JPH02293436A - Production of woven fabric - Google Patents

Abstract

PURPOSE:To easily obtain the subject woven fabric having excellent heat- resistance and flame-resistance, free from generation of fluff, etc., and useful as a cloth for catalyst carrier, etc., by dissolving a conjugate fiber containing a soluble organic fiber e. g. as a covering fiber. CONSTITUTION:The objective woven fabric is produced by covering or doubling a soluble organic fiber to an inorganic fiber yarn composed of an inorganic fiber such as ceramic fiber, weaving the obtained conjugate fiber and subjecting the woven fabric to dissolution treatment, preferably heat-treatment to eliminate said soluble organic fiber. Preferably, the conjugate fiber is used in combination with glass fiber yarn and subjected to dissolution treatment to effect the elimination of said organic fiber simultaneous to the leaching treatment of said conjugate fiber and the glass fiber yarn.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a method for producing a heat-resistant woven fabric suitable for use as a catalyst carrier cloth, etc.

(Prior Art) Conventionally, as a method for manufacturing this type of woven fabric, a method is known in which inorganic fiber yarn is woven into a desired woven fabric using a shuttle change type loom or a rapier type loom.

(Problems to be Solved by the Invention) However, inorganic fiber yarns made of inorganic fibers such as ceramic fibers have a tensile strength of 3 to 7 kg/200TE.
Not only does it have an extremely low bending strength of about 1.4 kg/200TEX, but it also has serious drawbacks in that the fibers are easily broken and fluffy.

For example, using a shirt torque change type loom, E glass cloth (200 count silica 54-56%, alumina 14-56%)
16%, alkali metal oxide (CaO) 21-23
When weaving at the same weaving speed (145 revolutions/min) as when weaving a woven fabric woven with glass fiber yarn consisting of Not only does the appearance deteriorate, but there are also problems such as having to stop the loom every time thread breakage, fuzzing, etc. occur. Furthermore, even if the weaving speed is lowered to 85 revolutions per minute (approximately 60% of the speed mentioned above), which is the lower limit of the speed of shirt torque change type looms, it is possible to reduce the incidence of thread breakage, fluffing, etc. However, these problems are not completely eliminated, and the weaving efficiency is further reduced because the loom is stopped every time thread breakage, fuzz, etc. occur, and the production speed is approximately 50% of the production speed of the E-glass cloth, which is extremely poor productivity.

SUMMARY OF THE INVENTION An object of the present invention is to provide a method for manufacturing a woven fabric that can solve the above-mentioned problems and can be woven at a weaving speed equivalent to that of E-glass cloth.

(Means for Solving the Problems) The method for producing a woven fabric of the present invention is a method for weaving inorganic fiber threads made of inorganic fibers such as ceramic fibers into a woven fabric.
It is characterized in that a composite yarn in which soluble organic fibers are covered or twisted together is used as the inorganic fiber yarn, and a woven fabric woven with the composite yarn is subjected to a dissolution treatment to eliminate the soluble organic fibers.

Another manufacturing method involves weaving inorganic fiber threads made of inorganic fibers such as ceramic fibers into a woven fabric.
The inorganic fiber yarn is a composite yarn in which soluble organic fibers are covered or twisted, and a glass fiber yarn is used, and the woven fabric is subjected to a dissolution treatment to eliminate the soluble organic fiber and the glass fiber yarn. It is characterized by performing the leaching process at the same time.

Yet another manufacturing method involves weaving inorganic fiber threads made of inorganic fibers such as ceramic fibers into a woven fabric.
It is characterized in that a composite yarn in which combustible organic fibers are covered or twisted together is used as the inorganic fiber yarn, and a woven fabric woven with the composite yarn is heat-treated to eliminate the combustible organic fibers.

The inorganic fibers used in the present invention are not particularly limited, but include, for example, silica fibers, alumina fibers, etc. produced by a leaching method, a sol-gel method, a colloid method, or the like.

Furthermore, examples of glass fibers that are made into a woven fabric and subjected to a leaching treatment to obtain heat-resistant fibers include E glass fibers, Vycor glass fibers, and the like.

The dissolution treatment of the soluble organic fibers is carried out using a suitable solvent such as acid, water, alcohol, etc. When an acid is used as the solvent, polyvinyl alcohol fibers, nylon 6 fibers, etc. are used as the soluble organic fibers.

Furthermore, when water is used as the solvent, polyvinyl alcohol fibers are used as the soluble organic fibers.

Furthermore, when alcohol is used as the solvent, polyvinyl alcohol fibers, acetate fibers, etc. are used as the soluble organic fibers.

Combustible organic fibers are not particularly limited, but include, for example, polyester fibers, polyvinyl alcohol fibers, polybrobylene fibers, polyethylene fibers, and the like.

The treatment temperature and treatment time during the dissolution treatment applied to the woven fabric are appropriately selected depending on the type of organic fiber to be treated and the type and concentration of the solvent used.

In addition, the heat treatment applied to the woven fabric is generally performed at a temperature of 40°C.
The temperature is 0 to 1200°C and the time is about 1 to 120 minutes.

Moreover, the covering pitch of the organic fibers to the inorganic fiber yarns is generally about 0.1 to 5011111.

(Function) A composite yarn made by covering or twisting inorganic fibers with organic fibers is reinforced with organic fibers and can improve loom speed by preventing yarn breakage and fuzzing due to fiber bending.

Further, when soluble organic fibers are used as organic fibers to be covered with inorganic fibers or twisted together, the soluble organic fibers disappear and are removed by dissolution treatment, resulting in a heat-resistant woven fabric.

Furthermore, when glass fiber is used as the inorganic fiber, the leaching treatment on the glass fiber is carried out simultaneously with the dissolving treatment on the organic fiber that has been covered or twisted together with the inorganic fiber that is applied to the woven fabric. Reached fiber becomes silicate fiber.

Further, when flammable organic fibers are used as organic fibers to be covered with inorganic fibers or twisted together, the flammable organic fibers disappear and are removed by heat treatment, resulting in a heat-resistant woven fabric.

(Example) Next, specific examples of the present invention will be described together with comparative examples.

Example 1 200 count alumina fiber “Product name Denka Arsene S-9”
A covered yarn was prepared by winding a 28 d polyvinyl alcohol fiber (trade name: SX-29, manufactured by Nichibi Co., Ltd.) yarn around one yarn of "No. 60, manufactured by Denki Kagaku Kogyo Co., Ltd." at a covering pitch of 0.5+n.

Next, the created covered yarn was woven on a shirt torque change type loom at a weaving speed of 145 revolutions/minute with a warp density of 29 threads/25++ m. A catalyst carrier cloth with a weft density of 5.5 threads/25 u+ was woven.

The tensile strength and bending strength of the obtained covered yarn, the number of stops of the shirt torque change type loom during weaving of the woven fabric (times/m), the actual weaving speed, and the visual appearance of the woven fabric (fuzziness) ), and the results are shown in the table.

The tensile strength and bending strength of the covered yarn were measured using Autograph RCE-500K (manufactured by Shimadzu Corporation). In addition, the number of times the shirt torque change type loom stops during weaving is the number of times the loom automatically stops each time due to thread breakage, fuzzing, etc. while weaving a 1 m wide catalyst carrier cloth to a length of 30 m. The number of times the machine was stopped to remove thread breaks, fluff, etc. The table also shows the theoretical woven fabric speed when the woven fabric is woven without stopping the loom.

The catalyst carrier cloth woven by the above method was immersed for 200 minutes in a hydrochloric acid solution with a concentration of 10% at a temperature of 95°C, and
After performing a dissolution treatment consisting of washing with water at a temperature of 0.degree. C., the catalyst carrier cloth was visually inspected to find that the polyvinyl alcohol fibers covering the alumina fibers had disappeared.

Example 2 270 count silica fiber “Product name Silica Yarn K-60”
1/3 3.8S, made by Asahi Glass Co., Ltd. 1 thread,
Two commercially available polyester fiber yarns of 50 d were twisted together to create a twisted yarn.

Next, a cloth for a catalyst carrier having a warp yarn density of 29 threads/25 mm and a weft thread density of 5.5 threads/25 threads was woven in the same manner as in Example 1, except that the prepared twisted yarns were used.

In addition, the tensile strength and bending strength of the plied yarn, the number of stops of the shirt torque change type loom during weaving, the actual weaving speed, and the appearance of the woven fabric were investigated using the same method as in Example 1, and the results were reported. Shown in the table.

The catalyst carrier cloth woven by the above method is heated in air at a temperature of 1
After heat treatment at 100° C. for 10 minutes, visual inspection of the catalyst carrier cloth revealed that the polyester fibers twisted together with the silica fibers had disappeared.

Example 3 200 count alumina fiber “Product name Denka Arsene S-9”
60, produced by Denki Kagaku Kogyo Co., Ltd., was wound with a 28 d polyvinyl alcohol fiber "trade name SX-28, produced by Nichibi Co., Ltd." yarn at a covering pitch of 0.5 layers to create a covered yarn. .

Next, the created covered yarn is made into a weft yarn, and 200
A catalyst carrier cloth with a warp density of 29 threads/25 mm and a weft thread density of 5.5 threads/25 mm was prepared in the same manner as in Example 1, except that a set of two count E glass fibers was used as the warp yarn. woven.

In addition, the tensile strength and bending strength of the covering yarn, the number of stops of the shuttle change type loom during weaving, the actual weaving speed, and the appearance of the woven fabric were investigated using the same method as in Example 1, and the results are shown in the table. Indicated.

The catalyst carrier cloth woven by the above method was immersed for 200 minutes in a 10% hydrochloric acid solution at a temperature of 95°C, and
℃ water to simultaneously dissolve the organic fibers covering the alumina fibers in the weft and leaching the E-glass fibers in the warp, the catalyst carrier cloth was visually inspected. The polyvinyl alcohol fibers covering the alumina fibers had disappeared.

Further, when the composition of the woven fabric was examined, it was found that the E glass fibers had become leached fibers.

Example 4 130 count alumina fiber “Product name Denka Arsene S-6”
40, one thread made by Denki Kagaku Kogyo Co., Ltd. and 600 d
Two polyvinyl alcohol fibers (trade name: sx-coo, manufactured by Nichibi Co., Ltd.) were twisted together to create a twisted yarn.

Next, the warp yarn density was 29 in the same manner as in Example 1, except that the created twisted yarn was used as the weft yarn, and a set of two 200 count E glass fibers was used as the warp yarn.
A catalyst carrier cloth was woven with a yarn density of 5.5 yarns/25+m and a weft yarn density of 5.5 yarns/25+m.

In addition, the tensile strength and bending strength of the plied yarn, the number of stops of the shirt torque change type loom during weaving, the actual weaving speed, and the appearance of the woven fabric were investigated using the same method as in Example 1, and the results were reported. Shown in the table.

The catalyst carrier cloth woven in the above method was subjected to a dissolution treatment to soluble organic fibers and a leaching treatment to E glass fibers at the same time in the same manner as in Example 3, and then the catalyst carrier cloth was visually inspected. However, the polyvinyl alcohol fibers that had been twisted together with the alumina fibers had disappeared. Also,
When the composition of the woven fabric was examined, it was found that the E-glass fibers had become leached fibers.

Example 5 200 count alumina fiber “Product name Denka Arsene S-9”
60, manufactured by Denki Kagaku Kogyo Co., Ltd., one thread is made of 50d commercially available polyester fiber yarn with a covering pitch of 0.5.
A covered yarn was created by winding the yarn with m■.

Next, the created covering yarn is made into a weft yarn, and 20
A catalyst carrier cloth with a warp density of 29 threads/25 mm and a weft thread density of 5.5 threads/25 mm was prepared in the same manner as in Example 1, except that a set of two 0-count E glass fibers was used as the warp yarn. woven.

In addition, the tensile strength and bending strength of the covering yarn, the number of stops of the shirt torque change type loom during weaving, the actual weaving speed, and the appearance of the woven fabric were investigated using the same method as in Example 1, and the results are presented. It was shown to.

The catalyst carrier cloth woven by the above method was immersed for 200 minutes in a hydrochloric acid solution with a concentration of 10% at a temperature of 95°C, and
After the warp E-glass fibers were subjected to a leaching process consisting of washing with water at a temperature of 110°C and drying for 60 minutes, the dried catalyst carrier cloth was heated in air at a temperature of 1100°C.
After heat treatment at 0.degree. C. for 10 minutes, visual inspection of the catalyst carrier cloth revealed that the polyester fibers covering the alumina fibers had disappeared. Further, when the composition of the woven fabric was examined, it was found that the E glass fibers were converted into leached fibers and silica fibers.

Example 6 270 count silica fiber “Product name Silica Yarn K-60”
1/3 3.83 Asahi Glass Co., Ltd. 1 thread, 50
d commercially available polyester fiber with a covering pitch of 0.5
A covered yarn was prepared by winding the yarn in mm.

Next, the created covered yarn is made into a weft yarn, and 200
A catalyst carrier cloth with a warp density of 29/25+am and a weft density of 5.5/25 mm was woven in the same manner as in Example 1, except that a set of two E glass fibers was used for the warp. Ta.

In addition, the tensile strength of the covered yarn was determined in the same manner as in Example 1.
The bending strength, the number of stops of the shirt torque change type loom during weaving, the actual weaving speed, and the appearance of the woven fabric were investigated, and the results are shown in the table.

After the catalyst carrier cloth woven in the above method was subjected to the leaching treatment of the warp E glass fiber and the heat treatment of the covered yarn in the same manner as in Example 5, visual inspection of the catalyst carrier cloth revealed that it contained silica. The polyester fiber that covered the fiber had disappeared. Further, when the composition of the woven fabric was examined, it was found that the E glass fibers had become leached fibers.

Comparative Example 1 200 count alumina fiber [trade name Denka Arsene S-9
60, manufactured by Denki Kagaku Kogyo Co., Ltd., was woven using a shuttle change type loom at a weaving speed of 145 revolutions/minute, with a warp density of 29 threads/25 mm and a weft thread density of 5.5 threads/25 am.
We woven a cloth for catalyst carriers.

In addition, the tensile strength of alumina fiber was determined by the same method as in Example 1.
The bending strength, the number of stops of the shuttle change type loom during weaving, the actual weaving speed, and the appearance of the woven fabric were investigated, and the results are shown in the table.

Comparative Example 2 200 count alumina fiber “Product name Denka Arsene S-9”
60, made by Denki Kagaku Kogyo Co., Ltd., was woven using a shuttle change type loom at a weaving speed of 85 revolutions/min to weave a catalyst carrier cloth with a warp density of 29 threads/25 m and a weft thread density of 5.5 threads/25 m. Ta.

In addition, the tensile strength of alumina fiber was determined by the same method as in Example 1.
The bending strength, the number of stops of the shirt torque change type loom during weaving, the actual weaving speed, and the appearance of the woven fabric were investigated, and the results are shown in the table.

(Left below) As is clear from the table, Example 1 in which organic fibers were covered or twisted together with inorganic fiber yarns. ,2,3,4,
Although the composite yarn of No. 5.6 was woven at a faster weaving speed of 145 revolutions per minute than the inorganic fiber yarn of Comparative Example 1.2, which was not covered or twisted at all, it The shuttle change type loom did not stop due to yarn breakage or fuzzing, and the actual weaving speed was the same as the theoretical weaving speed. On the other hand, only inorganic fiber yarns are used to weave the woven fabric, and the weaving speed is 1.
In Comparative Example 1, which had a high speed of 45 revolutions per minute, the shirt torque change type loom had many stoppages due to thread breakage or fuzzing during weaving, and the actual weaving speed was extremely low compared to the theoretical weaving speed. Ta. In addition, in Comparative Example 2, in which only inorganic fiber yarn was used as the thread for weaving the fabric, and the weaving speed was 85 revolutions/minute, thread breakage or fluff occurred during weaving despite the slow weaving speed of 85 revolutions/minute. The shirt torque change type loom stopped due to the occurrence of stand-up, and the actual woven fabric speed was extremely low compared to the theoretical woven fabric speed.

(Effects of the Invention) According to the present invention, the threads to be woven into a woven fabric are covered with inorganic fibers such as ceramic fibers with soluble organic fibers, or with composite threads made by twisting together or with combustible organic fibers. Or, since it is a composite yarn that is combined and twisted, the inorganic fiber yarn is reinforced with organic fiber, and it can be woven without yarn breakage or fluff caused by yarn bending, so the weaving speed of E-glass cloth can be reduced. The woven fabric can be woven at the same speed as the woven fabric, and the woven fabric is subjected to melting treatment or heat treatment, so the organic fibers that cover the inorganic fiber yarn or are twisted together disappear and are removed. Since it consists of only inorganic fibers, it has the advantage that it is possible to easily produce a woven fabric with excellent heat resistance and flame resistance.

In addition, when using a composite yarn in which soluble organic fibers are covered or twisted together with inorganic fiber yarns and glass fiber yarns, leaching treatment of the glass fibers is performed to eliminate and remove the soluble organic fibers from the woven fabric. Since it can be carried out simultaneously with the melting treatment for glass fibers, the leaching treatment of the glass fibers does not have to be carried out separately, so the treatment of the woven fabric is simple.

Patent applicant Nippon Inuki Co., Ltd.
Rihito Kitamura Kingai 3 people

Claims (1)

[Scope of Claims] 1. A method for weaving inorganic fiber threads made of inorganic fibers such as ceramic fibers into a woven fabric, in which a composite thread in which soluble organic fibers are covered or twisted together is used as the inorganic fiber threads; A method for producing a woven fabric, which comprises subjecting a woven fabric woven from yarn to a dissolution treatment to eliminate the soluble organic fibers. 2. A method of weaving inorganic fiber threads made of inorganic fibers such as ceramic fibers into a woven fabric, using a composite thread and glass fiber thread covered with or twisted together with soluble organic fibers as the inorganic fiber threads, A method for producing a woven fabric, which comprises subjecting the woven fabric to a dissolution treatment to eliminate the soluble organic fibers and leaching the glass fiber threads at the same time. 3. A method of weaving inorganic fiber threads made of inorganic fibers such as ceramic fibers into a woven fabric, using a composite yarn covered with or twisted together with combustible organic fibers as the inorganic fiber yarn, and producing a fabric woven with the composite yarn. A method for producing a woven fabric, which comprises heat-treating the fabric to eliminate the combustible organic fibers.