CN101090816A - 热反射非纺织衬里材料 - Google Patents

热反射非纺织衬里材料 Download PDF

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Publication number
CN101090816A
CN101090816A CNA2005800289400A CN200580028940A CN101090816A CN 101090816 A CN101090816 A CN 101090816A CN A2005800289400 A CNA2005800289400 A CN A2005800289400A CN 200580028940 A CN200580028940 A CN 200580028940A CN 101090816 A CN101090816 A CN 101090816A
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CN
China
Prior art keywords
layer
continuous filament
metallized
goods
filament
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Pending
Application number
CNA2005800289400A
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English (en)
Inventor
罗伯特·丹尼尔·拉塞尔
克丽思·哈斯
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
INNOVATIVE INSULATION Inc
PARRIMOE GROUP CO Ltd
Avintiv Specialty Materials Inc
Original Assignee
INNOVATIVE INSULATION Inc
PARRIMOE GROUP CO Ltd
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Publication date
Application filed by INNOVATIVE INSULATION Inc, PARRIMOE GROUP CO Ltd filed Critical INNOVATIVE INSULATION Inc
Publication of CN101090816A publication Critical patent/CN101090816A/zh
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    • Y10T442/678Olefin polymer or copolymer sheet or film [e.g., polypropylene, polyethylene, ethylene-butylene copolymer, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/681Spun-bonded nonwoven fabric

Abstract

本发明提供了一种包括连续细丝层和金属敷覆的热塑薄膜的热反射衣服内衬叠层。该叠层特有地低成本并且适于例如运动衣物、军用衣物、野营衣着、打猎/钓鱼衣物等的这些衣服应用。

Description

热反射非纺织衬里材料
相关申请的交叉引用
本申请要求2004年8月30日提交的临时申请No.60/605,624的优先权,其公开内容包含在此作为参考。
技术领域
本发明总体上涉及热反射叠层,并且更具体地说涉及金属敷覆的热反射非纺织叠层,该热反射非纺织叠层包括连续细丝织物和薄膜。
发明背景
衣服内衬在本领域中是已知并且通常包括两个或更多赋予衣服绝热性能的衬底。为此通常利用编织衬底;然而,传统纺织品的生产已知是成本抑制的复杂的多步骤工艺。相比较而言,非纺织物已知比传统纺织工艺更具有成本效益,因为织物是由梳理工艺直接制成的。非纺织物适合用于其中织物可以高效制造的多种应用,与传统织物相比,这些织物就提供了很大的经济优点。这种应用包括但是并不限于运动衣物、军用衣物、野营衣着、打猎和钓鱼衣物等。
非纺织物通常用作衣服内衬,因为它们可以向衣服提供均匀的覆盖和所需的绝热。在寒冷气候中所穿的衣服通常利用内衬来保持体温。在为提高内衬织物的性能而做出的努力中,金属箔由于固有的热反射特性而与之结合。如1986年11月11日公开的以发明者Levy的名义公开的题为“Thermal Laminated Lining and Method of Manufacture”的美国专利No.4,622,253中教导的那样,铝箔可以用于与一个或多个衬底结合。虽然箔由于其柔韧性而受到偏爱,但是箔有噪声,很难缝制,并且在衣服应用中缺少期望的悬垂性能。
于是仍然需要一种具有成本效益的内衬材料,该内衬材料可以热反射、安静、可悬垂并且易于缝制。因此,期望的内衬材料将始于衣服应用,包括军用服装、运动和户外衣料、工业应用等。
发明内容
本发明的目标是一种具有成本效益的金属敷覆热反射非纺织叠层,该热反射非纺织叠层包括连续细丝织物和金属敷覆的热塑薄膜。本发明的叠层尤其适于用作衣服应用中的衬里材料,例如运动衣物、军用衣物、野营衣着、打猎/钓鱼衣物等。叠层包括光滑的薄膜层和非纺织物层,其中,叠层的薄膜表面进行金属敷覆以赋予叠层反射性能。金属敷覆的表面用于改进衣服内体温的保持。
织物层包括连续细丝织物或纺粘织物。在一个实施例中,连续细丝织物可以包括由具有毫微-但尼尔(nano-denier)的细丝形成的那些织物。另外,连续细丝织物可以由传统细丝和毫微-但尼尔细丝混合形成。
根据本发明的一个实施例,限定了一种热反射衣服内衬叠层。该叠层包括连续细丝非纺织层和附着到该连续细丝非纺织层的金属敷覆的热塑薄膜层,该热塑薄膜层显示出至少大约0.85的反射率。
连续细丝非纺织层可以由细丝例如聚烯烃、聚酰胺、聚酯、其组合等形成。在特定实施例中,连续细丝非纺织层可以包括毫微-但尼尔细丝、变化几何横截面的细丝、可分裂细丝、多部件细丝,其中多部件细丝例如为并列式细丝、护皮-芯部细丝和海中岛式细丝。此外,连续细丝非纺织层也可以包括内部或局部应用的性能改性添加剂。
金属敷覆的热塑薄膜层包括由热塑性塑料例如聚烯烃、聚酰胺、聚酯、其衍生物及其组合形成。此外,金属敷覆的热塑薄膜层也可以包括内部或局部应用的性能改性添加剂。
可以预期,本发明的金属敷覆衣服内衬叠层可以被赋予生成双平面织物的一个或多个表面凸起。另外,叠层可以整个或部分穿孔从而向叠层材料施加可呼吸性能。此外,叠层可以包括表面凸起和孔的组合。除了孔之外一个或多个表面凸起的结合可以益于衣服内衬以更好地易于空气流过衣服。
本发明也可以体现在用于制造热反射衣服内衬叠层的方法中。该方法包括下列步骤:形成连续细丝层,对热塑薄膜层进行金属敷覆;并且将金属敷覆的热塑薄膜层附着到连续细丝层上。在这种方法中,连续细丝层可以由纺粘工艺形成。热塑薄膜层的金属敷覆可以包括任何已知的金属敷覆工艺,例如蒸发金属敷覆、金属浴、金属溅射、电子束金属汽相沉积及其组合。将金属敷覆的热塑层附着到连续细丝非纺织层上可以涉及层压工艺、化学结合工艺,并且可以使用任何其它适当的附着手段。
另一种制造热反射衣服内衬叠层的方法也体现在本发明中。该方法包括下列步骤:形成连续细丝层,将热塑层薄膜层附着到连续细丝层上,并且对附着的薄膜层和连续细丝非纺织层的热塑薄膜层进行金属敷覆,这样就显示出至少0.85的反射率。连续细丝层的步骤通常由纺粘工艺形成。热塑薄膜层的金属敷覆可以包括任何已知的金属敷覆工艺,例如蒸发金属敷覆、金属浴、金属溅射、电子束金属汽相沉积及其组合。将热塑层附着到连续细丝非纺织层上可以涉及层压工艺、化学结合工艺,并且可以使用任何其它适当的附着手段。在叠层形成之后,一层金属就通过蒸发金属敷覆应用到叠层的薄膜层上。该工艺通过将金属线蒸发到低压真空室中的加热坩埚上而在薄膜表面上沉积均匀的金属涂层。可选地,可以利用其它化学或机械金属敷覆工艺,这些工艺包括但是并不限于金属浴、金属溅射、电子束金属汽相沉积等。
可选地,多种附加的衬底可以机械或化学地粘合到本发明的金属敷覆叠层上,例如附加的纺粘或熔喷网,梳理网,例如通过空气结合或热结合网,稀洋纱例如丝网、织网,薄膜例如单片薄膜及其组合。性能和/或美学增强添加剂也可以包含或局部应用到金属敷覆叠层的一或多层中。通过下面的详细说明、附图和所附权利要求书,本发明的其它特征和优点将会变得更加显而易见。
因此,本发明生成了一种内衬材料,该内衬材料具有成本效益、安静、可悬垂并且易于缝制。该织物因此适于衣服内衬材料例如军用服装、运动和户外衣料、工业应用等。
附图说明
具有了因此以通用术语描述的本发明,现在将参见附图,而附图未必是按比例绘制的,并且其中:
图1是根据本发明实施例的热反射衣服内衬叠层的透视图;并且
图2是用于制造根据本发明实施例的热反射衣服内衬叠层的方法的示意图。
具体实施方式
现在将在下文中参照附图更完全地描述本发明,其中在附图中显示了本发明的优选实施例。然而,本发明能够体现在多种不同的形式中并且不应该解释为限于在此阐述的实施例;这些实施例提供用来使该公开更加充分和完整,并且将向本领域的技术人员完全地传达本发明的范围。相同的数字在全文中指示相同的元件。
根据本发明的实施例并如图1中所示,金属敷覆的衣服内衬织物10包括连续纤维非纺织层12和金属敷覆的热塑薄膜层14,其中金属敷覆的热塑薄膜层14将特有地显示出至少大约0.85的反射率。
连续细丝非纺织层通常由热塑性聚合物形成。可以用于形成细丝层的典型热塑性聚合物包括但是并不限于聚烯烃、聚酰胺和聚酯。示例性的聚烯烃可以包括聚丙烯、聚乙烯及其组合等。
另外,连续细丝非纺织层可以包括那些由具有毫微-但尼尔的细丝形成的织物,如2000年9月5日以发明者Fabbricante等人的名义公开的题为“Micro-denier Nonwoven Materials Made Using Modular DieUnits”的美国专利No.6,114,017。该专利包含在此作为参考,如同完全在此阐明一样。另外,连续细丝织物可以由传统细丝和毫微-但尼尔细丝的组合形成。
此外,本发明中所用的连续细丝的几何横截面可以变化。这种连续细丝公开在下列专利中:1991年10月15日以发明者Largman等人的名义公开的题为“Filaments Having Trilobal or QuadrilobalCross-sections”的美国专利No.5,057,368;1994年6月21日以发明者Boyle等人的名义公开的题为“Hollow-trilobal Cross-sectionFilaments”的美国专利No.5,322,736;以及1998年11月10日以发明者Roop等人的名义公开的题为“Filament Cross-Sections”的美国专利No.5,834,119。这些专利包含在此作为参考,如同完全在此阐明一样。同样可以利用多部件细丝,例如并列式细丝、护皮-芯部细丝和海中岛式细丝。可分裂纤维也适合用在本发明中,其中,一旦受到冲击,这种纤维的部件就会分开。上述细丝可以整体或部分地用于一或多层的金属敷覆的内衬叠层中。
此外,连续细丝非纺织层可以包括性能改性添加剂,例如热稳定剂、软化剂、抗菌剂、阻燃剂、交联剂、滑爽添加剂和润湿剂、UV、防静电、着色剂和成核剂。成核剂可以被特殊地复合以生成更稳定的纺纱工艺,并且在同等的工艺条件下,可以形成强度的进一步增强。织物可以在织物形成之后接触更多的性能增强添加剂。添加剂可以在细丝的内部或者添加剂可以在细丝层形成之前或之后局部施加到细丝上。
连续细丝非纺织层可以包括一或多个表面凸起和/或孔。表面凸起生成双平面织物。另外,叠层可以整个或部分穿孔从而向叠层材料施加可呼吸性能。此外,叠层可以包括表面凸起和孔的组合。除了孔之外一或多个表面凸起的结合可以益于衣服内衬以更好地易于空气流过衣服。
本发明的金属敷覆的热塑薄膜层可以由任意适当的热塑性塑料形成。适当热塑性塑料的实例可以包括但并不限于聚烯烃、聚酰胺、聚酯、其衍生物和其组合。另外,金属敷覆的薄膜可以包括任意适于物理汽相沉积的金属或者金属溅射工艺可以用于在弹性薄膜上形成金属涂层。示例性金属包括铝、铜、锡、锌、铅、镍、铁、金、银等。示例性金属合金包括铜基合金(例如,青铜、蒙乃尔铜-镍合金、铜镍合金和铝铜);铝基合金(铝硅、铝铁及其三价相应物);钛基合金;和铁基合金。有用的金属合金包括磁性材料(例如,镍铁和铝镍铁)和耐腐蚀和/或耐磨合金。
此外,金属敷覆的热塑薄膜层可以包括性能改性添加剂,这种添加剂包括但并不限于色素、表面活性剂、蜡、流动性促进剂、微粒和添加以提高组分的处理能力的材料。添加剂可以在细丝的内部或者添加剂可以在细丝层形成之前或之后局部施加到细丝上。
金属敷覆的热塑薄膜层将显示至少0.85的反射率。所需的反射率是允许叠层作为衣物应用中的保温织物工作所必要的。这种反射率在衣服应用例如军用服装、运动/户外衣物和工业衣物。
在一些实施例中,连续细丝非纺织层可以推进到成形装置上从而形成一或多个表面凸起,其中,这种成形装置包括三维表面皮带、金属筒、金属丝网筛和三维图像转印设备。适当成形装置的示教公开在共同转让的美国专利No.4,098,764、No.5,244,711、No.5,822,823和No.5,827,597中,它们包含在此作为参考。另外,连续细丝非纺织层可以包括一或多个孔或表面凸起和孔的组合。
本发明也可以体现在用于制造本发明的热反射衣服内衬叠层的方法中。该工艺包括下列步骤:形成连续细丝层,对热塑薄膜层进行金属敷覆;并且将金属敷覆的热塑层附着到连续细丝层上。
通常,连续细丝网的形成涉及“纺粘”的工艺。纺粘工艺涉及供给熔化聚合物,熔化聚合物然后在压力下挤压通过被称为喷丝头或模具的板内的多个孔。所生成的连续细丝由任意的多种方法例如狭槽拔出系统、衰减器枪或导丝辊冷淬并且拔出。连续细丝收集为移动的输送表面例如金属丝网传送带上的疏松网。当一个以上的喷丝头用于在一行中使用来形成多层织物时,后续的网就收集在此前形成的网的最上表面上。在授予Brock等人的美国专利No.4,041,203中详细示教了纺粘处理。如上文所述,连续细丝织物可以包括那些由具有毫微-但尼尔的细丝形成的织物,毫微-但尼尔细丝的纺粘处理公开在先前包含的美国专利No.5,678,379和6,114,017中。
热塑薄膜层可以由任何传统薄膜形成工艺形成,例如,作为实例,描述在下列专利中:在2004年8月3日以发明者Osborn等人的名义公开的题为“High temperature polyester film extrusion”的美国专利No.6,770,234;2002年3月12日以发明者Williams等人的名义公开的题为“Polyethylene blends and films”的美国专利No.6,355,733;和2001年2月20日以发明者McAmish等人的名义公开的题为“Breathablefilm compositions and articles and method”的美国专利No.6,191,221,所有这些在此引入作为参考。热塑薄膜层的金属敷覆可以涉及任何适当的金属敷覆工艺,例如蒸发金属敷覆、金属浴、金属溅射、电子束金属汽相沉积及其组合。
本发明的连续细丝非纺织层通常通过传统的层压工艺附着到金属敷覆的热塑薄膜层上。图2显示了一个典型的直接挤压薄膜工艺和叠层100。热塑薄膜的形成在混合和配量系统110中开始,该混合和配量系统110中包括至少两个料斗式装载机;一个用于聚合物切片并且一个用于添加剂片。两个料斗式装载机中的变速螺旋钻向混合和配量系统110内的混合料斗传递预定量的聚合物切片和添加剂片。混合漏斗包括混合推进器来促进混合物的均匀性。
聚合物切片供入区段挤压机120,例如由Pennsylvania的WelexCorporation of Blue Bell提供的挤压机。在这种特定系统中,使用具有二英寸水套孔和长度直径比为24比1的五区段挤压机。
一旦由多区段挤压机120中混合和挤压,聚合物混合物经由加热的聚合物管道140输送通过筛变换器130。通常,具有不同筛网的分断器板用在加热的聚合物管道中来保持固体或半熔化的聚合物切片和其它的宏观残余物。混合的聚合物然后供给到熔化泵150中。
熔化泵150以动态反馈操作且以多区段挤压机120来保持期望的压力水平。在一个特定实例中使用了齿轮型熔化泵,从而通过改变挤压机的速度补偿与压力设定点窗口偏离而响应压力水平。
然后计量和混合的聚合物混合物进入化合块160中。化合块允许挤压出多个薄膜层,薄膜层具有相同的组分或是由如上所述的不同系统供给。化合块160由附加的加热聚合物管道170指引到模具主体180中。
在该示例性系统中使用的特定模具主体180是37英寸宽的EDI自动模具,该模具具有由Wisconsin的Chippewa Falls的挤压模具工业(EDI)提供的板牙控制。模具主体180置于架空方位中这样熔化薄膜挤压件190沉积在铸造站200中展平辊210和铸造辊220之间的展压点处。
注释为B的连续细丝非纺织层以辊形提供给张力控制的开卷机240。连续细丝非纺织层从开卷机240上展开并且移动到展平辊210上,展平辊具有环境温度。来自模具主体180的熔化的薄膜挤压件190在展平辊210和铸造辊220之间的展压点上沉积到层B上,铸造辊具有冷糙面精整铬饰面。注释为C的新形成的叠层由回送辊230从铸造辊220移除,该回送辊具有冷抛光铬饰面。然后叠层材料C缠绕到变速卷线机250上的新辊子上。
在叠层形成之后,一层金属就通过蒸发金属敷覆应用到叠层的薄膜层上。该工艺通过将金属线蒸发到低压真空室中的加热坩埚上而在薄膜表面上沉积均匀的金属涂层。可选地,可以利用其它化学或机械金属敷覆工艺,这些工艺包括但是并不限于金属浴、金属溅射、电子束金属汽相沉积等。
依照本发明,金属敷覆的叠层也可以形成在连线工艺(in lineprocess)中。在叠层形成之后或是在将薄膜化学粘附到连续细丝层之前,薄膜层会受到金属敷覆工艺,其中,金属可以从各种金属化合物和相关合金中选取。金属敷覆工艺优选是蒸发工艺,其中,金属在真空室中应用到薄膜上。因此,铝线供给到陶瓷坩锅上并且熔融,然后与真空室中的低压而蒸发。还可以预期,金属敷覆工艺也可以包括金属浴、金属溅射、电子束金属汽相沉积等。
如先前所述,衣服内衬叠层进行金属敷覆处理,这样叠层就显示出至少每ASTM E1933-99a大约0.85的反射率,这是一种使用红外成像辐射计进行测量和补偿的方法。
因此,本发明提供了一种热反射衣服内衬叠层,该热反射衣服内衬叠层成本低并且适于例如运动衣物、军用衣物、野营衣着、打猎/钓鱼衣物等的这些衣服应用。另外,可选的最终用途包括毯子,例如绝热毯、紧急救生毯、慈善事业所用毯和航线用毯。
本领域的普通技术人员可以想到许多改进和本发明的其它实施例,且于本领域的普通技术人员而言,本发明具有在前述说明和相关附图中提出的示教的益处。因此,应当理解,本发明并不限于所公开的特定实施例,那些修改和其它实施例也预期包括在所附权利要求书的范围内虽然在此使用了特定的术语,但是它们是在类属和描述性的意义上使用的并且并非用于限制性的目的。

Claims (29)

1.一种热反射衣服内衬叠层制品,该制品包括:
连续细丝非纺织层;和
附着到所述连续细丝非纺织层的金属敷覆的热塑薄膜层,所述金属敷覆的热塑薄膜层显示出至少大约0.85的反射率。
2.如权利要求1所述的制品,其特征在于,所述连续细丝非纺织层包括从由聚烯烃、聚酰胺、聚酯及其组合构成的组中选取的细丝。
3.如权利要求1所述的制品,其特征在于,所述连续细丝非纺织层包括毫微-但尼尔细丝。
4.如权利要求1所述的制品,其特征在于,所述连续细丝非纺织层包括具有变化的几何横截面的细丝。
5.如权利要求1所述的制品,其特征在于,所述连续细丝非纺织层包括多部件细丝。
6.如权利要求5所述的制品,其特征在于,所述多部件细丝是从由并列式的细丝、护皮-芯部细丝和海中岛式细丝构成的组中选取的。
7.如权利要求1所述的制品,其特征在于,所述连续细丝非纺织层包括可分裂细丝。
8.如权利要求1所述的制品,其特征在于,所述连续细丝非纺织层还包括内部性能改性添加剂。
9.如权利要求1所述的制品,其特征在于,所述连续细丝非纺织层还包括局部性能改性添加剂。
10.如权利要求1所述的制品,其特征在于,所述金属敷覆的热塑薄膜层包括从由聚烯烃、聚酰胺、聚酯、其衍生物及其组合构成的组中选取的热塑性塑料。
11.如权利要求1所述的制品,其特征在于,所述金属敷覆的热塑薄膜层还包括局部性能改性添加剂。
12.如权利要求1所述的制品,其特征在于,所述金属敷覆的热塑薄膜层还包括内部性能改性添加剂。
13.如权利要求1所述的制品,其特征在于,所述叠层包括至少一个表面凸起。
14.如权利要求1所述的制品,其特征在于,所述叠层包括至少一个孔。
15.一种热反射衣服内衬叠层制品,该制品包括:
包括至少一个表面凸起的连续细丝非纺织层;和
显示至少大约0.85的反射率的金属敷覆的热塑薄膜层。
16.如权利要求15所述的制品,其特征在于,所述连续细丝非纺织层包括从由聚烯烃、聚酰胺、聚酯及其组合构成的组中选取的细丝。
17.如权利要求15所述的制品,其特征在于,所述连续细丝非纺织层包括毫微-但尼尔细丝。
18.如权利要求15所述的制品,其特征在于,所述金属敷覆的热塑薄膜层包括从由聚烯烃、聚酰胺、聚酯、其衍生物及其组合构成的组中选取的热塑性塑料。
19.如权利要求15所述的制品,其特征在于,所述叠层包括至少一个孔。
20.一种用于制造热反射衣服内衬叠层的方法,该方法包括下列步骤:
形成连续细丝层;
对热塑薄膜层进行金属敷覆;并且
将金属敷覆的热塑薄膜层附着到连续细丝层上。
21.如权利要求20所述的方法,其特征在于,所述形成连续细丝层的步骤包括通过纺粘工艺形成连续细丝层。
22.如权利要求20所述的方法,其特征在于,对热塑薄膜层进行金属敷覆的步骤包括从由蒸发金属敷覆、金属浴、金属溅射、电子束金属汽相沉积及其组合构成的组中选取的金属敷覆工艺。
23.如权利要求20所述的方法,其特征在于,所述将金属敷覆的热塑层附着到连续细丝非纺织层的步骤还包括将金属敷覆的热塑薄膜层层压到连续细丝层上。
24.如权利要求20所述的方法,其特征在于,所述将金属敷覆的热塑层附着到连续细丝非纺织层的步骤还包括将金属敷覆的热塑层化学结合到连续细丝层上。
25.一种用于制造热反射衣服内衬叠层的方法,该方法包括下列步骤:
形成连续细丝层;
将热塑层薄膜层附着到连续细丝层上;并且
对于附着的薄膜层和连续细丝非纺织层的热塑薄膜层进行金属敷覆,这样就显示出至少0.85的反射率。
26.如权利要求25所述的方法,其特征在于,所述形成连续细丝层的步骤还包括通过纺粘工艺形成连续细丝层。
27.如权利要求25所述的方法,其特征在于,对热塑薄膜层进行金属敷覆的步骤包括从由蒸发金属敷覆、金属浴、金属溅射、电子束金属汽相沉积及其组合构成的组中选取的金属敷覆工艺。
28.如权利要求25所述的方法,其特征在于,所述将金属敷覆的热塑层附着到连续细丝非纺织层的步骤还包括将热塑薄膜层层压到连续细丝层上。
29.如权利要求25所述的方法,其特征在于,所述将热塑层附着到连续细丝非纺织层的步骤还包括将热塑薄膜层化学结合到连续细丝层上。
CNA2005800289400A 2004-08-30 2005-08-30 热反射非纺织衬里材料 Pending CN101090816A (zh)

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