WO2020186544A1 - 一种气凝胶改性羽绒材料及其制品 - Google Patents

一种气凝胶改性羽绒材料及其制品 Download PDF

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Publication number
WO2020186544A1
WO2020186544A1 PCT/CN2019/079774 CN2019079774W WO2020186544A1 WO 2020186544 A1 WO2020186544 A1 WO 2020186544A1 CN 2019079774 W CN2019079774 W CN 2019079774W WO 2020186544 A1 WO2020186544 A1 WO 2020186544A1
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Prior art keywords
aerogel
powder
modified
modified down
aerogel powder
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PCT/CN2019/079774
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English (en)
French (fr)
Inventor
翁文灏
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翁文灏
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Publication of WO2020186544A1 publication Critical patent/WO2020186544A1/zh

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    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D1/00—Garments
    • A41D1/04—Vests, jerseys, sweaters or the like
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D3/00—Overgarments
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
    • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G9/00—Bed-covers; Counterpanes; Travelling rugs; Sleeping rugs; Sleeping bags; Pillows
    • A47G9/02—Bed linen; Blankets; Counterpanes
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M19/00—Treatment of feathers

Definitions

  • the invention belongs to the technical field of heat insulation and/or thermal insulation materials, and relates to an aerogel-modified down materials and products (Aerogel-modified down materials and products), and in particular to an ultra-thin down jacket, down duvet and down underwear .
  • Down is currently known natural fiber with the best thermal insulation performance.
  • the downy feathers ie, velvet flowers
  • the velvet flower does not contain the feather shaft, only contains a short and thick nucleus. Around the nucleus grow fine and soft filaments, which are radial and shaped like pompoms; on the longer first-order filaments grow shorter ones.
  • Each velvet contains ring-shaped scale nodes.
  • the next-level velvet is equivalent to its ring-shaped phosphorus node from a certain Extension in one or several directions. This unique structure gives down a large internal space to accommodate a large amount of still air, making it the natural fiber with the best thermal insulation performance.
  • Aerogel is the solid with the lowest density among all natural and artificial solids currently known, and its thermal insulation performance as an artificial solid is much better than that of down as a natural fiber. Aerogel has excellent properties such as extremely low density, extremely low thermal conductivity, extremely high porosity, non-combustibility, high temperature resistance, and excellent water repellency; in particular, aerogel can lock a large amount of still air in a small space with extremely high thermal conductivity. Low, light weight and not easy to absorb water, excellent performance as a thermal insulation material. However, aerogel is a brittle material and cannot be directly applied to clothing, shoes, and other products that need to be bent during use and/or storage. Therefore, the aerogel must be made into particles or powder first. Make it adhere to or be wrapped in other substrates for use.
  • the dust in down can also cause allergies, coughing, fainting eyes, sneezing, itching, chest tightness, dyspnea, dermatitis, rhinitis or other inflammations, long-term use can even cause serious diseases such as pneumoconiosis or silicosis. Therefore, in the existing known down quality evaluation system, the higher the dust content in the down, the worse the quality of the down product, and the lower the dust rate, the better the down quality. Therefore, the existing down factories have a special dust removal program in order to reduce the dust content in the down, the lower the better.
  • the purpose of the present invention is to develop an "aerogel-modified down" material and its products that can prevent the aerogel powder from falling off and exuding from down products and at the same time have the excellent thermal insulation properties of down and aerogel.
  • An aerogel modified down material includes down and aerogel powder.
  • the aerogel powder is silica aerogel powder or carbon-based aerogel powder.
  • the weight of the aerogel powder accounts for 1% to 99% of the total weight of the aerogel powder and down, preferably 30% to 60%.
  • the beneficial effect of adopting the above-mentioned further solution is: because the pile-like structure has a great expansion space, a large amount of aerogel powder can be contained between the piles, the pile filaments and/or the pile thorns, and a great
  • the weight ratio perfectly solves the problem that the aerogel content in the existing aerogel fiber does not exceed 1%, and the aerogel content in the aerogel composite felt generally does not exceed 30%. Since the density of aerogel can be made close to or far less than the density of fully expanded down feathers, the mass ratio of aerogel to down depends on the relaxation degree and material density of the feathers, from 1% to 99% is not a problem. It can easily break through the limitation of various existing technical solutions on aerogel content.
  • This ratio can make full use of the advantages of these two materials to the greatest extent, and can obtain super thermal insulation ability. It also has the advantages of down fiber flexibility, agglomeration and air permeability, and avoids various shortcomings such as aerogel brittleness, expensive down and poor availability.
  • the feathers of the above-mentioned down feathers are natural feather feather-like structures and/or artificial feather-like feather-like structures.
  • the artificially manufactured fleece-like structure is a pompons, a fleece, a flannel and/or a flock.
  • the pile cores of the pile-like structure can also be arranged or knitted together to form a pile, suede or pile-like structure;
  • the aerogel powder is mixed into these woolen yarns, suede surfaces or flock-like structures to obtain aerogel modified materials with better thermal insulation performance, powder resistance performance, flexibility and/or tensile resistance.
  • the present invention also provides an aerogel-modified down product, which is made of the above-mentioned aerogel-modified down material and a powder-repellent structure, the powder-repellent structure wraps or adheres outside the aerogel powder monomer particles ;
  • the powder-repellent structure wraps or adheres outside the flocks filled with aerogel powder.
  • the beneficial effect of the present invention is that the above-mentioned anti-powder structure fixes and/or confines the aerogel powder in or on the down, and the anti-powder structure may be a wrapping layer to wrap the aerogel particle monomer and/or Containing/adsorbing many aerogel particle monomers, velvet, velvet.
  • the aerogel powder can be firmly bonded or confined within the down products through the one- or multi-level powder-repellent structure, so as to avoid human allergies, coughing, annoyed eyes, sneezing, hair Itching, chest tightness, dyspnea, dermatitis, rhinitis or other inflammations, as well as serious diseases such as pneumoconiosis or silicosis that may be caused by long-term use of powdered aerogel products. It also prevents the aerogel powder from washing and rubbing. Falling off, or the reduction of aerogel due to powder falling makes the thermal insulation performance worse, which improves the use effect and service life of down products.
  • the above-mentioned aerogel-modified down product is made into a mass or a flat sheet, and the powder-repellent structure is wrapped or adhered to the surface of the mass or flat sheet of aerogel-modified down product.
  • the above-mentioned anti-powdering structure is an organic coating layer and/or an inorganic coating layer, a structural glue, an adhesive/adhesive, a curing agent, a crosslinking agent, a coupling agent, or a film structure
  • the organic coating layer is a cellulose derivative Type, polysulfone, polyamide, silicon-containing polymer, fluoropolymer, silicone glue, polyurethane glue, acrylate homopolymer or phase change polymer
  • the inorganic coating layer is a silicon dioxide film, Ceramic membrane, metal membrane, zeolite membrane, glass membrane or molecular sieve composite membrane.
  • aerogel-modified down material products are also filled with natural fibers, and/or artificial synthetic fibers, and/or high heat reflectivity materials, and/or far-infrared materials, and/or moisture-absorbing and heating materials, and/or relative Change material.
  • the beneficial effect of adopting the above-mentioned further technical solution is that the overall heat preservation performance of the final product can be further improved.
  • a high heat reflective material is provided in the down jacket to reflect the heat emitted by the human body back to the skin surface and reduce heat loss; far-infrared material It is more conducive to lock in heat, and can also reduce the heat loss of the human body; the moisture-absorbing heating 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, so that the human body can obtain more heat faster.
  • the above-mentioned modified down material is also filled with one or a mixture of cotton, wool, cashmere, feathers, hemp, polyester staple fiber, polyester filament, spandex yarn, and aramid fiber.
  • filling the above-mentioned materials can reduce the amount of aerogel or down and reduce the cost, and at the same time, the respective physical or chemical properties of these materials can be utilized.
  • the high elasticity of spandex fiber, the high strength of aramid fiber, the low cost of polyester yarn, and the skin affinity of cotton and linen fiber can be used to improve the performance of the aerogel-modified down product of the present invention.
  • the above-mentioned wrapping layer is made of a high thermal reflectivity material or a far-infrared material
  • the above-mentioned high thermal reflectivity material is an aluminum powder or an aluminum film
  • the above-mentioned far infrared material is a far-infrared fiber.
  • an electric heating device, a temperature sensor and/or a temperature control device are arranged inside or outside the modified down material.
  • the beneficial effect of adopting the above-mentioned further technical solution is that an electric heating device is provided at the modified down material, which greatly improves the thermal insulation performance, and also obtains an additional heat source beyond the body temperature of the human body, which can make the human body wrapped in it Get more and faster heating, less temperature loss, especially suitable for applications in extreme environments such as polar regions and mountains.
  • the temperature sensor and temperature control device can also be used to accurately control the temperature in the modified down material like the currently popular battery heating suit.
  • the preparation method of the aerogel modified down product is:
  • the modified down product is made into a mass or flat sheet, and the surface of the above-mentioned mass or flat sheet-shaped aerogel modified down material is sprayed or adhered to a powder-repellent structure to realize the fixation of the aerogel powder particles.
  • Down has good thermal performance and high bulkiness.
  • a large amount of aerogel powder can be filled in the voids formed by down and down.
  • the thermal resistance of aerogel is greater than that of down.
  • the final aerogel is Modified down material has much better thermal insulation effect than conventional down products; down is known natural fiber with the best thermal insulation performance, while aerogel thermal insulation performance is much better than down; both;
  • the overall thermal insulation performance after mixing can be significantly improved compared with simple down products, and can be greatly improved exponentially compared with other cotton, linen, wool, chemical fiber or common blended products.
  • Aerogel powder can be attached stably on the surface of down, which can increase the thermal resistance while obtaining relatively stable integrity.
  • aerogel has extremely good water repellency, which can effectively avoid the problem of rapid decrease in insulation performance caused by water absorption or moisture absorption of down.
  • the weight of aerogel required by the modified down material of the present invention is far lower than that required for down products with the same thermal insulation performance.
  • the total weight and storage volume of the modified down material of the present invention can be significantly reduced, and at the same time, the amount of down used is reduced, and the thermal insulation capacity of the thick traditional down products can be equal or even stronger.
  • ultra-thin down products such as ultra-thin down jackets, ultra-thin duvets, ultra-thin down caps, ultra-thin down gloves, ultra-thin down sleeping bags, ultra-thin down underwear and down shoes, etc.
  • ultra-thin down products not only provides better thermal insulation
  • the body movements are especially suitable for beauty-loving women and outdoor activity participants who require high mobility.
  • the modified down material of the present invention can also enable the aerogel powder to be very firmly bonded or sealed in the modified down material through the multi-stage leak-proof structure, and the aerogel powder is adhered or clamped in the down In the space between the velvets, velvet filaments and/or velvet spines, it is not easy to fall out or fall, and there will be no powder falling; avoiding the aerogel powder falling from being inhaled by the human body, causing itchy throat, etc. Pneumoconiosis/silicosis and other serious quality problems and safety hazards. It can also prevent human dander and external dust from entering the down products, or the reduction of aerogels leads to poor thermal insulation performance, which improves the use of down materials Effect and service life.
  • the density of aerogel is extremely small, the total weight of finished quilts, clothes, clothes and hats with the same thermal insulation performance can be significantly reduced; not only can reduce the pressing force to make people more comfortable, but also more convenient Carry and store.
  • the thermal insulation performance of aerogel can be greatly stronger than that of down itself, the total weight, thickness and/or volume of the finished quilt, clothing, clothing, and cap that obtain the same thermal insulation performance can also be significantly reduced; People are more flexible and comfortable, and they are easier to store.
  • the tensile strength, flexural strength and compressive strength are good. It becomes a good substrate for attaching or wrapping the aerogel powder.
  • the resultant product is more flexible than the bulk aerogel. Performance, flexibility and durability can be significantly improved.
  • the gaps between the first-order velvet, the second-order velvet and/or the spurs are relative to non-woven fabrics, cotton, hemp and other natural fibers, and polyester, aramid, spandex and other chemical fibers And/or the filament diameter and the inter-filament voids of the blended fibers of these materials are much larger, so the volume of aerogel can be quite large in the voids between the fleece filaments and/or thorns of various steps.
  • the maximum distance can reach several centimeters, even in the part close to the fleece core, it can reach the millimeter level, so it is crushed into millimeter level, silk meter level, micron level or even nanometer level.
  • the aerogel can be easily and massively placed into the velvet. Therefore, the weight ratio of aerogel in the above-mentioned aerogel down products with stable and reliable performance can not only easily exceed 1%, but also can exceed 99%. That is to say, the above-mentioned down feathers can even be used as a main insulation layer.
  • the shape of the substrate is used instead of as a thermal insulation material.
  • the common inherent contradictions of the above groups of down products can be easily solved: because the voids between or inside the feathers are mainly occupied by the aerogel powder, the inside or between the aerogel powder is still Air plays the main role of heat preservation and heat insulation.
  • the still air inside or between the velvet, velvet and/or velvet only serves as the weakened auxiliary main function; and the aerogel powder is in the velvet, velvet and/or Or the fluff spines are inserted into the gaps between the piles, filaments and/or fluff spines under the condition that they are fully and naturally unfolded in the airflow, and the fluffiness of the down has reached or approached its maximum value and can remain relatively stable. Therefore, the bulkiness is relegated to a secondary factor that does not require special emphasis.
  • the compression ratio of the down containing the aerogel powder will be significantly reduced, not only the thermal insulation performance is significantly improved, but also the product shape retention ability Can also be significantly improved. It is similar to the relationship between steel and concrete in the reinforced concrete structure of the building: although the simple steel has good tensile strength, it cannot bear the heavy pressure under the weight of the building, and it is easy to bend and fall; the simple concrete has good compressive strength, but no The pulling action of the steel bars is easy to crack or be crushed; after filling the concrete between the steel bars, both of them play their respective advantages, so that the reinforced concrete structure is resistant to compression and tension and will not easily crack, which greatly helps maintain the building The shape is not destroyed.
  • the down filaments and/or lint thorns of the above-mentioned down play a role similar to steel bars, and the above aerogel powder acts as a concrete-like function: the soft and wavy flexible lint and/or lint thorns and both are filled with
  • the flexible fluff/hair thorns can give full play to its tensile capacity and aerogel to exert its compressive capacity, and finally the shape retention performance of the product is greatly improved.
  • the above technical scheme of the present invention can significantly reduce the amount of down. Not only the improvement of the overall thermal insulation capacity can make the product thinner and smaller, thereby reducing the amount of down, but also the compression ratio of down and most of the inside of the down.
  • the single and combined effect of multiple factors such as space occupied by aerogel can significantly reduce the amount of down; this is also an important aspect worth considering at the time when the availability of down is getting worse and the price is getting more and more expensive.
  • the down as the base material plays a secondary or even negligible thermal insulation role, so it can be used with lower bulkiness, lower porosity, and down content.
  • the relatively inferior down with less and higher feather content has the same or even more thermal insulation performance. Therefore, relatively inferior down can be used to obtain the same or even more thermal insulation capacity, which can reduce costs and expand the source of raw materials.
  • aerogel is a material with good flame retardancy. Compared with the natural defects of traditional down jackets that are easy to catch fire and easy to spread to the down filling, the fire safety of aerogel modified down is significantly improved.
  • Duvets and down jackets are very mature industries, and their production processes and equipment are stable and reliable, easy to obtain, and low production costs.
  • the aerogel powder can be blown into a violent boiling state that moves synchronously with the airflow, and then sprayed at a high speed at a rate of no less than 3.2 m/s from the nozzle to the boiling aerogel powder stream, including silicone glue, polyurethane glue Fine droplets of organic and/or inorganic structural adhesives, adhesives/adhesives, curing agents, crosslinking agents, coupling agents, etc., including acrylate homopolymer structures, phase change polymers, etc.
  • the droplets of binder, curing agent, crosslinking agent, and coupling agent will wrap the aerogel powder and form a shell-like coating on the outside.
  • the high-speed fan is set at the bottom of the sealed space.
  • the aerogel particles with too thick coating layer are easy to layer to the bottom of the sealed space due to their high density and are hit by the high-speed rotating fan blades, causing the liquid coating layer to be scratched, Collision, reduction or even shedding, the density of aerogel particles becomes smaller, they can float to the middle and upper part of the confined space again with the airflow, so as to be picked up through the screen or re-sprayed.
  • the thickness of the wrapping layer can be controlled to be 3-8 ⁇ m.
  • the type and amount of the specific anti-powder structure should be appropriately selected according to its own physical and chemical properties and the type/physical and chemical properties of the aerogel material.
  • the silicon-based aerogel is silica
  • use glass glue that is easy to combine with silica /Silicone glue component as the wrapping layer.
  • the aerogel powder monomer is evenly wrapped, the down is blown into the closed space, and the blown down feathers will repeatedly roll and/or stir together with the wrapped aerogel powder particles in the closed space with the airflow ;
  • the velvet is repeatedly tumbling and/or stirred and fully unfolded with the airflow, the aerogel powder with the wrapped layer floating in the airflow can enter the velvet, the velvet filaments and/or the velvet thorns.
  • aerogel modified down products are prepared, and the surface of the shell layer outside the aerogel particles will be bonded with the down feathers, various steps of down and/or thorns to achieve air resistance. Fixation of gel powder particles. These mixtures are pressed into sheets or molded into dough shapes, which can be used as fillers for clothing, quilts, sleeping bags, cold-proof gloves, etc.
  • a purge step can be taken before pressing or molding the mixture: these freely movable aerogel powders are lightly clamped on the screen or formed The mixture in the mold is purged out and used in the subsequent mixing process.
  • the fixed or restricted free dust is reduced to a minimum or even zero.
  • the aerogel-modified down product prepared in this way has a large number of penetrating pinholes, and there is no phenomenon of powder falling or not obvious. Because the free dust has been swept away, the aerogel particles fixed in the down are wrapped by the coating layer and adhered to the down, and they are not easy to fall off; and during use, even the aerogel particles in the coating layer are squeezed by external force. The crumbs are more broken, and the debris is still wrapped in the wrapping layer, and will not leak, and will not cause the reduction of aerogel components in the product.
  • the sealed space into which the aerogel powder is blown can be made of existing machinery and equipment, including a sifter, a pile box, a pile divider, a five-box divider, a mixing box, and/or a pile filling machine. With a closed box and multiple nozzles and fans, the required mixing space can be obtained. These machines have reliable performance, easy operation and good availability.
  • crospovidone is used as the coating layer and sprayed uniformly on the fluidized bed formed by aerogel powder and down, and then cured and pressed into a flat structure with a length of about 5 mm, which is an ultra-lightweight The filling material of aerogel modified duvet.
  • polyvinyl alcohol-polyglutamic acid polymer is used as a coating layer and mixed on a fluidized bed formed by aerogel powder and down, and after curing, it is pressed into a planar structure with a length of about 2 mm.
  • the filling material of ultra-light aerogel modified down jacket is used as a coating layer and mixed on a fluidized bed formed by aerogel powder and down, and after curing, it is pressed into a planar structure with a length of about 2 mm.
  • a 6:2:1 mixture of aerogel powder, down and hot-melt adhesive powder is blown into a closed box; the extension machine is turned on for at least 20 minutes to mix them evenly; The body temperature rises to 113 degrees Celsius, turning the solid hot melt adhesive particles mixed therein into liquid hot melt adhesive droplets; continue to stir and mix the mixture containing hot melt adhesive droplets, and gradually stabilize the temperature in the box from 113 degrees Celsius When the temperature is lowered to room temperature, the hot-melt adhesive droplets solidify, and most of the aerogel powder and down are fixed together. Finally, the unfixed aerogel powder is purged out of the mixture and recycled. That is, it is worth an aerogel modified down material that can withstand high washing temperatures.
  • the aerogel powder is passed through a long-stroke folded trachea.
  • the inside and/or inner surface of the trachea has a certain electrostatic charge and electrostatic voltage.
  • the aerogel powder enters through the folded trachea in the form of fluid Before the mixing box, the aerogel powder continuously collides with the inner surface of the trachea with static electricity or the inner conductor of the tube.
  • the aerogel powder is charged during the collision, or the aerogel material is selected according to the friction of the aerogel material to generate static electricity.
  • the aerogel powder When the anti-powder structure is in powder form, the above method of making the aerogel powder electrostatically charged can also be used to make the anti-powder structure electrostatically charged; when the anti-powder structure is in liquid form, it can follow the similar principle of the electrostatic spinning method. When an electrostatic voltage is applied to the nozzles, the mist particles sprayed through these nozzles will carry the electrostatic charge transferred from the nozzles.
  • the aerogel powder When the aerogel powder is not easily combined with structural glue, adhesive/adhesive, curing agent, crosslinking agent or coupling agent, etc., it can also be used for aerogel powder and/or structural glue, adhesive/adhesive, etc.
  • the curing agent, crosslinking agent, and coupling agent droplets are charged with different kinds of electrostatic charges first, and then through the principle of electrostatic "same sex repulsion, opposite sex attraction" principle, not only can accelerate the aerogel powder and structural adhesive with opposite sex charge , Adhesive/adhesive, curing agent, crosslinking agent, coupling agent droplets, but also can selectively make certain types of powder and droplets less or not combined, for example, the same-charged liquid
  • the droplets are difficult to combine into large droplets due to mutual repulsion, so that the droplet distribution is more uniform and longer, and it is more conducive to find aerogel powder with opposite charges for combination.
  • the droplets can spread more uniformly and quickly on the surface of the aerogel particles and finally Enclose the aerogel powder particles completely.
  • the fleece and/or fleece itself can also be charged with static electricity opposite to the aerogel particles or the shell layer that wraps it, so that the fleece and the aerogel powder particles or the shell layer that wraps it can be faster, Better and stronger together.
  • the adhesive can be sprayed again on the aerogel-modified down that has been evenly mixed, or a wrapping layer can be arranged on the aerogel-modified down to further strengthen the aerogel powder particles and the feathers.
  • the fastness of the combination of velvet and velvet spines, and finally the aerogel down is made into down products including down jackets, duvets, down sleeping bags, and down caps.
  • This kind of aerogel powder has a multi-layered anti-powder structure, and it is more difficult to fall off and cause the phenomenon of powder fall.
  • this multi-layer protection can also reduce the impact of the external environment on the aerogel powder, reduce or even avoid aerogel Gum powder particles are further crushed or refined.
  • Another advantage of providing a shell layer outside the aerogel powder particles is that even if the aerogel powder particles are further crushed or refined during the use of the product, the crushed or refined powder will still be Tightly wrapped in the shell, it is not easy to drill out of the shell or fall off.
  • a moisture-absorbing heating fiber is added to the mixture of aerogel powder and down, and the moisture-absorbing heating fiber emits heat after absorbing the water vapor emitted by the human skin. Therefore, the aerogel with moisture-absorbing heating fiber is added Modified down can not only greatly improve the overall thermal insulation performance of the product, but also enable the human body wrapped in it to obtain an additional heat source besides body temperature, which can enable the human body to obtain more and faster heating and less temperature loss, especially Suitable for applications in extreme environments such as polar regions and mountains.
  • heating fiber blended fabric or electric heating device (such as fine electric heating wire, etc.) is provided at the modified down material, and the heating fiber blended fabric or electric heating device generates heat, which greatly improves the thermal insulation performance. At the same time, it can also obtain an additional heat source besides the body temperature of the human body, which can make the human body wrapped in it get more and faster heating up and less temperature loss, especially suitable for applications in extreme environments such as polar regions and mountains.
  • a temperature sensor and a temperature control device are used to accurately control the temperature in the modified down material.
  • Setting a voltage or current regulating circuit at the battery power supply can realize temperature regulation. It is also possible to install a temperature sensor sheet on the clothing, and use the liquid crystal microcrystals in the temperature sensor sheet to become transparent or fuzzy at different temperatures to indicate the temperature so that the user can adjust the temperature reasonably.
  • a far-infrared material that is, a ceramic powder with far-infrared radiation function
  • Far-infrared ceramic powder particles can absorb electromagnetic waves emitted by the environment and the human body in a wide wavelength range and radiate far-infrared rays with a wavelength range of 2.5-30 ⁇ M, of which the infrared rays with a wavelength range of 4-14 ⁇ M are related to the vibration of water molecules in human cells.
  • a high-reflectivity material such as aluminum powder
  • the high-reflectivity material can reflect the heat emitted by the human body, reduce heat loss, and further improve the aerogel modification. The warmth retention performance of sexual down material products.
  • an aluminum film or aluminum film can also be attached to the inner surface of the aerogel-modified down. It can achieve the purpose of improving heat reflectivity and warmth retention.
  • the mixture of aerogel powder and down is mixed with spandex filaments with an initial volume ratio of about 20%, stirred uniformly and sprayed with polyvinyl acetate aerosol, and the thickness of the resulting mixture is about 1 mm at the compression position The surface structure.
  • the spandex filaments are uniformly cured between the piles, piles and/or aerogel wrapping layers. Since the spandex yarn has excellent elasticity and toughness, the elasticity and toughness of the spandex aerogel modified down products prepared thereby can be greatly improved.
  • silk, cotton, and/or hemp cloth can also be pasted on the inner and outer surfaces of the 1 mm planar structure to obtain better skin contact comfort.
  • the spandex aerogel modified down in this embodiment is particularly good for its warmth retention, elasticity and toughness, and is especially suitable for making thermal underwear.
  • a spandex filament with an initial volume ratio of about 3% is mixed into the mixture of aerogel powder and down, and the final mixture is not compacted to about 1 mm but is allowed to deposit and solidify in a natural way .
  • the bulkiness of the obtained spandex aerogel modified down will be particularly good, and the bulkiness recovery performance after being compressed and decompressed will be much better than conventional down products.
  • a simple down product has a bulkiness of 600, 700 or even higher, its down is always in a state of being squeezed to varying degrees.
  • the down Duo has been fully expanded when mixed with aerogel powder, so its bulkiness will be much greater than that of piles in different degrees of squeezed state.
  • the bulkiness can reach 800, 1000, 2000 or even 3000.
  • the fully expanded down feathers and/or down yarns are filled with aerogel powder. Therefore, when the aerogel modified down is compressed, its volume is not easy to shrink compared to pure down, so the bulkiness can be The larger the thermal insulation performance, the better. After adding a small amount of spandex yarn, these flocks and/or aerogel flocks can be connected elastically and toughly, and the product shape can be better maintained.
  • the initial temperature in the box is the dry temperature of the washed down, about 110 degrees; the box size is 5 meters long, 5 meters wide, and 20 meters high, and at least methyl methacrylate and polybutyl acrylate are set in the box And/or the nozzle of the mixture of poly-2-ethyl ethyl acrylate, spray the mist of methyl methacrylate, polybutyl acrylate and/or poly-2-ethyl ethyl acrylate mixture after the two are mixed uniformly Droplets and cool the box at a rate of 5 degrees Celsius every 10 minutes, down, aerogel, methyl methacrylate, polybutyl acrylate and/or poly-2-ethyl ethyl acrylate mixture will gradually Decrease
  • polybutyl acrylate has a glass transition temperature of -54 degrees Celsius and poly-2-ethyl ethyl acrylate The glass transition temperature is -72 degrees Celsius. Both polybutyl acrylate and poly-2-ethyl acrylate are very soft polymers. In this way, the degree of softness and hardness of the homopolymer and the final mixed material can be achieved by controlling the cooling process control.
  • thermal curing is achieved by adjusting the temperature of the mixture. If necessary, select the appropriate type of aerogel and curing agent.
  • a wide variety of chemical reaction curing, UV curing, and material phase change curing (sublimation-sublimation , Vaporization-liquefaction, melting-condensation and other reversible processes).
  • the thermal conductivity of 95 velvet is about 0.09 W/m-degree Celsius, while the thermal conductivity of the 2 mm soft felt is only about 0.03 W/m-degree Celsius.
  • the down aerogel soft felt can not only be made into one-tenth the thickness of the same 95 velvet, but also can increase the thermal insulation and cold resistance by about 3 times.

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Abstract

一种气凝胶改性羽绒材料及其制品，该气凝胶改性羽绒材料包括羽绒、气凝胶粉末和防掉粉结构，防掉粉结构将气凝胶粉末固定和/或限定在羽绒之内或之上；防掉粉结构可以是粘黏物和/或包裹层，通过一级或多级防掉粉结构令气凝胶粉末牢固地被粘合或限制在羽绒制品内，避免由于气凝胶掉粉导致人体过敏、咳嗽、咳痰、喷嚏、发痒、迷眼、胸闷、呼吸困难、皮炎、鼻炎或其他炎症等、以及长期使用会导致尘肺或硅肺等严重疾病，还能防止清洗和搓揉过程中粉末脱落，或者由于掉粉导致的气凝胶减少使保温隔热性能变差等，提高了羽绒制品的使用效果和使用寿命。该气凝胶改性羽绒材料制备方法简单易行、工艺设备成熟可靠、成本低、适合大规模生产。

Description

一种气凝胶改性羽绒材料及其制品 技术领域
本发明属于隔热和/或保暖材料技术领域，涉及一种气凝胶改性羽绒材料及其制品(Aerogel-modified down materials and products),尤其涉及一种超薄的羽绒服、羽绒被和羽绒内衣。
背景技术
羽绒为目前已知的保温隔热性能最好的天然纤维。通常情况下用来作保暖材料的是舒展开后内部空间极大的绒羽(即绒朵)。绒朵不含羽轴，仅含一个短粗的绒核，绒核四周长出微细而柔软的绒丝，呈放射状，形如绒球；在较长的一阶绒丝上又长出较短的二阶绒丝，二阶绒丝上则长有单根或双根绒刺，在各阶绒丝上都含有环状鳞节，下一阶绒丝相当于其环状磷节物从某一或某几个方向上的延伸。这一独特结构使羽绒具有极大的内部空间容纳大量的静止空气使之成为保温隔热性能最好的天然纤维。
气凝胶(Aerogel)为目前已知的所有天然和人造固体中密度最低的固体，且作为人造固体其保温隔热性能比作为天然纤维的羽绒还要好很多。气凝胶具有极低密度、极低导热性、极高孔隙率、不燃、耐高温、拒水性极好等优越性能；尤其是气凝胶能大量锁定微小空间内的静止空气、热导率极低、重量极轻且不易吸水，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/整体地应用到服饰鞋被这类在使用和/或收纳时需要弯折的产品上，因此必须将气凝胶先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复合到无纺布、发泡材料或塑料膜中，然后再将此类复合材料作为保温隔热夹层缝制成被服鞋帽之类的产品；也有少数公司尝试将气凝胶微粉直接混合到诸如涤纶、氨纶和/或芳纶之类的熔融原料中制成纤维 后纺纱再制成被服衣帽之类。
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/表面张力以及疏水/疏物性，能够混合入纤维之中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)。就此类技术而言，即便是将来能够提高气凝胶颗粒的含量，由于气凝胶颗粒极大的脆性和疏物性等固有特点，制得的纤维强度肯定会被严重降低，此类技术的实用性不会很强。
[根据细则91更正 24.07.2019]　
将气凝胶粉末混入闭孔发泡材料和/或膜材料的方案，不但同样面临气凝胶粉末难以高比例混入的难题、发泡产品不但气味严重，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，导致最终产品透气性差、闷热、易过敏、皮肤适应性极极差。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，均出现了不透气、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。
将气凝胶粉末夹在开孔发泡结构、纤维束或膜结构之间的方案，虽已在无需弯折的墙体或管道用气凝胶保温隔热材料上获得广泛的商业应用，但是却未能直接应用的需要反复弯折和/或清洗的服饰、被子、睡袋、垫子等穿着坐卧用具中。因为这些产品的气凝胶夹层在缝制过程中必定会产生大量的亚毫米甚至毫米级贯穿性针眼和贯通性缝纫线孔，而夹层内的气凝胶颗粒并未被束缚住、气凝胶粉末会如羽绒服跑绒现象那样在这些针眼或缝纫线孔处溢出并掉粉。而且，人肢体的运动会导致这些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气流不断地从针眼或缝纫线孔处溢出并掉粉。此外，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，气凝胶颗粒会在使用过程被反复挤压和/或冲击，被粉碎成粒径更小的颗粒；这些被压碎的气凝粉末不但会从这些针孔或线孔中漏出，而且在长时间使用后颗粒变得足够小时，甚至会从服饰或被子、睡袋等制品并无针孔部位的面料表面纤 维缝隙里大量直接渗出。这样一来，不但产品上有粉末导致不美观、污染环境、气凝胶含量减少导致产品保温隔热性能降低、而且更为严重的是气凝胶粉末会导致人体过敏、咳嗽、咳痰、喷嚏、发痒、迷眼、胸闷、呼吸困难、皮炎、鼻炎或其他炎症等、长期使用甚至可能会导致尘肺或硅肺等严重疾病。所以，现有将气凝胶粉末作为夹层加在薄膜结构中的技术方案因为惧怕被服缝制过程中的贯通性针孔，其实用性和/或可靠性并不理想；而将气凝胶简单附着在纤维的二维丝状/线状结构的外表面的各种技术方案，气凝胶粉末的附着效果差、均容易掉粉。
为了充分利用羽绒为保温隔热性能最好的天然纤维和气凝胶为所有固体中重量最轻、保温性能比羽绒还要好很多的突出特点，可以考虑将羽绒和气凝胶粉末复合起来，制得性能更好的服饰鞋被用保温隔热材料，即气凝胶改性羽绒材料(Aerogel Modified Down)。但是，在现有羽绒制品质量评价标准中，粉尘及粉尘率是影响羽绒质量的一个重要的负面指标,不但不能主动加入粉尘类物质，而且还唯恐粉尘太多、必欲先除之而后快。因为，羽绒中的粉尘同样会导致人体过敏、咳嗽、迷眼、喷嚏、发痒、胸闷、呼吸困难、皮炎、鼻炎或其他炎症、长期使用甚至会造成尘肺或硅肺等严重疾病。因此，在现有的公知羽绒质量评价体系中，羽绒中的粉尘含量越多则该羽绒制品的质量就会被认为是越差，粉尘率越低则羽绒质量会被认为越好。所以，现有羽绒工厂都有一个专门除尘程序，以期将羽绒中的粉尘含量降低，越低越好。如果要与现有公知认识相反地反其道而行之，将气凝胶粉末大比例混入羽绒当中，必须先解决掉粉问题才可能避免粉尘所导致的严重质量问题和安全隐患，才可能充分利用这两种材料各自优点获得保温隔热性能更好的高质量安全产品。
因此，研发一种既能利用羽绒优异的保温隔热性能，又能利用气凝胶更加卓越的保温隔热性能、密度和厚度均极小且具有拒水性等性能，且能够防止气凝胶粉末从羽绒制品中脱落或渗出的气凝胶改性羽绒材料及其制品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能够防止气凝胶粉末从羽绒制品中脱落渗出且同时兼具羽绒和气凝胶优异的保温隔热性能的“气凝胶改性羽绒”材料及其制品。
为了实现本发明上述目的，本发明采用以下技术方案：
一种气凝胶改性羽绒材料，包括羽绒和气凝胶粉末。
进一步，上述气凝胶粉末为二氧化硅气凝胶粉末或碳系气凝胶粉末。
进一步，上述气凝胶粉末的重量占上述气凝胶粉末和羽绒总重量的1％-99％，优选为30％-60％。
采用上述进一步方案的有益效果是：由于绒朵状结构具有极大的展开空间，所以绒朵、各阶绒丝和/或绒刺之间均可容纳大量的气凝胶粉末，获得极大的重量比，从而完美地解决现有气凝胶纤维内气凝胶含量不超过1％、气凝胶复合毡内气凝胶含量一般不超过30％的问题。由于气凝胶密度可以做得接近或者远小于完全舒张开的羽绒绒朵的密度，因此就气凝胶与羽绒的质量比而言，根据绒朵的舒张程度和材料密度，从1％到99％都不是问题，可以轻松突破各种现有技术方案对气凝胶含量的限制，这样的比例可以最大限度地充分利用这两种材料各自的优点，既可获得超强的保温隔热能力，又可具有羽绒纤维的柔韧度、聚团性和透气性等优点、还避免了气凝胶脆性、羽绒价格昂贵和可获得性差等各种缺点。
进一步，上述羽绒的绒朵为天然羽绒的绒朵状结构和/或人工制造的仿绒朵状结构。
进一步，上述人工制造的仿绒朵状结构为绒球、绒线、绒布和/或绒团。
采用上述进一步方案的有益效果是：在人工制造的仿绒朵状结构中，还可将仿绒朵状结构的绒核排列或编织在一起，形成绒线、绒面或绒团状结构；再在这些绒线、绒面或绒团状结构中混入气凝胶粉末，获得保温隔热性能、防掉粉性能、柔韧性和/或抗拉性等性能均更好的气凝胶改性材料。
本发明还提供了一种气凝胶改性羽绒制品，由上述气凝胶改性羽绒材料及 防掉粉结构制成，所述防掉粉结构包裹或黏附在气凝胶粉末单体颗粒外；
和/或，所述防掉粉结构包裹或黏附在填充了气凝胶粉末的绒朵之外。
本发明的有益效果是：上述防掉粉结构将气凝胶粉末固定和/或限定在羽绒之内或之上，防掉粉结构可以是包裹层，包裹住气凝胶颗粒单体和/或内含/吸附有众多气凝胶颗粒单体的绒朵、绒丝。这样就可通过一级或多级防掉粉结构令气凝胶粉末牢固地被粘合或限制在羽绒制品之内，避免由于气凝胶掉粉导致人体过敏、咳嗽、迷眼、喷嚏、发痒、胸闷、呼吸困难、皮炎、鼻炎或其他炎症等、以及长期使用掉粉气凝胶产品可能会造成的尘肺或硅肺等严重疾病，同时也能防止气凝胶粉末在清洗搓揉过程中脱落，或者由于掉粉导致的气凝胶减少使保温隔热性能变差等，提高了羽绒制品的使用效果和使用寿命。
进一步，将上述气凝胶改性羽绒制品制成团状或者平面片状，在所述团状或者平面片状的气凝胶改性羽绒制品表面包裹或黏附防掉粉结构。
进一步，上述防掉粉结构为有机包裹层和/或无机包裹层、结构胶、粘/黏合剂、固化剂、交联剂、偶联剂或膜结构，所述有机包裹层为纤维素衍生物类、聚砜类、聚酰胺类、含硅聚合物、含氟聚合物类、硅酮胶、聚氨酯胶、丙烯酸酯均聚物或相变聚合物；所述无机包裹层为二氧化硅膜、陶瓷膜、金属膜、沸石膜、玻璃膜或分子筛复合膜。
进一步，上述气凝胶改性羽绒材料制品还填充有天然纤维、和/或人工合成纤维、和/或高热反射率材料、和/或远红外材料、和/或吸湿发热材料、和/或相变材料。
采用上述进一步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，例如，在羽绒服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，也可减少人体热量散失；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。
优选地，上述改性羽绒材料中还填充有棉花、羊毛、羊绒、羽毛、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。
采用上述优选地的技术方案的有益效果是：填充上述材料可以减少气凝胶或羽绒的用量，降低成本，同时也可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改性羽绒制品的性能。
进一步，上述包裹层为高热反射率材料或远红外材料，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。
进一步，上述改性羽绒材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：在改性羽绒材料处设置电发热装置，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，尤其适于在极地、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，准确控制改性羽绒材料内的温度。
上述气凝胶改性羽绒制品的制备方法为：
称取气凝胶粉末灌入密封空间内，用设置在该密封空间内的风扇将灌入的气凝胶粉末吹成沸腾状，然后再向沸腾的气凝胶粉末包裹或黏附防掉粉结构，再向该密闭空间吹入羽绒；和/或，将气凝胶粉末和羽绒充分混合，在填充了气凝胶粉末羽绒绒朵表面设置防掉粉结构；和/或，将上述气凝胶改性羽绒制品制成团状或者平面片状，在上述团状或者平面片状的气凝胶改性羽绒材料表面再喷涂或黏附防掉粉结构，实现对气凝胶粉末颗粒的固定。
本发明的有益效果是：
羽绒保暖性能本来就好，蓬松度高，在绒朵和绒丝形成的空隙间可以填充入大量的气凝胶粉末，而气凝胶热阻较羽绒热阻更大，最终得到的气凝胶改性羽绒材料比常规羽绒制品具有好很多的保温隔热效果；羽绒为已经是已知的保温隔热性能最好的天然纤维，而气凝胶保温隔热性能比羽绒还要好很多；二者混合后的整体保温隔热性能较单纯的羽绒制品可以获得明显的提高，较其他棉、麻、羊毛、化纤或常见混纺制品更是能获得指数级别的极大提高。
气凝胶粉末可以在羽绒表面稳定附着，在增大热阻的同时获得相对稳定的整体性。
同时，羽绒的柔韧性和聚团性等均得以保留以弥补气凝胶的脆性、粘合性和聚团性差等缺点。
而且，气凝胶具有极其良好的拒水性，可以有效地避免羽绒吸水或受潮导致保温性能迅速降低的问题。要获得同等的保温能力，本发明改性羽绒材料所需要的气凝胶重量远远低于同等保温性能羽绒制品所需要的羽绒重量。与常规羽绒制品相比，本发明改性羽绒材料总重量以及收纳体积均可明显减小，并同时减少羽绒的使用量，可以获得与厚厚的传统羽绒制品同等保温能力甚至保温能力更强很多的超薄羽绒制品(例如超薄羽绒服、超薄羽绒被、超薄羽绒帽、超薄羽绒手套、超薄羽绒睡袋、超薄羽绒内衣以及羽绒鞋等)；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羽绒服臃肿肥胖的问题，令使用者在寒冷天气也能保持苗条的身形和利索的形体动作，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。
本发明改性羽绒材料还可通过多级防漏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羽绒材料之内，上述气凝胶粉末被粘连或夹紧在上述羽绒的绒朵、各阶绒丝和/或绒刺之间空隙内，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，还能防止人体皮屑和外界灰尘等进入羽绒制品，或者由于气凝胶的减少导致保温隔热性能变差，提高了羽绒材料的使用效果和使用寿命。
因为气凝胶的密度极小，获得同等保温隔热性能的被、服、衣、帽的成品总重可以明显变小；不但使用起来可减少压覆力从而使人更舒适，而且还更便于携带和储藏。
因为气凝胶的保温隔热性能可极大地强于羽绒本身，获得同等保温隔热性能的被、服、衣、帽的成品总重、厚度和/或体积也可以明显变小；不但可使人 活动更加灵活从而更舒适，而且也更便于收纳。
此外，由于在所述羽绒绒朵之间、绒丝之间、绒刺之间、气凝胶颗粒之间、气凝胶颗粒与绒朵、绒丝和或绒刺之间均具有大量的贯通型空隙，因此所述气凝胶改性羽绒的透气性会比较好。
作为单体耐拉、耐折和耐压强度均为较好绒朵，成为附着或包裹上述气凝胶粉末的良好基材，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。
在上述羽绒绒朵舒展开后，其一阶绒丝、二阶绒丝和/或绒刺之间的空隙相对于无纺布、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丝径和丝间空隙都要大很多，因此可以置入各阶绒丝和/或绒刺之间空隙内气凝胶的体积相当大。特别是在自然舒展开的绒丝之间，其最大间距可达数厘米，即便是在靠近绒核的部位也可达到毫米级别，因此被粉碎为毫米级别、丝米级别、微米级别甚至纳米级别的气凝胶就可以轻松且大量地被置入绒朵之内。因此，在性能稳定可靠的上述气凝胶羽绒制品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，上述羽绒绒朵甚至可以主要作为保持隔热层形状的基材使用而不是作为隔热材料使用。
单纯羽绒产品不但隔热性能明显弱于气凝胶，而且还要充分考虑羽绒的蓬松度、压缩比、材料用量和保温隔热性能之间的矛盾：
包括羽绒在内的材料之所以能保温隔热的主要原因在于这些材料微小的内部空隙内含有众多的静止空气，所含静止空气越多保温隔热性能越好、所含静止空气越少保温隔热性能越差。在临界蓬松度范围之内，蓬松度越大，所含静止空气就越多、保温隔热性能就越好，但产品厚度和体积就越大，不但降低使用舒适性和不便行动而且携带和收纳也更加不便。在临界蓬松度范围内，为了获得更好的保温隔热性能即保留更多静止空气，需要充入的羽绒就越多，不但耗费在羽绒上的成本明显增加，而且同样会使产品厚度/体积变大、降低舒适性、不便使用者行动、携带和收纳。一旦继续充入的羽绒超过临界蓬松度，由于盛绒空间是固定的，再继续充入羽绒则不但不能增加产品的整体保温隔热性能， 反而因为过多的羽绒材料导致保温隔热层被压的太严实和紧密导致大量的静止空气被排出，保温隔热性能反而被降低，类似于棉被的“板结变冷”现象，不但增加了成本而且还降低了性能。反过来，如果充入的羽绒过少，则会使保温隔热层的整体瑞利数(Ra)超过临界值时，热量传递的主要形式会从导热能力相对较小的传导转化为导热能力相对较高甚至极高的对流，成品的保温隔热性能以及维持形状的能力均会明显降低，也就是所谓的“充绒不足”。
而采用本发明技术方案以后，以上几组羽绒制品常见的固有矛盾就可以轻易解决：因为绒朵之间或内部的空隙均主要被气凝胶粉末所占据，气凝胶粉末内部或之间的静止空气起主要保温隔热作用，绒朵、绒丝和/或绒刺内部或之间的静止空气只是起到被弱化了的辅助主用；而且气凝胶粉末是在绒朵、绒丝和/或绒刺在气流中充分自然舒展开的情况下被置入绒朵、绒丝和/或绒刺之间空隙的，羽绒的蓬松度已到达或接近其最大值并可保持相对稳定不变，因此蓬松度就退居为不需特别强调考虑的次要因素了。
而且，因为绒朵之间和内部的空隙已被气凝胶粉末所占据，所以上述含气凝胶粉末的羽绒的压缩比会明显降低，不但保暖隔热性能明显提高，而且产品的形状保持能力也可以明显地提高。类似于建筑上的钢筋混凝土结构中钢筋和混凝土的关系：单纯的钢筋尽管抗拉强度好但在建筑物自重之下不堪重压，容易弯折倒伏；单纯的混凝土尽管抗压强度好，但是没有钢筋的拉扯作用就容易开裂或被压碎；将混凝土填充到钢筋之间后，二者均发挥各自的优点，使钢筋混凝土结构既耐压又耐拉不会轻易开裂，极大地利于保持建筑物的形状不被破坏。上述羽绒的绒丝和/或绒刺即起到了类似钢筋的作用，上述气凝胶粉末即起到了类似混凝土的作用：在柔弱飘荡的柔性的绒丝、绒刺和二者之间都填充满了刚性的气凝胶粉末，使柔性的绒丝/绒刺充分发挥其抗拉能力、气凝胶发挥其抗压能力，最终使产品的形状保持性能获得极大的提高。
这样最终导致的结果是不会存在临界蓬松度的担忧，上述气凝胶羽绒材料用的越多，保温隔热性能就越好。上述气凝胶羽绒材料可以很好地解决传统羽绒制品蓬松度、压缩比、材料用量和保温隔热性能之间的矛盾。
本发明上述的技术方案可以明显地减少羽绒的用量，不但整体保温隔热能力的提高可以使产品做的更薄更小从而减少羽绒的用量，而且羽绒的压缩比降低以及绒朵内部的大部分空间被气凝胶所占据等多重因素的单独和共同作用，均可明显地减少羽绒的用量；这在羽绒获得性越来越差且价格越来越贵的当下也是值得考虑的重要方面。
由于在本发明中气凝胶的保温隔热性能起主要作用，作为基材的羽绒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、含绒量更少、含羽量更高的相对劣质的羽绒获得同等甚至还要超过的保温隔热性能。因此，可使用相对劣质的羽绒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。
羽绒作为基材，其本身的三维立体放射状结构比起其他纤维的二维线状或是丝状物叠加而来的絮状物所占的单位体积更大，密度更小。
传统的羽绒被服在受潮或在被包括汗水和雨水在内的水浸之后，不但潮气或吸入水分的传导、对流会降低产品的保温隔热性能，而且吸入水分的毛细管效应将进一步加强这种对流和传导；更为关键的是，潮气或吸入水分会部分取代羽绒内部的静止空气，会使传统羽绒被服的保温性能急剧下降。历史上，大量的登山运动员就是因为自身运动产生的汗水或降雨导致羽绒服保温性能降低被冻伤甚至冻死。采用本发明中的方案后，由于常见的二氧化硅或碳气凝胶粉末的比表面积大、与水不浸润、疏水性好、孔隙极小，液态的水在其表面张力的作用下根本就进不到气凝胶粉末内部，因此，相对于经脱脂处理后的羽绒容易吸收水分，气凝胶粉末的疏水性极强，人体散发的汗水或外界的雨水均不容易被吸收或渗透到上述保温隔热层之中，因羽绒服受潮或吸水所导致的保温性能降低的可能性会明显减少。
而且，气凝胶为阻燃性很好的材料，相对传统羽绒服容易着火和火焰容易向羽绒填充蔓延的天然缺陷，气凝胶改性羽绒的耐火安全性提高明显。
羽绒被、羽绒服为非常成熟的产业，其生产工艺、设备均稳定可靠、容易获得，且生产成本也较低。
具体实施方式
下面结合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。
称取气凝胶粉末灌入密封空间内，用设置在该密封空间内的风扇将灌入的气凝胶粉末吹成沸腾状，因为气凝胶粉末的密度极低，只要用很小的风力就可以将气凝胶粉末吹成随气流同步运动的剧烈沸腾状，然后再向沸腾的气凝胶粉末流以不低于3.2米/秒的离嘴射速高速喷洒包括硅酮胶、聚氨酯胶、丙烯酸酯均聚物结构、相变聚合物等在内的有机和/或无机结构胶、粘/黏合剂、固化剂、交联剂、偶联剂等的微细液滴，这些结构胶、粘/黏合剂、固化剂、交联剂、偶联剂的液滴就会包裹住气凝胶粉末，在其外形成壳状包裹层。将高速风机设置在密封空间的底部，包裹层过厚的气凝胶颗粒因密度大易于层积到密封空间的底部并被高速旋转的风机叶片所击打，导致液态的包裹层被刮擦、碰撞、削减甚至脱落，气凝胶颗粒密度变小，就可随气流重新漂浮到密闭空间的中上部去，以便通过筛网捞取或重新加喷。通过控制合适的粘合剂种类、密度、温度和捞取高度，可以控制包裹层的厚度在3-8μm。具体防掉粉结构的种类和用量应视其自身物理化学性能和气凝胶材料种类/物化性能适当地选用，当硅系气凝胶为二氧化硅时，采用容易与二氧化硅结合的玻璃胶/硅酮胶成分作为包裹层。在气凝胶粉末单体被均匀包裹后，再向该密闭空间吹入羽绒，吹入的羽绒绒朵将与被包裹了气凝胶粉末颗粒一起随气流在封闭空间内反复翻滚和/或搅拌；绒朵随气流反复翻滚和/或搅拌充分舒展开后，与之一起漂浮在气流中的带包裹层的气凝胶粉末就能进入绒朵、各阶绒丝和/或绒刺之间舒展开的空隙之内，制得气凝胶改性羽绒制品，气凝胶颗粒外包裹的壳层表面将与羽绒的绒朵、各阶绒丝和/或绒刺粘合在一起，实现对气凝胶粉末颗粒的固定。将这些混合物压制成片状或模制成团状，即可作为服饰、被子、睡袋、防寒手套等的填充物使用。
对于小部分未能及时被固定或限定到羽绒上的气凝胶粉末，可在压制或模制混合物前采取吹扫步骤：将这些可自由移动的气凝胶粉末从轻夹在筛网或成 型模中的混物内吹扫出来在循环到后续混合工序中继续使用。当然，为了降低未被固定或限定的自由粉尘的含量，还可在所述片状、絮状、团状半成品的后续加工前后，以及填充入被服前后，再次或多次实施吹扫，使未被固定或限定的自由粉尘被降至最低甚至为零。这样制得的气凝胶改性羽绒制品，就其上有大量的贯穿性针孔，也不会有掉粉现象或不明显。因为自由粉尘已经被吹扫干净，固定在羽绒内部气凝胶颗粒被包裹层所包裹并粘连在羽绒上，并不易脱落；而且在使用过程中，即使是包裹层内气凝胶颗粒被外力挤的更碎，其碎屑依旧是被包裹在包裹层之内，并不会泄漏，也不会导致产品中气凝胶成分的减少。
在一个实施例中，气凝胶粉末吹入的密封空间可以用包括筛绒机、分绒箱、分毛机、五箱分箱机、混合箱和/或充绒机在内现有机器设备加上一个密闭箱体和多个喷嘴和风机，即可获得所需的混合空间，这些机器性能可靠、操作简便、获得性好。
在一个实施例中，使用交联聚维酮作为包裹层同时均匀喷洒在气凝胶粉末和羽绒形成的流化床上，再固化后压制成为后多约5毫米的平面结构，以作为超轻气凝胶改性羽绒被的填充材料。
在一个实施例中，使用聚乙烯醇-聚谷氨酸聚合物作为包裹层混合在气凝胶粉末和羽绒形成的流化床上，固化后压制成为后多约2毫米的平面结构，以作为超轻气凝胶改性羽绒服的填充材料。
在一个实施例中，将质量份为6:2：1的气凝胶粉末、羽绒和热熔胶粉末的混合物吹入密闭箱体；开动分机至少20分钟使他们均匀混合；混合均匀后将箱体内温度升至113摄氏度，使混合在其中的热熔胶颗粒固体变成液态热熔胶微滴；继续搅拌和混合这些含热熔胶微滴的混合物，并将箱体内温度从113摄氏度逐渐平稳降至室温，热熔胶微滴固化，将大部分气凝胶粉末和羽绒固定在一起。最后将尚未固定的气凝胶粉末吹扫出混合物并循环使用。即可值得一种可耐高水洗温度的气凝胶改性羽绒材料。
在一个实施例中，让气凝胶粉末通过一段行程较长的折叠气管，该气管内部和/或内表面具有一定的静电荷和静电压，当气凝胶粉末以流体形式通过这些 折叠气管进入混合箱之前，气凝胶粉末不断地与带静电的气管内表面或管内导体相互碰撞，气凝胶粉末在碰撞过程中带上电荷，或者根据气凝胶材料选用与之摩擦会产生静电的材料做折叠充入管内壁(例如，在主要成分为二氧化硅气凝胶时，选用丝绸制布料作为长程折叠充入管的内衬，在气凝胶粉末通过该充入管不断与丝质内衬碰撞摩擦的过程中，带上静电)。当防掉粉结构为粉末状时，也可采用上述让气凝胶粉末带静电的方法令防掉粉结构带静电；当防掉粉结构为液态时，则可按照静电纺丝法类似原理，在喷嘴上施加静电压，通过这些喷嘴喷出的雾状微粒就都会带上喷嘴那里转移过来的静电荷。当气凝胶粉末与结构胶、粘/黏合剂、固化剂、交联剂或偶联剂等不容易结合的情况下，也可以让气凝胶粉末和/或结构胶、粘/黏合剂、固化剂、交联剂、偶联剂液滴先带上不同种类的静电荷，再通过静电的“同性相斥、异性相吸”原理，不但可加速带了异性电荷气凝胶粉末和结构胶、粘/黏合剂、固化剂、交联剂、偶联剂液滴的结合，而且还能选择性地使某些种类的粉末和液滴少结合或不结合，例如，带了同性电荷的液滴就会因为互相排斥而不易结合为大液滴，从而使液滴分布更均匀、更长久，更利于其寻找到带异性电荷的气凝胶粉末进行结合。而且，带异性电荷的液滴和气凝胶粉末在互相接触后，在电荷斥力和液滴自身表面张力的共同作用下，液滴可以更均匀、更迅速地在气凝胶颗粒表面扩散开并最终完整地包裹住气凝胶粉末颗粒。此外，还可以使绒朵和/或绒丝自身也带上与气凝胶颗粒或包裹其的壳层相反的静电，使绒朵与气凝胶粉末颗粒或包裹其的壳层可以更快、更好、更牢固地结合在一起。
在一个实施例中，还可在已混合均匀的气凝胶改性羽绒上再次喷洒粘合剂，或是在气凝胶改性羽绒外设置包裹层，进一步加强气凝胶粉末颗粒与绒朵、绒丝或绒刺的结合牢度，最后再将气凝胶羽绒制成包括羽绒服、羽绒被、羽绒睡袋、羽绒帽在内的羽绒制品。这样的气凝胶粉末就有多层次的防掉粉结构，更加不易脱落导致掉粉现象，此外，这样的多层次保护也可以减少外界环境对气凝胶粉末的冲击力，减少甚至避免气凝胶粉末颗粒的进一步粉碎或细化。而且，在气凝胶粉末颗粒外设置了壳层的另一个好处在于，即便是气凝胶粉末颗粒在 产品使用过程中被进一步粉碎或细化，其粉碎或细化后的碎末依旧会被严实地包裹在壳层中，并不容易钻出壳层或脱落。
在一个实施例中，在气凝胶粉末和羽绒混合物中加入吸湿发热纤维，吸湿发热纤维在吸收了人体皮肤所散发出来的水汽以后，散发出热量，因此，添加了吸湿发热纤维的气凝胶改性羽绒不但可以大幅提高了产品的整体保温隔热性能，还可使包裹在其中的人体获得体温之外的额外热源，可以使人体获得更多更快的升温、更少的温度丧失，尤其适于在极地、高山等极端环境下应用。
在一个实施例中，在改性羽绒材料处设置发热纤维混织布或电发热装置(如微细电热丝等)，发热纤维混织布或电发热装置发热，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，尤其适于在极地、高山等极端环境下应用。
在一个实施例中，利用温度传感器和温度调控装置，准确控制改性羽绒材料内的温度。在电池电源处设置调压或调节电流的电路，即可实现对温度的调控。还可在该服装处设置温度传感片，利用温度传感片里面的液晶微晶在不同温度下会变得透明还是模糊，指示温度，以便使用者合理调节温度。
在一个实施例中，在气凝胶粉末和羽绒的混合物中混入远红外材料，即具有远红外辐射功能的陶瓷粉末。远红外陶瓷粉末颗粒可以在很宽的波长范围内吸收环境和人体发射出的电磁波并辐射出波长范围在2.5-30μM的远红外线，其中4-14μM波长范围的红外线与人体细胞中水分子的振动频率相同，当人体表面受到这种红外线辐射时，会引起人体表面细胞分子的共振，产生热效应，并激活人体表面细胞，促进人体皮下组织血液的微循环，达到保暖的目的，进一步提高气凝胶改性羽绒材料制品的保暖性能。
在一个实施例中，在气凝胶粉末和羽绒的混合物中混入高反射率的材料，如铝粉，高反射率材料可以反射人体发射出来的热量，减少热量的散失，进一步提高气凝胶改性羽绒材料制品的保暖性能。
在一个实施例中，除了在气凝胶粉末和羽绒的混合物中混入高反射率的铝 粉之外，还可在诉述气凝胶改性羽绒的内表面贴附铝膜或铝膜片，同样能达到提高热反射率和保暖性能的目的。
在一个实施例中，在气凝胶粉末和羽绒的混合物中混入初始体积比约为20％的氨纶丝，搅拌均匀并喷洒聚醋酸乙烯酯气雾，在将所得混合物压制位厚度约为1毫米的面状结构。氨纶丝被均匀地固化在绒朵、绒丝和/或气凝胶包裹层之间。由于氨纶丝具有极好的弹性和韧性，因此由此制得的加氨纶气凝胶改性羽绒制品的弹性和韧性均可获得极大的提高。
在一个实施例中，还可在1毫米的面状结构的内外表面贴和丝织、全棉和/或全麻布料，以便获得更好的皮肤接触舒适性。本实施例中的加氨纶气凝胶改性羽绒因其保暖性、弹性和韧性均特别好，尤其适于制作保暖内衣。
在一个实施例中，在气凝胶粉末和羽绒的混合物中混入初始体积比约为3％的氨纶丝，且最终混合物不予压实到1毫米左右而是让其以自然方式沉积并获得固化,则所获得加氨纶气凝胶改性羽绒的蓬松度将会特别好，被压缩再解压后蓬松度恢复性能也会较常规羽绒制品好很多。与现有技术相比，单纯的羽绒制品，蓬松度达到600、700甚至更高时，其绒朵始终处于不同程度的被挤压状态，而在本发明的气凝胶改性羽绒中，绒朵已在混合气凝胶粉末时获得了充分的展开，因此其蓬松度将远远大于处于不同程度的被挤压状态的绒朵，单纯的羽绒制品，蓬松度达到700已经是非常难得和昂贵的羽绒制品了，但在本发明气凝胶改性羽绒中，蓬松度可以达到800、1000、2000甚至3000。尤其是在被充分张开的羽绒绒朵和/或绒丝之间填充满了气凝胶粉末，因此在压缩气凝胶改性羽绒时，其体积相对纯羽绒不容易收缩，因此蓬松度可以更大，保温隔热性能也就越好。而添加了少量的氨纶丝后，更有力地将这些绒朵和/或气凝胶絮团有弹性和有韧性地连接在一起，可以更好地保持产品形状。
实施例1
称取气凝胶粉末5千克，羽绒5千克，在密闭的筛绒机内，先将气凝胶粉末和羽绒充分混合，再使用喷胶棉设备向气凝胶粉末和羽绒的混合物喷洒聚醋酸乙烯酯微细液滴形成的雾状粘合剂(Bonding Agent)，获得初步的气凝胶改 性羽绒，然后再将这些已填入气凝胶粉末的羽绒集合成厚度约为3毫米的平面状结构，再次喷洒聚醋酸乙烯酯气雾，再将多个平面状结构集合成适于填入气凝胶羽绒服的平面状或团状结构，在其最外表面上再次喷洒聚醋酸乙烯酯气雾，最后将这些经多次喷洒聚醋酸乙烯酯气雾的平面状结构填充至羽绒服面料中，即可获得一种具有多重防掉粉结构气凝胶羽绒服。
实施例2
称取气凝胶粉末10千克，羽绒1千克，将气凝胶粉末和羽绒置于密闭的分绒机或混合箱内充分混合，在填入气凝胶粉末后的绒朵表面喷洒聚醋酸乙烯酯气雾，再将喷洒聚醋酸乙烯酯气雾的绒朵集合成多个团状结构，再将多个团状结构集合成多个适于填入气凝胶羽绒被中的平面状结构，在平面状结构表面上再次喷洒聚醋酸乙烯酯气雾，最后将喷涂好喷洒聚醋酸乙烯酯的平面状结构填充至羽绒被面料中，即可获得一种防掉粉、保温效果极好、但极轻的气凝胶羽绒被。
实施例3
称取气凝胶粉末5千克灌入容积约为40立方米的密封空间内，用设置在该密封空间内的风扇将灌入的气凝胶粉末吹成沸腾状，然后再向沸腾的气凝胶粉末流高速喷洒硅酮胶液滴，在以上气凝胶粉末单体被均匀包裹后，再向该密闭空间吹入5千克羽绒，吹入的羽绒绒朵将与被包裹了气凝胶粉末颗粒一起随气流在封闭空间内反复翻滚、搅拌后压实至厚度为约2毫米的薄层，制得一种防掉粉、较密实气凝胶改性羽绒，作为服装保温隔热夹层使用。
实施例4
称取气凝胶粉末14千克，羽绒6千克，将气凝胶粉末和绒朵状结构置于容积为500立方的混合箱内通过风机吹至沸腾态不少于15分钟，以实现二者的充分混合，箱内初始温度为水洗羽绒的干燥气温，约为110度；箱体规格长5米、宽5米、高20米，且在箱内设置至少甲基丙烯酸甲酯、聚丙烯酸丁酯和/或聚丙烯酸-2-乙基乙酯混合物的喷嘴，在二者混合均匀后喷入甲基丙烯酸甲酯、聚丙烯酸丁酯和/或聚丙烯酸-2-乙基乙酯混合物的雾状液滴并以约每10分钟降温 5摄氏度的速率对箱体进行降温，羽绒、气凝胶、甲基丙烯酸甲酯、聚丙烯酸丁酯和/或聚丙烯酸-2-乙基乙酯混合物将逐渐降温并逐渐均匀沉积，由于甲基丙烯酸甲酯的玻璃化温度为105摄氏度且是很硬的聚合物，聚丙烯酸丁酯的玻璃化温度为-54摄氏度、聚丙烯酸-2-乙基乙酯的玻璃化温度为-72摄氏度，聚丙烯酸丁酯和聚丙烯酸-2-乙基乙酯均是很软的聚合物，这样就可以通过控制降温过程，实现对均聚物以及最终混合材料软硬程度的控制。
本实施例通过调节混合物的温度实现热固化，如有需要，选取适当的气凝胶种类和固化剂种类，还可应用种类繁多的化学反应固化、UV固化、材料相变固化(升华-凝华、汽化-液化、熔化-凝结等可逆过程)。
效果实验：
称取气凝胶粉末30千克，羽绒20千克在混合箱内混合均匀，通过网眼直径约为0.5厘米的筛网将充分吸附了气凝胶粉末的绒朵捞出并吹入50千克的聚酰胺或热塑性聚氨酯液态粘合剂，然后挤压摊平或风干，获得厚度约为5毫米的软毡状混合物。尽管此时在绒朵内的部分气凝胶粉末并未被胶水粘住，但是由于其位于绒朵内部而整个绒朵却已经被聚酰胺或热塑性聚氨酯粘合剂所完全包围，所以气凝胶粉末并无法掉落到外界。对该5毫米软毡和5厘米厚的95绒在30％湿度和0摄氏度室温条件、进行对比测试：
95绒的热导率约为0.09瓦/米-摄氏度，而该2毫米软毡热导率仅约为0.03瓦/米-摄氏度。
由此可见，该羽绒气凝胶软毡不但厚度可以做成同等95绒的十分之一，而且保温防寒性能还能提高约3倍。
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. 一种气凝胶改性羽绒材料，其特征在于，包括羽绒和气凝胶粉末。
  2. 根据权利要求1所述一种气凝胶改性羽绒材料，其特征在于，所述气凝胶粉末为二氧化硅气凝胶粉末或碳气凝胶粉末。
  3. 根据权利要求1所述一种气凝胶改性羽绒材料，其特征在于，所述气凝胶粉末的重量占所述气凝胶粉末和羽绒总重量的1％-99％。
  4. 根据权利要求1所述一种气凝胶改性羽绒材料，其特征在于，所述羽绒的绒朵为天然羽绒的绒朵状结构和/或人工制造的仿绒朵状结构。
  5. 根据权利要求4所述一种气凝胶改性羽绒材料，其特征在于，所述人工制造的仿绒朵状结构为绒球、绒线、绒布和/或绒团。
  6. 一种气凝胶改性羽绒制品，其特征在于，由防掉粉结构和权利要求1-5任一项所述气凝胶改性羽绒材料制成；
    所述防掉粉结构包裹或黏附在气凝胶粉末单体颗粒外；
    和/或
    所述防掉粉结构包裹或黏附在填充了气凝胶粉末的绒朵之外。
  7. 根据权利要求6所述一种气凝胶改性羽绒制品，其特征在于，将所述气凝胶改性羽绒制品制成团状或者平面片状，在所述团状或者平面片状的气凝胶改性羽绒制品表面包裹或黏附防掉粉结构。
  8. 根据权利要求6所述一种气凝胶改性羽绒制品，其特征在于，所述防掉粉结构为有机包裹层和/或无机包裹层、结构胶、粘/黏合剂、固化剂、交联剂、偶联剂或膜结构；
    所述有机包裹层为纤维素衍生物类、聚砜类、聚酰胺类、含硅聚合物、含氟聚合物类、硅酮胶、聚氨酯胶、丙烯酸酯均聚物或相变聚合物；
    所述无机包裹层为二氧化硅膜、陶瓷膜、金属膜、沸石膜、玻璃膜或分子筛复合膜。
  9. 根据权利要求6所述一种气凝胶改性羽绒制品，其特征在于，所述气凝胶改性羽绒材料制品还填充有天然纤维、和/或人工合成纤维、和/或高热反射 率材料、和/或远红外材料、和/或吸湿发热材料、和/或相变材料。
  10. 根据权利要求6所述一种气凝胶改性羽绒制品，其特征在于，所述包裹层为高热反射率材料或远红外材料；
    所述高热反射率材料为铝粉或铝膜，所述远红外材料为远红外纤维。
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