CN1082610C - Composite fibre products and processes for their production - Google Patents

Composite fibre products and processes for their production Download PDF

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Publication number
CN1082610C
CN1082610C CN97194098A CN97194098A CN1082610C CN 1082610 C CN1082610 C CN 1082610C CN 97194098 A CN97194098 A CN 97194098A CN 97194098 A CN97194098 A CN 97194098A CN 1082610 C CN1082610 C CN 1082610C
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China
Prior art keywords
cellulon
compound
goods
fibre
flooded
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CN97194098A
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Chinese (zh)
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CN1216595A (en
Inventor
S·S·伯菲
P·M·L·阿舍尔
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Serfell Ltd
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SERFELL Ltd
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Priority claimed from GBGB9604097.7A external-priority patent/GB9604097D0/en
Priority claimed from GBGB9615770.6A external-priority patent/GB9615770D0/en
Application filed by SERFELL Ltd filed Critical SERFELL Ltd
Publication of CN1216595A publication Critical patent/CN1216595A/en
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Publication of CN1082610C publication Critical patent/CN1082610C/en
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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • D04H1/645—Impregnation followed by a solidification process
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00—Other non-woven fabrics
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
    • F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
    • F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
    • F01N3/28—Construction of catalytic reactors
    • F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration

Abstract

A composite fibre product is described which comprises a plurality of inorganic fibres and a binder which is substantially uniformly distributed throughout the fibre product. The composite fibre product has a laminar shear strength of at least 0.1 MPa. Also described is a process for the production of a composite fibre product which comprises impregnating a fibre mass comprising a plurality of inorganic fibres with a liquid binder system comprising a binder material and a carrier liquid and then subjecting the impregnated fibre mass to a heating step which involves the use of dielectric heating.

Description

Compound cellulon and production method thereof
The present invention relates to compound cellulon and production method thereof that a class comprises the many inorfils that are bonded together with tackiness agent.More particularly, the present invention relates to the compound fiber cushion of a class, its can be used for be present in brittle ceramic in catalytic converter and the diesel particulate filter or metal body flexiblely be fixed on around metal shell in.
Catalytic converter and diesel particulate filter device often are contained on automobile and other Motor Vehicle that on the way travel, so that the waste gas that purifying engine produces.This kind equipment generally includes one and is installed in and provides the ceramic honeycomb body of carrier for catalyzer in the metal shell.Ceramic body is comprising many threads road, and it is a kind of friable structure, is easy to damage during the vibration force that often produces during its Motor Vehicle operation that is subjected on the way travelling when any.And, this object and around metal shell in use stand high temperature, this expands their, but its degree is inequality.Therefore, fixedly ceramic body employed installation system in its metal shell must make the vibration force of this ceramic body and existence isolated, and the differences in expansion between energy compensation porcelain body and shell.By this method, as the result of differential expansion or vibration force, the stress that ceramic body is suffered in use can maintain acceptable level.
Known, use compound fiber cushion, will be present in the brittle ceramic body in catalytic converter and the diesel particulate filter device.Flexiblely be fixed on around metal shell in, referring to, for example, U. S. Patent 4011651 and WO-94/24425.Fiber cushion be installed in ceramic body and around metal shell between annular intermittently in, and under pressure, be fixed in this annular space, so just radial pressure is applied on ceramic body and the shell, thereby ceramic body is clamped on the appropriate location.
The invention provides a kind of compound cellulon that comprises many inorfils and tackiness agent with and production method.Compound cellulon can be got the form of cushion, can be fixed in its metal shell with pottery or the metal body that it will be present in catalytic converter and the diesel particulate filter.
According to a first aspect of the present invention, a kind of compound cellulon is provided, specifically a kind of pad, it comprises many inorfils and is uniformly distributed in tackiness agent in the whole cellulon substantially.The layer shear strength of described compound cellulon is 0.1MPa (megapascal (MPa)) at least.
Inorfil can be any inorfil known in the art.Yet, when compound cellulon is when being used for flexiblely fixedly being loaded on the pad of pottery in catalytic converter and the diesel particulate filter or metal body, needing under the high running temperature that this fiber often produces in this device is heat-staple (promptly non-degradable).In general, in this class the fiber that comprises in the employed compound fiber cushion of purposes being installed, is more than 700 ℃ the time in temperature, is heat-staple, and preferred temperature is more than 800 ℃, more preferably more than 900 ℃.
Heat-staple inorfil comprises ceramic fiber, for example: aluminium oxide, mullite, alumino-silicate, boroalumino silicate (aluminoborosilicate), zirconium oxide and titania fiber and transparent glass fibre.Preferred thermally-stabilised inorfil is the polycrystalline inorfil, polycrystalline inorganic oxide fibres particularly, for example: aluminium oxide, mullite, alumino-silicate, boroalumino silicate, zirconium oxide and titania fiber.Wherein, this term of so-called alumina fibre, we also stipulate to comprise, comprise the alumina fibre of the silica of a few percent (weight) that adds as phase stabiliser, alumina fibre is particularly preferred.Preferred this fibrid be length range 1～10cm (centimetre), the short cut staple of 1～10 micron of average diameter scope.Particularly preferred alumina fibre be by Imperial Chemical Industries catalogues circular (PLC) with untwisting close, low density pulvilliform formula sale person, its commodity are called Saffil, its be still more than 1000 ℃ heat-staple.
Compound cellulon of the present invention can comprise two or more dissimilar inorfil.In its embodiment, dissimilar fibers can be closely to mix, and perhaps, they can separate and arrangement by certain pattern, for example, and with the form of discontinuity layer.
Tackiness agent can be an inorganic material, but is preferably organic material, and suitable organic bond more specifically is described among U. S. Patent 4011651 and the WO-94/24425.Its disclosure is incorporated herein and is made for reference.Preferably, tackiness agent is an organic polymer.
A kind of suitable adhesive is to be based copolymers with n-butyl acrylate and acrylonitrile.
Institute's preferred adhesive is by making curable polymeric composition solidify the person of obtaining.The preferred embodiment of curable polymeric composition is to comprise acrylic polymer and crosslinking agent particularly such as the mixture of the crosslinking agent that contains epoxy group of epoxy resin.Such curable polymeric composition generally always comprises preferred 95.0～99.0% (weight) acrylic polymers of 90.0～99.0% (weight) and 1.0～10.0% (weight) preferred 1.0～5.0% (weight) crosslinking agent.The acrylic polymer that is suitable for is that the monomeric unit that comprised is derived from least a (C that is selected from 1-4Alkyl) acrylic acid C 1-8The homopolymer of the acrylic monomer of Arrcostab or copolymer, and in preferred embodiments, it is that the monomeric unit that comprised is derived from least a being selected from (methyl) acrylic acid C 1-4The homopolymer of the acrylic monomer units of Arrcostab or copolymer, described (methyl) acrylic acid C 1-4Arrcostab, for example methyl methacrylate, methyl acrylate, ethyl acrylate, propyl acrylate and butyl acrylate.A kind of particularly preferred tackiness agent is to solidify the person of obtaining by making to comprise based on the acrylic polymer of butyl acrylate and the composition of epoxy resin cross-linking agent.
When compound fiber cushion of the present invention was used for being fixed on pottery or metal body in catalytic converter or the diesel particulate filter, the preferred organic bond that uses through the basic pyrolysis of high temperature/burning-outs, described high temperature were the temperature that pad is stood when application.In addition, preferred organic bond is not produce poisonous resultant person when its pyrolysis/burning-out, for this reason, and preferred its not chloride and nitrogen.
The tackiness agent that comprises in compound cellulon of the present invention is evenly distributed in the whole cellulon substantially.Preferably, the distribution of the tackiness agent in the compound cellulon is as follows, every 1mm of goods 3(millimeter 3) binder wt percentage in the zone, in the goods gross weight in this zone is benchmark, for being in 40% scope of tackiness agent overall weight percent in the goods of benchmark in the goods gross weight, more preferably in 30% scope, be preferably especially in 20% scope.In an especially preferred embodiment, the distribution of the tackiness agent in the compound cellulon is as follows, every 1mm of goods 3(millimeter 3) binder wt percentage in the zone, be benchmark in the goods gross weight in this zone, for being in 10% scope of tackiness agent overall weight percent in the goods of benchmark in the goods gross weight.
The thickness of compound cellulon depends on the purpose end use of product.Yet, when product be fixedly pottery or metal body in catalytic converter or diesel particulate filter, use compound fiber cushion the time, its general thickness range always is 3～15mm (millimeter), preferably its scope is 5～12mm, more preferably its scope is 5～9mm.
The quantitative range of tackiness agent in compound cellulon generally is 2～15% (weight) of product gross weight, is preferably 5～15% (weight).
The density range of compound cellulon of the present invention is generally 30～700kg/m 3(kilogram/rice 3), preferably its scope is 100～500kg/m 3, more preferably its scope is 100～350kg/m 3
The layer shear strength of compound cellulon of the present invention is 0.1MPa at least, is preferably 0.2MPa at least, 0.3MPa at least more preferably, the meaning of so-called layer shear strength be for make product generation layering the power that must apply.Layer shear strength can be at Instron or similarly adopted three-point bending (three point bend) test to measure easily on the instrument.Preferably, when thickness range be the compound cellulon sample of 5～10mm to be forced into thickness between two boards be 3mm and remove when bonding, the compound cellulon 1.0kgf/cm at least that also can exert pressure 2(kilogram force/centimetre 2), more preferably its scope is 1.5～4.0kgf/cm 2
According to a second aspect of the present invention, a kind of method of producing compound cellulon is provided, particularly produce the method for pad, comprise: the fibre body that comprises many inorfils with the fluid binder system dipping that comprises adhesive material and carrier liquid, the fibre body that is flooded is handled through comprising the drying process that heats it, so that remove carrier liquid at least substantially, its characteristics are that the fibre body that is flooded remains under the pressure in the process that continues to the small part drying process.
According to a third aspect of the present invention, a kind of method of producing compound cellulon is provided, particularly produce the method for pad, comprise: the fibre body that comprises many inorfils with the fluid binder system dipping that comprises adhesive material and carrier liquid, the fibre body that is flooded is handled through heating process, its characteristics are that the fibre body that is flooded remains under the pressure in the process that continues to the small part heating process.
According to a fourth aspect of the present invention, a kind of method of producing compound cellulon is provided, particularly produce the method for pad, comprise: the fibre body that comprises many inorfils with the fluid binder system dipping that comprises adhesive material and carrier liquid, the fibre body that is flooded is handled through heating process, its characteristics are that heating process comprises uses the dielectric heating, for example microwave or radio frequency heating.In a fourth aspect of the present invention, the preferred fibre body that floods remains under the pressure in the process that at least a portion heating process continues.
The fibre body that floods according to the inventive method can comprise many defibres, perhaps, it can get the form of multifilament (multi-fibre) goods, wherein single fiber is combined into a kind of low density pad or felt pan, it is to adopt fiber entanglement and the loose combination that realizes, perhaps, adopt such as woven, knitting, loop bonding, pin and dash or some other means of vacuum packed, perhaps can be more firmly fixing.Preferably, the fibre body that floods by the inventive method is the multifilament goods, and its thickness range is 10～60mm, 30～50mm more preferably, and the surface density scope is 0.2～2.0kg/m 2(kilogram/rice 2), 1.0～2.0kg/m more preferably 2The preferred inorfil of inorfil and use in the methods of the invention is as mentioned with the described person of compound cellulon.
The inventive method can be used for preparing compound cellulon from the inorfil of two kinds or number of different types.In its embodiment, dissimilar fibers can closely mix, and perhaps, they can separate and arrangement by certain pattern, for example, and with the form of discontinuity layer.
The fluid binder system can comprise inorganic adhesive material, but preferably comprises organic adhesive material, polymer for example, and comprise and can dissolve and disperse the organic of organic adhesive material or aqueous carrier liquid.Suitable organic bond material more specifically is described among U. S. Patent 4011651 and the WO 94/24425, its disclosure is incorporated herein and is made for reference, comprise polymer and curable polymer or prepolymer, they can be along with the part drying process, or is solidificated on the fibre body that is flooded on the spot in manufacturing procedure subsequently.Polymer can be to be convenient to in the methods of the invention or the material of the waste recovery fiber that produces in the processing/housekeeping operation subsequently.
It is the aqueous dispersion of based copolymers with n-butyl acrylate and acrylonitrile that a kind of suitable adhesive system comprises a kind of.
The preferred adhesive system is the dispersion person who comprises curable polymeric composition, is preferably the aqueous dispersion person who comprises it, is called as resin or latex sometimes.The example of preferred curable polymeric composition be to comprise acrylic polymer and crosslinking agent particularly such as the mixture of the crosslinking agent that contains epoxy group of epoxy resin.Such curable polymeric composition generally always comprises preferred 95.0～99.0% (weight) acrylic polymers of 90.0～99.0% (weight) and 1.0～10.0% (weight) preferred 1.0～5.0% (weight) crosslinking agent.The acrylic polymer that is suitable for is that the monomeric unit that comprised is derived from least a (C that is selected from 1-4Alkyl) acrylic acid C 1-8The homopolymer of the acrylic monomer of Arrcostab or copolymer, and in preferred embodiments, it is that the monomeric unit that comprised is derived from least a being selected from (methyl) acrylic acid C 1-4The homopolymer of the acrylic monomer units of Arrcostab or copolymer, described (methyl) acrylic acid C 1-4Arrcostab, for example methyl methacrylate, methyl acrylate, ethyl acrylate, propyl acrylate and butyl acrylate.A kind of particularly preferred adhesive system is the aqueous dispersion person who comprises a kind of acrylic polymer and epoxy resin cross-linking agent based on butyl acrylate.
When the fluid binder system was the person that comprises the curable polymeric composition, it also can comprise catalyzer, so that accelerate the curing process.
Can be appreciated that from above-mentioned, so-called term fluid binder system, we also stipulate to comprise, are included in the dispersion of the solid in small, broken bits in the liquid-carrier or the adhesive system of suspension.
The fluid binder system generally always comprises 0.5～50.0% (weight) adhesive material and 50.0～99.5% (weight) carrier liquid.Preferred fluid binder system always comprises more preferably more preferably 95.0～99.0% (weight) carrier liquid of adhesive material and 90.0～99.5% (weight) of 1.0～5.0% (weight) of 0.5～10.0% (weight).
Can use various technology dipping inorganic fiber articles.For example: single fiber can be dispersed in the fluid binder system fully, adopt again to comprise the papermaking process of removing excessive carrier liquid, for example, that dispersions obtained casting is in blocks by vacuum.Another kind method is got the form part that single fiber is combined into the multifilament goods of low density pad or felt pan at inorganic fiber article, pad or felt pan can be immersed simply or steeps in the fluid binder system.Another method can be sprayed the low-density fibre pad with the fluid binder system.
Before the fiber drying of being flooded/heating process was handled, removing any excessive carrier liquid usually was easily.Carrying out this step can adopt the fibre body that will be flooded between roller or pressurization between plate, be placed under the vacuum or adopt the method for centrifugation.
Through fluid binder system dipping and after removing excessive carrier liquid usually subsequently, the fibre body that is flooded also drying/heating process is handled at fibre body.Of the present invention second or the method for the third aspect in, and also preferred in the method for a fourth aspect of the present invention, remain under the pressured state at the fibre body that is flooded to small part drying/heating process and to carry out.Institute's impregnation of fibers body should remain under pressure that adhesive material can combine fiber and in case when can limit compound cellulon significantly when removing pressure and expand.In general, whole drying/heating process is to carry out when the fibre body that is flooded remains under the pressure, but only the final step of drying/heating process also is possible by this way, so still can obtain satisfied result.In drying/heating process, always removing is all any unnecessary carrier liquids basically, and preferably removes all.
During drying/heating process to the fibre body that flooded pressurization institute applied pressure scope generally be 5～500KPa (kPa), be preferably 5～200KPa.In general, institute's applied pressure should be able to the production density scope be 30～700kg/m 3Compound cellulon, preferred 100～500kg/m 3, more preferably 100～350kg/m 3When the fibre body that is flooded is thickness range 10～60mm, 30～50mm for example, the surface density scope is 0.2～2.0kg/m 2, 1.0～2.0kg/m for example 2The multifilament goods time, gained impregnation of fibers body generally is forced into thickness in drying/heating process be 2～5mm.The method that applies this pressure in batch technology easily is, by for example clamp device, spring load folder or hydraulic press the fibre body that is flooded is clipped between plate, then plate rolled over.Another kind method in continuous processing, by impregnated fibre body is sent into roller or carrying device, can produce the necessary pressure to it easily.
Of the present invention second and the method for the third aspect in, can use baking oven commonly used to carry out drying/heating process, but in preferred embodiments, the dielectric heating of use such as microwave or radio frequency heating is because it helps to make tackiness agent to distribute more evenly quite significantly in final compound cellulon.In every kind of method in second, third and fourth aspect of the present invention, the method for preferably using the dielectric heating to combine with conventional heater means such as thermal air current.In general, drying/heating process always comprises the fibre body that is flooded is heated to 80～200 ℃ that preferred range is 100～170 ℃.Particularly preferred temperature range is 140～160 ℃.
When the fluid binder system comprised curable polymeric composition, like that preferred just as institute, drying/heating process can be succeeded by other manufacturing procedures that curable polymeric composition is solidified.The preferred consolidation process comprises makes polymer composition through certain type cross-linking reaction.Yet the temperature of using in drying/heating process is enough to remove any unnecessary carrier liquid usually and curable polymeric composition is solidified, thereby need not to carry out independently curing process.Yet, when using independently curing process, generally the fibre body that is flooded is kept the time that curing process continued under pressure.
Compound cellulon of the present invention also can comprise one or more other materials.The appropriate materials that is included in the compound cellulon comprises layer mineral, particularly such as the inflatable stratiform silicate mineral of vermiculite.Can be by other materials being added in the fluid binder system that these goods of preparation use, and it is sneaked in the compound cellulon.On the other hand, can be according to the compound cellulon of the present invention preparation with waiting that the solution or the dispersion of sneaking into material carry out reprocessing.
Compound cellulon of the present invention can perhaps be used for being supported on the ceramic body in hot gas filtration equipment and the coal gasification apparatus as being fixed on the pottery in catalytic converter and the diesel particulate filter and the fixed bolster of metal body.Compound cellulon of the present invention also can be made gasket applications effectively, can also be as high temperature insulating material.
Refer now to the explanation of following example but do not limit the present invention.
Example 1
From known surface density is 1.2～1.6kg/m 2, thickness is to downcut the pad sample that is of a size of about 500mm * 200mm on " Saffil " low density chunk products of 30～50mm.These products of weighing are delivered on the dish then, at this its bubble are being diluted in the latex that solid content is about 3% (w/w) (Acronal 35 D, BASF produce, and are 50% aqueous dispersion of based copolymers with n-butylacrylate and acrylonitrile).Then with the specimen holder that flooded between the glass fiber mesh of two polytetrafluoroethylene (PTFE) coatings, again this sandwich structure is placed two and is of a size of between the glass fibre filled silicone resin plate of 500mm * 200mm * 12mm.With the G clamp device resin plate is forced together then, dropping to the suitable institute of about 5mm applied pressure up to the thickness of " Saffil " that flooded layer is about 0.5 to cling to (50KPa)], and be fixed on this position with clip.This combination continue during in, from sample, discharge excessive latex.
Then the set of molds zoarium of being finished is placed on the conveyor belt of the auxiliary baking oven of air/radio frequency (RF), regulating belt speed to the waiting time is 15～45 minutes.The RF power of regulating baking oven is about 5.5 kilowatts, with extremely about 150 ℃ of the air temperature modification in the baking oven.When abundant drying of latex and curing (crosslinked), take out sample from baking oven.Remove clip and plate from sample carefully then, and peel off the PTFE net, show final compound fiber cushion, its thickness range is 7～8.5mm.
Example 2
From known surface density is 1.0～2.0kg/m 2, thickness is to downcut the pad sample that is of a size of about 500mm * 200mm on " Saffil " low density chunk products of 30～50mm.These samples of weighing, deliver to then on the dish, its bubble is being diluted in the latex that solid content is about 5% (w/w) (60% aqueous dispersion that contains the butyl acrylate based polyalcohol of 3% (w/w) Epikote (TM), 828 epoxy resin cross-linking agents) at this.Then with the specimen holder that flooded between the glass fiber mesh of two polytetrafluoroethylene (PTFE) coatings, again this sandwich structure is placed two and is of a size of between the glass fibre filled silicone resin plate of 500mm * 200mm * 12mm.With the G clamp device resin plate is forced together then, dropping to the suitable institute of about 5mm applied pressure up to the thickness of " Saffil " that flooded layer is about 0.5 to cling to (50KPa)], and be fixed on this position with clip.This combination continue during in, from sample, discharge excessive latex.
Then the set of molds zoarium of being finished is placed on the conveyor belt of the auxiliary baking oven of air/radio frequency (RF), regulating belt speed to the waiting time is 15～45 minutes.The RF power of regulating baking oven is about 5.5 kilowatts, with extremely about 150 ℃ of the air temperature modification in the baking oven.When abundant drying of latex and curing (crosslinked), take out sample from baking oven.Remove clip and plate from sample carefully then, and peel off the PTFE net, show final compound fiber cushion, its thickness range is 7～8.5mm.

Claims (47)

1. compound cellulon, it comprises many inorfils and is uniformly distributed in tackiness agent in the whole cellulon substantially, and the layer shear strength of described compound cellulon is 0.1MPa at least.
2. as desired compound cellulon in the claim 1, wherein to be higher than under 700 ℃ in temperature be heat-staple to inorfil.
3. as claim 1 or the desired compound cellulon of claim 2, wherein inorfil is a ceramic fiber.
4. as claim 2 or the desired compound cellulon of claim 3, wherein inorfil is the polycrystalline inorganic oxide fibres, and it is selected from alumina fibre, mullite fiber, aluminosilicate fiber, boroalumino silicate fiber, Zirconium oxide fibre and titania fiber.
5. as the desired composite fiber product of claim 4, wherein inorfil is an alumina fibre.
6. as any one desired compound cellulon in the claim 1～5, wherein inorfil is that length range is that 1～10cm, average diameter scope are 1～10 micron short fibre.
7. as any one desired compound cellulon in the claim 1～6, wherein tackiness agent is an organic material.
8. as the desired compound cellulon of claim 7, wherein tackiness agent is an organic polymer.
9. as claim 7 or the desired compound cellulon of claim 8, wherein tackiness agent is a kind of so that the curable polymeric composition that comprises acrylic polymer and contain the crosslinking agent of epoxy group solidifies the material of deriving.
10. as the desired compound cellulon of claim 9, wherein acrylic polymer is that the monomeric unit that comprised is derived from least a methacrylic acid C that is selected from 1～4Arrcostab and acrylic acid C 1-4The homopolymer of the acrylic monomer of Arrcostab or copolymer.
11. as the desired compound cellulon of claim 9, wherein tackiness agent is to solidify the material of deriving from making to comprise based on the acrylic polymer of butyl acrylate and the curable polymeric composition of epoxy resin cross-linking agent.
12. any one desired compound cellulon in the claim as described above, the distribution of the tackiness agent in the wherein compound cellulon is as follows, per 1 millimeter of goods 3Binder wt percentage in the zone is benchmark in the goods gross weight in this zone, for being in 40% scope of tackiness agent overall weight percent in the goods of benchmark in the goods gross weight.
13. as desired compound cellulon in the claim 12, the distribution of the tackiness agent in the wherein compound cellulon is as follows, per 1 millimeter of goods 3Binder wt percentage in the zone is benchmark in the goods gross weight in this zone, for being in 30% scope of tackiness agent overall weight percent in the goods of benchmark in the goods gross weight.
14. any one desired compound cellulon in the claim as described above, this products thickness scope is 3～15mm.
15. any one desired compound cellulon in the claim as described above, wherein the quantitative range of tackiness agent in goods is 2～15% weight, is benchmark in the goods gross weight.
16. any one desired composite fiber product in the claim as described above, the density range of these goods is 30～700kg/m 3
17. as the desired composite fiber product of claim 16, the density range of these goods is 100～500kg/m 3
18. any one desired compound cellulon in the claim as described above, the layer shear strength of these goods is 0.2MPa at least.
19. any one desired composite fiber product in the claim as described above, when thickness range be the product sample of 5～100mm to be compressed into thickness between two boards be 3mm and when removing tackiness agent, these goods 1.0kgf/cm at least that can exert pressure 2
20. as the desired compound cellulon of claim 19, when thickness range be the product sample of 5～100mm to be compressed into thickness between two boards be 3mm and when removing tackiness agent, it is 1.5～4.0kgf/cm that these goods can be exerted pressure 2
21. method of producing compound cellulon, this method comprises, the fibre body that will comprise many inorfils floods with the fluid binder system that comprises adhesive material and carrier liquid, the fibre body that is flooded is handled through heating process, be it is characterized in that heating process comprises the heating of use dielectric.
22. as the desired method of claim 21, wherein the fibre body that is flooded remains under the pressure in the process that continues to the small part heating process.
23. method of producing compound cellulon, this method comprises, the fibre body that will comprise many inorfils floods with the fluid binder system that comprises adhesive material and carrier liquid, the drying process of fibre body through comprising the fibre body that heating is flooded that is flooded handled, so that remove carrier liquid at least substantially, it is characterized in that the fibre body of institute's proofing remains under the pressure in the process that continues to the small part drying process.
24. method of producing compound cellulon, this method comprises, the fibre body that will comprise many inorfils floods with the fluid binder system that comprises adhesive material and carrier liquid, the fibre body that is flooded is handled through heating process, be it is characterized in that the fibre body that is flooded remains under the pressure in the process that continues to the small part heating process.
25. as any one desired method in the claim 21～24, wherein the fibre body that is flooded is the multifilament goods that are combined into low density pad and felt pan by single fiber.
26. as the desired method of claim 25, wherein the thickness range of multifilament goods is 10～60mm, the surface density scope is 0.2～2.0kg/m 2
27. as any one desired method in the claim 21～26, wherein to be higher than under 700 ℃ in temperature be thermally-stabilised to inorfil.
28. as the desired method of claim 27, wherein inorfil is a ceramic fiber.
29. as claim 27 or the desired method of claim 28, wherein inorfil is the polycrystalline inorganic oxide fibres, and it is selected from alumina fibre, mullite fiber, aluminosilicate fiber, boroalumino silicate fiber, Zirconium oxide fibre and titania fiber.
30. as the desired method of claim 29, wherein inorfil is an alumina fibre.
31. as any one desired method in the claim 21～30, wherein inorfil is that length range is that 1～10cm, average diameter scope are 1～10 micron short fibre.
32. as any one desired method in the claim 21～31, wherein the fluid binder system comprises organic adhesive material and can dissolve or disperse the organic of organic adhesive material or aqueous carrier liquid.
33. as the desired method of claim 32, wherein the organic bond material is a polymer.
34. as claim 32 or the desired method of claim 33, wherein the fluid binder system comprises the dispersion of the curable polymeric composition of the crosslinking agent that contains acrylic polymer and contain epoxy group.
35. as the desired method of claim 34, wherein acrylic polymer is that the monomeric unit that comprised is derived from least a methacrylic acid C that is selected from 1-4Arrcostab and acrylic acid C 1-4The homopolymer of the acrylic monomer of Arrcostab or copolymer.
36. as the desired method of claim 34, wherein the fluid binder system comprises the dispersion that contains based on the curable polymeric composition of the acrylic polymer of butyl acrylate and epoxy resin cross-linking agent.
37. as any one desired method in the claim 32～36, wherein dispersion is an aqueous dispersion.
38. as any one desired method in the claim 21～37, wherein the fluid binder system comprises 0.5～50.0% weight adhesive material and 50.0～99.5% weight carrier liquids.
39. as the desired method of claim 38, wherein the fluid binder system comprises 1.0～5.0% weight adhesive materials and 95.0～99.0% weight carrier liquids.
40. as any one desired method in the claim 22～24, wherein whole drying/heating process is carried out when the fibre body that is flooded remains under the pressure.
41., in the process that drying/heating process continues, be 5～500KPa wherein for institute's applied pressure scope that the fibre body that is flooded is pressurizeed as any one desired method in the claim 22～24.
42., in the process that drying/heating process continues, be 5～200KPa wherein for institute's applied pressure scope that the fibre body that is flooded is pressurizeed as the desired method of claim 41.
43., wherein in drying/heating process, use the dielectric heating as claim 23 or the desired method of claim 24.
44. as any one desired method in the claim 21,22 or 43, wherein the dielectric heater means is microwave or radio frequency heating.
45., wherein in drying/heating process, dielectric heating and conventional heating are used in combination as any one desired method in the claim 21,22,43 or 44.
46. as any one desired method in the claim 21～45, wherein to be heated to temperature range in drying/heating process be 80～200 ℃ to the fibre body that is flooded.
47. as the desired method of claim 46, wherein to be heated to temperature range in drying/heating process be 100～170 ℃ to the fibre body that is flooded.
CN97194098A 1996-02-27 1997-02-20 Composite fibre products and processes for their production Expired - Fee Related CN1082610C (en)

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EP0883736A1 (en) 1998-12-16
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DE69701796T2 (en) 2000-11-09
EP0883736B1 (en) 2000-04-26
AU1885097A (en) 1997-09-16
DE69701796D1 (en) 2000-05-31
WO1997032118A1 (en) 1997-09-04

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