CN102317065A - 热阻件材料 - Google Patents
热阻件材料 Download PDFInfo
- Publication number
- CN102317065A CN102317065A CN2009801454437A CN200980145443A CN102317065A CN 102317065 A CN102317065 A CN 102317065A CN 2009801454437 A CN2009801454437 A CN 2009801454437A CN 200980145443 A CN200980145443 A CN 200980145443A CN 102317065 A CN102317065 A CN 102317065A
- Authority
- CN
- China
- Prior art keywords
- barrier material
- heat
- pottery
- layer
- polymeric layer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
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Images
Classifications
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Abstract
提供一种具有多种结构和设计的隔热材料(4000)，所述多种结构和设计使相对于材料体积的真空区最大化并使对着要被隔热的区域的接触面积最小化，从而在被接触区与外环境之间提供最大热阻。
Description
发明背景
根据美国法典35§119(e)，本申请要求在2008年9月15日提出的美国临时专利申请序列号61/097,051的优先权。该临时专利申请所公开的内容通过整体引用并入本文。
1.发明领域
该发明大体上涉及隔热材料。具体地说，本发明涉及开孔构造的隔热材料，该构造所具有的结构和设计相对于材料体积使真空区最大化，并使相对要被隔热区域的接触面积最小化，以在接触面积与外环境之间提供最大的热阻。
2.相关领域的说明
为了将物体调节或保持一所期望的温度，许多行业使用热阻材料。为提供隔热性，人们已使用过各种各样的隔热体。其中一个例子就是泡沫隔热体。泡沫隔热体具有孔状结构，并且包含两个相，即气相和固相。泡沫隔热体的导热性是由通过包含在这些孔中的气体和通过孔壁的网状体的热流量之和决定的。典型的泡沫隔热体结构包括聚氨酯、聚苯乙烯、聚异氰尿酸酯、聚酰亚胺和泡沫玻璃。
其他隔热体***包括各种形状的被排空的空间，所述各种形状的被排空的空间包含体积填充材料，如玻璃纤维、硅氧气溶胶或复合材料。传导性热流途径受限于颗粒或纤维之间的接触点并被相中断所阻止。对流热流的贡献可以靠减小间隙气压和/或减小颗粒大小而最小化，从而空隙的等价直径等于或小于在给定温度和压力下气体分子的平均自由程。
发明概述
本发明的实施方案是针对包括陶瓷或聚合物层形成的开孔网状体的隔热材料，其中，陶瓷或聚合物层包括具有至少一种结构的基底，并且其中陶瓷或聚合物层的排布允许在每层内产生接近于真空压力的大体积腔，所述大体积腔可以采用在所述陶瓷或聚合物层周边的真空阻隔件密封。在某些实施方案中，所述至少一种结构对所述腔提供结构支撑，同时又产生大体积区域，由此使能所述的开孔结构。
本发明的其他实施方案是针对隔热材料器件的，所述隔热材料器件包括一四个层的分层(stratum)，其中所述分层也可以由两个或三个层构成，所述两个或三个层包括第一陶瓷或聚合物层形成的开孔网状体(open cell network)，其中，所述第一陶瓷或聚合物层包括第一结构；第二陶瓷或聚合物层，其中所述第二陶瓷或聚合物层包括第二结构；第一中间层，其中所述第一中间层包括第三结构；第二中间层，其中所述第二中间层包括第四结构和反射材料层。该第一和第二陶瓷或聚合物层、第一和第二中间层以及反射材料层的排布允许在每个可以被密封的层中产生真空。该隔热材料还包括保护性聚合物敷层，该保护性聚合物敷层起着产生隔热材料的真空阻隔件的作用，其中第一、第二、第三和第四结构的总表面积的约1％或更低互相接触。
在本发明的某些实施方案中，隔热材料器件可以进一步包括至少两个、三个或四个层的第二分层。四个层的第二分层可以包括第一陶瓷或聚合物层形成的开孔网状体，其中所述第一陶瓷和聚合物层包括第一结构；第二陶瓷或聚合物层，其中所述第二陶瓷或聚合物层包括第二结构；第一中间层，其中所述第一中间层包括第三结构；第二中间层，其中所述第二中间层包括第四结构和反射材料层，其中所述第一和第二陶瓷或聚合物层、所述第一和第二中间层和反射材料层的排布允许在每个可以被密封的层内产生真空。
在一些实施方案中，隔热材料器件进一步包括每层的气体阻隔层、每层的潮湿阻隔层、纳米敷层材料、热密封层和/或包括金属的真空沉积材料的层。在另一些实施方案中，隔热材料器件包括第二分层。在再一些其他的实施方案中，隔热器件包括多个内周边真空密封层。在进一步的实施方案中，隔热材料器件是在容器表面的预定部分形成，并且在某些实施方案中，隔热材料器件被形成为圆柱形或基本上以圆柱形的方式成型，并在接近真空压力下密封以产生针对饮料或其他容器的隔热内层或外层。
根据其他实施方案，相邻层可以被安置成相互垂直。还有再一些实施方案中，分层中的第一个陶瓷或聚合物层可以偏离第二中间层放置，而第二陶瓷或聚合物可以偏离第一中间层放置。在本发明的再一些方面中，隔热材料器件被干燥、真空密封的和/或热封。
附图的简要说明
鉴于以下对本发明的各种实施方案的详细说明并结合附图，本发明可以被更完全地理解，其中：
图1是根据本发明的一个实施方案的凸凹式凸出体(lenticular projection)结构的剖面图；
图2图示根据本发明又一个实施方案的柱结构；
图3是根据本发明的另一个实施方案的风琴褶形(accordion-shape)结构的剖面图；并且
图4描绘了根据本发明的一个实施方案的隔热材料器件的四个层的分层。
说明性实施方案的描述
本文所使用的术语仅是为了描述特定版本或实施方案的目的，并不用来限制本发明的范围。除非另有规定，否则，此处使用的所有工艺、符号和其他科学术语或用语与该发明所属的技术领域中普通技术人员的一般性理解具有相同含义。在某些情况下，具有通常理解的含义的术语在此为了清晰和/或方便查找而被定义，而且这种定义的引入不应解释为代表了与在此工艺中人们通常的理解的实质性区别。然而，在有冲突的情况下，应以专利说明书、包括其定义为准。
在描述本发明时，以下解释被认为是针对所使用的术语的。
除非在上下文中另有明确规定，如在本文中所使用的单数形式“a”、“an”和“the”指至少一个，但也可能包括复数的对象。
如在本文中使用的，术语“大约”意味着正被使用的数的上、下百分之十数值。因此，大约50％意味着在40％-60％的范围内。
如在本文中使用的，术语“器件”和“隔热材料器件”是指在其最终使用的应用中本发明的隔热材料。
术语“隔热材料(insulating material)”、“隔热膜(insulating film)”、“热阻层(heat resistantlayer)”在本文中可以互换使用。
本发明的实施方案针对的是隔热材料，所述隔热材料包括开孔结构形式的多个层，这种开孔结构被整体地或者单独地真空密封在保护性聚合物敷层中以保持在这些层之间的近真空。这里使用的术语“开孔(open cell)”是指具有一系列的通道和互联的通路的结构，这些通道和互联的通路定义了基本上开放的构造。在某些实施方案中，该隔热材料的开孔网状体可以具有这样的特征，即相对于材料体积至少40％的真空区。不希望被理论所束缚，该开孔结构允许相对于材料体积真空区的最大化。另外，本发明的隔热材料对保持材料的完整性提供了支持，或在其他实施方案中赋予了柔韧性。
本发明的各种实施方案针对的是包含开孔结构形式的多个层的隔热材料，该材料在最小化材料的厚度、相对于材料体积最大化真空区的同时，实现了期望的热阻，并且提供了结构支撑和柔韧性两者。
本发明实施方案中的隔热材料包括至少一个层、优选至少两个层。在一些实施方案中，每个层可以具有约0.01到1mm的厚度。本发明的隔热材料可以由各种材料形成，比如聚合物层、陶瓷层、复合材料层和反射材料层。陶瓷层材料的非限制性实施例，仅举几项，包括富铝红柱石、钠钙玻璃、硼硅酸盐和氧化锆。当隔热材料由聚合物形成时，可以使用具有低导热率的不透明材料。在可以按照本发明使用的大量聚合物中，下列可以作为非限制性实施例被提及：聚苯乙烯、聚氯乙烯、聚乙烯、聚丙烯、聚丙烯腈、聚丁二烯、聚异戊二烯、聚四氟乙烯、聚酯、三聚氰胺、尿素、酚醛树脂、硅酸盐树脂、聚缩醛树脂、聚环氧化物、聚乙内酰脲、聚脲类、聚醚、聚氨酯、聚异氰尿酸酯、聚酰亚胺、聚酰胺、聚砜、聚碳酸酯以及它们的共聚物和混合物。一些实施方案中的隔热材料可以进一步包括添加剂，例如，着色剂、紫外稳定剂、防腐剂、脱气剂、补强剂、抗氧剂、填充剂、黏着剂、增稠剂的类似物质。
根据本发明的实施方案，每个层可以包括一种或更多种各种形状的结构，使得这些种结构的形状和排布允许在每个层中产生真空，所述每个层可以由该层上或下的层封闭，并且在周围压力被降低时，最终在保护性聚合物阻隔敷层的周边被真空密封。在某些实施方案中，隔热材料的每个层可以包括一种或更多种结构，这些结构包括但不限于凸凹式凸出体结构，风琴褶形结构，t-形、u-形、正方形、矩形或任何不规则或规则多边形的柱及柱横截面，弯曲的，例如圆的、钩状的、椭圆等的柱及柱横截面，及其组合。在某些实施方案中，所述的层可以包括相同形状的结构，而在可供替换的实施方案中，所述的层可以包括不同形状的结构。在还有一些实施方案中，结构的数目被最小化以使真空区最大化，由此提供最大化的热阻。
本发明的结构可以以各种不同形式被安置以允许隔热材料的真空密封。在本发明的一些实施方案中，这些结构可以从底部基底伸出并且在这样的基底上可以相等间隔地或不规则间隔地排列。本发明的基底可以具有单一的结构或者多种结构，所述结构从基底的一侧或两侧伸出。在一些实施方案中，多个基底可以以提高隔热材料热阻的方式被叠置。在某些实施方案中，底部基底可以包括起到有效地阻挡UV、可见和IR辐射的组分。底部基底也可以包含具有相关吸收剂的颜料。
在一些实施方案中，所述结构与基底成一体。其他实施方案的所述结构可以仅从底部基底的一侧伸出。在其他的实施方案中，所述结构可以从所述基底的两侧伸出。在本发明的某些实施方案中，从所述底部基底伸出的结构部分可以大过该结构的顶部。从一些理由来看，这可能是有益的，这些理由包括但不限于：当压力降低时提供结构强度、减除质量以及提高每层的热阻。另外，随着所述结构的顶部接触面积作为总面积的百分比被降低，热阻提高。在优选的实施方案中，任何层的结构的总表面积的约1％或更低与相邻层的结构接触。
本发明的特别方面的结构可以采取从底部基底伸出的凸凹式或交叉凸凹式凸出体的形式。具有凸凹式凸出体结构的隔热材料的横截面在图1中示出，所述凸凹式凸出体结构针对本发明一个实施方案的被隔热面积将接触面积最小化。各种实施方案的凸凹式凸出体结构可以是弯曲的、直的或它们的组合。在某些实施方案中，凸凹式凸出体的底部可以大于该凸出体的顶部。
在本发明的其他方面，所述结构可包括柱，如图2所示。本发明的柱不受形状所限，可以是本领域中任何已知的形状，如，举例说来，矩形或正方型。这些柱的截面，例如梯形等等，可以是任何形状，包括弯曲的，使得这些形状在产生大体积区域的同时提过足够的结构支撑。除了凸凹式凸出体结构是周期性地间断的，这种结构排布类似于凸凹式凸出体结构，是交叉凸凹式凸出体的等价物，如果在垂直方向周期性是相同的，则产生正方形柱，或者如果在垂直方向周期性是不同的，则产生矩形柱。在优选的实施方案中，柱的数量被最小化，例如通过增加柱之间的周期性/间距。周期间断导致柱之间增加的间距，这使真空区最大化，从而使材料的热阻最大化。
在一些有两个或更多个层并且使用凸凹式凸出体的实施方案中，第二层可以以对应的底部基底接触或以凸凹式凸出体结构接触放置在第一层上。在本发明的一些实施方案中，第二层可以被放置，使得所述第二层的凸凹式凸出体结构平行于第一层的凸出体。不希望被理论所束缚，在两个层被放置使得凸出体平行的实施方案中，热阻可以由圆柱形导热体进行估计。在优选的实施方案中，两个层被放置使得凸出体相互垂直，由此提供比多个凸出体呈平行构造时相对更高的热阻。在这种多个凸出体垂直的实施方案中，为不希望被理论所约束，热阻可用球形导热体进行估计。
热阻分析模型可分别被应用于圆柱形的和球形的导热体。为计算方便，所分析的结构是在隔热材料中形状为等腰梯形的凹陷(indentation)，这些凹陷变成了真空区。在真空区之间的凸凹式凸出体结构具有凸出体底部的宽度(B)、具有宽度(b)的凸出体顶部的夹角90°+θ以及凸出体高度(H)。不希望受理论的约束，等腰三角形的区域可以被假设成是一真空并且所有热损失都可假设为是通过含凹陷的隔热材料的传导所发生的。由于那个区域是真空，凹陷中的热流可能受到限制。不希望受理论的约束，真空区域中的有效热阻可以被认为足够大，以至隔热材料的有效热阻可以等于单单材料区域(该区域包含该结构)的热阻。例如，如果真空区域的热阻是材料区域热阻的十倍，该组合的热阻较之于单单材料区域的热阻仅减低了9％，这是因为真空和材料区域处于平行构造。
依照在本发明某些实施方案中的热阻分析模型，一单个层具有仅在一侧的凹陷，而另一侧是平滑的。该层的厚度可以被定义为(t)。在一些实施方案中，隔热材料至少有两个这样的层，在那里，第二层可以是第一层的镜像，并且如在前面针对所述的第二层讨论过的具有两种可能的构造(即平行和垂直)。例如，在一些实施方案中，第二层的凸凹式凸出体是平行于与第一层的凸凹式凸出体，这时隔热材料便用两同轴圆柱形间径向热流来近似。供替代的是，第二层的凸凹式凸出体可以以垂直于与第一层的凸凹式凸出体被放置，这时隔热材料便用两同心球间径向热流来近似。
不希望受理论的约束，具有两个层的隔热材料器件的热阻能够当作一单个层热阻(REFF)的两倍来近似。而且，数目(N)个、每一个都具有两个层的隔热器件可以被叠置，叠置体会具有单个器件的热阻的(N)倍的热阻。等腰三角型间的分开(separation)可以由半径(r1)、角大小(q)的部分圆周近似。依据结构参数，半径(r1)在下面被推导出。热流能够被近似地表达为沿着角大小(q)的等腰三角形的边的径向流。热流出到定义为(r2)的半径，r2在下面作为结构参数的函数被推导。一旦热膨胀超过等腰三角型的顶点，任何由该结构以向侧面的方式流出的热将由从相邻结构的热流入所补充。
单个层的有效热阻与有效导热率(kEFF)和层厚度(t)通过下式相关：
REFF＝t/kEFF (1)
针对包含具有平行凸出体的多个层的隔热材料的有效导热率能够由针对同轴圆柱形的导热率方程近似。该方程包含层的物理性质。该方程如下：
dQ/dt＝-k(θπ/180)r L dT/dr (2)
其中，L＝横截面为等腰三角形的层的长度
dQ/dt＝热流速率
k＝该层材料的导热率
r＝热流的径向
dT/dr＝径向温度梯度
积分可以被写成：
(dQ/dt)∫(dr/r)＝-k(θπ/180)L∫dT (3)
其中，对径向积分的限在r1和r2之间，而对温度积分的限在内部温度(TI)和在外部温度TO时在所述第一层中间的温度[(TO+TI)/2n]之间。尽管假设内部温度不变，但这将不影响所述单个层的有效热阻(REFF)的计算，所述单个层的有效热阻(REFF)是***的物理参数。该方法不提供该***时间依赖性温度行为的计算。
解该积分方程产生：：
dQ/dt＝k(θπ/180)[ln(r2/r1)]-1L{TI-[(TO+TI)/2n]} (4)
从方程(4)可以观察到等号和(L)之间的项是kEFF，它包括结构参数和材料导热率的影响。
kEFF＝k(θπ/180)[ln(r2/r1)]-1 (5)
将方程(5)代入方程(1)得到有效热阻(REFF)：
REFF＝t ln(r2/r1)[k(θπ/180)]-1 (6)
***参数(θ，r1，r2)可以依据该器件的已知的结构参数计算。基于几何学，可推导出这些参数为：
θ＝2 tan-1(B/2H) (7)
r1＝(b/2)[1+(4H2/B2)]1/2 (8)
r2＝H[1+(B2/4H2)]1/2+(b/2)[1+(4H2/B2)1/2 (9)
不希望受理论的约束，针对层中含垂直凸出体的隔热材料的kEFF可以从同心球的导热率方程近似。该近似包括该层的物理性质。其方程为：
dQ/dt＝-k 2π(L/t)(1-cosθ)r2 dT/dr (10)
其中L＝该层的长度，它等于由同心球所表示的器件的厚度(t)
dQ/dt＝热流速率
k＝层材料的导热率
r＝热流的径向
dT/dr＝径向温度梯度
随后，其积分可以被写成：
(dQ/dt)∫(dr/r2)＝-k 2π(L/t)(1-cosθ)∫dT (11)
其中，径向积分的限在r1和r2之间，而温度积分的限在内部温度(TI)和在外部温度TO时在所述第一层中间的温度[(TO+TI)/2n]之间。尽管任何温度变化不会影响所述单个层的REFF的计算，所述单个层的REFF是该***的物理参数，但还是假定内部温度不变。然而，这种方法不把该***的时间依赖性温度行为的计算考虑进去。
解该积分方程得到：
dQ/dt＝k 2π(1-cosθ){r1r2/[(r2-r1)t]}L{TI-[(TO+TI)/2n]} (12)
从方程(12)可以很容易地观察到，像在方程(4)中那样，等号和L之间的项是kEFF，kEFF包含结构参数和材料的导热率的影响。
kEFF＝k 2π(1-cosθ){r1r2/[(r2-r1)t]} (13)
可以把方程(13)代入方程(1)得到有效热阻(REFF)：
REFF＝t{k 2π(1-cosθ){r1r2/[(r2-r1)t]}-1 (14)
***的参数(θ，r1，r2)可以基于以上方程(7)，(8)和(9)进行计算。
隔热材料的至少两个层的构造形成隔热材料的分层。此处所用的术语“分层”是指材料的多个层，其中一个层的至少一部分排布在另一个层的至少一部分之上。在本发明的一些实施方案中，隔热材料器件包括一个分层，但其他实施方案可能包括多个分层。在各种实施方案中，构成分层的每一个层可以是约10至约1000μm厚。在某些实施方案中，构成分层的每一个层也可以是约100μm厚。在其他实施方案中，隔热材料器件可以具有约0.1mm至约10mm的厚度。在还有的其他实施方案中，所述器件可以具有约5mm的厚度。
在隔热材料器件中的分层数目决定了隔热件的热阻(R)值。分层的R值可以基于所述一个或多个层的几何形状、构成所述一个或多个层的材料的导热率、真空压、以及所述一个或多个层的材料的体积与真空体积的比率来确定。增加突起体之间的间距增加真空对所述一个或多个层材料体积的比率。凸出体高度的减小减小真空区域的高度。取决于真空压，真空压可以导致真空区域中分子间较少的碰撞并容许针对给定热阻的较高的压力。这样，较高真空压可以被用来获得给定的热阻，使得隔热材料的制造变得更简单，并使能柔韧真空隔热板的批量生产。另外，在某些实施方案中，如果期望预定的R值，获得该期望的R所必须的分层的数目能够被计算。本发明中的隔热材料器件可以具有从约2.5到约6的以K-m2/W为单位的R值。在某些实施方案中，当使用相对薄的多个层时，由于薄的层针对给定器件厚度允许更多分层，R值甚至可能更高。
为了提高分层的热阻，其他中间层可以***在分层的现有的多个层之间或被安置成对分层的现有的多个层为一角度。在一些实施方案中，中间层可以包括具有至少一种结构的基底。该中间层材料可以是任何和最终应用一致的聚合物、陶瓷或复合材料。在一些实施方案中，中间层具有特别的设计，这种特别的设计使中间层材料体积相对于其真空体积最小化，并且最小化与上、下层的接触面积，因而，通过这些层的材料降低热导。一个同时最大化真空区同时提供结构支撑的中间层设计的非限定性实施例是薄的风琴褶样结构。风琴褶形的横剖面图示于图3。风琴褶的三角形结构的顶部可以被制成预设的宽度，使得对上、下表面的接触面积可以被控制。当凸出体被以互相垂直放置时，双中间层的设计可以被用来在抽真空时使热阻和结构强度最大化。
在本发明的一些实施方案中，第二陶瓷或聚合物层的至少一种结构的形状可以与第一陶瓷或聚合物层的至少一种结构的形状相同。该第二陶瓷或聚合物层的结构可以以与不同于第一陶瓷或聚合物层的结构的方式旋转或取角度。在其他的实施方案中，第二陶瓷或聚合物层的结构可以不同于第一陶瓷或聚合物层的结构的形状。在本发明的特定实施方案中，第二陶瓷或聚合物层可以用对应的结构接触安置在第一陶瓷或聚合物层上。在另外的实施方案中，第二陶瓷或聚合物层可以用对应的基底接触安置在第一陶瓷或聚合物层上。
在本发明的再一些实施方案中，每个层的结构周期性可能不同，这样使分层的多个层被有效地错开，以使热导途径最小化而热阻最大化。在某些实施方案中，隔热材料器件可以包括至少两个分层，其中一个分层可以具有与第二分层不同的周期性组。另外，两个分层可以有相同的周期性组，但是一个分层可以被偏置或错开于第二个分层。另外，隔热材料的两个层的垂直构造可以形成刚性结构，所以，在一些实施方案中，为了赋予隔热材料的柔韧性，每层的内部断点可以相互对齐。
在本发明的各种实施方案中，如图4所示，四个层、每种类型两个层，产生一分层。特别是，图4是有四个层的分层400的横截面图，其中，第一个层420具有凸凹式凸出体设计，并且凸出体尖端背向要被隔热的区，第二层440具有风琴褶型结构，且被垂直第一层420放置，第三层460也是风琴褶型结构，且被垂直第二层440放置，而凸凹式凸出体设计的第四层480被垂直第三层460放置，其宽的端或底部部分面向周围环境或另一个分层。对于具有来自两个侧的凸出体的单个基底的情况，(或在两层中基底相互接触的情况)，凸出体尖端将面向要被隔热的区。在某些实施方案中，分层的第三层或第二层可以偏置于在它下方的第一层安置，以增加热阻。在某些实施方案中，分层中的第四层可以偏置于在它下方的第二层安置，以增加热阻。
本发明的隔热材料器件可以以相互协力的方式被使用，以进一步提高热阻值(R)。在一些实施方案中，这些器件的结构可以被尽可能最大间距地放置，以通过减小作为对真空区比例的材料质量来提高热阻。距离仅受其结构强度的限制，因此在减压产生真空时固有能力不塌陷。另外，所述的距离被设计来限制结构间材料向下拉，而结构间材料向下拉通过迫使两个层中的一个层的底部碰到被热阻件或外部热储(也即，周围环境)覆盖或保护的区域而热“短路”所述真空区域。当这种情况发生时，通过每个层的传导增加，并且，热阻由此降低。
在任何两个层之间，或在每个分层中的一个中，可能存在一个或更多个高反射材料或表面反射材料的层，在这里，反射性可以是像镜子那样的或者是漫射的。在另外的实施方案中，陶瓷或聚合物层可以包含表面反射材料。这里所有的术语“高反射”意指超过约80％。高反光材料可以包括金属箔或金属化的膜。非限定性实施例包括铝箔、金箔以及镀铝的和双镀铝的MYLAR膜(MYLAR
是在美国特拉华州的E.I.Du Pont De Nemours andCompany的商标)。在另外的实施方案中，高反光材料可以包括介电材料，比如二氧化钛。在本发明的特别实施方案中，所述反射材料层包括高反射材料的单层。在其他的实施方案中，高反射材料层构成高反射材料的多层叠置体。
在一些实施方案中，高反光材料层将具有约0.025微米到约10微米的厚度。约0.025微米到约1微米的厚度值对于金属箔是常见的，而约1微米到约10微米的值对于金属化膜是常见的。在优选的实施方案中，高反光材料层将具有小于或等于约1.0微米的厚度。高反光材料的存在通过降低真空区域的厚度、以至于在真空中剩余颗粒的平均自由路径更加接近真空厚度，并且反光材料反射红外线来提高热阻。在发明的特定实施方案中，反射材料敷层可以被应用到所述多个结构的一部分，例如凸出体，以防止或最小化通过各层的辐射。在一些实施方案中，所述多个结构的各侧或面都敷有反射金属，这意味着每个分层可以包含四个金属化表面。在本发明的一些多层实施方案中，第一陶瓷或聚合物层的表面反射材料可以面向第二陶瓷或聚合物层的表面反射材料。
在本发明的各种实施方案中，分层可以被包含在使能并保护真空的、带有或不带有反射表面的保护性聚合物敷层内。在某些实施方案中，分层可以被包含在能够维持真空板约6个月到约50年的聚合物袋或套内。在一些实施方案中，袋可以包括呈多层的结构，所述结构包括每层的气体和/或潮湿阻隔件、纳米敷层材料及热密封层。
所述气体和/或潮湿阻隔层可以包含薄的(约30至60微米)的真空沉积材料层(例如，铝)，真空沉积材料的层可以提供对气体扩散的物理上不渗透的阻隔件并作为对辐射反射体。此外，所述的气体和/或潮湿阻隔层可以包含有机材料来加强气体阻隔性能，所述的有机材料，例如，聚偏二氯乙烯(PVdC)、乙烯乙烯醇(EVOH)或聚乙烯醇(PVOH)。在还有的其他实施方案中，温度可被设计成以周期方式波动，以促进脱气，并且周期性脉冲运动可以被添加以在多个分层被脱气的同时促进多个层的分子运动。其他材料，例如，纳米尺寸的氧化铝，能够被作为充当吸气剂的表面敷层使用。
在分层被放置在袋或套内之后，在本发明的一些实施方案中，惰性气体，例如氩或氙，可在拉真空和密缝袋之前被泵入袋以代替环境空气。惰性气体的泵入改善了隔热材料器件的热阻，因为氩和氙的导热率相对地低于空气的导热率。在另一个实施方案中，分层在被保持在真空下之前，于50℃至90℃被干燥。要求的真空度基于多项因素而变化，这些因素包括但不限于，期望的应用，各层的结构、设计和构造，层的数目及要求的隔热值(R)。在各种实施方案中，近真空压力约为10-6巴或更低，在某些实施方案中，要求的真空度可以在从约10-3巴到约10-6巴的范围。在本发明的某些实施方案中，采用双腔或多腔组装***，由此所述多个分层和保护性聚合物阻隔敷层被同时脱气，而压力被分别地降低。脱气可以发生在处于真空前或处于真空时、或者可能地在处于真空前或处于真空时两者使用烘焙，以达到最佳效果。
在某些实施方案中，可以经由使用高密度聚乙烯(HDPE)、取向聚丙烯(OPP)、流延聚丙烯(CPP)或无规聚对苯二甲酸乙二醇酯(A-PET)的热封完成袋的封闭。
本发明的隔热材料可以通过行业内本领域技术人员认可的任何方法制造，包括但不限于注塑和/或微复制技术。在一个实施方案中，母型可以被机加工成期望的结构。取决于，例如结构要件的尺寸，母型可以被金刚石车削、激光蚀刻或化学腐蚀。然后可以通过压花(热)、浇铸和固化(紫外线引发)或其他注塑技术形成结构。可以采用基于网状结构的辊压工艺或其他辊压工艺。在某些实施方案中，辊压工艺最初以每分钟约30至50米的线速度运行。由此产生的板材可达两米宽，并可定制期望的长度和宽度。在一些实施方案中，可以采用自动化工艺加工操纵板材并将板材放入聚合物套内，在被置于真空状态下之前，用例如氩或氙的气体增强套的气氛。
在本发明的一些实施方案中，可以在真空密封之后使用额外的热封技术添加胞腔样(cell-like)密封基质。这在以下应用中优选的，例如，存在隔热材料器件要被刺穿的可能性从而最小化隔热效果。
依照本发明的隔热材料可以用于使任何物体隔热。在一些实施方案中，隔热材料可以用于协助维持在期望的温度下物品的温度。在其他实施方案中，隔热材料可以防止物品的热损失。应用的实例包括但不限于食品包装、饮料罐、瓶、柔性饮料袋、输电线缆和设备的隔热、用于液体冷冻剂的传送和运输***、热管、热泵、空间运载工具的推进剂贮箱和供料管线、制冷单元、器具、医用包装(例如疫苗)、医用运输箱、任何类型的容器、二氧化碳、氨、急冷水或盐水、油和蒸汽的传送和运输，以及例如木板衬料、石膏板、屋顶隔热、真空隔热材料等类似材料的住宅应用。
在本发明的特定实施方案中，隔热材料器件可以是容器的一个构件，例如具有双壁的金属容器。例如，隔热材料可以被形成为对应于双壁金属饮料容器的形状的圆柱形状并用于使该容器的内容物隔热。在一些实施方案中，隔热材料可以具有小于约2毫米的壁厚并被安置在双壁饮料容器的两壁之间。然后可以密封双壁容器。按照所属领域技术人员的理解，双壁饮料容器可以被真空密封，或在可替代的实施方案中，可以不被真空密封，而仅被密封以保护位于其中的内容物。
虽然上述涉及特定的优选实施方案，但应当认识到，本发明并非受到上述实施方案的限制。所属领域的技术人员可以对公开的实施方案进行各种更改，并且此类更改被旨在处于本发明的范围之内，本发明的范围由权利要求书所定义。
Claims (96)
1.一种隔热材料，包括：
陶瓷或聚合物层形成的开孔网状体，其中所述陶瓷或聚合物层包括具有至少一种结构的基底，并且其中所述陶瓷或聚合物层的排布允许在每一个所述层内产生近真空压力的大体积腔，利用在所述陶瓷或聚合物层周边的真空阻隔件，所述大体积腔可以被密封。
2.根据权利要求1所述的隔热材料，其中所述开孔网状体的特征在于相对于材料体积至少40％的真空区。
3.根据权利要求1所述的隔热材料，其中所述结构为所述腔提供结构支撑，同时产生使能所述开孔结构的大体积区域。
4.根据权利要求1所述的隔热材料，其中所述结构的特征在于底部部分，所述底部部分大于顶部部分。
5.根据权利要求1所述的隔热材料，其中所述结构包括凸凹式凸出体，风琴褶样结构，t-形、u-形、正方形、矩形或任何不规则或规则多边形的柱及柱横截面，弯曲的、圆的、钩状的、椭圆的柱及柱横截面，及其组合。
6.根据权利要求1所述的隔热材料，其中所述结构是凸凹式凸出体。
7.根据权利要求6所述的隔热材料，其中所述凸凹式凸出体的侧面是弯曲的、直线的或其组合。
8.根据权利要求1所述的隔热材料，其中所述陶瓷或聚合物层包括多种结构。
9.根据权利要求8所述的隔热材料，其中所述结构从所述基底的一个侧伸出。
10.根据权利要求8所述的隔热材料，其中所述结构从所述基底的两个侧伸出。
11.根据权利要求1所述的隔热材料，其中所述陶瓷或聚合物层包括以这样的方式叠置的多个基底，所述方式提高所述隔热材料的热阻。
12.根据权利要求1所述的隔热材料，其中陶瓷或聚合物层包括表面反射材料。
13.根据权利要求12所述的隔热材料，其中表面反射材料是由铝箔、金箔、敷铝的或双敷铝的MYLAR
膜构成的。
14.根据权利要求12所述的隔热材料，其中所述表面反射材料包括高反射介电材料。
15.根据权利要求14所述的隔热材料，其中所述高反射介电材料是二氧化钛。
16.根据权利要求12所述的隔热材料，其中所述表面反射材料的厚度小于或等于约1.0微米。
17.根据权利要求12所述的隔热材料，其中所述表面反射材料被耦合到所述至少一个结构的每个面。
18.根据权利要求1所述的隔热材料，其中所述近真空压力最大为约10-3巴。
19.根据权利要求1所述的隔热材料，其中所述近真空压力为约10-6巴或更低。
20.根据权利要求1所述的隔热材料，其中隔热结构材料的厚度从约0.01毫米到约1毫米。
21.根据权利要求1所述的隔热材料，进一步包括第二陶瓷或聚合物层，其中所述第二陶瓷或聚合物层包括具有至少一种结构以形成分层的基底。
22.根据权利要求21所述的隔热材料，其中所述陶瓷或聚合物层包括多种结构。
23.根据权利要求22所述的隔热材料，其中所述结构从所述基底的一个侧伸出。
24.根据权利要求22所述的隔热材料，其中所述结构从所述基底的两个侧伸出。
25.根据权利要求21所述的隔热材料，其中所述结构与所述基底成一体。
26.根据权利要求21所述的隔热材料，其中所述第二陶瓷或聚合物层的所述至少一种结构的形状与所述第一陶瓷或聚合物层的所述至少一种结构的形状相同。
27.根据权利要求22所述的隔热材料，其中所述第二陶瓷或聚合物层的所述至少一种结构以与所述第一陶瓷或聚合物层的所述至少一种结构不同的方式被旋转和取角度。
28.根据权利要求21所述的隔热材料，其中所述第二陶瓷或聚合物层的所述至少一种结构的形状与所述第一陶瓷或聚合物层的所述至少一种结构的形状不同。
29.根据权利要求21所述的隔热材料，其中所述第二陶瓷或聚合物层的所述至少一种结构的周期性与所述第一陶瓷或聚合物层的所述至少一种结构的周期性相同。
30.根据权利要求21所述的隔热材料，其中所述第二陶瓷或聚合物层的所述至少一种结构的周期性与所述第一陶瓷或聚合物层的所述至少一种结构的周期性不同。
31.根据权利要求21所述的隔热材料，其中所述第二陶瓷或聚合物层安置于所述第一陶瓷或聚合物层之上，对应的结构接触。
32.根据权利要求21所述的隔热材料，其中所述第二陶瓷或聚合物层安置于所述第一陶瓷或聚合物层之上，对应的基底接触。
33.根据权利要求21所述的隔热材料，其中所述第二陶瓷或聚合物层的所述至少一种结构平行于所述第一陶瓷或聚合物层的所述至少一种结构安置。
34.根据权利要求33所述的隔热材料，其中所述隔热材料的热阻由圆柱形导热体进行估计。
35.根据权利要求21所述的隔热材料，其中所述第二陶瓷或聚合物层的至少一种结构垂直于所述第一陶瓷或聚合物层的至少一种结构安置。
36.根据权利要求35所述的隔热材料，其中所述隔热材料的热阻由球形导热体进行估计。
37.根据权利要求21所述的隔热材料，其中所述第二陶瓷或聚合物层包括表面反射材料。
38.根据权利要求37所述的隔热材料，其中所述第二陶瓷或聚合物层的所述表面反射材料是由铝箔、金箔或敷铝的或双敷铝的MYLAR
膜构成的。
39.根据权利要求37所述的隔热材料，其中所述第二陶瓷或聚合物层的表面反射材料包括高反射介电材料。
40.根据权利要求39所述的隔热材料，其中所述高反射介电材料为二氧化钛。
41.根据权利要求37所述的隔热材料，其中所述第二陶瓷或聚合物层的所述表面反射材料的厚度小于或等于约1.0微米。
42.根据权利要求37所述的隔热材料，其中所述第二陶瓷或聚合物层的表面反射材料被耦合到所述至少一种结构的每个面。
43.根据权利要求37所述的隔热材料，其中所述第二陶瓷或聚合物层的表面反射材料面向所述第一陶瓷或聚合物层的所述表面反射材料。
44.根据权利要求21所述的隔热材料，进一步包括中间层，其中所述中间层包括具有至少一种结构的基底。
45.根据权利要求44所述的隔热材料，其中所述中间层位于所述第一陶瓷或聚合物层与所述第二陶瓷或聚合物层之间，以形成分层。
46.根据权利要求44所述的隔热材料，其中所述中间层包括多种结构。
47.根据权利要求44所述的隔热材料，其中所述中间层以对所述第一陶瓷或聚合物层成一角度安置。
48.根据权利要求44所述的隔热材料，其中所述中间层以对所述第二陶瓷或聚合物层一角度安置。
49.根据权利要求48所述的隔热材料，其中所述中间层的所述结构从所述基底的一个侧伸出。
50.根据权利要求48所述的隔热材料，其中所述中间层的所述结构从所述基底的两侧伸出。
51.根据权利要求44所述的隔热材料，其中所述结构与所述基底成一体。
52.根据权利要求44所述的隔热材料，其中所述中间层的所述至少一种结构的形状与所述第二陶瓷或聚合物层的所述至少一种结构的形状以及所述第一陶瓷或聚合物层的所述至少一种结构的形状相同。
53.根据权利要求44所述的隔热材料，其中所述中间层的所述至少一种结构的形状与所述第二陶瓷或聚合物层的所述至少一种结构的形状以及所述第一陶瓷或聚合物层的所述至少一种结构的形状不同。
54.根据权利要求44所述的隔热材料，其中所述中间层的所述至少一种结构是风琴褶样结构。
55.根据权利要求54所述的隔热材料，其中所述风琴褶样结构的三角部分的顶部具有预定宽度，从而对着所述风琴褶样结构上下表面的接触区被控制。
56.根据权利要求1-55中任何一项权利要求所述的隔热材料，其中所述隔热材料被真空密封在保护性聚合物敷层中，所述保护性聚合物敷层使能并保护所述真空，并且具有或不具有反射表面。
57.根据权利要求1-55中任何一项权利要求所述的隔热材料，所述隔热材料是柔性板。
58.根据权利要求1-55中任何一项权利要求所述的隔热材料，所述隔热材料是通过浇铸、固化或压花方法制造的微复制结构。
59.包括根据权利要求1所述的隔热材料的制造的物品，选自包括以下各项组成的组：食品包装；饮料罐；瓶；柔性饮料袋；输电线缆和设备的隔热；用于液体冷冻剂的传送和运输***；热管、热泵、运载工具推进剂贮箱；供料管线；制冷单元；器具；医用包装；医用运输箱；容器；用于二氧化碳、氨、急冷水或盐水、油和蒸汽的传送和运输***；木板；石膏板；屋顶隔热；真空隔热材料。
60.一种隔热材料器件，包括：
四层分层，包括第一陶瓷或聚合物层形成的开孔网状体，其中所述第一陶瓷或聚合物层包括第一结构；第二陶瓷或聚合物层，其中所述第二陶瓷或聚合物层包括第二结构；第一中间层，其中所述第一中间层包括第三结构；第二中间层，其中所述第二中间层包括第四结构和反射材料层，其中所述第一和第二陶瓷或聚合物层、所述第一和第二中间层以及反射材料层的排布允许在每个可以被密封的所述层内产生真空；以及
保护性聚合物敷层，其中所述第一、第二、第三和第四结构的总表面积的约1％或更低彼此接触。
61.根据权利要求60所述的隔热材料器件，进一步包括一种表面反射材料。
62.根据权利要求60所述的隔热材料器件，其中所述开孔网状体的特征在于相对于材料体积至少40％的真空区。
63.根据权利要求60所述的隔热材料器件，其中所述第一和第二中间层是陶瓷或聚合物层。
64.根据权利要求60所述的隔热材料器件，其中任何所述第一、第二、第三和第四结构的特征在于大于顶部部分的底部部分。
65.根据权利要求64所述的隔热材料器件，其中所述底部部分附接至底部基底。
66.根据权利要求60所述的隔热材料器件，其中任何所述第一、第二、第三和第四结构均为凸凹式凸出体。
67.根据权利要求60所述的隔热材料器件，其中任何所述第一、第二、第三和第四结构均为风琴褶样结构。
68.根据权利要求60所述的隔热材料器件，其中所述反射材料层是由铝箔、金箔或敷铝的或双敷铝的MYLAR
膜构成的。
69.根据权利要求60所述的隔热材料器件，其中所述反射材料层包括高反射介电材料。
70.根据权利要求69所述的隔热材料器件，其中所述高反射介电材料为二氧化钛。
71.根据权利要求60所述的隔热材料器件，其中所述反射材料层的厚度低于或等于约1.0微米。
72.根据权利要求60所述的隔热材料器件，其中所述反射材料层被耦合至所述第一、第二、第三和第四结构中的至少一个的至少一部分。
73.根据权利要求60所述的隔热材料器件，其中所述反射材料层是一个多层叠置。
74.根据权利要求60所述的隔热材料器件，进一步包括细胞样密封基质层。
75.根据权利要求60所述的隔热材料器件，其中所述隔热材料器件能够维持真空从约6个月到约50年。
76.根据权利要求60所述的隔热材料器件，进一步包括每层的气体阻隔件。
77.根据权利要求60所述的隔热材料器件，进一步包括每层的潮湿阻隔件。
78.根据权利要求60所述的隔热材料器件，进一步包括纳米敷层材料，其中纳米敷层材料充当吸气剂。
79.根据权利要求60所述的隔热材料器件，进一步包括多个内周边真空密封层。
80.根据权利要求60所述的隔热材料器件，进一步包括真空沉积金属层。
81.根据权利要求60所述的隔热材料器件，其中所述隔热材料器件被形成为容器表面的预定部分。
82.根据权利要求60所述的隔热材料器件，进一步包括四个层的至少一第二分层，其中所述第二分层包括第一陶瓷或聚合物层形成的开孔网状体，其中所述第一陶瓷或聚合物层包括第一结构；第二陶瓷或聚合物层，其中所述第二陶瓷或聚合物层包括第二结构；第一中间层，其中所述第一中间层包括第三结构；第二中间层，其中所述第二中间层包括第四结构和反射材料层，其中所述第一和第二陶瓷或聚合物层、所述第一和第二中间层和所述反射材料层的排布允许在每个可以被密封的所述层内产生真空。
83.根据权利要求82所述的隔热材料器件，其中所述第一分层的所述第一、第二、第三和第四结构的形状与所述第二分层的所述第一、第二、第三和第四结构的对应形状相同。
84.根据权利要求82所述的隔热材料器件，其中所述第一分层的所述第一、第二、第三和第四结构的形状与所述第二分层的所述第一、第二、第三和第四结构的对应形状的至少一个不同。
85.根据权利要求82所述的隔热材料器件，其中所述第一分层与所述第二分层具有对应层的相同周期性层。
86.根据权利要求82所述的隔热材料器件，其中所述第一分层与所述第二分层在至少一个对应层中具有不同的周期。
87.根据权利要求82所述的隔热材料器件，其中所述第一分层的至少一个层与所述第二分层的对应层偏离。
88.根据权利要求82所述的隔热材料器件，其中所述第一和第二分层的每个均有一内部断点，其中所述第一和所述第二分层的所述内部断点对齐以赋予所述隔热材料器件柔韧性水平。
89.根据权利要求82所述的隔热材料器件，形成为圆柱体的形状或基本上以圆柱体的方式成形，并在近真空压力密封，以为饮料或其他容器产生隔热内部或外部层。
90.根据权利要求82所述的隔热材料器件，其中所述第一分层的所述第一、第二、第三和第四结构的至少一个以与所述第二分层的所述第一、第二、第三和第四结构的至少一个成一角度安置。
91.根据权利要求82所述的隔热材料器件，其中所述第一分层的所述第一、第二、第三和第四结构的至少一个以垂直于所述第二分层的所述第一、第二、第三和第四结构的至少一个安置。
92.根据权利要求82所述的隔热材料器件，其中所述第一分层的所述第一、第二、第三和第四结构的至少一个以平行于所述第二分层的所述第一、第二、第三和第四结构的至少一个安置。
93.根据权利要求82所述的隔热材料器件，其中所述隔热材料器件被干燥。
94.根据权利要求82所述的隔热材料器件，其中所述隔热材料器件被真空密封以在所述层之间保持近真空。
95.根据权利要求82所述的隔热材料器件，其中所述隔热材料器件真空下在所述器件的周边被热封。
96.根据权利要求82所述的隔热材料器件，其中所述隔热材料器件在器件周边同时用气体和潮湿阻隔材料真空热封，所述气体和潮湿阻隔材料延伸至所述器件的周边。
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US9705108P | 2008-09-15 | 2008-09-15 | |
| US61/097,051 | 2008-09-15 | ||
| PCT/US2009/056674 WO2010030890A2 (en) | 2008-09-15 | 2009-09-11 | Thermal resistor material |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN102317065A true CN102317065A (zh) | 2012-01-11 |
Family
ID=41460140
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN2009801454437A Pending CN102317065A (zh) | 2008-09-15 | 2009-09-11 | 热阻件材料 |
Country Status (8)
| Country | Link |
|---|---|
| US (1) | US20100068471A1 (zh) |
| EP (1) | EP2334492A2 (zh) |
| JP (1) | JP2012503149A (zh) |
| CN (1) | CN102317065A (zh) |
| AU (1) | AU2009291631A1 (zh) |
| CA (1) | CA2737157A1 (zh) |
| TW (1) | TW201022570A (zh) |
| WO (1) | WO2010030890A2 (zh) |
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| KR101507541B1 (ko) | 2014-07-08 | 2015-03-31 | 이영주 | 단열필름 |
| CN105246955A (zh) * | 2013-06-12 | 2016-01-13 | 金伯利-克拉克环球有限公司 | 用于隔热的聚合材料 |
| CN112157967A (zh) * | 2020-10-27 | 2021-01-01 | 李纪用 | 一种高性能生态板 |
| CN114263664A (zh) * | 2021-10-19 | 2022-04-01 | 大连理工大学 | 一种高效兼顾承载与隔热需求的连接机构 |
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| US10753023B2 (en) | 2010-08-13 | 2020-08-25 | Kimberly-Clark Worldwide, Inc. | Toughened polylactic acid fibers |
| CN102383703A (zh) * | 2011-08-12 | 2012-03-21 | 浙江天泉表面技术有限公司 | 一种防火门 |
| US20130101789A1 (en) * | 2011-10-25 | 2013-04-25 | Neil D. Lubart | Thermal resistor material |
| US11965083B2 (en) | 2013-06-12 | 2024-04-23 | Kimberly-Clark Worldwide, Inc. | Polyolefin material having a low density |
| AU2014279791B2 (en) | 2013-06-12 | 2018-11-29 | Kimberly-Clark Worldwide, Inc. | Absorbent article containing a porous polyolefin film |
| CN104131624B (zh) * | 2014-06-26 | 2016-08-24 | 成都绿迪科技有限公司 | 复合真空隔热板 |
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| CN114263664A (zh) * | 2021-10-19 | 2022-04-01 | 大连理工大学 | 一种高效兼顾承载与隔热需求的连接机构 |
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Also Published As
| Publication number | Publication date |
|---|---|
| EP2334492A2 (en) | 2011-06-22 |
| WO2010030890A3 (en) | 2010-09-16 |
| CA2737157A1 (en) | 2010-03-18 |
| WO2010030890A2 (en) | 2010-03-18 |
| AU2009291631A1 (en) | 2010-03-18 |
| US20100068471A1 (en) | 2010-03-18 |
| JP2012503149A (ja) | 2012-02-02 |
| TW201022570A (en) | 2010-06-16 |
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