WO2006080933A2 - Composite contenant du charbon actif et son procede de fabrication - Google Patents

Composite contenant du charbon actif et son procede de fabrication Download PDF

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Publication number
WO2006080933A2
WO2006080933A2 PCT/US2005/013072 US2005013072W WO2006080933A2 WO 2006080933 A2 WO2006080933 A2 WO 2006080933A2 US 2005013072 W US2005013072 W US 2005013072W WO 2006080933 A2 WO2006080933 A2 WO 2006080933A2
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WIPO (PCT)
Prior art keywords
layer
adhesive
carbon granules
composite structure
composite
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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.)
Ceased
Application number
PCT/US2005/013072
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English (en)
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WO2006080933A3 (fr
Inventor
Shulong Li
Nathan B. Emery
Julie A. O. Smallfield
Zeb W. Atkinson
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Milliken and Co
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Milliken and Co
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Publication of WO2006080933A2 publication Critical patent/WO2006080933A2/fr
Anticipated expiration legal-status Critical
Publication of WO2006080933A3 publication Critical patent/WO2006080933A3/fr
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B32B7/14—Interconnection of layers using interposed adhesives or interposed materials with bonding properties applied in spaced arrangements, e.g. in stripes
    • 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
    • A41D31/14—Air permeable, i.e. capable of being penetrated by gases
    • A41D31/145—Air permeable, i.e. capable of being penetrated by gases using layered materials
    • 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
    • A41D31/30—Antimicrobial, e.g. antibacterial
    • A41D31/305—Antimicrobial, e.g. antibacterial using layered materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/026—Knitted fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/16—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer formed of particles, e.g. chips, powder or granules
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/30—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being formed of particles, e.g. chips, granules, powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/107—Ceramic
    • B32B2264/108—Carbon, e.g. graphite particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/73—Hydrophobic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2437/00—Clothing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2571/00—Protective equipment
    • B32B2571/02—Protective equipment defensive, e.g. armour plates or anti-ballistic clothing

Definitions

  • the present disclosure is related to a textile composite, containing a core of activated carbon granules, suitable for inclusion in a military garment protective against biological and chemical warfare agents.
  • the activated carbon granules are randomly positioned between, and secured to, textile outer layers by either continuous or discontinuous layers of adhesive.
  • the activated carbon granules are derived from coconut shells and have a non-spherical shape.
  • the resulting composite is both breathable and flexible.
  • Exposure may occur as part of a job-related task (e.g., spraying fertilizer or insecticide) or as part of an enemy or terrorist action (e.g., chemical or biological warfare).
  • a job-related task e.g., spraying fertilizer or insecticide
  • an enemy or terrorist action e.g., chemical or biological warfare.
  • One substance commonly used to create protective gear or apparel is activated carbon.
  • Activated carbon comes in a variety of forms. Initially, it was made in the form of granules or powder. More recently, it has been made in the form of a fabric known as charcoal cloth or carbon cloth. Activated carbon is used to adsorb undesirable components from the atmosphere or from a local environment. However, it is known that the effectiveness of activated carbon can be comprised by other components, not necessarily undesirable per se, that saturate the activated carbon and prevent it from adsorbing the undesirable components. The most common component that leads to such saturation of activated carbon is water.
  • Activated carbon is used in clothing to provide protection against undesirable components, but when such clothing is wet, the effectiveness of the activated carbon in adsorbing the undesirable component is drastically reduced. Also, the additional weight of such wet clothing presents a further disadvantage. To overcome this problem, activated carbon is often used as one component in a composite structure that includes at least one relatively waterproof fabric layer around the activated carbon.
  • a waterproof barrier fabric as either the outer layer of activated carbon composite, the inner layer of such a composite, or both. Because the barrier fabric cannot prevent moisture condensation on the activated carbon, liquids (e.g, sweat or water) can reach the activated carbon and inhibit its adsorption ability.
  • barrier fabric(s) actually traps the moisture on the activated carbon, preventing evaporation.
  • the so-called barrier fabrics are especially incapable of performing their intended role — that is, preserving the adsorptive properties of the activated carbon — in the laundering process, where the composite is exposed not only to large amounts of water, but also to detergents, soil, and other contaminants.
  • an activated carbon composite in which the activated carbon has a large surface area available for adsorbing contaminants and is sufficiently durable for use in protective garments.
  • a flexible, breathable, five-layer textile composite in which the core of the composite contains non-spherical activated carbon granules that are positioned between, and secured to, two opposing textile layers by the use of adhesive.
  • the activated carbon granules are formed from the shells of coconuts, because of their requisite hardness as well as other properties.
  • the use of the non- spherical carbon granules of varying sizes allows tighter packing of the particles on the textile substrate, thereby providing greater available surface area for adsorbing chemical or biological hazards.
  • a water and oil repellent finish e.g., a fluorochemical
  • FIG. 1 is a schematic cross-sectional view of a composite according to the present disclosure. DETAILED DESCRIPTION
  • Composite 100 includes a layer of non-spherically activated carbon granules 20 that are positioned between two layers of textile substrates 10, 30. Carbon granules 20 are secured, relative to textile substrate 30, by a substantially continuous layer of adhesive 14. Carbon granules 20 may be further secured, relative to textile substrate 10, by discontinuous adhesive layer 12 formed by a plurality of spaced adhesive dots. Although a continuous (or a substantially continuous) layer of adhesive could also be employed for this purpose, the use of adhesive dots imparts enhanced flexibility to the finished composite 100. Having generally described the components of, and the structure of, composite 100, each component will now be described in more detail.
  • Textile substrates 10, 30 are constructed from synthetic fibers, filaments, or yarns.
  • textile substrates 10, 30 may be comprised of fibers or yarns made from commonly available materials such as nylon, polyester, polypropylene, acrylic, olefins such as polyethylene and polypropylene, polyaramid (e.g., Nomex® or Kevlar®), and other materials having a synthetic construction.
  • polyaramid e.g., Nomex® or Kevlar®
  • any specific polymer herein is intended to include not only homopolymers, but also copolymers thereof.
  • the textile substrate can be printed or dyed before application of the repellent treatment described herein.
  • one or more of the textile substrates can be subjected to surface finishing procedures, such as brushing, sanding, or napping before application of the repellent treatment. It is preferred that at least one of the textile substrates 10, 30 is dyed black or another dark color to avoid poor appearance that may result from staining or from show-through of activated carbon granules 20.
  • textile substrate 30 is a tricot knit polyester fabric, with a weight of about 2.3 oz/yd 2 , which has been brushed on one side. It is contemplated that adhesive layer 14 is preferably applied to the brushed side of textile substrate 30. Also present in the preferred embodiment, textile substrate 10 is a nonwoven fabric. Representative examples of suitable nonwoven fabrics include a powder-bonded polyester nonwoven textile, which contains some polyester adhesive and has a weight of about 0.9 oz/yd 2 and a point-bonded nonwoven containing polyester, nylon, and combinations thereof.
  • textile substrate 30 In circumstances where composite 100 is being used as a garment, or as a part of a garment, it is contemplated that the knit fabric (in this case, textile substrate 30) would be the side contacting the wearer of the garment.
  • textile substrates 30 Preferably, textile substrates 30 have a weight in the range of about 1.8 oz/yd 2 to about 3.0 oz/yd 2
  • textile substrates 10 have a weight in the range of about 0.5 oz/yd 2 to about 2.0 oz/yd 2 .
  • Adhesive layers 12, 14 suitable for this invention are comprised of one or more of the class of polymeric resins with good adhesive strength, laundry resistance, and flexibility. Suitable resins include copolyamides (such as nylon 6 and nylon 12 copolymers), polyurethane, aliphatic polyesters, polyacrylics, ethylene vinyl acetate copolymers, epoxies, and the like. Of these, copolyamides and polyurethane are preferred. The same adhesive material can be used for adhesive layers 12, 14, or different adhesive materials may be used for each layer.
  • the adhesive layer is preferably present at a weight of 0.2 oz/yd 2 to 3 oz/yd 2 , and more preferably in the range of 0.5 oz/yd 2 to 1 oz/yd 2 for each of the layers.
  • adhesive layer 14 is a substantially continuous layer of adhesive material to provide uniform bonding between activated carbon granules 20 and textile substrate 30.
  • Adhesive layer 14 may be applied by transfer coating, knife coating, foam coating, roll coating, slot die coating, or other methods as are known in the art.
  • Adhesive layer 14 comprises a plurality of tiny adhesive particles (typically on the order of 40 to 60 microns in size) that are in close proximity to each other when applied as a foam or paste. Unlike a polymeric film, for example, the tiny particles provide more flexibility to composite 100, and they further greatly increases the air permeability of composite 100 (when compared to the air permeability of a film).
  • adhesive layer 12 is a discontinuous layer of adhesive material.
  • the discontinuous nature of adhesive layer 12 enables composite 100 to have enhanced flexibility for use as part of a garment.
  • Layer 12 can be formed from a plurality of dots of optional shapes (e.g., circular, square, elliptical, etc.) applied in a spaced, patternwise arrangement over one surface of textile substrate 10. Although dots are preferred, other configurations could also be used, including stripes, curlicues, broken lines, and the like.
  • adhesive layer 12 could be a substantially continuous layer that is formed by scattered powder coating, paste coating, foam coating, and the like.
  • the core of composite 100 is comprised of activated carbon granules 20 that are capable of adsorbing liquid and gas molecules from chemical and biological hazards (that is, such molecules adhere to the surfaces of such granules).
  • Such carbon granules 20 are present within composite 100 at a weight of about 1 oz/yd 2 to 10 oz/yd 2 , and preferably 4 oz/yd 2 to 7 oz/yd 2 .
  • the non-spherical activated carbon granules 20 may be made from coconut starting material to provide resistance to crushing of the granules.
  • This particular type of activated carbon exhibits a micro-porous structure that is especially well suited for effective gas phase adsorption.
  • the preferred surface area parameters will be discussed in further detail herein. It should be noted that the adsorbency of carbon granules 20 is directly related to pore size. If the pores are too small, relative to the molecules of hazardous materials being adsorbed, carbon granules 20 will lack sufficient surface area for adequate adsorption. If the pores are too large, relative to the molecules of hazardous materials being adsorped, carbon granules 20 will be less effective at adsorption. For instance, if the pores are large, gas molecules are able to pass through them without being adsorbed.
  • carbon granules 20 have a hardness of at least 90% and, more preferably, 95% or greater, as determined by ASTM Test Method D3802-79, "Standard Test Method for Ball-Pan Hardness of Activated Carbon.” This level of hardness prevents carbon granules 20 from being crushed or broken during ordinary use of a garment made from composite 100.
  • carbon granules 20 Besides hardness, another important feature of carbon granules 20 is their size and shape.
  • the size and shape of carbon granules 20 contributes to the surface area available for adsorbing chemical or biological agents.
  • carbon granules 20 have sizes in the range of 12 to 80 US Mesh and, more preferably, in the range of 20 to 50 US Mesh.
  • carbon granules 20, as used herein have a non-uniform size and a non- spherical shape, characterized by the presence of granules of various sizes and shapes.
  • Carbon granules 20 exhibit a surface area of at least 1000 m 2 /g and, more preferably, of at least 1300 m 2 /g, as measured using the Brunauer-Emmett-Teller (BET) model of physical adsorption, where nitrogen is the adsorbed substance.
  • BET Brunauer-Emmett-Teller
  • Another means for evaluating the adsorptive capacity of the activated carbon granules is ASTM D4607-94, "Standard Test Method for Determination of Iodine Number of Activated Carbon.” When measured by ASTM D4607-94, the iodine number of the activated carbon granules is at least 1000 mg/g and, more preferably, at least 1300 mg/g.
  • adhesive layer 14 may be applied to textile substrate 30 by coating, extruding, spraying, foam coating, powder scattering coating, printing, or laminating, or other suitable processes known to one of ordinary skill in the art.
  • Activated carbon granules 20 are then applied by static powder scattering head, powder spraying apparatus, or other similar means to adhesive layer 14.
  • the non-uniformity of the size of carbon granules 20 permits the random orientation and close packing of carbon granules 20 on continuous adhesive layer 14 attached to textile substrate 30, which provides exceptionally higher surface area and less void spaces between activated carbon granules 20, a feature not presently achievable with spherical carbon granules that have a relatively uniform size and that are typically applied to discontinuous adhesive dots.
  • Textile substrate 10 to which has been applied a pattemwise arrangement of adhesive layer 12, is subsequently disposed over the layer of activated carbon granules 20, with adhesive layer 12 positioned against activated carbon granules 20.
  • the various layers are then pressed together at temperatures between about 70 0 C and about 250 0 C for a period of time sufficient to activate adhesive layers 12, 14 (typically, between 10 and 45 seconds and, more preferably, between 15 and 30 seconds).
  • the resulting composite (100) is then cooled to room temperature before further processing.
  • composite 100 is impregnated with a water repellent and oil repellent fluorocarbon emulsion or solution to render the whole composite, including the activated carbon layer, water- and oil-repellent.
  • the impregnation process can be achieved by dipping the composite in a fluorocarbon resin emulsion or solution or by spraying the fluorocarbon liquid on the composite, followed by drying.
  • a wash-durable repellent formulation containing a cross-linking agent, such as a polyisocyanate compound, is preferred.
  • Such a formulation is applied at a level in the range of about 0,1% to about 8% of the weight of the composite and, more preferably, in the range of about 0.5% to about 2% of the weight of the composite.
  • the fluorocarbon-impregnated composite resists contamination of the activated carbon layer by sweat, rain, seawater, fuels, and other liquids.
  • a composite structure was constructed, according to the teachings herein, using components as will be described below.
  • Textile substrate 10 A powder-bonded nonwoven fabric comprised of polyester fibers and having a finished weight of 0.9 oz/ yd 2 .
  • Adhesive layer 12 A co-polyamide hot-melt fine-powder paste applied to textile substrate 10 as a series of dots using a gravure printing process, which were subsequently dried at 140 0 C to form a discontinuous layer having a weight of about 0.6 oz/yd 2 .
  • Carbon granules 20 Activated carbon granules made from coconut shell and having a US mesh size of 20 to 50, a hardness of at least 96% (as measured by ASTM D3802-79), and an iodine number of about 1400 mg/g; sold by Japan Enviro Chemicals, Ltd. under the tradename "Wh2c20"; applied to adhesive layer 14 at an initial weight of about 7 oz/yd 2 .
  • Adhesive layer 14 A co-polyamide hot-melt fine-powder paste applied to textile substrate 30 using a foam coating method and subsequently dried at
  • Textile substrate 30 A dyed (black) polyester tricot knit fabric having a weight of
  • Adhesive layer 14 was applied to textile substrate 30 (i.e., the tricot knit fabric) using a foam coating apparatus and was subsequently dried at 140 0 C to form a continuous layer having a weight of about 0.9 oz/yd 2 .
  • Carbon granules 20 were applied to adhesive layer 14, using a particle scattering apparatus, to create an initial add-on weight of about 7 oz/yd 2 .
  • the first composite intermediate was then pressed in a Meyer belt laminator at 140
  • the adhesive layer firmly secured almost all of the activated carbon granules to the tricot knit fabric. Granules that were not adhesively bonded to the knit fabric were removed. The non-uniform shape and size of the granules resulted in close packing of granules 20 on adhesive layer 14. By visual inspection, a majority of the adhesive layer 14 was covered by granules, with a final add-on weight of about 6 oz/yd 2 .
  • the second intermediate structure (i.e., the nonwoven fabric to which the adhesive dots had been applied) was disposed over and contacted with the first intermediate structure, such that the adhesive dots were in contact with the activated carbon granules.
  • the new five-layer structure was passed through the same lamination equipment at a temperature of 140 0 C for about 20 seconds, where the machine setting on the rollers was set at about 10 Newtons of force.
  • the resulting five-layer composite was evaluated for wash durability of the adsorptive properties of the composite. The evaluation procedure and results are described below.
  • the five-layer composite passed visual inspection for creases and folds, and showed no evidence of delamination.
  • the gas adsorptive properties of the composite were tested according to the following procedure.
  • a one-inch square of the composite was enclosed in a 22-milliliter glass vial with a rubber septum stopper.
  • the vial was placed in an oven at 50 0 C for about one hour.
  • a solid phase microextraction (SPME) fiber was then inserted into the vial to sample the gas vapor.
  • SPME solid phase microextraction
  • An Agilent 6890 gas chromatograph with a 5973 mass selective detector was used to measure the relative concentration of each of the four compounds in the vial's headspace. The area under the peak of each component's gas chromatograph signal was representative of the relative concentration of each component.
  • the test was also completed on a composite sample that had been washed six times in an industrial laundry machine (with drying after each wash), according to the procedure below.
  • the textile composite was washed in a 35-pound Milnor front-load washing machine, with a total load of 30 pounds of textile, using type 2 laundry detergent NSN 7930- 00-252-6797 available from Cosco Company of Brooklyn, New York.
  • the textile composite was dried in a 50-pound gas dryer for 30 minutes at a "Low Delicates" setting (about 120 0 F), followed by a 5-minute cool-down period.
  • the drying step (30-minute cycle, 5-minute cool-down) was repeated after the sixth drying cycle to ensure that the composite was completely dry.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un composite destiné à être utilisé dans la fabrication d'une tenue de protection militaire contre des agents de guerre biologiques et chimiques. Ce composite comprend au moins cinq couches, dont deux couches extrêmes. Ces couches extrêmes sont constituées de substrats textiles, tels que des tissés, des tissus à mailles et des non-tissés. La couche intermédiaire est constituée de granules de charbon actif, fixés entre les deux substrats textiles à l'aide d'un adhésif. Les couches adhésives permettent de fixer les substrats textiles et la couche de charbon actif de façon durable. Le composite résultant est à la fois perméable à l'air et flexible.
PCT/US2005/013072 2004-05-26 2005-04-18 Composite contenant du charbon actif et son procede de fabrication Ceased WO2006080933A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US74864704A 2004-05-26 2004-05-26
US10/748,647 2004-05-26

Publications (2)

Publication Number Publication Date
WO2006080933A2 true WO2006080933A2 (fr) 2006-08-03
WO2006080933A3 WO2006080933A3 (fr) 2006-11-30

Family

ID=36740915

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2005/013072 Ceased WO2006080933A2 (fr) 2004-05-26 2005-04-18 Composite contenant du charbon actif et son procede de fabrication

Country Status (1)

Country Link
WO (1) WO2006080933A2 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR101406311B1 (ko) 2014-03-31 2014-06-12 주식회사 산청 화생방 보호의용 원단 및 이에 의한 화생방 보호의
FR3066431A1 (fr) * 2017-05-16 2018-11-23 Faurecia Automotive Industrie Piece structurelle anti composes organiques volatils, notamment pour un vehicule automobile
CN112044394A (zh) * 2019-06-06 2020-12-08 深圳市环球绿地新材料有限公司 包含活性炭的复合材料及其制备方法和用途
CN113119540A (zh) * 2021-04-15 2021-07-16 福建凤竹纺织科技股份有限公司 一种多层复合防水透气面料及其制备方法

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4459332A (en) * 1983-09-12 1984-07-10 American Cyanamid Company Flocked fabric laminate for protection against chemical agents
JPH04285006A (ja) * 1991-03-15 1992-10-09 Kuraray Chem Corp 活性炭粒子の製法
US5925441A (en) * 1994-04-04 1999-07-20 Blauer Manufacturing Company, Inc. Breathable shell for outerwear
US5660918A (en) * 1996-04-17 1997-08-26 W. L. Gore & Associates, Inc. Wash durable fabric laminates

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR101406311B1 (ko) 2014-03-31 2014-06-12 주식회사 산청 화생방 보호의용 원단 및 이에 의한 화생방 보호의
FR3066431A1 (fr) * 2017-05-16 2018-11-23 Faurecia Automotive Industrie Piece structurelle anti composes organiques volatils, notamment pour un vehicule automobile
CN112044394A (zh) * 2019-06-06 2020-12-08 深圳市环球绿地新材料有限公司 包含活性炭的复合材料及其制备方法和用途
CN113119540A (zh) * 2021-04-15 2021-07-16 福建凤竹纺织科技股份有限公司 一种多层复合防水透气面料及其制备方法
CN113119540B (zh) * 2021-04-15 2022-06-28 福建凤竹纺织科技股份有限公司 一种多层复合防水透气面料及其制备方法

Also Published As

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