝胶颗粒未被束缚住、气凝胶粉末就会如羽绒服跑绒现象那样在这些针线孔处逸出、掉粉。此外，人肢体的运动会也必然导致这些气凝胶夹层被极多次反复地挤压和解压，这些夹层内的气凝胶粉末就会随被反复挤出的汽流不断地从针线孔处逸出、掉粉。最后，不管夹层内的气凝胶粉末的初始粒径控制为多少，由于气凝胶很脆，气凝胶颗粒因在使用过程会被反复挤压和/或冲击而被粉碎成粒径更小的颗粒；这些被压碎的汽凝粉末不但会从这些针线孔中漏出；而且在长时间使用后颗粒变得足够小时，甚至会从这些服饰、被子或睡袋等制品并无针线孔的面料纤维缝隙里直接大量渗出。所以，现有的包括将气凝胶粉末作为夹层加在甚至不透汽的薄膜结构中的技术方案也因为惧怕被服缝制过程中的贯通性针孔和掉粉，其实用性和/或可靠性均不理想。
为解决掉粉问题，也有部分公司尝试将气凝胶微粉直接混合到诸如涤纶、氨纶和/或芳纶之类的熔融料中制成纤维后纺纱再制成被服衣帽之类的产品。将气凝胶粉末混入纤维丝内部的方案，由于气凝胶颗粒极低的密度、极大的比表面/表面张力及其疏水/疏物特性，能够混合入纤维丝内部的气凝胶颗粒含量极低，目前已知的最大混入比例还不到1％，因此并不能充分发挥气凝胶成分的保温隔热性能。而且，就此类技术而言，即便是将来能够提高气凝胶颗粒在纺丝内部(而不是纺丝之间)的含量，也会由于气凝胶颗粒极大的脆性和疏物性等固有特点，使制得的纺丝和纤维的强度被严重降低，其可纺性和纤维强度都会有极大的问题，因此此类技术的可行性和实用性均不会很强。
目前，还有部分公司将气凝胶粉末直接混入闭孔发泡材料和/或闭孔膜材料之中。
此类技术方案不但同样面临气凝胶粉末难以高比例均匀混入闭孔结构、发泡产品化工汽味严重、发泡材料在使用过程中经过挤、压、碰撞或坐卧后隔热 厚度变薄、保温能力明显下降等难题，而且为了防止产品掉粉必须将发泡材料做成闭孔结构的基材，导致必然最终成品透汽性差、闷热、易导致过敏、皮肤适应性极差等问题。目前市场上已有几款基于将气凝胶粉末复合入闭孔发泡材料的气凝胶服装，均出现了不透汽和气凝胶含量太小导致其保温防寒效果远达不到其宣传的效果等问题；将其产品放到电镜上分析，其主要结构还是常规的发泡结构，气凝胶粉末只是作为附着点缀的次要材料；其原因是可以理解的：发泡材料在发泡前后的体积差异巨大，发泡后的体积一般会膨胀至发泡前的几十至上百倍，一般为40-60倍；但是气凝胶材料却是不可膨胀的，其在发泡后就等于是被稀释了40-60倍，甚至上百倍；其主体结构已经根本不是气凝胶材料。因此，在搜索网站baidu.com上输入“气凝胶服装”这个词汇时，系统自动跳出来的最高频被搜关键词竟然是“气凝胶服装骗局”这样令人遗憾的结果。
甚至还有公司，如原美国的ASPEN SYSTEM公司旗下的ZEROLOFT(http://zeroloft.com)、AEROTHREM(www.aerotherminsulation.com)和中国深圳的中凝科技有限公司(www.agel-tech.com)等，将气凝胶粉末用塑胶膜、铝膜或其他的气密材料密封成大小和形状不一的扁平薄膜囊后再如穿铠甲或贴膏药似地将其固定到服饰的部分位置上去。
此类技术方案因为覆盖面积有限或覆盖区域不连续导致其保温效果并不理想，而且其含气凝胶粉末的扁平薄膜囊本体也同样十分惧怕针线孔，因此其实用性也不强。扁平薄膜囊在使用、清洗、收纳或运输过程中被戳破或因自然老化开裂以后，大量的气凝胶粉末将会一次性大量或长期慢性泄漏出来，对消费者的呼吸系统和皮肤等构成严重的安全隐患和健康威胁。正因如此，这些产品经CHAMPION(HANESBRANDS)、ELEMENT 21、RUSSELL OUTDOORS等公司多年推广却并未被市场所广泛接受。如果采用大面积的全封闭材料制造含气凝胶的扁平薄膜囊做服饰夹层，虽然可以克服掉粉现象，但却又会导致被服产品没有透汽性，闷热、积汗、使用效果差；而且同样无法克服长期使用或意外戳破后漏粉等严重的安全隐患。
以上种种现有的气凝胶服饰技术方案都是试图利用气凝胶卓越的保温隔热 性能做出极薄的纺织材料或夹层，这固然是一个值得努力的方向；但是却忽视了一个重要的问题：在人体皮肤和这些极薄的纺织材料或夹层之间，始终会存在或多或少的空气层；尤其是人体各部存在大量诸如人体生理弯曲、躯干截面凹陷、关节曲面等凹凸弯曲结构，这些凹凸弯曲结构和极薄的织物或夹层自然下垂后形成的空间导致其并不能紧密贴和人体，从而导致大量的自由空气层。这些自由空气层内不但对流散热能力很强，而且，由于人体运动对这些空间的挤压会不停地将其中的热空气挤压到外界去、同时也会由于这些空间被挤压后的外围布料和/或夹层被拉扯绷紧后又会将外界冷空气吸入这些空间，导致这些空间内的热空气会被不断吐出，冷空气会被不断吸入，二者随人体运动被不断地置换，保温隔热效果自然就会被大打折扣。现有几个品牌的气凝胶服饰被大量消费者投诉为“保温隔热效果不佳”甚至是“气凝胶衣服骗局”的主要原因就在这里：单纯测量这些气凝胶服饰夹层的热导率、热阻、克罗值或保温率时，其保温隔热效果是好的(甚至是超好的)，但是将其做成成品服饰后穿到消费者身上，消费者却并不能感受到这些夹层良好或优秀的保温隔热性能，由此导致大量的投诉。因此，如果能够减少或消除这些自由空气层或自由空气空间、减少或消除这些空间内的空气热对流和传导、尤其是减少或消除这些空间内的热空气与外界冷空气的不断交换，将能明显提高这些气凝胶服饰的最终实际保温效果。极薄的纺织材料或夹层由于其自身极薄的特性，对此类凹凸弯曲结构内的自由空气的消除或减少的效果并不理想；但是如果把此类极薄的纺织材料或夹层换成具有一定厚度的填充结构，由于填充物天然具有一定的蓬松度、抛度和膨胀能力，此类凹凸弯曲结构或自由下垂结构内的自由空间就会被填充物或其顶压着的连续布料所挤占，就可减少甚至消除自由空气层，抑制甚至消除冷热空气的相互交换和热空气内部的对流和传导，可极大地提高最终被服成品的保温隔热性能。
因此，将气凝胶保温隔热被服的研发方向从“研发极薄的织物或夹层”方向调整为“研发具有一定厚度的气凝胶服饰填充材料”不失为一个值得研究的方向(鉴于气凝胶成分卓越的保温隔热能力，该新型填充材料的厚度会远远地 小于常规填充材料的厚度)；而且作为离散型的填充材料，填充组分间自然存在的透汽空隙和透汽空间也可以同时解决透汽性这个服饰领域的重要问题。
因此，研发一种既能利用气凝胶极其优异的保温隔热性能、又能防止气凝胶粉末从制品中脱落或渗出、还能透汽、且能消除或减少现有气凝胶服饰织物和/或夹层处的自由空气层的气凝胶填充结构及其制得的服饰寝具是本领域技术人员亟需解决的技术问题。
发明内容
本发明的目的在于研发出一种既能利用气凝胶极其优异的保温隔热性能，又能透汽、还能减少或消除被服内的自由空气层、且又能防止气凝胶粉末从制品中脱落或渗出的气凝胶填充材料。
为了实现本发明上述目的，本发明采用以下技术方案：
一种被服气凝胶填充结构，包括：透汽面料和/或透汽膜与气凝胶大颗粒单体和/或气凝胶小颗粒聚集体；
所述气凝胶大颗粒单体包括气凝胶大颗粒及包裹在气凝胶大颗粒外的包裹层；
所述气凝胶小颗粒聚集体为气凝胶小颗粒通过包括粘合剂、黏合剂、结构胶、固化剂、交联剂、偶联剂在内的一种或几种的混合物被连结而成；
所述透汽面料和/或透汽膜完全包裹住多个所述气凝胶大颗粒单体和/或气凝胶小颗粒聚集体，所述气凝胶大颗粒单体和/或气凝胶小颗粒聚集体的尺寸大于所述透汽面料和/或透汽膜透汽空隙和针线孔的尺寸；
所述气凝胶大颗粒单体和气凝胶小颗粒聚集体的尺寸范围为0.1微米-2.5厘米，优选0.6-1毫米。
采用上述技术方案的有益效果是：气凝胶颗粒为有包裹层的气凝胶大颗粒，或，气凝胶小颗粒聚集体内的气凝胶小颗粒被紧密地粘结在一起，成为一体，不会轻易散开；人体散发的湿汽可以轻松通过上述透汽面料和/或透汽膜上的透汽空隙，以及纤维丝和/或纤维束之间的空隙，还有气凝胶大颗粒单体和/或气 凝胶小颗粒聚集体之间的颗粒间透汽空隙排出，而且，上述气凝胶大颗粒单体和/或气凝胶小颗粒聚集体的最小尺寸大于上述透汽面料和/或透汽膜上的透汽空隙和针线孔(如有)的尺寸，气凝胶粉末颗粒均不能从上述透汽面料和/或透汽膜上的透汽空隙和针线孔中漏出。而且，所述气凝胶大颗粒单体外设置包裹层、气凝胶小颗粒通过粘合剂被彼此紧密连接成为不会轻易散开的气凝胶小颗粒聚集体，因此，这些气凝胶制品在反复折叠过程中并不易被压碎。构成气凝集小颗粒聚集体的气凝胶小颗粒被粘合剂牢固地限定/固定在一起且不会进一步被挤碎(例如，要通过特殊研磨工序才能获得纳米级的气凝胶小颗粒被粘合成丝米或毫米级的气凝胶小颗粒聚集体后，其气凝胶小颗粒聚集体在压力作用下的形变范围是纳米级小颗粒的几千倍、几万倍甚至几十万倍；这么大的形变范围内纳米级小颗粒上的压力根本不足以挤碎它)，这些气凝胶颗粒也可在常规填充材料里被稳定附着或限定，还可通过多级固定结构令气凝胶粉末可以非常牢固地被粘合或密封在该改性填充材料之内，不易掉出或掉落，就不会出现掉粉现象。而且，即便部分所述气凝胶大颗粒1在长期过程中被压碎了，所述气凝胶大颗粒单体外设置包裹层依旧可以将这些挤碎的气凝胶小颗粒(粉末)继续封闭在包裹层内，成为另外一种形式的不会轻易散开的气凝胶小颗粒聚集体(即:这种被挤碎的气凝胶小颗粒聚集体是包裹层内的小颗粒没被完全固定住可以在包裹层内部做相对运动但却不能分散开,而前述小颗粒聚集体内的小颗粒被粘合剂等固定住不会分散开，甚至被固定住后再在聚集体外设置包裹层，更难散开；这两种形式的气凝胶颗粒都不会渗漏出尺寸比他们小的空隙)。这是本发明中“通过粘合和/或设置包裹层且通过颗粒尺寸选择的气凝胶颗粒”的方案相对于“将常规气凝胶颗粒简单直接地混合在基材中”的方案最明显的优点。
而且，以上优选的0.6-1毫米被妥善包覆或粘合的气凝胶颗粒，其尺寸小于或接近于缝纫针径。在缝纫过程中，此类尺寸小于或接近于缝纫针径的颗粒将被针头往其四周推挤开，而很难被针头戳到正中而破裂。尽管如此：
就气凝胶小颗粒聚集体而言，因为可以选择粘合强度很大的粘合剂所以即便是有少量聚集体被缝纫针击打开裂，也仅仅是聚集体开裂而已，开裂后的聚集体不是部分继续粘连就是开裂后的裂片尺寸还是大于面料透汽空隙和针线孔尺寸，同样不会掉粉。即便是极其微量的裂片因为尺寸小于针线孔尺寸，由于这些极其微量的裂片依旧为被粘结剂所固定聚集的微米级颗粒上和/或其他填充纤维上，其中的纳米级气凝胶粉末并不会轻易地在空气中飘扬而是直接掉落到地面。因此，这些可能的泄漏不但在数量上远远不会超过安全标准，而且在重量上也可控制其为垂直下落到地面而非在空气中飘扬被消费者吸入产生健康威胁。
就气凝胶大颗粒聚集体而言，即便是有极少量的大颗粒被缝纫针击打开裂，因在数量上远远不会超过安全标准所以也不会对消费者产生健康威胁。更何况，没如果选用的填充物里面是有气凝胶大颗粒的，在缝纫完成后通过常规的吹扫工序，既可除去服装生产中常规粉尘也可除去这些极少量的因针头击碎而导致的极少量的泄漏。
为便于生产、降低成本和进一步控制掉粉风险，优选使用有粘合剂的气凝胶小颗粒聚集体。
进一步，上述被服气凝胶填充结构，还包括：纤维、发泡材料、玻璃微珠和/或功能性材料；
所述纤维、发泡材料、玻璃微珠和/或功能性材料填充在所述透汽面料和/或透汽膜与气凝胶大颗粒单体和/或气凝胶小颗粒聚集体之间，所述气凝胶大颗粒单体和/或气凝胶小颗粒聚集体通过结构胶、粘/黏合剂、固化剂、交联剂、偶联剂中的一种或几种的混合物粘合在所述纤维、发泡材料、玻璃微珠和/或功能性材料之内或表面。
进一步，上述纤维为棉花、羊毛、羊绒、麻絮、涤短纤、涤长丝、氨纶丝、芳纶絮中的一种或几种的混合物。
采用上述优选技术方案的有益效果是：填充上述材料可以减少气凝胶填充的用量，降低成本，同时还可充分利用这些材料各自的物理或化学性能。例如， 可利用氨纶纤维的高弹性、利用芳纶纤维的高强度、利用涤纶丝的低成本、利用棉麻纤维的亲肤性，以提高本发明气凝胶被服填充制品的综合性能。
进一步，所述气凝胶大颗粒单体和/或气凝胶小颗粒聚集体为水性二氧化硅气凝胶、水性二氧化钛气凝胶、水性碳气凝胶或水性聚酰亚胺气凝胶。
进一步，所述透汽面料或透汽膜包括两层，第一层透汽面料或透汽膜完全包裹住多个所述气凝胶大颗粒单体和/或气凝胶小颗粒聚集体后制成层状或团状结构，在所述层状或团状结构表面再包裹第二层透汽面料或透汽膜；
和/或，在所述层状或团状结构和/或透汽膜或透汽面料的表面再设置包裹层。
进一步，上述被服气凝胶填充结构，还包括：
高热反射率材料或远红外材料，所述层状或团状结构表面包裹有高热反射率材料或远红外材料。
进一步，所述包裹层为有机包裹层和/或无机包裹层；
所述有机包裹层材料为结构胶、粘/黏合剂、固化剂、交联剂、偶联剂中的一种或几种的混合物；
所述无机包裹层材料为二氧化硅膜、陶瓷膜、金属膜、沸石膜、玻璃膜和/或分子筛复合膜中的一种或几种的混合物。
进一步，上述粘合剂为水性纯丙乳液、水性醋丙乳液、水性苯丙乳液、水性丙烯酸酯乳液、水性聚氨酯乳液、水性环氧树脂乳液、水性有机硅乳液中的任一种或几种的混合物。
进一步，所述功能性材料为高热反射率材料、和/或远红外材料、和/或吸湿发热材料、和/或相变材料。
采用上述优选技术方案的有益效果是：可以进一步地提高最终产品的整体保温性能，吸湿发热材料可以吸收人体皮肤散发出的水分而产生热量，包裹在其中的人体可获得额外的热源，使人体更快更多地获得热量。
进一步，上述高热反射率材料为铝粉或铝膜，上述远红外材料为远红外纤维。
采用上述优选技术方案的有益效果是：可以进一步地提高最终产品的整体保温性能，在上述填充料内设置高热反射材料可将人体所发出的热量反射回到皮肤表面，减少热量丧失；远红外材料更有利于锁定热量，也可减少热量散失。
进一步，上述气凝胶服饰寝具还包括：电发热装置、温度传感器和/或温度调控装置。上述气凝胶服饰寝具的面料内侧或外侧设置有电发热装置、温度传感器和/或温度调控装置。
采用上述进一步技术方案的有益效果是：在气凝胶服饰寝具的面料内侧或外侧设置电发热装置，在大幅提高了保温隔热性能的同时，还可获得人体体温之外的额外热源，可以使包裹在其中的人体获得更多更快的升温、更少的温度丧失，尤其适于极地、高山等极端环境下应用。此外，还可与现在已经流行的电池发热服那样利用温度传感器和温度调控装置，准确控制填充材料内的温度。
进一步，所述透汽面料为涤纶布、尼龙布、春亚纺、棉布、麻布、无纺布、提花夹层布、拉丝布、太空层(空气层)中的任一种或是几种的混合、拼接和/或叠加。
所述气凝胶大颗粒单体和气凝胶小颗粒为颗粒状、小片状、短杆状、纤维状、絮状中的任一种或几种的混合。只要这些颗粒状、小片状、短杆状、纤维状、絮状气凝胶颗粒或聚集体的最小尺寸大于面料空隙或针线孔(如有)的尺寸，即可避免气凝胶掉粉现象。甚至，如果将气凝胶小颗粒聚集体直接做成有包裹层的纤维状或絮状气凝胶聚集体，即可直接拿来做填充物使用，减少制作工序。
本发明中的被服气凝胶填充结构可在制备服装、被子、睡袋、帽子和/或手套中应用。
上述气凝胶服饰寝具的其中一种制备方法为：
气凝胶颗粒包括气凝胶大颗粒单体和/或小颗粒聚集体。气凝胶小颗粒聚集体的制备方法为将水性气凝胶浆料通过挤压网眼造粒、挤出线/条状物多道切割造粒、浆料干燥或半干燥后的反复剁切造粒、甚至是如中国专利授权号CN106517219B所述的制备方法进行制备。通过以上的非专利常规技术、已过期 专利的技术或已公开专利技术制得的气凝胶颗粒均已经可在市场上方便便宜地大量购买到，我们只要选择颗粒尺寸符合我们要求的即可。
获得这些最小尺寸大于布料透汽空隙尺寸和针线孔尺寸的气凝胶颗粒以后，称取适量的这些气凝胶颗粒灌入密封空间内，用设置在该密封空间内的风扇将灌入的气凝胶颗粒吹成沸腾状，然后再向该密闭空间吹入纤维、发泡材料和/或功能性材料，或，再向沸腾的气凝胶颗粒喷涂或黏附包裹层；即可制得本发明气凝胶填充材料；还可再继续将其制成层状或团状结构，在上述层状或团状结构表面再喷涂或黏附包裹层，实现对气凝胶颗粒的进一步固定，制得本发明气凝胶填充材料，将本发明气凝胶填充材料填充到透汽面料和/或透汽膜制成的填充囊体中或经进一步裁剪加工制成所需的含气凝胶的超级保暖或超薄服饰寝具。
本发明的有益效果是：
本发明中一个最明显的优点在于气凝胶大颗粒被包裹在其外的包裹层所限定/固定(即便是在长期的使用过程中被进一步粉碎其碎屑也不会掉出包裹层)，和/或，构成聚集体的气凝胶小颗粒被粘合剂牢固地限定/固定在一起且不会进一步被挤碎(例如，要通过特殊研磨工序才能获得纳米级的气凝胶小颗粒被粘合成丝米或毫米级的聚集体后，其聚集体在压力作用下的形变范围是纳米级小颗粒的几千倍、几万倍甚至几十万倍；这么大的形变范围内被分散到纳米级小颗粒上的压力根本不足以挤碎它，而仅会使小颗粒聚集体产生一定的整体形变而已，且这些形变是可恢复或对宏观尺度的成品并无实质影响)。而且，这些气凝胶颗粒均可在常规填充材料里被稳定附着或限定，还可通过多级固定结构令气凝胶粉末可以非常牢固地被粘合或密封在该改性填充材料之内，不易掉出或掉落，不会出现掉粉现象；避免由于气凝胶掉粉被人体吸入导致过敏、喉咙发痒等甚至造成尘肺/硅肺等各种严重的质量问题和安全隐患，还可避免由于气凝胶的减少导致保温隔热性能变差，提高了填充材料的使用效果和使用寿命。
本发明充分利用了气凝胶优异的保暖性能，得到比常规填充材料好很多的保温隔热效果，要获得同等的保温能力，本发明改性填充材料所需要的气凝胶 重量和/或体积远远低于同等保温性能的常规填充制品所需要的填充重量和/或体积。与常规填充材料相比，本发明改性填充材料总重量以及收纳体积均可明显减小，并同时减少填充的使用量，可轻松获得与厚厚的传统填充制品同等保温能力甚至保温能力更强，可制成很多的超薄和/或超轻的填充制品，不但提供了更佳的保温隔热效果，而且还可以使产品更轻、更薄、收纳体积更小、穿着使用更方便，尤其是可以完美克服传统的有填充料的被服产品臃肿肥胖的问题，令使用者在寒冷天汽也能保持苗条的身形和利索的动作，尤其适合爱美的女性和对行动便捷性要求高的户外活动参与者。
本发明将气凝胶保温隔热被服的研发方向从已公开的各种技术方案“研发极薄的织物或夹层”的方向调整为“研发具有一定厚度的气凝胶服饰填充材料(鉴于气凝胶成分卓越的保温隔热能力，该新型填充材料的厚度会远远地小于常规填充材料的厚度)”后，做出的成品可由以上公知方案产品的0.5毫米，1毫米或2-3毫米调整为并不明显影响服饰使用性能的2-30毫米左右(优选2-9毫米)，减少或消除了这些服饰及其夹层内的自由空气层或自由空气空间，减少甚至消除这些空间内的空气热对流和这些空间内的热空气与外界冷空气的不断交换，能明显提高这些气凝胶服饰的最终实际保温效果。已公知技术方案中2毫米、1毫米甚至0.5毫米这类极薄的纺织材料或夹层由于其自身极薄的特性，使用时其被悬垂和支顶后对人体凹凸弯曲结构内的自由空气的消除或减少的效果并不理想；但是本发明中将此类极薄的纺织材料或夹层换成具有一定厚度的填充结构后，由于填充物天然具有一定的蓬松度、抛度和膨胀能力，此类凹凸弯曲结构或自由下垂结构内的自由空间就会被填充物或其顶压着的连续布料所挤占，就可减少甚至消除自由空气层，抑制甚至消除冷热空气的相互交换和热空气内部的对流和传导，可极大地提高最终被服成品的保温隔热性能。
此外，由于在填充的基材之间、气凝胶大颗粒单体和/或气凝胶小颗粒聚集体之间、基材与气凝胶大颗粒单体和/或气凝胶小颗粒聚集体之间均具有大量的贯通型空隙，因此上述气凝胶服饰寝具的透汽性会很好。这点相对于现在市场上已有的将气凝胶做成不透汽夹层的各种技术方案优势明显，而且还能克服这 些技术方案中气凝胶含量不高，保温隔热效果不好的问题。此外，通过在气凝胶颗粒外设置包裹层或将气凝胶小颗粒粘结成为不会轻易散开的气凝胶小颗粒聚集体，其主要过程为简单的气凝胶物理混合或黏附过程，相对于将气凝胶粉末包裹入闭孔发泡结构这类复杂的化学过程，制造成本和工艺难度都会低很多，更适于商业化和大规模推广。退一步讲，在不考虑制造成本和气凝胶含量的情况下，甚至也可考虑将市场上现有含气凝胶的不透汽夹层剪碎或打碎成为颗粒度大于布料纤维间隙和针线孔的颗粒状或片状填充物，再填充到面料制成的填充囊中，也可实现透汽(因为不透汽的夹层被剪碎或打碎成许多颗粒状或片状填充物后，这些颗粒或絮片之间就可产生大量的可透汽空隙)和不掉粉(因为这些产品的气凝胶粉末是被限定在闭孔发泡结构中的)。但是，考虑降低制造成本、减少工序和提高气凝胶含量，则本发明中将不会掉粉的气凝胶颗粒直接混合在传统填充纤维中的技术方案显然更合理、更便宜、更可行且更可靠。
而且，作为耐拉、耐折和耐压强度均为较好的各种常规纤维，可成为附着或包裹上述气凝胶粉末颗粒的良好基材，由此制得的成品与块状气凝胶相比其弯折性、柔韧性和耐用性均可以获得十分明显的提高，符合服饰寝具产品会被反复折叠、卷起、挤压和收放等使用要求。
上述气凝胶服饰寝具内部空隙在置入气凝胶颗粒后，其相对于常规无纺布、棉、麻等天然纤维，涤纶、芳纶、氨纶等化学纤维和/或这些材料的混纺纤维自身的保温隔热能力都会大很多，因此其保温隔热性能可以获得极大的提高。特别是在自然舒展开的纤维丝之间，其最大间距可达数毫米甚至厘米级别，因此气凝胶粉末颗粒就可以大量且轻松地被置入这些基材之内。因此，在性能稳定可靠的上述气凝胶服饰寝具中气凝胶的重量比不但可以轻松突破1％，甚至还可以突破99％，也就是说，上述常规填充基材甚至可以主要作为保持隔热层维持形状的支撑性基材使用而不是作为隔热材料使用。
由于在本发明中气凝胶的保温隔热性能起主要作用，作为基材的填充物起次要甚至可以忽略的保温隔热作用，因此可以使用蓬松度更低、孔隙率更小、相对劣质的填充物以获得同等甚至还要远超过的保温隔热性能。因此，可使用 相对劣质的填充获得同等甚至超过的保温隔热能力，既可降低成本，也可扩大原料来源。
上述气凝胶填充材料可用于制备超薄和/或超级防寒保暖服、超薄和/或超级保暖被子、超薄和/或超级保暖睡袋、超薄和/或超级保暖内衣、超薄和/或超级保暖帽、超薄和/或超级保暖手套以及超级保暖鞋等。在以上产品填充材料中混入符合要求的气凝胶颗粒以后，这些产品的生产制造为非常成熟的产业，其生产工艺、设备均稳定可靠、容易获得，且生产成本不会明显增加。
附图说明
图1为本发明中的气凝胶大颗粒填充结构示意图；
图2为图1中的气凝胶大颗粒在使用过程中被部分挤碎后的填充结构示意图；
图3为本发明中的气凝胶小颗粒聚集体填充结构示意图；
图4为本发明中的气凝胶小颗粒聚集体和纤维材料共同形成的填充结构示意图；
图5为本发明中的气凝胶大颗粒与陶瓷或玻璃微珠共同形成的填充结构示意图；
图6为本发明中的气凝胶小颗粒聚集体、气凝胶大颗粒、陶瓷或玻璃微珠以及相变材料微珠共同形成的填充结构示意图。
其中：
1-气凝胶大颗粒；2-包裹层；3-透汽面料和/或透汽膜；4-透汽面料和/或透汽膜上的透汽空隙；5-针线孔；6-缝纫线；7-颗粒间透汽空隙；8-气凝胶小颗粒；9-粘合剂；10-气凝胶小颗粒聚集体；11-纤维；12-玻璃微珠；13-相变材料微珠，14-纤维丝和/或纤维束之间的空隙。
具体实施方式
下面结合附图和具体实施例对本发明所述内容做进一步详细的说明，所举 实例只用于解释本发明，并非用于限定本发明的范围。
本发明气凝胶填充物的一种具体制备方法如下：
先通过市场购买或自行制备气凝胶小颗粒聚集体10或带包裹层2的气凝胶大颗粒单体。如图2所示，即便部分所述气凝胶大颗粒1在长期过程中被压碎了，所述气凝胶大颗粒1单体外设置包裹层2依旧可以将这些挤碎的气凝胶小颗粒8(粉末)继续封闭在包裹层2内，成为另外一种形式的不会轻易散开的气凝胶小颗粒聚集体(即:这种被挤碎的气凝胶小颗粒聚集体是包裹层内的小颗粒没被完全固定住可以在包裹层内部做相对运动但却不能分散开,而前述小颗粒聚集体内的小颗粒被粘合剂等固定住不会分散开，甚至被固定住后再在聚集体外设置包裹层，更难散开其中。)如图3所示，气凝胶小颗粒聚集体10可通过粘合剂9将气凝胶小颗粒8牢固粘合制的；如图1所示，气凝胶大颗粒单体可通过在气凝胶大颗粒1外均匀喷洒包裹液后再干燥或固化形成包裹层2。然后再将这些气凝胶小颗粒聚集体10或气凝胶大颗粒1单体制成或筛分出一定尺寸(优选0.6-1毫米)的气凝胶颗粒。
再称取最小尺寸大于透汽面料和/或透汽膜上的透汽空隙4的尺寸和针线孔5的尺寸(面料透汽空隙尺寸一般约为0.01-0.05毫米、针线孔尺寸一般约为0.5毫米)的气凝胶大颗粒单体和/或气凝胶小颗粒聚集体10灌入密封空间内，用设置在该密封空间内的风扇将灌入的气凝胶大颗粒1单体和/或气凝胶小颗粒聚集体10吹成沸腾状，然后再向该密闭空间吹入图4所示的纤维11、发泡材料和/或其他功能性材料(例如：图5-6所示的陶瓷或玻璃微珠、图6所示的相变材料微珠13)，充分混合均匀后再填充到透汽面料和/或透汽膜3制成的囊体中即可获得本发明中保温能力超强的气凝胶填充制品。
当然，还可进一步将以上已充分混合均匀的混合物再继续制成层状或团状结构，在上述层状或团状结构表面再喷涂粘合剂9、固定剂或黏附包裹层2，实现对气凝胶颗粒的进一步和多层级的固定或限定，制得本发明中的多级固定气凝胶填充材料，然后再将本发明气凝胶填充材料填充到透汽面料和/或透汽膜3制成的囊体中或经进一步裁剪加工成夹层再缝制成各种服饰寝具。
气凝胶大颗粒单体或气凝胶小颗粒聚集体10吹入的密封或半密封空间可用包括疏棉机、喷胶棉生产线、羽绒分绒箱/分毛机、拼堆机和/或充绒机在内现有机器设备，这些机器性能可靠、操作简便、获得性好。
实施例1
称取3千克尺寸为0.6-1毫米的气凝胶大颗粒单体吹入密封的拼堆机内，向翻滚气凝胶大颗粒单体喷洒聚醋酸乙烯酯微细液滴制备包裹层，控制包裹层的厚度在3-8μm，在这些包裹层干燥或固化以后，将制得的带包裹层的气凝胶颗粒灌入疏棉机内，使疏棉机输出的纤维与所述气凝胶粉末大颗粒单体混合均匀。选取3-5平方米纤维之间的空隙小于上述气凝胶大颗粒单体的棉布或涤纶布，缝制成被套，在缝制过程中选用适当的针号或线粗，控制针号为号制号数6(即公制号数55，英制号数022，其针身直径为0.55毫米)使缝纫过程中形成的针线孔尺寸也小于上述气凝胶粉末单体的颗粒尺寸。最后再将喷涂好包裹层的气凝胶大颗粒单体和/或其他填充料一起充入已缝制好的被套，就可得到一种不掉粉且透汽的气凝胶被。
实施例2
在已经经过亲水性改性的气凝胶小颗粒粉末上滴入水性粘合剂液滴，即水性聚氨酯乳液液滴，此类液滴可以通过滴漏板和/或喷雾器一次性大量生成。水性粘合剂液滴将会把其接触到的水性气凝胶小颗粒粉末粘合在一起。通过控制液滴的大小(即单位液滴中的粘合剂的总量)即可初步控制可粘合成的气凝胶小颗粒聚集体的大小。在这些气凝胶小颗粒聚集体固化或干燥以后，先通过剧烈吹扫或吹至剧烈沸腾相互极多次碰撞状态，以剥离那些结合牢度不够的气凝胶小颗粒，然后再通过风动和/或震动筛筛取指定尺寸的气凝胶小颗粒聚集体，筛上份用来做本发明中的气凝胶填充份，筛下份可以回送到液滴滴入工序与新加入的气凝胶小颗粒一道继续参与小颗粒聚集体的形成过程，直到其形成的颗粒度足够大成为筛上份为止。
称取1.5kg上述尺寸为0.6-1毫米气凝胶小颗粒聚集体灌入松棉机内，使松棉机松出的纤维与所述气凝胶小颗粒聚集体混合均匀，将上述气凝胶被服填 充制品制成平面层状，再在上述平面层状的气凝胶被服填充材料表面再喷涂3-8μm厚度的固定剂，实现对气凝胶粉末颗粒的进一步固定。
选取布料纤维之间的空隙小于上述气凝胶粉末聚集体的布料，与上述平面层状填充夹层一起缝制成防寒被服制品。
在缝制过程中控制针号为号制号数6，使缝纫过程中形成的针线孔尺寸也小于上述气凝胶粉末聚集体的颗粒尺寸。
缝制完毕后即可获得本发明中所述的再一种不掉粉且透汽的被服填充料使用。
实施例3
称取采购自其它气凝胶材料供应商(例如深圳中凝科技有限公司、苏州同玄新材料有限公司、广东埃力生高新科技有限公司等国内外气凝胶材料厂家)生产的气凝胶浆料，加入固化剂拌合均匀并干燥、固化成块料。然后用粉碎机或搅拌机将干燥固化后的块料进行粉碎。粉碎后，先通过剧烈吹扫或吹至剧烈沸腾相互极多次碰撞状态，以剥离那些结合牢度不够的气凝胶小颗粒，然后再通过风动和/或震动筛筛取指定尺寸的气凝胶小颗粒聚集体，筛上份用来做本发明中的气凝胶填充份，筛下份可以回送到之前的浆料拌合工序与新加入的浆料一道继续参与气凝胶拌合块体的形成过程，直到其再次被粉碎并形成的颗粒度足够大成为筛上份为止。
将以上筛上份(气凝胶小颗粒聚集体)与松棉机已经松出的棉或化纤一齐灌入梳棉机内，使梳棉机输出的疏松纤维与所述气凝胶粉末大颗粒单体和/或小颗粒聚集体混合均匀，再将上述混合物制成平面层状，即可裁剪为本发明中所述的另一种不掉粉且透汽的被服填充料使用。
实施例4
直接将上述实施例2或实施例3中的筛上份(气凝胶粉末聚集体)直接灌入已缝制好的被服布套做为填充料使用，即可获得本发明所述的又一种不掉粉且透汽的气凝胶被服制品。
该被服制品的填充料100％为上述实施例2或实施例3中的筛上份(气凝胶 粉末聚集体)，其气凝胶成分含量高，保温隔热能力极强，可以做出各种超薄和/或超轻的保温隔热被服制品。
实施例5
称取采购自其它气凝胶材料供应商(例如深圳中凝科技有限公司、苏州同玄新材料有限公司、广东埃力生高新科技有限公司等国内外气凝胶材料厂家)生产的气凝胶颗粒，加入针刺无纺布的生产过程中，将已紧密结合的气凝胶颗粒挤入无纺布纤维之间，再针刺成毡。
再吹扫掉那些在针刺过程中被过度粉碎的离散颗粒(吹扫掉落份可以混入气凝胶浆料回收使用)。
最后再在吹扫完毕的针刺无纺布上下表面复合人体体感更好的棉布或亲肤氨纶布，即可获得本发明中所述的另一种不掉粉且透汽的气凝胶服装夹层。
实施例6
称取采购自其它气凝胶材料供应商生产的尺寸合适的气凝胶颗粒，均匀混入氨纶和/或晴纶絮中，将上述混合物做成平面毡，再在上述平面毡的上下表面复合人体体感更好的亲肤氨纶布或棉布，即可获得本发明中所述的一种不掉粉且透汽的气凝胶保暖内衣。
实施例7
称取采购自其它气凝胶材料供应商生产的尺寸合适的气凝胶颗粒，直接灌入亲肤氨纶布或棉布织成的拉丝太空层面料的空气层内，最后封闭太空层的所有残留开口，即可获得本发明中所述的另一种不掉粉且透汽的气凝胶保暖内衣或潜水服。
实施例8
称取采购自其它气凝胶材料供应商生产的粒径大于1厘米的气凝胶颗粒，直接灌入通过大圆机织得的大提花拉丝夹层面料(其面料层纤维孔隙直径约为1.5毫米)的空气层内，最后再将大提花拉丝夹层面料的所有切口缝纫好，即可获得本发明中所述的一种不掉粉且透汽的气凝胶保暖坐垫。
实施例9
图4所示为一种气凝胶小颗粒聚集体10与常规的纤维11一起被缝纫线6缝制在透汽面料和/或透汽膜3构成的一种被服保温隔热填充结构。
实施例10
图5所示为一种气凝胶大颗粒1单体与陶瓷或玻璃微珠12一起在透汽面料和/或透汽膜3内构成保温隔热填充结构的被服。当然，图中所示的陶瓷或玻璃微珠12的尺寸也优选为大于透汽面料和/或透汽膜上的透汽空隙4以避免其泄漏。如果在某些特殊情况下这些陶瓷或玻璃微珠12的尺寸要小于透汽面料和/或透汽膜上的透汽空隙4，则只需要如已在油漆工业中被广泛使用的那样将这些陶瓷或玻璃微珠12彼此之间和/或与气凝胶大颗粒1单体进行粘连即可。
陶瓷或玻璃微珠12的内部为真空或是充有热导率比空气更低的稀薄二氧化碳汽体，其与本发明中的气凝胶大颗粒1单体共同配合，成品可获得更好的保温隔热效果；尤其是所述陶瓷或玻璃微珠12的内部为真空的时候。
实施例11
图6所示为一种气凝胶大颗粒1单体、气凝胶小颗粒聚集体10、纤维11、陶瓷或玻璃微珠12与相变材料微珠13一起在透汽面料和/或透汽膜3内构成保温隔热填充结构的被服。气凝胶大颗粒1单体、气凝胶小颗粒聚集体10、纤维11、陶瓷或玻璃微珠12共同配合设置在暴露在外界空气中的一侧，可获得极好的保温隔热效果；相变材料微珠13设置在靠近人体皮肤或内衣的一侧。
当然，图中所示的陶瓷或玻璃微珠12和相变材料微珠13的尺寸最好优选为大于透汽面料和/或透汽膜上的透汽空隙4以避免其泄漏。如果在某些特殊情况下这些陶瓷或玻璃微珠12或相变材料微珠13的尺寸要小于透汽面料和/或透汽膜上的透汽空隙4，则只需要如已在油漆工业中被广泛使用的那样将这些临近的陶瓷或玻璃微珠12、相变材料微珠13、纤维11、气凝胶大颗粒1单体、气凝胶小颗粒聚集体10彼此之间进行粘连即可。
陶瓷或玻璃微珠12的内部为真空或是充有热导率比空气更低的稀薄二氧化碳汽体，相变材料微珠13内的相变材料的相变点设置为与人体皮肤舒适温度相匹配的30或32摄氏度。相变材料微珠13内的相变材料的特点是，当其周围温 度高于相变点时，它就会从周围环境吸收热量(相变热)以从固态变为液态；当其周围温度低于相变点时，它就会向周围环境释放热量(相变热)以从液态变为固态。选取适当的相变材料，其单位体积或重量的相变热可以相当可观。由此值得的服装杯子耐温度剧烈变化的效果特别好。相变材料服装方案已有大量的不同专利公开，在此不再赘述。
如果在低温环境下使用在本实施例中的被服，则相变材料可以释放出大量的相变热并将人体皮肤附近的温度快速调整到相变点，使人体皮肤更加快速达到舒适温度并保持在该舒适温度。如果在高温环境下(如夏天在骄阳下的户外工作或炼钢车间等)使用在本实施例中的服饰，则相变材料可以从人体皮肤附近吸收大量的相变热并将人体皮肤附近的温度快速调整到相变点，同样使人体皮肤更加快速达到舒适温度并保持在该舒适温度。
在本实施例中，由气凝胶大颗粒1单体、气凝胶小颗粒聚集体10、纤维11、陶瓷或玻璃微珠12一起构成的结构的隔热性能超强，导致相变材料微珠13内的相变热只能释放到皮肤侧或自皮肤侧吸收，而难以释放到外界环境侧或自外界环境侧吸收。这些材料互相配合，可以获得功能性更强、使用效果更好的被服制品。
以上气凝胶大颗粒单体或小颗粒聚集体，既可在市场上直接采购，也可通过传统的非专利技术(如上述实施例3中的现成浆料固化粉碎后再筛选的技术)自行制造，可获得性好，选择余地大。
以上仅为本发明的较佳实施例，并不用以限制本发明，凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (10)

  1. 一种被服气凝胶填充结构，其特征在于，包括：透汽面料和/或透汽膜(3)与气凝胶大颗粒单体，和/或气凝胶小颗粒聚集体(10)；
    所述气凝胶大颗粒单体包括气凝胶大颗粒(1)及包裹在气凝胶大颗粒外的包裹层(2)；
    所述气凝胶小颗粒聚集体(10)为气凝胶小颗粒(8)通过包括粘合剂(9)、黏合剂、结构胶、固化剂、交联剂、偶联剂在内的一种或几种的混合物被连结而成；
    所述透汽面料和/或透汽膜(3)完全包裹住多个所述气凝胶大颗粒单体和/或气凝胶小颗粒聚集体(10)，所述气凝胶大颗粒单体和/或气凝胶小颗粒聚集体(10)的尺寸大于所述透汽面料和/或透汽膜透汽空隙(4)和针线孔(5)的尺寸；
    所述气凝胶大颗粒单体和气凝胶小颗粒聚集体(10)的尺寸范围为0.1微米-2.5厘米。
  2. 根据权利要求1所述一种被服气凝胶填充结构，其特征在于，还包括：纤维(11)、玻璃微珠(12)和/或功能性材料；
    所述纤维(11)、玻璃微珠(12)和/或功能性材料填充在所述透汽面料和/或透汽膜(3)与气凝胶大颗粒单体和/或气凝胶小颗粒聚集体(10)之间，所述气凝胶大颗粒单体和/或气凝胶小颗粒聚集体(10)通过包括结构胶、粘/黏合剂、固化剂、交联剂、偶联剂在内的一种或几种的混合物粘合在所述纤维(11)、玻璃微珠(12)和/或功能性材料之内或表面。
  3. 根据权利要求1所述一种被服气凝胶填充结构，其特征在于，所述气凝胶大颗粒单体和/或气凝胶小颗粒聚集体(10)为包括水性二氧化硅气凝胶、水性二氧化钛气凝胶、水性碳气凝胶或水性聚酰亚胺气凝胶在内的一种或几种。
  4. 根据权利要求1所述一种被服气凝胶填充结构，其特征在于，所述透汽面料或透汽膜(3)包括两层，第一层透汽面料或透汽膜完全包裹住多个所述气 凝胶大颗粒单体和/或气凝胶小颗粒聚集体后制成层状或团状结构，在所述层状或团状结构表面再包裹第二层透汽面料或透汽膜；
    和/或，在所述层状或团状结构和/或透汽膜或透汽面料的表面再设置包裹层(2)。
  5. 根据权利要求1所述一种被服气凝胶填充结构，其特征在于，包括透汽面料和透汽膜与气凝胶大颗粒单体和/或气凝胶小颗粒聚集体(10)时，所述透汽面料完全包裹透汽膜或所述透汽膜完全包裹透汽面料。
  6. 根据权利要求1所述一种被服气凝胶填充结构，其特征在于，还包括：高热反射率材料或远红外材料，所述层状或团状结构表面包裹有高热反射率材料或远红外材料。
  7. 根据权利要求1所述一种被服气凝胶填充结构，其特征在于，所述包裹层(2)为有机包裹层和/或无机包裹层；
    所述有机包裹层材料为结构胶、粘/黏合剂、固化剂、交联剂、偶联剂中的一种或几种的混合物；
    所述无机包裹层材料为二氧化硅膜、陶瓷膜、金属膜、沸石膜、玻璃膜和/或分子筛复合膜中的一种或几种的混合物。
  8. 根据权利要求2所述一种被服气凝胶填充结构，其特征在于，所述功能性材料为高热反射率材料、和/或远红外材料、和/或吸湿发热材料、和/或相变材料。
  9. 根据权利要求1所述一种被服气凝胶填充结构，其特征在于，所述透汽面料为涤纶布、尼龙布、春亚纺、棉布、麻布、无纺布、拉丝布、大提花夹层布、太空层、空气层中的任一种或是几种的混合、拼接和/或叠加；
    所述气凝胶大颗粒单体和气凝胶小颗粒为颗粒状、小片状、短杆状、纤维状、絮状中的任一种或几种的混合。
  10. 一种权利要求1至9任一项所述被服气凝胶填充结构在制做服装、被子、睡袋、帽子和/或手套中的应用。
PCT/CN2019/084609 2019-04-17 2019-04-26 一种被服气凝胶填充结构及其应用 WO2020211115A1 (zh)

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IT202100003509A1 (it) * 2021-02-16 2022-08-16 Gabriele Brembilla Tessuto laminato per applicazioni sartoriali, metodo di realizzazione, ed indumento

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