WO2018012423A1 - アルミナ繊維集合体及びその製造方法 - Google Patents
アルミナ繊維集合体及びその製造方法 Download PDFInfo
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- WO2018012423A1 WO2018012423A1 PCT/JP2017/024953 JP2017024953W WO2018012423A1 WO 2018012423 A1 WO2018012423 A1 WO 2018012423A1 JP 2017024953 W JP2017024953 W JP 2017024953W WO 2018012423 A1 WO2018012423 A1 WO 2018012423A1
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- alumina
- less
- fiber
- alumina fiber
- polyvinyl alcohol
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/27—Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/682—Needled nonwoven fabric
Definitions
- the present invention relates to an alumina fiber aggregate and a method for producing the same.
- Inorganic fiber molded bodies represented by ceramic fibers have been used for applications exposed to high-temperature conditions such as industrial heat insulating materials, refractory materials, and packing materials.
- a cushioning material for an exhaust gas cleaning device for automobiles, that is, a catalyst carrier, is wound around a catalyst carrier and is interposed between the catalyst carrier and the metal casing.
- An alumina fiber aggregate is used as an exhaust gas cleaning mat to be loaded.
- Patent Document 1 discloses an alumina fiber assembly in which a value obtained by subtracting twice the standard error from the value is 6.0 ⁇ m or less.
- An object of the present invention is to provide an alumina fiber aggregate that has a large average fiber diameter of short alumina fibers, is less likely to scatter, and can be sufficiently used as a gripping material for a catalytic converter, and a method for producing the same. It is in.
- the gist of the present invention is as follows.
- a needling-treated alumina fiber aggregate made of alumina short fibers wherein the alumina short fibers have an average fiber diameter of 6.0 ⁇ m to 10.0 ⁇ m, and the alumina short fibers have a specific surface area of 0 .2m and 2 / g or more 1.0 m 2 / g or less, and was needling treatment temperature cycle open side pressure residual ratio of the alumina fiber aggregate (%) is equal to or 45% or more Alumina fiber assembly.
- the bulk density in water of the alumina fiber aggregate is 1.40 ⁇ 10 ⁇ 2 g / ml or more and 2.00 ⁇ 10 ⁇ 2 g / ml or less, according to any one of [1] to [6] Alumina fiber assembly.
- a method for producing an alumina fiber assembly comprising the alumina short fibers according to any one of [1] to [9], Spinning solution preparation step for preparing a spinning solution containing an alumina source, a silica source, a spinning aid and water, spinning to obtain an aggregate of alumina fiber precursors by extruding the spinning solution into the atmosphere through pores and drying
- Spinning solution preparation step for preparing a spinning solution containing an alumina source, a silica source, a spinning aid and water, spinning to obtain an aggregate of alumina fiber precursors by extruding the spinning solution into the atmosphere through pores and drying
- a firing step of firing the aggregate of the alumina fiber precursor subjected to the needling treatment and a firing step of firing the aggregate of the alumina fiber precursor subjected to the needling treatment.
- the spinning aid comprises at least a polyvinyl alcohol A having a polymerization degree of 1.8 ⁇ 10 3 or more and 2.4 ⁇ 10 3 or less and a saponification degree of 85.0 or more and less than 92.0, and a polymerization degree of 2.2. ⁇ 10 3 or more 3.0 ⁇ 10 3 or less, and includes a polyvinyl alcohol B is a saponification degree 92.0 99.5 less,
- the weight ratio of the polyvinyl alcohol A and the polyvinyl alcohol B is 9 to 5: 1 to 5, and the weighted average of the degree of polymerization in the polyvinyl alcohol A and the polyvinyl alcohol B is 2.0 ⁇ 10 3 or more and 3.0 ⁇ 10 3.
- the average fiber diameter is 6.0 ⁇ m or more in the needling-treated alumina fiber aggregate made of short alumina fibers, the average fiber diameter is large, so that the short alumina fibers are not easily pliable, and are not easily broken. Since the number of the fibers decreases, the cycle surface pressure value of the alumina fiber aggregate becomes low, but the silica sol having an average particle size distribution mode diameter of 20 nm to 60 nm and a standard deviation of the particle size distribution of 20 nm to 35 nm.
- a water-soluble polymer having a saponification degree and a polymerization degree in a specific range as a spinning aid, the physical properties of single fibers and fiber aggregates can be improved.
- the alumina fiber aggregate provided by the present invention is an alumina fiber aggregate composed of short alumina fibers having a small specific surface area and high density, even if the average fiber diameter is relatively large as 6.0 ⁇ m or more, The high temperature cycle surface pressure residual ratio of the alumina short fiber aggregate is maintained high. Accordingly, the alumina fiber aggregate exhibits high performance when used as a catalyst gripping material. Since the alumina short fiber of the alumina fiber aggregate of the present invention has a large average fiber diameter of 6.0 ⁇ m or more, there is little scattering of fibers during handling, and the handleability is excellent.
- the average fiber diameter of the short alumina fibers of the alumina fiber aggregate of the present invention is 6.0 ⁇ m or more and 10.0 ⁇ m or less, and particularly preferably 6.0 ⁇ m or more and 8.0 ⁇ m or less.
- the average fiber diameter of the short alumina fibers is within the above range, which is preferable in that the ratio of the rigid and easy-to-break fibers decreases.
- the ratio of fibers having a fiber diameter of the alumina short fibers exceeding 10.0 ⁇ m is reduced in that the ratio of rigid and easy-to-break fibers decreases. It is preferably 5.0% or less, and particularly preferably 2.5% or less on the basis of the number.
- the average fiber diameter is measured by putting 0.2 to 0.5 g of an alumina fiber aggregate, which is a measurement sample, into a 40 mm ⁇ mold and crushing the measurement sample by applying a 10 kN load twice with a hydraulic press. . The ground sample is photographed with a scanning electron microscope (SEM) (selected as appropriate within a magnification range of 1000 to 3000).
- SEM scanning electron microscope
- the value obtained by subtracting twice the standard error from the length-weighted geometric mean diameter of the short fiber diameter of alumina is 6.0 ⁇ m or more. Or it is applied from the fiber diameter-based carcinogenicity classification exclusion rule, and it is judged that it does not contain fibers having a carcinogenicity of less than 3.0 ⁇ m, which is preferable from the viewpoint of safety.
- the Testing Method of European Chemicals Bureau states that the length-weighted geometric mean diameter of mineral fibers can be approximated by the following formula in DRAFT-4 of ECB / TM / 1 (00) rev2. .
- the length-weighted geometric mean diameter of the alumina short fiber of the present invention represents a value calculated by the following equation (1).
- LWGMD EXP (( ⁇ InD 1 ) / n) (1)
- “length-weighted geometric mean diameter ⁇ 2 ⁇ standard error” calculated from the following equations (a) to (d) is 6.0 ⁇ m or more. It is preferably 10.0 ⁇ m or less, particularly 6.0 ⁇ m or more and 8.0 ⁇ m or less.
- the specific surface area of the alumina short fibers used in the present invention is 0.2 m 2 / g or more and 1.0 m 2 / g or less, more preferably 0.2 m 2 / g or more and 0.9 m 2 / g or less, particularly preferably, it is 0.2 m 2 / g or more 0.8 m 2 / g or less.
- the specific surface area of the short alumina fiber is within the above range, the fiber has high density and is not easily broken, so that the physical properties when matted are excellent.
- the total pore volume of the short alumina fibers used in the present invention is not particularly limited, but is usually 2.0 ⁇ 10 ⁇ 4 ml / g or more and 2.5 ⁇ 10 ⁇ 3 ml / g or less, preferably 2.0 ⁇ 10 ⁇ 4 ml / g or more and 2.2 ⁇ 10 ⁇ 3 ml / g or less, particularly preferably 2.0 ⁇ 10 ⁇ 4 ml / g or more and 1.9 ⁇ 10 ⁇ 3 ml / g or less. .
- the fiber When the total pore volume of the short alumina fiber is within the above range, the fiber has high density and is not easily broken, so that the physical properties when matted are excellent.
- the total pore volume is measured by BJH analysis using adsorption side and desorption side adsorption isotherms.
- the average single fiber tensile strength of the short alumina fibers used in the present invention is not particularly limited, but is usually 1.20 ⁇ 10 3 MPa or more, preferably 1.30 ⁇ 10 3 MPa, particularly preferably 1. It is 40 ⁇ 10 3 MPa or more.
- the average single fiber tensile strength of the short alumina fibers is within the above range, the fibers are not easily broken, so that the physical properties when matted are excellent.
- the fiber length of the alumina short fiber used in the present invention is not particularly limited, it is 1 mm to 1000 mm, preferably 30 mm to 800 mm. When the fiber length of the short alumina fibers is within the above range, the entanglement between the fibers increases, and the strength of the alumina fiber aggregate increases.
- the bulk density in water of the alumina fiber aggregate used in the present invention is usually 1.40 ⁇ 10 ⁇ 2 g / ml or more and 2.00 ⁇ 10 ⁇ 2 g / ml or less, preferably 1.40 ⁇ 10 ⁇ 2 g / ml or more and 1.95 ⁇ 10 ⁇ 2 g / ml, particularly preferably 1.40 ⁇ 10 ⁇ 2 g / ml or more and 1.90 ⁇ 10 ⁇ 2 g / ml or less. If the bulk specific gravity in water of the alumina short fibers is within the above range, the fibers are not easily broken, and the physical properties when matted are excellent.
- the mullite conversion rate of alumina fibers of the alumina fiber aggregate of the present invention (the ratio of mullite (3Al 2 O 3 .2SiO 2 ) in alumina fibers) is not particularly limited, but the fiber strength is 5.0% or less. It is preferable in that it does not easily decrease and a decrease in surface pressure is suppressed.
- the method for measuring the mullite conversion rate is as described later.
- the high temperature cycle open side pressure residual rate of the needling-treated alumina fiber assembly of the present invention is 45% or more, preferably 50% or more, more preferably 55% or more.
- the high temperature cycle open side pressure residual ratio is within the above range, the characteristics of the catalyst gripping material are improved.
- the high temperature cycle compression side pressure residual ratio of the needling-treated alumina fiber aggregate of the present invention is 67% or more, preferably 70% or more, more preferably 72% or more.
- the high temperature cycle open side pressure residual ratio is within the above range, the characteristics of the catalyst gripping material are improved.
- the open side pressure means the surface pressure when the compression rate is the lowest when the alumina fiber aggregate is compressed.
- the compression side pressure refers to the surface pressure when the compression rate is the highest when the alumina fiber aggregate is compressed.
- the measuring method of the high temperature cycle opening side pressure (retention rate) and the compression side pressure (retention rate) is as described later.
- limiting about an upper limit, Usually, it is below the 1st open side pressure value (GBD 0.33g / cm ⁇ 3 >) in 600 degreeC.
- limiting about an upper limit, Usually, it is below the 1st compression side pressure value (GBD 0.38g / cm ⁇ 3 >) in 600 degreeC.
- the cycle opening side pressure residual ratio at 25 ° C. of the alumina fiber aggregate subjected to the needling treatment of the present invention is not particularly limited, but is 58% or more, more preferably 60% or more, particularly preferably 62% or more. It is. When the cycle open side pressure residual ratio at 25 ° C. of the alumina fiber aggregate is within the above range, the characteristics of the catalyst gripping material are improved.
- the cycle rate side pressure residual ratio at 25 ° C. of the needling-treated alumina fiber aggregate of the present invention is 60% or more, preferably 66% or more, more preferably 72% or more.
- the cycle compression side pressure residual ratio is within the above range, the characteristics of the catalyst gripping material are improved.
- the method of measuring the cycle opening side pressure (retention rate) at 25 ° C. is as described later.
- the temperature condition is set to 25 ° C.
- the alumina fiber aggregate is an alumina fiber aggregate that has been needled using a needle punch to increase the peel strength of the alumina fiber aggregate and to improve the cycle surface pressure retention of the alumina fiber aggregate. It is preferable in that it can be performed. By this needling treatment, needle marks remain on the alumina fiber aggregate.
- the number of needle marks (needle mark density) per unit area on the surface of the alumina fiber aggregate is usually 1 / cm 2 or more, preferably 5 / cm 2 or more, and particularly preferably 8 pieces. / Cm 2 or more, usually 150 pieces / cm 2 or less, preferably 100 pieces / cm 2 or less, particularly preferably 80 pieces / cm 2 or less.
- the alumina fiber aggregate is produced by the following steps (1) to (4).
- Spinning step for obtaining a body (3) Needling step for performing a needling treatment on the aggregate of the alumina fiber precursors (4) Firing step for firing the alumina fiber precursor subjected to the needling treatment
- the alumina source and the silica source are mixed in the ratio of the alumina component to the silica component so that the final alumina fiber has the desired chemical composition, and further mixed with a spinning aid. Then, it is preferable to concentrate under reduced pressure.
- alumina source it is preferable to use basic aluminum chloride (Al (OH) 3 ⁇ x Cl x ).
- Al (OH) 3 ⁇ x Cl x it can be prepared by dissolving metallic aluminum in hydrochloric acid or aluminum chloride aqueous solution.
- the value of x in the above chemical formula is usually 0.45 to 0.54, preferably 0.50 to 0.53.
- Silica sol is used as the silica source.
- a silica sol having a particle diameter distribution mode diameter (mode particle diameter) measured by a dynamic light scattering method of 20 nm to 60 nm and a standard deviation of the particle diameter distribution of 20 nm to 35 nm is used.
- the mode diameter of the particle size distribution is preferably 25 nm to 60 nm, particularly preferably 30 nm to 60 nm.
- the standard deviation of the particle size distribution is preferably 20 nm or more and 32 nm or less, and particularly preferably 22 nm or more and 28 nm or less.
- Silica sol having a mode diameter and standard deviation of the above particle size distribution is uneven in the dispersion of the silica sol by spinning and drying at a low temperature, due to various particle sizes, and is unevenly distributed at a constant distance from the fiber center. In the end, the resulting silica sol is uniformly present, resulting in excellent durability at high temperatures.
- the method for measuring the particle size distribution of the silica sol is as follows.
- a silica sol in an amount necessary for the measurement is diluted with hydrochloric acid having a concentration of 0.002N so that the final concentration is 0.5%, and is adjusted to 25 ° C., and then a dynamic light scattering apparatus (for example, ELS-Z manufactured by Otsuka Electronics Co., Ltd.) Measure with
- a water-soluble silicon compound such as tetraethyl silicate or a water-soluble siloxane derivative may be used as a part of the silica source.
- the ratio of aluminum (Al) to silicon (Si) in the spinning solution is converted to the mass ratio of Al 2 O 3 and SiO 2 (oxide conversion), and is usually 99: 1 to 65:35, preferably 90:10. It is preferable to be 68:32, more preferably 75:25 to 70:30.
- the aluminum concentration of basic aluminum chloride in the spinning solution is preferably 150 to 190 g / L.
- the spinning aid at least one water-soluble polymer compound of polyvinyl alcohol, polyethylene glycol, and polyacrylamide is preferable, and polyvinyl alcohol is particularly preferable.
- the polyvinyl alcohol the weighted average polymerization degree is 2.0 ⁇ 10 3 or more and 3.0 ⁇ 10 3 or less and the weighted average saponification degree is 85.0 or more and 95.0 or less, or the polymerization degree 1.8 ⁇ 10 3 to 2.4 ⁇ 10 3 and polyvinyl alcohol A having a degree of saponification of 85.0 to less than 92.0 and a degree of polymerization of 2.2 ⁇ 10 3 to 3.0 ⁇ 10 3
- Polyvinyl alcohol B having a saponification degree of 92.0 or more and 99.5 or less is included, and the mass ratio of the polyvinyl alcohol A and the polyvinyl alcohol B is 9 to 5: 1 to 5, and in the polyvinyl alcohol A and the polyvinyl alcohol B, the weighted average degree of polymerization is at 2.0 ⁇ 10 3 or
- the weighted average of the degree of polymerization in the polyvinyl alcohol is equal to the degree of polymerization of the polyvinyl alcohol in the case of a single case, and in the case of a mixture of a plurality of polyvinyl alcohols, each degree of polymerization in each polyvinyl alcohol The product multiplied by all the polyvinyl alcohols.
- the weighted average of the saponification degree in the polyvinyl alcohol is equal to the saponification degree of the polyvinyl alcohol in a single case, and in the case of a mixture of a plurality of polyvinyl alcohols, A product obtained by multiplying each ratio and adding all the polyvinyl alcohols.
- the polymerization degree and saponification degree of polyvinyl alcohol are measured according to JIS K 6726.
- the ratio of the spinning aid in the spinning solution is usually 5% by mass or more and 15% by mass or less with respect to the total solid content of the alumina component and the silica component of 100% by mass, whereby a desired fiber diameter and strong fiber can be produced. This is preferable.
- the viscosity of the spinning solution at 25 ° C. measured by a B-type viscometer is 5.0 ⁇ 10 3 mPa ⁇ s or more and 1.5 ⁇ 10 4 mPa ⁇ s or less, preferably 6.0 ⁇ 10 3 mPa ⁇ s or more. It is 2 ⁇ 10 4 mPa ⁇ s or less.
- the viscosity of the spinning solution at 25 ° C. measured by a B-type viscometer was measured using a B-type viscometer (for example, manufactured by Toki Sangyo Co., Ltd. (TVB-10M viscometer, rotor TM3 (radius 12.7 mm, thickness 1.7 mm), rotational speed 12 rpm). ) To measure.
- a B-type viscometer for example, manufactured by Toki Sangyo Co., Ltd. (TVB-10M viscometer, rotor TM3 (radius 12.7 mm, thickness 1.7 mm), rotational speed 12 rpm).
- the spinning step is preferably performed by a blowing method in which a spinning solution is supplied into a high-speed spinning air stream, thereby obtaining an aggregate of alumina short fiber precursors having a length of several tens to several hundreds of millimeters.
- the structure of the spinning nozzle used in the above spinning is not particularly limited. For example, as described in Japanese Patent No. 2602460, the air flow blown from the air nozzle and the spinning liquid supply nozzle are pushed out.
- the spinning liquid flow is preferably a parallel flow, and the parallel air flow is sufficiently rectified to come into contact with the spinning liquid.
- the diameter of the spinning nozzle is usually 0.1 to 0.5 mm
- the liquid amount per spinning solution supply nozzle is usually 0.1 to 120 ml / h, preferably 0.3 to 50 ml / h.
- the gas flow rate per slit from the air nozzle is usually 40 to 200 m / s.
- the variation in the amount of liquid per spinning solution supply nozzle is usually within ⁇ 5%, preferably within ⁇ 2%, and the variation in gas flow rate per slit from the air nozzle is usually within ⁇ 15%, preferably ⁇ It is within 8%.
- the fact that the liquid and gas flow rates can be controlled more precisely is considered to be an extremely important factor for sharpening the fiber diameter distribution.
- the fine pulsation of the pump that supplies the liquid is controlled, and the flow rate per spinning nozzle is made constant by eliminating the flow rate variation between the spinning nozzles.
- a pump that suppresses pulsation by operating multiple cylinders out of phase such as a triple diaphragm type, or rotating A mono-pump type in which a helically bent circular cross-section rotor rotates in a spiral pipe with an oval cross-section like a positive displacement single-shaft eccentric screw pump, and the fluid is transferred in the axial direction.
- a pump that suppresses pulsation by operating multiple cylinders out of phase such as a triple diaphragm type, or rotating A mono-pump type in which a helically bent circular cross-section rotor rotates in a spiral pipe with an oval cross-section like a positive displacement single-shaft eccentric screw pump, and the fluid is transferred in the axial direction.
- the flow rate variation among the spinning nozzles occurs because the discharge pressure (back pressure) increases as the nozzle is closer to the spinning solution inlet.
- a stainless steel wool-like material is filled in the liquid flow path before the spinning nozzle to make the back pressure of the spinning nozzle uniform.
- the fluctuation of the discharge pressure of the air nozzle has a high gas flow rate because the distance from the gas inlet is close at the center of the slit-like air nozzle, and the distance from the gas inlet at both ends of the slit-like air nozzle is high. This occurs due to the slow gas flow rate due to the distance.
- an introduction plate (baffle plate) or the like is incorporated in the gas flow path, or the air nozzle slit interval is distributed, and the slit interval is set at a portion where the gas flow velocity is high. It can be narrowed.
- the spinning solution extruded from the spinning solution supply nozzle is sufficiently stretched without being sprayed (mist-like) and hardly fused with the fibers.
- a uniform alumina fiber precursor with a narrow fiber diameter distribution can be obtained.
- the relative humidity in the vicinity where the spinning solution starts to contact the airflow is usually 20% or more, preferably 30% or more. There is no particular limitation on the upper limit of the relative humidity.
- the temperature condition in the vicinity of where the spinning solution starts to contact the airflow is usually 50 ° C.
- the relative humidity of the airflow in the vicinity of the fiber collector is preferably less than 35%, particularly preferably 30% or less.
- the temperature of the airflow in the vicinity of the fiber collector is usually 30 ° C. or more and 55 ° C. or less, particularly 35 ° C. or more and 50 ° C. or less.
- the aggregate of short alumina fiber precursors is installed with an endless belt made of wire mesh so as to be substantially perpendicular to the spinning airflow, and the spinning airflow containing the alumina short fiber precursor collides with this while rotating the endless belt. It can collect
- the thin-layer sheet can be made into a laminated sheet by continuously pulling it out, sending it to a folding device, folding it to a predetermined width and stacking it, and continuously moving it in a direction perpendicular to the folding direction.
- a folding device the one described in JP 2000-80547 A can be used.
- the number of needling strokes is usually 1 stroke / cm 2 or more and 150 strokes / cm 2 or less, preferably 5 or more and 100 strokes / cm 2 or less per unit area of the surface of the alumina fiber aggregate after firing, Particularly preferably, it is 8 or more and 80 shots / cm 2 or less.
- the fibers entangled in a complicated manner are oriented in the stacking direction, and the alumina fiber aggregate can be strengthened in the stacking direction.
- the pressure residual ratio (%) is preferable in that it is 45% or more.
- the firing step the aggregate of alumina short fiber precursors subjected to the needling treatment is fired in an air atmosphere.
- the firing temperature is usually 500 ° C. or higher, preferably 700 ° C. or higher and 1400 ° C. or lower.
- the firing temperature is less than 500 ° C., crystallization is insufficient, so that only weak alumina fibers with low strength can be obtained.
- the firing temperature exceeds 1400 ° C., fiber crystal grain growth proceeds and the strength is low. Only fragile alumina fibers are obtained.
- the maximum baking temperature in the baking step is 1000 ° C. or higher and 1300 ° C.
- the rate of temperature increase up to the maximum baking temperature is 40 ° C./min or lower, more preferably 30 ° C./min or lower, more preferably 20 ° C. 1 ° C./min or more, preferably 1 ° C./min or more, more preferably 3 ° C./min or more, and further preferably 5 ° C./min or more. This is preferable in that high productivity can be secured while maintaining the structure.
- the chemical composition of the short alumina fibers produced by spinning and firing the spinning solution is usually 65% by mass to 99% by mass of alumina and 1% by mass to 35% by mass of silica, preferably 68% by mass of alumina. % To 90% by mass, silica 10% to 32% by mass, particularly preferably 70% to 75% by mass of alumina, and 25% to 30% by mass of silica.
- the chemical composition of the alumina short fiber is within the above range, it is preferable in that the alumina particles are hardly coarsened and a dense structure is easily obtained.
- a measurement sample was pulverized by repeatedly applying a load of 10 kN / m 2 to 0.2 to 0.5 g of an alumina fiber aggregate as a measurement sample.
- the pulverized sample was photographed using a scanning electron microscope (SEM) while appropriately selecting within a magnification range of 1000 to 3000. From the SEM photograph, weigh out in units of 0.1 mm with a caliper or a straight ruler. Then, a total of 300 fiber diameters were arbitrarily measured, and the average fiber diameter was calculated by the following formula. At this time, the calculated value was rounded off to two digits after the decimal point to obtain one digit after the decimal point.
- SEM scanning electron microscope
- the ratio (%) of fibers having a fiber diameter exceeding 10.0 ⁇ m was calculated on the basis of the number of fibers with respect to a total of 300 (provided that the fibers do not include fused fibers).
- Fiber diameter ( ⁇ m) (measured value) / (observation magnification) ⁇ 1000
- Average fiber diameter ( ⁇ m) total value of 300 fiber diameters / 300 (Length weighted geometric mean diameter-2 x standard error)
- the length-weighted geometric mean diameter is defined by the above equation (1).
- Length-weighted geometric mean diameter-2 ⁇ standard error was calculated by the above formulas (a) to (d).
- a sample of alumina fiber was placed on a 1 mm square diamond substrate, and a micro-compression tester MCTM-500 manufactured by Shimadzu Corporation was used to measure the breaking load per alumina fiber using a flat indenter with a diameter of 50 ⁇ m. It was measured.
- the single fiber tensile strength was determined from the breaking load according to the following formula, and the average value of 10 single fiber tensile strengths was calculated to obtain the average single fiber tensile strength.
- the compression from GBD 0.33 g / cm 3 (open side) to 0.38 g / cm 3 (compression side) was repeated 800 times.
- Alumina fiber aggregates are punched into 50 mm squares, and a plurality of sheets are adjusted so as to have a mass of 5.0 ⁇ 0.03 g. Place in a 50 mm square and 4 mm thick mold and apply a 10 kN load for 10 minutes with a press. After compression, the sample was split into about 5 to 10 mm square, and placed in a 1 L beaker together with 400 ml of ion-exchanged water having a water temperature of 23 degrees so as not to spill. After stirring and defibrating for 10 minutes at a stirring speed of 1000 rpm, it was transferred to a 1 L graduated cylinder. At that time, the attached fibers on the inner wall and the stirring blade were collected while being washed off with ion exchange water, and the total amount of ion exchange water was 500 ml.
- the mullitization rate at this time is a value represented by the following equation.
- the alumina fiber precursor was calcined in air at a temperature increase rate of up to 1200 ° C. at 5 ° C./minute and 1200 ° C. for 30 minutes to obtain an alumina fiber aggregate.
- Table 1 shows the evaluation of the obtained alumina fiber assembly.
- Example 1 [Spinning liquid preparation process] In the same manner as in Reference Example 1, 20.5 mass% silica sol solution 0.490 L, 10.5 mass% polyvinyl alcohol (polymerization degree 2100, saponification degree) per 1.0 L of an aqueous solution of basic aluminum chloride having an aluminum concentration of 163 g / L. 88.0) 0.243 L of an aqueous solution was added and mixed, and then concentrated under reduced pressure to obtain a spinning solution. The concentration of the spinning solution was 8.0 ⁇ 10 3 mPa ⁇ s.
- the spinning solution was spun by a blowing method.
- a spinning nozzle having the same structure as that described in FIG. 6 of Japanese Patent No. 2602460 was used. Also, when collecting the fibers, by introducing warm air of 165 ° C. (heated at 30 ° C. and 40% relative humidity in the atmosphere) dried in parallel with the high-speed air flow to the screen, the vicinity of the fiber collector The air flow was adjusted to a temperature of 45 ° C. and a relative humidity of 30% or less.
- an endless belt made of wire mesh is installed so as to be substantially perpendicular to the spinning airflow, and the endless belt is rotated, and the structure in which the spinning airflow including the spinning airflow containing the alumina short fiber precursor collides with the endless belt is integrated. It collect
- the thin layer sheet collected from the stacking device was continuously drawn out, sent to a folding device, folded into a predetermined width and stacked, and continuously moved in a direction perpendicular to the folding direction to form a laminated sheet.
- a folding device having the same structure as that described in Japanese Patent Laid-Open No. 2000-80547 was used.
- the above laminated sheet (aggregate of alumina short fiber precursors) is subjected to needling and then fired in air at a temperature increase rate of up to 800 ° C. at 16 ° C./minute and 1200 ° C. for 30 minutes to obtain an alumina fiber aggregate.
- the above needling is performed by a needle punching machine so that the needle mark density in the calcined alumina fiber aggregate is 5 to 30 times / cm 2 , and the needling-treated alumina fiber aggregate (alumina fiber needle) Blanket).
- Table 2 shows the evaluation of the obtained alumina fiber needle blanket.
- Example 2 An aqueous solution containing polyvinyl alcohol A and polyvinyl alcohol B described in Reference Example 2 was prepared instead of 0.243 L of an aqueous solution of 10.5% by mass polyvinyl alcohol (polymerization degree 2100, saponification degree 88.0). Then, 0.258 L of the aqueous solution was added, and an alumina fiber needle blanket was obtained in the same manner as in Example 1 except that the viscosity of the spinning solution after concentration under reduced pressure was 6.5 ⁇ 10 3 mPa ⁇ s. Table 2 shows the evaluation of the obtained alumina fiber needle blanket.
- Comparative Example 1 An alumina fiber needle blanket was obtained in the same manner as in Example 1 based on the conditions described in JP-A-2005-120560. Table 2 shows the evaluation of the obtained alumina fiber needle blanket.
- the silica sol used was that described in Reference Example 3.
- the alumina fiber aggregate of the present invention has a moderate strength even if the fiber exceeds 6.0 ⁇ m by combining a specific material composition and specific production conditions, compared to the conventional product.
- the durability at high temperature was improved, and it had an appropriate function as a catalyst carrier holding material.
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Abstract
Description
アルミナ源、シリカ源、紡糸助剤及び水を含有する紡糸液を調製する紡糸液調製工程、該紡糸液を細孔より大気中に押出し、乾燥することによりアルミナ繊維前駆体の集合体を得る紡糸工程、該アルミナ繊維前駆体の集合体をニードリング処理するニードリング工程、及びニードリング処理された該アルミナ繊維前駆体の集合体を焼成する焼成工程を有し、該シリカ源は、動的光散乱法によって測定される、平均粒子径分布のモード径が20nm以上60nm以下かつ該粒子径分布の標準偏差が20nm以上35nm以下のシリカゾルであり、該紡糸助剤は、重合度の加重平均が2.0×103以上3.0×103以下であり、ケン化度の加重平均が85.0以上95.0以下のポリビニルアルコールであり、該紡糸液のB型粘度計による25℃での粘度が5.0×103mPa・s以上1.5×104mPa・s以下であるアルミナ繊維集合体の製造方法。
該ポリビニルアルコールAとポリビニルアルコールBとの質量比率が9~5:1~5であり、該ポリビニルアルコールA及びポリビニルアルコールBにおける重合度の加重平均が2.0×103以上3.0×103以下であり、該ポリビニルアルコールA及びポリビニルアルコールBにおけるケン化度の加重平均が85.0以上95.0以下である、[10]に記載のアルミナ繊維集合体の製造方法。
繊維径(μm)=(測定値)/(観察倍率)×1000
平均繊維径(μm)=300点の繊維径の合計値/300
ECB/TM/1(00)rev2のDRAFT-4の記載に沿って、次式(a)~(d)より算出された「長さ加重幾何平均径-2×標準誤差」は6.0μm以上10.0μm以下、特に6.0μm以上8.0μm以下であることが好ましい。
(1) アルミナ源、シリカ源、紡糸助剤及び水を含有する紡糸液を得る紡糸液調製工程
(2) 該紡糸液を細孔より大気中に押出し、乾燥することでアルミナ繊維前駆体の集合体を得る紡糸工程
(3) 該アルミナ繊維前駆体の集合体にニードリング処理を行うニードリング工程
(4) 該ニードリング処理されたアルミナ繊維前駆体を焼成する焼成工程
紡糸液調製工程では、例えばアルミナ源とシリカ源を、最終的なアルミナ質繊維が所望する化学組成となるようにアルミナ成分とシリカ成分の比に混ぜ、さらに紡糸助剤を配合して均一に混合してから減圧濃縮するのが好ましい。
紡糸工程は好ましくは、高速の紡糸気流中に紡糸液を供給するブローイング法によって行われ、これにより長さが数十mm~数百mmのアルミナ短繊維前駆体の集合体が得られる。上記の紡糸の際に使用する紡糸ノズルの構造は、特に制限はないが、例えば、特許第2602460号公報に記載されているような、エアーノズルより吹き出される空気流と紡糸液供給ノズルより押し出される紡糸液流とは並行流となり、しかも、空気の並行流は充分に整流されて紡糸液と接触する構造のものが好ましい。この場合、紡糸ノズルの直径は通常0.1~0.5mmであり、紡糸液供給ノズル1本あたりの液量は、通常0.1~120ml/h、好ましくは0.3~50ml/hであり、エアーノズルからのスリットあたりのガス流速は通常40~200m/sである。また、紡糸液供給ノズル1本あたりの液量のばらつきは通常±5%以内、好ましくは±2%以内であり、エアノズルからのスリットあたりのガス流速のばらつきは通常±15%以内、好ましくは±8%以内である。かかる液、ガス流速をより精密に制御できることは、繊維径分布をよりシャープにするための極めて重要な要因となっているものと考えられる。
ニードリング工程では、アルミナ短繊維前駆体の集合体(積層シート)にニードリングを施すことにより、厚さ方向にも配向された機械的強度の大きいアルミナ繊維集合体(アルミナ繊維ニードルブランケットという場合がある)とする。
焼成工程では、上記ニードリング処理されたアルミナ短繊維前駆体の集合体を空気雰囲気中で焼成する。焼成温度は、通常500℃以上、好ましくは700℃以上1400℃以下の温度で行う。焼成温度が500℃未満の場合は結晶化が不十分なため強度の小さい脆弱なアルミナ繊維しか得られず、焼成温度が1400℃を越える場合は繊維の結晶の粒成長が進行して強度の小さい脆弱なアルミナ繊維しか得られない。好ましくは、焼成工程の最高焼成温度が1000℃以上1300℃以下であり、最高焼成温度までの昇温速度が40℃/分以下であり、より好ましくは30℃/分以下、さらに好ましくは20℃/分以下であり、一方、1℃/分以上が好ましく、より好ましくは3℃/分以上、さらに好ましくは5℃/分以上であり、上記焼成工程を上記条件とすることで、緻密な繊維構造を維持しつつ、高生産性を確保できる点で好ましい。
測定サンプルとしてアルミナ繊維集合体0.2~0.5gに荷重10kN/m2を2回繰り返し与えることで測定サンプルを粉砕した。粉砕サンプルを走査型電子顕微鏡(SEM)を用いて、倍率1000~3000の範囲で適宜選択しながら撮影した。該SEM写真から、ノギス又は直定規で0.1mm単位で量り取る。そして、任意に合計300本の繊維径を測定し、次式により平均繊維径を算出した。この際、計算値は小数点以下2ケタを四捨五入して小数点以下1桁とした。また、合計300本に対して、繊維径が10.0μmを超える繊維の割合(%)を本数基準で算出した(但し該繊維は、融着した繊維を含まないものとする。)。
繊維径(μm)=(測定値)/(観察倍率)×1000
平均繊維径(μm)=300点の繊維径の合計値/300
(長さ加重幾何平均径-2×標準誤差)
長さ加重幾何平均径は前記(1)式で定義される。
測定サンプル(SiO2濃度20.5%溶液、10ml)を濃度0.002Nの塩酸で40倍に希釈して25℃にした後の希釈溶液5ml(最終濃度 0.5%)を、動的光散乱装置(大塚電子社製ELS-Z)により、以下の測定条件で、シリカゾル粒子径分布を測定した。得られたシリカゾル粒子径分布からモード径及び標準偏差を算出した。
[測定条件]
Correlation Method : T.D
Correlation Channel: 440
Angle(°) : 165.0
Incident Filter(%) : 10.12%
積算回数 : 70
サンプルであるアルミナ繊維一本を、1mm角のダイヤモンド基板上に載せ、島津製作所製微小圧縮試験機 MCTM-500にて、直径50μmの平面圧子を用いて、該アルミナ繊維一本あたりの破壊荷重を測定した。次式に従って破壊荷重より単繊維引張強度を求め、10点の単繊維引張強度の平均値を算出して、平均単繊維引張強度とした。
測定サンプル1gを乳鉢にて粉砕し、150℃、真空下で3時間減圧加熱処理を行った後、カンタークローム社製・オートソーブ3Bにて、液体窒素温度下で吸着等温線(吸着ガス:窒素)を測定した。得られた吸着側等温線を用いて、BET多点法解析を実施し比表面積を、また得られた吸着側及び脱離側吸着等温線を用いて、BJH法解析により全細孔分布を求めた。
温度条件を25℃にし、アルミナ繊維集合体をGBD(嵩密度)=0.33g/cm3から0.38g/cm3まで圧縮することを20回繰り返した。その際、第1回目のGBD=0.33g/cm3での面圧値と第20回目のGBD=0.33g/cm3での面圧値を測定し、以下の式より面圧の劣化度合いの指標となる面圧残存率(%)を求めた。結果を表1に示す。
高温サイクル面圧の測定方法は、アルミナ繊維集合体をGBD(嵩密度)=0.38g/cm3で30分間圧縮した後、上下のプレートを昇温速度15℃/分で600℃まで昇温し、GBD=0.33g/cm3(開放側)から0.38g/cm3(圧縮側)まで圧縮することを800回繰り返した。その際、第1回目のGBD=0.33g/cm3(開放側)又は0.38g/cm3(圧縮側)での面圧値と第800回目のGBD=0.33g/cm3(開放側)又は0.38g/cm3(圧縮側)での面圧値を測定し、以下の式より、面圧の劣化度合いの指標となる高温サイクル面圧残存率(%)を求めた。
[高温サイクル開放側面圧残存率(%)]=[第800回目の面圧値(GBD=0.33g/cm3)]/[第1回目の面圧値(GBD=0.33g/cm3)]×100
[高温サイクル圧縮側面圧残存率(%)]=[第800回目の面圧値(GBD=0.38g/cm3)]/[第1回目の面圧値(GBD=0.38g/cm3)]×100
アルミナ繊維集合体を50mm角に打ち抜き、質量が5.0±0.03gになるように複数枚重ねて調整する。幅50mm角、厚み4mmの金型に入れ、プレス機で10kNの荷重を10分間かける。圧縮後、上記サンプルを5~10mm角程度に裂き、こぼれないように1Lのビーカーに水温23度のイオン交換水400mlと共に入れた。撹拌速度1000rpmにて10分間撹拌・解繊したのち、1Lメスシリンダーへ移した。その際、内壁や撹拌羽についた付着繊維をイオン交換水で洗い落しながら回収し、イオン交換水の総量を500mlとした。
測定サンプルを乳鉢にて粉砕し、X線回折装置(例えばRIGAKU社製)で感電圧30kv、感電流40mA、4°/分の速度で測定し、ムライトのピーク2θ=26.3°の高さhを読み取った。また、同じ条件でムライト標準物質(例えばNIST Alpha Quartz)を測定し、2θ=26.3°のピーク高h0を読み取る。このときのムライト化率は以下の式で表す値となる。
[紡糸液の調整工程]
先ず、アルミニウム濃度が163g/Lの塩基性塩化アルミニウムの水溶液1.0L当たり、モード径43nm(標準偏差24nm)、濃度20.5質量%のシリカゾル溶液0.496L、10質量%ポリビニルアルコール(重合度2400、ケン化度88.0)水溶液0.257Lを添加して混合した後、減圧濃縮し、紡糸液を得た。紡糸液の粘度は7.1×103mPa・s(25℃におけるB型粘度計(東機産業製(形式TVB-10M粘度計、ロータTM3(半径12.7mm、厚み1.67mm)回転速度12rpm))による測定、以下の実施例について同様)による測定値)であった。
上記の紡糸液をブローイング法で紡糸し、アルミナ繊維前駆体を得た。なお、紡糸ノズルとしては、特許第2602460号公報図6に記載されたものと同様の構造の紡糸ノズルを使用し、製造条件等は特許第2602460号に準じて実施した。
上記のアルミナ繊維前駆体を、1200℃までの昇温速度を5℃/分、1200℃で30分間空気中で焼成し、アルミナ繊維集積体を得た。得られたアルミナ繊維集積体の評価を表1に示す。
参考例1において、10質量%ポリビニルアルコール(重合度2400、ケン化度88.0)水溶液の代わりに、ポリビニルアルコールA(重合度2100、ケン化度88.0)及びポリビニルアルコールB(重合度2600、ケン化度97.6)を比率8:2で混合し、ポリビニルアルコールとして10質量%の水溶液(重合度の加重平均2200、ケン化度の加重平均89.9)を同量添加して混合した後、減圧濃縮し得られた紡糸液の粘度が8.2×103mPa・sであること以外は、参考例1と同様にしてアルミナ繊維集積体を得た。得られたアルミナ繊維集積体の評価を表1に示す。
参考例1において、モード径43nm(標準偏差24nm)、濃度20.5質量%のシリカゾル溶液0.490Lの代わりに、シリカゾルのモード径22nm(標準偏差8nm)、濃度10.5%のシリカゾル0.957Lを添加し、減圧濃縮し得られた紡糸液の粘度が6.7×103mPa・sであり、ゲル状であったこと以外は、参考例1と同様にアルミナ繊維集積体を得た。得られたアルミナ繊維集積体の評価を表1に示す。
参考例1において、10質量%ポリビニルアルコール(重合度2400、ケン化度88.0)の代わりに、10質量%ポリビニルアルコール(重合度1700、ケン化度88.0)を同量添加して混合した後、減圧濃縮し得られた紡糸液の粘度が2.7×103mPa・sであった以外は、参考例1と同様にアルミナ繊維集積体を得た。得られたアルミナ繊維集積体の評価を表1に示す。
[紡糸液の調製工程]
参考例1と同様に、アルミニウム濃度が163g/Lの塩基性塩化アルミニウムの水溶液1.0L当たり20.5質量%シリカゾル溶液0.490L、10.5質量%ポリビニルアルコール(重合度2100、ケン化度88.0)水溶液0.243Lを添加して混合した後、減圧濃縮し、紡糸液を得た。紡糸液の濃度は8.0×103mPa・sであった。
次に、上記の紡糸液をブローイング法で紡糸した。紡糸ノズルとしては、特許第2602460号公報図6に記載されたものと同様の構造の紡糸ノズルを使用した。また、繊維捕集に際しては、高速気流に並行流で乾燥した165℃の温風(温度30℃、相対湿度40%の大気を加温)をスクリーンに導入することにより、繊維捕集器付近の空気流を温度45℃、相対湿度30%以下に調整した。そして、紡糸気流に対して略直角となる様に金網製の無端ベルトを設置し、無端ベルトを回転させつつ、これにアルミナ短繊維前駆体を含む紡糸気流を含む紡糸気流を衝突させる構造の集積装置により連続シート(薄層シート)として回収した。
集積装置より回収された薄層シートは、連続的に引出して折畳み装置に送り、所定の幅に折り畳んで積み重ねつつ、折り畳み方向に対して直角方向に連続的に移動させることにより積層シートにした。上記の折畳み装置としては、特開2000―80547号公報に記載されたものと同様の構造の折畳み装置を使用した。
上記の積層シート(アルミナ短繊維前駆体の集合体)にニードリングを施した後、800℃までの昇温速度を16℃/分、1200℃で30分間空気中で焼成し、アルミナ繊維集合体を得た。上記のニードリングはニードルパンチング機械により、焼成後のアルミナ繊維集合体におけるニードル痕密度が5~30回/cm2となるようにパンチングを行い、ニードリング処理されたアルミナ繊維集合体(アルミナ繊維ニードルブランケット)を得た。得られたアルミナ繊維ニードルブランケットの評価を表2に示す。
実施例1において、10.5質量%ポリビニルアルコール(重合度2100、ケン化度88.0)水溶液0.243Lの代わりに、参考例2に記載のポリビニルアルコールA及びポリビニルアルコールBを含む水溶液を調整し、該水溶液0.258Lを添加し、減圧濃縮後の紡糸液の粘度が6.5×103mPa・sであったこと以外は、実施例1と同様にアルミナ繊維ニードルブランケットを得た。得られたアルミナ繊維ニードルブランケットの評価を表2に示す。
比較例1において、特開2005-120560に記載の条件に基づき、実施例1と同様にアルミナ繊維ニードルブランケットを得た。得られたアルミナ繊維ニードルブランケットの評価を表2に示す。なお、シリカゾルは参考例3に記載のものを使用した。
本出願は、2016年7月11日付で出願された日本特許出願2016-136958に基づいており、その全体が引用により援用される。
Claims (12)
- アルミナ短繊維からなるニードリング処理されたアルミナ繊維集合体であって、
該アルミナ短繊維の平均繊維径が6.0μm以上10.0μm以下であり、該アルミナ短繊維の比表面積が0.2m2/g以上1.0m2/g以下であり、
かつ、該アルミナ繊維集合体の高温サイクル開放側面圧残存率(%)が45%以上であることを特徴とするニードリング処理されたアルミナ繊維集合体。 - 前記アルミナ短繊維の繊維径の長さ加重幾何平均径からその標準誤差の2倍値を引いた値が6.0μm以上である、請求項1に記載のアルミナ繊維集合体。
- 前記アルミナ短繊維の繊維径が10.0μmを超える繊維の割合が本数基準で5.0%以下である、請求項1又は2に記載のアルミナ繊維集合体。
- 前記アルミナ短繊維の全細孔容積が2.5×10-3ml/g以下である、請求項1~3のいずれか1項に記載のアルミナ繊維集合体。
- 前記アルミナ短繊維の平均単繊維引張強度が1.20×103MPa以上である、請求項1~4のいずれか1項に記載のアルミナ繊維集合体。
- 前記アルミナ短繊維の化学組成がアルミナ70質量%以上75質量%以下、かつシリカ25質量%以上30質量%以下である、請求項1~5のいずれか1項に記載のアルミナ繊維集合体。
- 該アルミナ繊維集合体の水中嵩比重が1.40×10-2g/ml以上2.00×10-2g/ml以下である、請求項1~6のいずれか1項に記載のアルミナ繊維集合体。
- 前記アルミナ繊維集合体のムライト化率が5.0%以下である請求項1~7のいずれか1項に記載のアルミナ繊維集合体。
- 前記ニードリング処理により生じたニードル痕を有する請求項1~8のいずれか1項に記載のアルミナ繊維集合体。
- 請求項1~9のいずれか1項に記載のアルミナ短繊維からなるアルミナ繊維集合体を製造する方法であって、アルミナ源、シリカ源、紡糸助剤及び水を含有する紡糸液を調製する紡糸液調製工程、該紡糸液を細孔より大気中に押出し、乾燥することによりアルミナ繊維前駆体の集合体を得る紡糸工程、該アルミナ繊維前駆体の集合体をニードリング処理するニードリング工程、及びニードリング処理された該アルミナ繊維前駆体の集合体を焼成する焼成工程を有し、該シリカ源は、動的光散乱法によって測定される、平均粒子径分布のモード径が20nm以上60nm以下かつ該粒子径分布の標準偏差が20nm以上35nm以下のシリカゾルであり、該紡糸助剤は、重合度の加重平均が2.0×103以上3.0×103以下であり、ケン化度の加重平均が85.0以上95.0以下のポリビニルアルコールであり、該紡糸液のB型粘度計による25℃での粘度が5.0×103mPa・s以上1.5×104mPa・s以下であるアルミナ繊維集合体の製造方法。
- 前記紡糸助剤が、少なくとも、重合度1.8×103以上2.4×103以下かつケン化度85.0以上92.0未満のポリビニルアルコールAと、重合度2.2×103以上3.0×103以下、かつケン化度92.0以上99.5以下であるポリビニルアルコールBとを含み、
該ポリビニルアルコールAとポリビニルアルコールBとの質量比率が9~5:1~5であり、該ポリビニルアルコールA及びポリビニルアルコールBにおける重合度の加重平均が2.0×103以上3.0×103以下であり、該ポリビニルアルコールA及びポリビニルアルコールBにおけるケン化度の加重平均が85.0以上95.0以下である、
請求項10に記載のアルミナ繊維集合体の製造方法。 - 前記焼成工程の最高焼成温度が1000℃以上1300℃以下であり、最高焼成温度までの昇温速度が40℃/分以下である、請求項10又は11に記載のアルミナ繊維集合体の製造方法。
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