CN1093021C - 金属纤维团及其制造方法 - Google Patents

金属纤维团及其制造方法 Download PDF

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CN1093021C
CN1093021C CN98800038A CN98800038A CN1093021C CN 1093021 C CN1093021 C CN 1093021C CN 98800038 A CN98800038 A CN 98800038A CN 98800038 A CN98800038 A CN 98800038A CN 1093021 C CN1093021 C CN 1093021C
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D·德克赖克
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Abstract

本发明涉及一种包含当量直径为1μm到30μm、长度为1mm到20mm的纤维的金属纤维团，该纤维团的特点是所述纤维团的芯(1)包含至少一束基本上相互平行排列的纤维，而所述纤维团的壳(2)由随机排列的纤维网状物构成。本发明还涉及一种制造这些金属纤维团的方法，其特征是在一系列工艺步骤过程中所述纤维团要经受连续的滚磨。

Description

金属纤维团及其制造方法
本发明涉及一种金属纤维团和制造所述纤维团的方法，所述纤维团用于生产金属纤维悬浮体或用于采用湿法生产金属纤维网。
生产含有金属纤维的悬浮体，需要使用易于处理和计量的金属纤维团，其中金属纤维要尽可能不相互缠绕，从而使所述的金属纤维团能容易而均匀地悬浮。通常，这些悬浮体采用松散纤维体或纤维颗粒制造，所述的纤维颗粒中的纤维是利用一种能溶于悬浮介质如溶于水的胶，如PVA(聚乙烯醇)粘结在一起的。
如在美国专利2050298中描述的一种已知方法，生产这些纤维体的过程如下：在硝酸中连续酸洗一种包含在铁铜基体中的不锈钢纤维束的复合体，随后所述的纤维束浸入例如PVA的胶中。这样制得的复合体切割成颗粒状并就此出售或以美国专利3977069的第4栏5～29行中所述的方法，将胶溶去后以作为松散纤维体出售。
然而，松散纤维体不易处理和计量。并且，用松散金属纤维体制备均匀纤维悬浮体会引起很大问题。另一方面，当使用前述颗粒时，实际几乎不可能完全去掉胶，而这在用湿法生产金属纤维网时，尤其是在随后烧结金属纤维网时会造成很多问题。
在说明书以下的部分使用的专门术语解释如下：
“Fe/Cu/SS”复合体是指一束不锈钢纤维，其中的每根纤维都有铜包皮，而所述的纤维束包封在一个铁壳中。
“金属纤维团的当量直径”是指与根据本发明得到的椭球状纤维团体积相同的一个假想球状纤维团的直径。
“纤维的当量直径”是指与实际纤维截面积相等的假想的圆纤维的直径。
本发明的一个目的是提供一种可处理和可计量的金属纤维团，可用于诸如生产均匀金属纤维悬浮体和采用湿法生产金属纤维网。
此外，本发明的另一个目标是提供一种制造所述金属纤维团的方法。
更确切地说，本发明提供一种金属纤维团，它包含当量直径为1μm至30μm、长度在1mm至20mm之间的纤维，所述纤维团的芯包含至少一束相互之间基本平行排列的纤维，而所述纤维团的壳由随机排列的纤维的网状物构成。
所述的纤维团具有相当高的孔隙率(因而其质量密度低)，从而当浸于液体中时，它们下降缓慢，这能够提高所制得的悬浮体的悬浮性能和均匀性。
因为所述的芯主要由基本平行，不相互缠绕的纤维的小束构成，所以这些纤维易于彼此分离以便悬浮。
此外，本发明的另一个目的是提供一种用Fe/Cu/SS复合体切块制造这些金属纤维团的方法，并包含以下步骤：(a)用硫酸对包裹所述复合体切块的铁壳进行化学酸洗；(b)随后对残留铁壳和所述复合体的铜包皮进行电解质去除；(c)用稀硫酸对所述纤维清洗；(d)用水对所述纤维清洗；(e)对所述纤维干燥，其中，在步骤(a)到(d)所述基体连续经受滚磨。
通常，对所述基体(如纤维体、纤维团、复合体)进行滚磨的这样一个不连续工艺方法，很适用于对例如在这些不同基体上的包皮进行的酸洗操作和浸洗。这些方法通常在工业上使用。浸洗也用于例如通过刨削具有聚合物覆层的金属薄片来生产直径100μm以下的金属纤维。
根据本发明生产所述金属纤维团的另一种方法包括：为了去除胶，在滚筒中在一种胶溶解介质中清洗现有技术的金属纤维颗粒(即浸过胶的金属纤维束)。通过使所述纤维颗粒在清洗中进行滚磨，可去除大部分所述的胶，并且变得松散和分离的纤维会聚拢、卷绕在一起形成预想的纤维团小球。
以下参照示于附图的特定实施例阐述本发明。
图1是本发明的所述金属纤维团的示意图。
图2是电解质酸洗浴中滚筒的示意图。
图3是所述生产工艺连续步骤的示意图。
本发明的金属纤维团示于图1中。所述纤维团的芯1由多束相互平行的定向排列的纤维构成。另一方面，所述纤维团的壳2由随机排列的纤维网状物构成。为了清楚地显示所述纤维团，在图1中去掉了所述壳的一部分。
生产所述金属纤维团的一个可能的工艺过程示于图2和3中。该生产过程构成如下：在一个由塑料如聚丙烯制成的滚筒中，在硫酸中不连续地酸洗Fe/Cu/SS复合体切块。所述的滚筒置于酸洗液中，并在一个外置马达带动下能够沿其长轴以可调整速率旋转。此外，为了改善电解质进出所述滚筒的循环流动状态，所述滚筒还可垂直和水平运动。
通过盖子3可将复合体切块放入所述的滚筒4中。所述滚筒的壁具有孔5，用于改善流经滚筒的电解质(硫酸)的循环。为了防止所述复合体切块通过这些孔从滚筒中逸出，提供了一张过滤布(未在图中显示)。所述的过滤布可固定在滚筒的外侧，或夹在滚筒内壁与一个具有外开孔的板之间。
一根端部具有钛阳极10的塑化的柔性铜缆9从滚筒端部上的开口6通入所述滚筒中。该方法也可以使用金属圆片作阳极。该阳板固定在所述滚筒的平直侧壁上，其中电流通过滑动触点传导。
本工艺过程一个具体实施方案在下面实施例中描述。所提及的工艺条件涉及对由已知的成束拉拔方法得到的3kg Fe/Cu/SS进行的酸洗。该工艺过程的各个步骤将参照图2和3详细描述。
在所述酸洗工艺的第一步骤A中，所述的铁壳全部或部分通过化学酸洗去除，并释放出氢气。
为了实现上述过程，所述的滚筒4置于硫酸液7中，并在该液中至少旋转20分钟。在所述的酸液中硫酸的浓度是300g/l，温度为50℃。硫酸立即(不通电流)与所述Fe/Cu/SS复合体的铁壳发生化学反应，生成氢气和硫酸亚铁。
随后，在该工艺的步骤B中，所有残留的铁壳采用电解去除。为此使用了铅阴板8和钛阳板10、一根端部具有钛阳板的塑化柔性铜缆9从所述滚筒的端壁上的开口6穿入。所述的铅阴板8浸入所述的酸洗液中。
所述滚筒在硫酸液11中连续旋转。这种旋转使所述的酸能够良好地循环，并保持电流稳定。在所述酸液11中所述复合体的保持时间取决于电流、复合体的量和在本工艺步骤A所述铁壳的去除程度。在本实施例中，以50A的电流最短用3.5小时可完成酸洗将复合体上的铜包皮除去。
在第三个步骤C中，所述的复合体在稀硫酸中清洗，以防止随后在第四个步骤中形成铁的氢氧化物。在所述酸液12中将滚筒旋转15到30分钟。此外，为了改善在滚筒中液体的循环，所述的滚筒还要进行垂直和水平运动。
在第四个步骤D中，所述的纤维体用水清洗。所述的滚筒在水浴13中旋转几个小时。
在最后步骤E中，从滚筒中取出所述纤维体，并在烘箱中干燥。
根据上述工艺过程，使用当量直径在1μm到30μm之间，长度为1mm到20mm的纤维，可制成含有2×104到2×106根纤维的纤维团。所述纤维团的尺寸取决于所使用的纤维尺寸。所述纤维团的平均当量直径在很大程度上取决于所用纤维长度与纤维当量直径之比(L/D)。如果使用L/D为400的纤维，可得到平均当量直径为1cm的纤维团。类似地，用L/D比为750的纤维，可得到平均当量直径2cm的纤维团。为了生产根据此处所述工艺方法的金属纤维团，应优选使用L/D比在100到2000之间的纤维。
所述纤维团的密度取决于所用纤维的几何尺寸，它通常小于0.8kg/dm3。这样，使用具有当量直径6.5μm和长为1mm的纤维，可制得密度为0.19kg/dm3的纤维团。
如果在同一个酸洗液中实施步骤A和B，而不更换电解质，废酸将包括H2SO4，FeSO4和CuSO4。在所述工艺过程中，步骤A和B在独立的酸洗液中进行，从步骤A产生的废酸只含有H2SO4和FeSO4(不含Cu也不含CuSO4)，而这对其后续工艺过程有利。在所述的电解酸洗之后，废酸的构成是H2SO4，CuSO4和FeSO4(如果在步骤A中铁壳没有完全溶解，它由该铁壳的可能的残余部分产生)和Cu(所述阴极上的沉积物)。
而且，最好使此处所述的工艺中所制得的金属纤维团所含有的纤维不含任何胶，如PVA。
此处所述工艺的另一个优点是在所述酸洗工艺中不使用硝酸，这从生态观点来看是非常受欢迎的。
步骤B中的酸洗时间和所用的硫酸浓度是非常重要的工艺参数。如果电解酸洗时间过长或者使用的硫酸浓度太高，酸会严重腐蚀所述纤维。尤其是在酸洗去Cu时，酸洗时间和硫酸浓度是非常关键的。
虽然所述滚筒的容量通常是有限的，但是可以将几个滚筒同时投入运行以提高本工艺的总产量。而且，通过提高酸洗时的电流，就可能降低酸洗时间，这也会提高该过程的产量。
本发明的金属纤维团与其它各种原料相比，很适合生产含有均匀分散的金属纤维的塑料，
所述的塑料可用于例如在塑料制品中产生电磁屏蔽效应。
并且，可以将本发明金属纤维团以给定数量添加到另一种纤维悬浮体中。这样所述的金属纤维可以均匀分散并分布于其它纤维中。用这种方式，可利用湿法制造混合纤维网。如美国专利4265703中所述，通过向纸浆纤维悬浮体均匀添加金属纤维，可以随后得到具有稳定金属纤维含量的纸张，这些纤维在纸面内均匀分布。
除此以外，所述工艺也可以用于酸洗Fe/Fe/SS复合体或Fe/Fe/Fe/SS复合体。在这种情况下，废酸不再含有Cu，从而可将电解酸洗步骤省略(是上述工艺的步骤B)。拉拔多根各自具有Fe包皮的不锈钢丝，可得到一种Fe/Fe/SS基体。这些拉拔钢丝随后聚结成束，并包封铁壳后拉拔。如美国专利3379000所述，这样得到的多个构件随后再次一起打捆，包封铁壳，并再次拉拔以形成预想的基体。
所述工艺适用于酸洗任何类型的复合体，甚至长度很短如0.1mm的复合体，这样得到的纤维体随后可以用于例如生产雷达伪装覆层。

Claims (6)

1.一种含有当量直径为1μm到30μm、长度为1mm到20mm的纤维的金属纤维团，特征在于所述纤维团的芯(1)包含至少一束基本上相互平行排列的纤维，而所述纤维团的壳(2)由随机排列的纤维的网状物构成。
2.根据权利要求1的金属纤维团，其中的金属纤维的长度与直径之比在100到2000之间。
3.根据权利要求1的金属纤维团，其中所述纤维团含有2×104到2×106根纤维。
4.一种用Fe/Cu/SS复合体切块制造如权利要求1所述的金属纤维团的方法，包含以下步骤：
(a)用硫酸对包裹所述复合体切块的铁壳进行化学酸洗；
(b)随后对残余的所述铁壳和所述复合体的铜包皮进行电解去除；
(c)用稀硫酸对所述纤维进行清洗；
(d)用水对所述纤维清洗；
(e)对所述纤维干燥，
并且，其中基体在步骤(a)到(d)中连续地经受滚磨。
5.一种制造如权利要求1所述的金属纤维团的方法，其中浸了胶的金属纤维束在经受连续滚磨的同时在一种胶溶解介质中清洗，以去除所述的胶。
6.根据权利要求5的一种方法，其中所述的胶是PVA，胶溶解介质为水。
CN98800038A 1997-01-17 1998-01-12 金属纤维团及其制造方法 Expired - Fee Related CN1093021C (zh)

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