JP2022537390A - 軽量不織マット - Google Patents
軽量不織マット Download PDFInfo
- Publication number
- JP2022537390A JP2022537390A JP2021575893A JP2021575893A JP2022537390A JP 2022537390 A JP2022537390 A JP 2022537390A JP 2021575893 A JP2021575893 A JP 2021575893A JP 2021575893 A JP2021575893 A JP 2021575893A JP 2022537390 A JP2022537390 A JP 2022537390A
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- JP
- Japan
- Prior art keywords
- mat
- separator
- fiber mat
- nonwoven
- microns
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
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Images
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Electrochemistry (AREA)
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Wood Science & Technology (AREA)
- Life Sciences & Earth Sciences (AREA)
- Inorganic Chemistry (AREA)
- Textile Engineering (AREA)
- Ceramic Engineering (AREA)
- Composite Materials (AREA)
- Materials Engineering (AREA)
- Dispersion Chemistry (AREA)
- Cell Separators (AREA)
- Nonwoven Fabrics (AREA)
Abstract
Description
本出願は、2019年6月20日に出願された「Lightweight Nonwoven Fiber Mats」と題する米国仮出願第62/864,244号の優先権を主張するものであり、その開示内容は、その全体が参照により本明細書に組み込まれる。
● BX9繊維-平均繊維径0.5ミクロン未満、比表面積5.0~7.0m2/g
● B00繊維-平均繊維径0.65ミクロン未満、比表面積3.8~5.8m2/g
● B02繊維-平均繊維径0.7ミクロン未満、比表面積2.5~3.5m2/g
超薄型マットのベースとなるBX9ガラス繊維と乾燥デンプンを必要量配合した懸濁液を形成した。まず、BX9ガラス繊維0.45gを50℃の水100gに加え、10%硫酸(H2SO4)でpHを約3.0に酸性化した後、実験用強力ブレンダーで2分間混合して繊維を分散させた。次に、乾燥デンプン0.25gと水20gの溶液を、50℃で実験室用スタンドミキサーを用いて1000RPMで2分間またはデンプンが溶解するまで混合した。この2つの成分を混合し、50℃の3ガロンの温水に懸濁させ、10%H2SO4でpH3.0に酸性化した。
実験室用スタンドミキサーを用いて、0.16gの乾燥デンプンを、酸性のpH(2.8~3.5の間)の熱水(50℃)500mLに入れて混合した。次に、0.19gのBX9ガラス繊維を加えて5分間予備混合し、スラリーを形成した。次に、このスラリーを実験室用ブレンダーに入れ、1分間混合した。ブレンダーの側面を洗浄し、さらに500mLの水(10%H2SO4で2.8~3.5のpHに酸性化)をブレンダーに加え、さらに1分間混合した。
まず、アクリルラテックスエマルジョン5.0g、乾燥デンプン1.6g、ヒドロキシエチルセルロース増粘剤0.12gを、140gの水とともに実験室用スタンドミキサーを用いて50℃の温度で混合した。この混合物を10% H2SO4でpH3.0に酸性化した。これを、スタンドミキサーを用いて600RPMで10分間混合した。次に、5.0gのBX9ガラス繊維を、さらに80gの水と一緒にゆっくりと混合した。繊維を加えた後、スラリーを10分間混合して均質性を確保し、必要に応じてミキサーの速度を調整した。次に、19.9gのスラリーを4ガロンのタンクに入れた1ガロンの水に加え、10分間混合した。この混合物を3ガロンの水(50℃)に希釈し、10%H2SO4でpH3.0に酸性化し、5分間混合した後、真空形成を用いてマットを形成した。
あらかじめ混合しておいた1%NFCの懸濁液2.1gを、500mLの水とともに実験室用ブレンダーで20秒間混合した。この懸濁液に、0.5gのBX9ガラス繊維を加え、同じ速度でさらに10秒間混合した。次に、10%H2SO4でpH3.0~3.5に酸性化した1ガロンの水に各成分を懸濁した。この懸濁液を3~5分間混合させた。この混合物を3ガロンの熱水(50℃)に希釈し、10%のH2SO4でpH3.0に酸性化し、5分間混合した後、真空形成を用いてマットを形成した。
実験室用スタンドミキサーを用いて、NFC 0.08gを酸性のpH(2.8~3.5の間)の熱水(50℃)500mLに入れて混合した。次に、0.19gのBX9繊維を加えて5分間予備混合し、スラリーを形成した。次に、このスラリーを実験室のブレンダーに入れ、1分間混合した。ブレンダーの側面を洗浄し、さらに500mLの水(10%H2SO4で2.8~3.5のpHに酸性化)をブレンダーに加え、さらに1分間混合した。
ポリビニルアルコールの1%懸濁液は、使用直前に実験室用スタンドミキサーを用いてポリビニルアルコールを45秒間激しく混合することにより、水中で調製された。本実施形態では、予備混合したポリビニルアルコールの1%懸濁液2.1gが、実験室用ブレンダーを用いて、500mLの水と20秒間激しく混合された。この懸濁液に、0.45gのBX9ガラス繊維を加え、さらに60秒間同じ速度で混合した。
3.2gのアクリルラテックスエマルジョン、3.1gの乾燥デンプン、0.1gのヒドロキシエチルセルロースを、140gの熱水(50℃)とともに実験室用スタンドミキサーを用いて混合した。この混合物を10%H2SO4でpH3.0に酸性化し、10分間混合した後、3.8gのアルコールアルコキシ速度湿潤剤を添加し、5分間混合させた。5.1gのBX9ガラス繊維を、追加の80gの水とともにゆっくりと混合した。繊維を加えた後、スラリーをさらに10分間混合して均質性を確保し、必要に応じてミキサーの速度を調整した。
セルロースガム増粘剤0.75gを225gの温水(35℃)中で実験室用スタンドミキサーを用いて、混合物が増粘するまで激しく混合した。この混合物に、2.5gのNFCを加え、均一に分散するまで激しく混合した。この混合物を10%H2SO4でpH3.0に酸性化し、10分間混合した。3.5gのBX9ガラス繊維および3.0gの粉砕されたBX9ガラス繊維を、1000mlの温水(35℃)とともに混合物にゆっくりと加えて、繊維の添加を助けた。粉砕されたBX9繊維は、BX9繊維を6時間ボールミルで粉砕することによって調製された。得られたスラリーを実験室用ブレンダーにより高濃度で3分間混合した。
タンクに250ガロンの水を入れ、10%のH2SO4でpHを2~4に調整した。その後、344.2gのBX9ガラス繊維と143.3gのNFCをタンクに入れ、よく分散したスラリーとなるように混合した。
タンクに250ガロンの水を入れ、10%のH2SO4でpHを2~4に調整した。その後、344.2gのBX9ガラス繊維と143.3gのNFCをタンクに入れ、よく分散したスラリーになるように混合した。
タンクに250ガロンの水を入れ、10%のH2SO4でpHを2~4に調整した。その後、344.2gのBX9ガラス繊維と143.3gのNFCをタンクに入れ、よく分散したスラリーとなるように混合した。
この出願の発明に関連する先行技術文献情報としては、以下のものがある(国際出願日以降国際段階で引用された文献及び他国に国内移行した際に引用された文献を含む)。
(先行技術文献)
(特許文献)
(特許文献1) 米国特許出願公開第2017/0288188号明細書
(特許文献2) 特許第4491075号公報
(特許文献3) 米国特許出願公開第2015/0099155号明細書
(特許文献4) 米国特許出願公開第2006/0068294号明細書
(非特許文献)
(非特許文献1) Raj Borax Private Limited,"Boron in Glass and Glass Fibre"www.rajborax.com,29 April 2016.[online],[retrieved on 2020.24.09]. Retrieved from the Internet:<URL:http://www.rajborax.com/Boron%20in%20glass.html>
(非特許文献2) North American High Temperature Insulation Wool Industry,"Refractory Ceramic Fiber",www.htiwcoalition.org,2019.[online],[retreived on 2020-16-09].Retreived from the internet:<URL:https://www.htiwcoalition.org/rcf.html>
(非特許文献3) Nittobo Group."Special Materials-T-Glass",www.nittobo.co.jp,2020.[online],[retreived on 2020-16-09].Retreived from the Internet:<URL:https://www.nittobo.co.jp/eng/business/glassfiber/sp_material/t-glass.htm>
Claims (24)
- 不織繊維マットであって、
B-ガラス繊維、耐火性セラミック繊維、または多結晶ウール繊維を有し、
前記繊維マットは、約10~約700ミクロンの厚さと、約1~約70g/m2の秤量を有する、
不織繊維マット。 - 請求項1記載の不織繊維マットにおいて、前記B-ガラス繊維は、約1ミクロン以下の平均直径を有し、前記繊維マットの約50~約100重量パーセントの量で存在する、不織繊維マット。
- 請求項2記載の不織繊維マットにおいて、前記B-ガラス繊維は、0.5ミクロン未満の平均直径を有する、不織繊維マット。
- 請求項1記載の不織繊維マットであって、さらに結合剤を有する、不織繊維マット。
- 請求項4記載の不織繊維マットにおいて、前記結合剤は、ナノフィブリル化セルロース、デンプン、ポリビニルアルコール、ポリ酢酸ビニル、またはアクリルラテックスを有する、不織繊維マット。
- 請求項4記載の不織繊維マットにおいて、前記結合剤は前記繊維マットの最大20重量%の量で存在する、不織繊維マット。
- 請求項1記載の不織繊維マットであって、さらにコンディショニング剤を有する、不織繊維マット。
- 請求項7記載の不織繊維マットにおいて、前記コンディショニング剤は前記繊維マットの約1~約20重量%の量で存在する、不織繊維マット。
- 請求項7記載の不織繊維マットにおいて、前記コンディショニング剤は、アルコールアルコキシレート、アクリルアミドとアクリル酸の共重合体、またはポリアクリルアミド樹脂を有する、不織繊維マット。
- 請求項1記載の不織繊維マットであって、追加のガラス繊維タイプをさらに有する、不織繊維マット。
- 請求項10記載の不織繊維マットにおいて、前記追加のガラス繊維タイプはC-ガラス繊維を有する、不織繊維マット。
- 請求項1記載の不織繊維マットであって、650℃までの熱安定性を有する、不織繊維マット。
- 請求項1記載の不織繊維マットにおいて、前記繊維マットは、約10~約100ミクロンの厚さと、約1~約25g/m2の秤量を有する、不織繊維マット。
- 請求項1記載の不織繊維マットにおいて、前記繊維マットは、約200~約700ミクロンの厚さと、約30~約70g/m2の秤量を有する、不織繊維マット。
- 請求項1記載の不織繊維マットであって、約80~約99重量%のBガラスマイクロ繊維と、約1~約20重量%のナノフィブリル化セルロースとを有する、不織繊維マット。
- 請求項1記載の不織マイクロ繊維マットを有する、電池。
- 負極と、
正極と、
電解質溶液と、および、
前記負極と前記正極との間に配置されたセパレータと
を有する電池であって、前記セパレータはB-ガラス繊維を有し、および、約10~約700ミクロンの厚さと、約1~約70g/m2の秤量を有する、電池。 - 請求項17記載の電池において、前記セパレータは、約10~約100ミクロンの厚さと、約1~約25g/m2の秤量を有する、電池。
- 請求項17記載の電池において、前記セパレータは、約200~約700ミクロンの厚さと、約30~約70g/m2の秤量を有する、電池。
- 請求項17記載の電池において、前記セパレータは650℃までの熱安定性を有する、電池。
- 不織繊維マットを製造する方法であって、前記方法は、
B-ガラス繊維および結合剤を有する懸濁液を形成する工程と、
前記懸濁液を約2.8~3.5のpHに酸性化してスラリーを形成する工程と、
スクリーン上に前記スラリーを散布する工程と、
約10~約700ミクロンの厚さと、約1~約70g/m2の秤量を有する不織繊維マットを提供するために、前記スラリーから液体を除去する工程と
を有する、方法。 - 請求項21記載の方法において、前記結合剤は、ナノフィブリル化セルロース、ポリビニルアルコール、ポリ酢酸ビニル、デンプン、またはアクリルラテックスを有する、方法。
- 請求項21記載の方法であって、前記懸濁液にコンディショニング剤を添加する工程をさらに有する、方法。
- 請求項21記載の方法において、前記スラリーから液体を除去する工程は、前記スラリーに真空を適用する工程を有する、方法。
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US201962864244P | 2019-06-20 | 2019-06-20 | |
US62/864,244 | 2019-06-20 | ||
PCT/US2020/038540 WO2020257526A1 (en) | 2019-06-20 | 2020-06-18 | Lightweight nonwoven fiber mats |
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- 2020-06-18 WO PCT/US2020/038540 patent/WO2020257526A1/en active Application Filing
- 2020-06-18 CN CN202080058731.5A patent/CN114287081A/zh active Pending
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KR20220024715A (ko) | 2022-03-03 |
US20220247036A1 (en) | 2022-08-04 |
EP3987602A1 (en) | 2022-04-27 |
CN114287081A (zh) | 2022-04-05 |
WO2020257526A1 (en) | 2020-12-24 |
EP3987602A4 (en) | 2023-06-28 |
JP7471327B2 (ja) | 2024-04-19 |
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