CN101341282A - 由天然材料制成的可吹制隔离丝团 - Google Patents

由天然材料制成的可吹制隔离丝团 Download PDF

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CN101341282A
CN101341282A CNA2006800483513A CN200680048351A CN101341282A CN 101341282 A CN101341282 A CN 101341282A CN A2006800483513 A CNA2006800483513 A CN A2006800483513A CN 200680048351 A CN200680048351 A CN 200680048351A CN 101341282 A CN101341282 A CN 101341282A
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弗朗西斯·L·达文波特
约瑟夫·鲁梅什
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Abstract

一种可吹制隔离材料，其包括由天然纤维或材料构成的任意形状的可吹制丝团。在优选的实施方案中，该丝团还包括人造纤维或材料。还公开了生产可吹制丝团的方法。

Description

由天然材料制成的可吹制隔离丝团
技术领域
本发明涉及羽绒状隔离丝团及其制造方法。
背景技术
已经进行了许多尝试以获得用于隔离制品例如服装、睡袋、鸭绒被等的具有羽绒状品质的隔离材料。之前开发可行材料的努力大多产生了太沉重和密实而不被视为羽绒状的材料。
一个例外是例如Donovan的美国专利4588635，其公开了一种优良的合成羽绒，尤其涉及可以通过使用低密度组合的细纤维来获得的轻质隔热系统，并且描述了用于制作隔离絮时的纤维混合物的范围，提供了有利的羽绒状品质，例如高的温暖-重量比、柔软的手感和良好的压缩恢复性能。该材料达到、在一些情况下甚至可能超过天然羽绒的隔热性能。然而，从力学观点来看，极细纤维具有刚度和强度的缺陷，这使其难于生产、操纵和使用。较大的纤维直径增强了这种合成隔离材料的恢复性能，但是大纤维组分的增加会严重降低整体的隔热性能。与细纤维组合的机械稳定性相关的问题在湿状态下加剧，原因在于与毛细水的存在有关的表面张力显著大于由重力或其它正常使用载荷引起的表面张力，并且它们对结构具有更为有害的作用。然而，与水禽羽绒不同，所公开的纤维组合提供优异的耐湿性。
另一个例外是Donovan等人的美国专利4992327，其公开了使用粘合纤维成分来改善隔离物品的整体性，而不损害期望的属性。更具体而言，在该专利中公开的发明涉及形式为粘着纤维结构的合成纤维隔热材料，该结构包括如下组合：(a)70～95重量％的直径为3～12微米的合成聚合物超细纤维，和(b)5～30重量％的直径为12～50微米的合成聚合物粗纤，其特征在于至少一些纤维在其接触点处粘合，该粘合使得所得结构的密度为3～16kg/m3，所述粘合的组合的隔热性能等于或基本不低于相应的未粘合组合的隔热性能。该文献还描述了羽绒状丝团形式的优选纤维混合物。该专利还公开了丝团形式相对于絮形式而言的明显性能优势。
然而，这些现有技术的丝团经常是以缓慢、冗长的分批工艺手工制造的。而且，现有技术的材料不是可以使用常规制造设备易吹制的材料。因此，需要一种可吹制的材料，其可以部分或全部代替羽绒，并且可利用常规设备制造和吹制。
部分地因为这种需要，开发了如美国专利6329051中所记载的可吹制隔离丝团。’051专利中记载了由切碎的粘合絮或粘合纤维网制成的可吹制丝团。所描述的纤维网或絮与Donovan的‘327专利中描述的纤维混合物相同。通过切碎由‘327专利中描述的材料形成的絮或纤维网，发现丝团获得了包括膨松和隔离性能的羽绒状品质。与天然材料混合的这种丝团记载于美国专利6329052中。注意，前述专利的公开内容通过引用全部并入本文。
然而，‘051和‘052专利的可吹制隔离丝团仅引入了合成纤维。与此相比，本发明旨在提供由天然的人造材料或与人造材料组合的天然材料制成的可吹制隔离丝团。
发明内容
本发明的一个目的是提供用于部分或全部代替羽绒的可吹制隔离材料。
本发明的一个实施方案是可吹制隔离材料，包括一种或更多种材料，例如絮、纤维网、粘合絮、粘合纤维网、粘合絮的一部分和粘合纤维网的一部分，经过一次或更多次切碎而成为任意形状的可吹制丝团，该可吹制丝团由天然纤维或材料的混合物或者天然纤维或材料与人造纤维或材料相组合的混合物形成。在另一优选的实施方案中，该丝团包括与其混合的经防水剂或润滑剂处理的纤维和/或干燥纤维和/或粘合纤维。还公开了生产可吹制丝团的方法。
表现出本发明新颖性的各种特征在所附权利要求中具体指出，所述权利要求构成本发明公开内容的一部分。为了更好地理解本发明、其操作优点和通过使用其而获得的特定目的，参见所附说明内容，其中示出本发明的优选实施方案。
由此，通过本发明，其目的和优点得以实现，下面将结合以下详细说明对其进行说明。
具体实施方式
在本发明的一个实施方案中，本发明包括由天然纤维或材料单独或与人造纤维或材料组合而制成的丝团。起始物料可以为如前所述的絮或纤维网等形式或适用于该目的的其它形式的材料，并且可以是或可以不是热定形材料(heatset)。对于某些应用，所述絮或纤维网可以包含经防水剂处理或经润滑剂处理的纤维和/或干燥纤维和/或粘合纤维。然后，将所述絮或纤维网经一次或更多次切成可吹制的并具有期望的羽绒状品质的小丝团。一般而言考虑到可以使用纤维网(一般为单层材料)和絮(一般为多层材料)或其部分来制造本发明的丝团。
被视为在本发明范围内的天然纤维或材料包括但不限于羊毛、棉花、亚麻、动物毛发、丝、羽绒以及其它天然纤维或材料。
纤维丝团可由利用合适的纤维材料或混合物制成的轻质粗梳条子制成。在将人造纤维与天然纤维或材料一起引入单个絮中时，人造纤维的纤维混合物优选为Donovan等人的美国专利4992327中公开的纤维混合物。如前所述，该专利公开了一种隔离材料，其中粗纤维可粘合起来形成超细纤维的支承结构。还可以在粗纤维和部分超细纤维之间的各个接触点处进行粘合。然而，优选地，在使用时，在人造纤维的粗纤维之间的触点处进行粘合。这提供支承结构，明显有助于隔离材料的机械性能。而且，该絮的人造组分的纤维结构一般还包括70～95重量％的直径为3～12微米的合成聚合物超细纤维和5～30重量％的直径为12～50微米的合成聚合物粗纤维。其它一些优选实施方案使用包括经防水剂处理或经润滑剂处理的纤维和/或干燥纤维和/或粘合纤维的纤维混合物。
通常，首先在梳理机的出口侧收集条子，并且，根据需要或期望，使其直接穿过加热的管，该加热的管(如果使用的话)会对粘合纤维混合物进行热粘合。重要的是，完成所采用的任何粘合步骤，但不使膨松的粗疏条子收缩和密实化。每个条子末端在通过导环进行中心定位的同时向下穿过竖直的管，同时加热的空气向上吹并穿过所述管，从而使膨松的直线状纤维组粘合。在从所述加热的管出来之后，将条子牵引到铡刀型短纤维切断机的入口侧。进行干净利落的切割，而不在切口处产生纤维熔化的密实化效果。该方法收集到非常膨松的纤维丝团。
优选的方法采用由合股的粗梳卷(card-laps)构成的絮，但是其它纤维形式也同样适用。然而，注意，如果在天然材料和人造材料都包括的情况下使用常规梳理，则应该注意这种梳理并未将例如天然材料(如羽绒)从纤维网中分离出来。而且，优选将粗疏卷或纤维网形成为密度与羽绒的密度特征相当的絮。粗疏卷或纤维网还可由0.5～6.0旦尼尔的粘合纤维和/或干燥纤维(即没有润滑剂/抗静电剂)和/或防水纤维制成。在优选的方法中，粗疏卷或纤维网包括粘合纤维、干燥纤维和防水纤维。这些纤维可以是如上所述的天然纤维和材料以及人造纤维和材料的组合。可以优选对这些选定的纤维进行梳理，只要不出现不期望的分离即可。可以通过具有固定扁钢的单缸金属针布梳理机进行组合。例如，在制备天然和人造纤维的絮时，可以使梳理机的输出物穿过电加热源和/或燃气加热源来使粘合纤维热定形。给絮加热一段时间，温度足以使纤维粘合，例如在300～400°F之间。热定形后，或者如果使用非热定形的絮或纤维网，则在形成絮之后将絮切碎，优选在混合机中切碎两次以形成可吹制的丝团。
可以修改各种其它可变因素以在可吹制的丝团上获得期望的效果，这些因素包括：
1.将短纤维长度增加至可梳理的限度以改善丝团的整体性和耐久性；
2.改变粘合纤维的含量以“微调”该丝团的可切碎性、可切割性、粘着性和工作特性；
3.改变丝团的尺寸、形状和长径比；
4.如果合适的话，使用超声粘合装置；
5.多于一次地切碎该丝团；
6.只切碎絮或纤维网的一部分。
本领域的技术人员会理解，其它因素也可以影响可吹制的丝团，并且可以针对期望的目的进行优化，而不会超出本发明的范围。
已经观察到，切碎两次的丝团通常比只切碎一次的丝团更光滑和更易于混合。此外，可以采用已经切条的热定形絮的条带或条子，然后对这些部分进行标准的切碎工艺来形成丝团。
本发明还考虑使用上文未讨论的人造纤维混合物或者天然纤维和人造纤维共混物的混合物。这些纤维混合物的范围限定平均纤维直径以确保高水平的隔离性能。在一些情况下，可以期望使用比上述引用专利限定的平均纤维直径大的平均纤维直径。例如，如果最终产品是枕头或室内装饰并且抗压刚度是重要的要求时，可以使用直径相对大的纤维。
此外，根据应用，可以期望将如此形成的丝团以与由不同天然和/或人造材料制成的其它丝团的混合物或与天然和/或人造纤维或材料的混合物的形式进行混合，这取决于所追求的期望结果。
因此，通过本发明，其优点得以实现，尽管本文中详细公开并说明了优选的实施方案，但是本发明的范围不应该限定于此，而是应该由所附权利要求的范围来确定。

Claims (10)

1.一种可吹制隔离材料，其包括一种或更多种选自絮、纤维网、粘合絮、粘合纤维网、粘合絮的一部分和粘合纤维网的一部分的材料，经一次或更多次切碎而成为任意形状的可吹制丝团，所述可吹制丝团包括天然纤维或材料。
2.权利要求1所述的可吹制隔离材料，其中所述可吹制丝团还包括人造纤维或材料。
3.权利要求1所述的可吹制隔离材料，其中所述絮、纤维网、粘合絮、粘合纤维网、粘合絮的一部分和粘合纤维网的一部分只包括天然纤维或材料。
4.权利要求1所述的可吹制隔离材料，其中所述絮、纤维网、粘合絮、粘合纤维网、粘合絮的一部分和粘合纤维网的一部分包括人造纤维或材料和天然纤维或材料的组合。
5.权利要求2所述的可吹制隔离材料，其中所述粘合絮、粘合纤维网、粘合絮的一部分和粘合纤维网的一部分是热定形的。
6.权利要求5所述的可吹制隔离材料，其中所述可吹制丝团包括在多个接触点处粘合起来的任意纤维。
7.权利要求6所述的可吹制隔离材料，其中人造纤维包括70～95重量％的直径为3～12微米的合成聚合物超细纤维和5～30重量％的直径为12～50微米的合成聚合物粗纤维。
8.权利要求1所述的可吹制隔离材料，其中所述絮、纤维网、粘合絮、粘合纤维网、粘合絮的一部分和粘合纤维网的一部分、切碎的絮包括选自0.5～6.0旦尼尔的经防水剂或润滑剂处理的纤维、干燥纤维和粘合纤维的一种或更多种材料。
9.权利要求1所述的可吹制隔离材料，所述可吹制隔离材料与选自天然材料和人造材料的一种或更多种材料混合。
10.权利要求2所述的可吹制隔离材料，所述可吹制隔离材料与选自天然材料和人造材料的的一种或更多种材料混合。
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JP2009521612A (ja) 2009-06-04
US7790639B2 (en) 2010-09-07
KR101318109B1 (ko) 2013-10-16
ZA200805466B (en) 2009-08-26
EP1969168B1 (en) 2012-10-03
WO2007078450A3 (en) 2007-10-04
TWI405884B (zh) 2013-08-21
BRPI0620279A2 (pt) 2013-03-12
TW200730685A (en) 2007-08-16
AU2006333444B2 (en) 2012-04-19
US20070148426A1 (en) 2007-06-28
AU2006333444A1 (en) 2007-07-12
CN101341282B (zh) 2012-10-24
CA2633915C (en) 2013-10-22
CA2633915A1 (en) 2007-07-12
WO2007078450A2 (en) 2007-07-12
RU2443812C2 (ru) 2012-02-27
NO20083227L (no) 2008-09-15
ES2395050T3 (es) 2013-02-07
JP5157912B2 (ja) 2013-03-06
KR20080081336A (ko) 2008-09-09

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