WO2018131658A1 - 金属繊維不織布 - Google Patents
金属繊維不織布 Download PDFInfo
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- WO2018131658A1 WO2018131658A1 PCT/JP2018/000506 JP2018000506W WO2018131658A1 WO 2018131658 A1 WO2018131658 A1 WO 2018131658A1 JP 2018000506 W JP2018000506 W JP 2018000506W WO 2018131658 A1 WO2018131658 A1 WO 2018131658A1
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- nonwoven fabric
- metal
- fiber nonwoven
- metal fiber
- fibers
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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
- D21H13/36—Inorganic fibres or flakes
- D21H13/46—Non-siliceous fibres, e.g. from metal oxides
- D21H13/48—Metal or metallised fibres
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- 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
- D04H1/4234—Metal fibres
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- 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
- D04H1/54—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 welding together the fibres, e.g. by partially melting or dissolving
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- 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
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
- D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
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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]
- Y10T442/654—Including a free metal or alloy constituent
- Y10T442/655—Metal or metal-coated strand or fiber material
Definitions
- the present invention relates to a metal fiber nonwoven fabric in which metal fibers are bound.
- a sheet-like material having fine holes composed of 100% metal a woven fabric such as a wire mesh, a dry web, a wet web, a powder sintered body, and a nonwoven fabric are plated, and then the nonwoven fabric is degreased.
- a metal sheet obtained are utilized.
- a sheet-like material composed of metal fibers, metal powders, and the like is sintered in a vacuum or in a non-oxidizing atmosphere to fix the overlapping portions of the metal fibers to form a sheet.
- a metal fiber nonwoven fabric obtained by papermaking a slurry containing metal fibers by a wet papermaking method is known.
- the metal fiber nonwoven fabric obtained by the wet papermaking method has metal sheet irregularly oriented, uniform sheet formation, thinness and denseness due to the characteristics of the manufacturing method called papermaking. For this reason, the metal fiber nonwoven fabric obtained by the wet papermaking method can be used in many fields such as filter materials, buffer materials, and electromagnetic shielding materials.
- Examples of the paper making method as described above include, for example, water-soluble polyvinyl alcohol, a water-insoluble thermoplastic resin, and a metal fiber mixed with an organic polymer viscosity agent, and then paper-making, which is higher than the melting point of the water-insoluble thermoplastic resin.
- a method for producing a metal fiber nonwoven fabric for use in electromagnetic shielding pressed under heating for example, Patent Document 1.
- the metal fiber nonwoven fabric can be used in many fields such as filter materials, cushioning materials, electromagnetic wave shielding materials, etc., but there may be a relatively large weight variation of one metal fiber nonwoven fabric, etc. Applications were sometimes limited. For this reason, metal fiber nonwoven fabrics having higher homogeneity than conventional metal fiber nonwoven fabrics have been desired for various applications.
- the metal fiber nonwoven fabric when used as a member for precision electronic components, the metal fiber nonwoven fabric is used in a small area (individual pieces).
- the conventional metal fiber nonwoven fabric it has been difficult to produce a small area metal fiber nonwoven fabric having high homogeneity with a high product yield.
- Conventional metal fiber nonwoven fabrics as members for precision electronic components have not always been sufficiently dense and homogeneous.
- a metal fiber nonwoven fabric that suppresses in-plane variations such as electrical characteristics, physical characteristics, and air permeability characteristics has been desired.
- the metal fiber nonwoven fabric is excellent in flexibility, disposition property in a narrow place, shape flexibility, and the like, and there is a high demand for a metal fiber nonwoven fabric with higher homogeneity from this aspect.
- the metal fiber nonwoven fabric and the method for producing the metal fiber nonwoven fabric disclosed in Patent Documents 1 and 2 are not conscious of obtaining a metal fiber nonwoven fabric with high homogeneity, and therefore have a sufficiently high homogeneity. I could't say that.
- the present invention has been made in view of the above circumstances, and even when it is a small-area piece, the variation between the pieces is small, and therefore the in-plane variation is small and high even if the area is relatively large. It aims at providing the metal fiber nonwoven fabric which has homogeneity.
- the inventors of the present invention have a high basis weight coefficient of variation (CV value) defined in JIS Z8101 per cm 2 of 10% or less in a metal fiber nonwoven fabric in which metal fibers are bound to each other.
- CV value basis weight coefficient of variation
- the present inventors have found that homogeneity can be obtained and have completed the present invention. Furthermore, it has been found that a metal fiber nonwoven fabric having higher homogeneity can be obtained by adjusting the average fiber length, average fiber diameter, and space factor of the metal fibers.
- this invention provides the following metal nonwoven fabrics.
- a metal characterized by binding between metal fibers, and a coefficient of variation (CV value) of basis weight as defined in JIS Z8101 (ISO 3534: 2006) per 1 cm 2 is 10% or less.
- the metal fiber nonwoven fabric of the present invention has high density and is homogeneous, it is used for various applications including members for electronic components. Furthermore, when the metal fibers have a specific average fiber length, the metal fibers can be appropriately entangled with each other, so that a so-called metal fiber non-woven fabric can be obtained.
- the metal fiber nonwoven fabric of the present invention can be produced in an industrially sufficient area, and even if processed into a very small area form, a relatively large area capable of obtaining individual pieces with extremely small quality differences. Even if it is used in, the in-plane variation can be kept small.
- FIG. 2 is an enlarged photograph of FIG. 1 and an SEM photograph showing a state in which copper fibers are bound together. It is a mapping figure of the metal fiber nonwoven fabric cut piece for measuring the variation coefficient of the basic weight based on this invention.
- 4 is a photograph of a highly homogenous copper fiber nonwoven fabric of Example 3.
- 2 is a photograph of a copper fiber nonwoven fabric with low homogeneity in Comparative Example 1.
- It is a schematic diagram which shows the sheet resistance measuring method of a metal fiber nonwoven fabric piece.
- metal fiber nonwoven fabric of this invention is demonstrated in detail, embodiment of the metal fiber nonwoven fabric of this invention is not restricted to this.
- the metal fiber nonwoven fabric of this invention may be comprised only from the metal fiber, and may have things other than a metal fiber in addition to a metal fiber.
- the binding between the metal fibers refers to a state in which the metal fibers are physically fixed, and a portion where the metal fibers are physically fixed is referred to as a binding portion. In the binding portion, the metal fibers may be directly fixed, or part of the metal fibers may be indirectly fixed via a component other than the metal component.
- FIG. 1 is an SEM photograph of a metal fiber nonwoven fabric prepared using copper fibers, and reference numeral 1 indicates copper fibers. 2 is an enlarged SEM photograph of FIG. 1, and reference numeral 2 indicates a copper fiber binding portion.
- metal fiber nonwoven fabric of the present invention will be described in more detail.
- Materials constituting metal fiber nonwoven fabric include, but are not limited to, stainless steel, iron, copper, aluminum, bronze, brass, nickel, chromium, and gold, platinum, silver, palladium, rhodium, iridium, ruthenium. And noble metals such as osmium.
- copper fibers are preferable because the balance between rigidity and plastic deformability is moderate and it is easy to obtain a metal fiber nonwoven fabric having sufficient homogeneity.
- Components other than the above metal components include polyolefin resins such as polyethylene resin and polypropylene resin, polyethylene terephthalate (PET) resin, polyvinyl alcohol (PVA) resin, polyvinyl chloride resin, aramid resin, nylon, acrylic series Resins and the like, and fibrous materials made of these resins can be exemplified. Furthermore, an organic substance having a binding property and a supporting property with respect to the metal fiber can be used for the binding portion.
- the average fiber diameter of the metal fibers used in the present invention can be arbitrarily set as long as the homogeneity of the nonwoven fabric is not impaired, but is preferably 1 ⁇ m to 30 ⁇ m, more preferably 2 ⁇ m to 20 ⁇ m. If the average fiber diameter of the metal fibers is 1 ⁇ m or more, moderate rigidity of the metal fibers can be obtained, and so-called lumps tend not to occur when forming a nonwoven fabric. If the average fiber diameter of the metal fibers is 30 ⁇ m or less, moderate flexibility of the metal fibers can be obtained, and the fibers tend to be entangled appropriately.
- the “average fiber diameter” in the present specification is calculated by calculating the cross-sectional area of the metal fiber in an arbitrary vertical cross section with respect to the longitudinal direction of the metal fiber nonwoven fabric imaged with a microscope (for example, by using known software). ), An average value of area diameters derived by calculating the diameter of a circle having the same area as the cross-sectional area (for example, the average value of 20 fibers).
- the cross-sectional shape perpendicular to the longitudinal direction of the metal fiber may be any of a circle, an ellipse, a substantially quadrangle, an indeterminate shape, etc., but preferably a circle.
- the circular cross section is not necessarily a perfect circular cross section because it may be a circular cross sectional shape that is likely to cause a curved portion in the stress that is normally applied when producing the metal fiber nonwoven fabric.
- a metal fiber having a circular cross section is more likely to bend with respect to stress than a fiber having a prismatic cross section, and the bending degree of the metal fiber is less likely to be different from the stressed portion. There is a tendency to homogenize.
- the metal fiber having a circular cross section tends to bend due to contact with a slurry stirring blade or the like.
- a tendency which becomes easy to improve the homogeneity of a metal fiber nonwoven fabric because the metal fibers which have a curved part moderately interlace.
- the average fiber length of the metal fibers according to the present invention is preferably in the range of 1 mm to 10 mm, more preferably in the range of 3 mm to 5 mm.
- the average fiber length is in the range of 1 mm to 10 mm, for example, when the metal fiber nonwoven fabric of the present invention is produced by papermaking, so-called metal fiber lumps are less likely to occur, and the degree of dispersion of the metal fibers can be easily controlled.
- the “average fiber length” in this specification is a value obtained by measuring 20 fibers with a microscope and averaging the measured values.
- the aspect ratio of the metal fiber according to the present invention is preferably 33 to 10,000, and more preferably 150 to 1,500.
- the aspect ratio is 33 or more, so-called lumps are less likely to occur, and appropriate entanglement of the metal fibers is likely to occur, so that the appropriate handling strength of the metal fiber nonwoven fabric tends to be maintained.
- the aspect ratio is 10,000 or less, the handling strength can be sufficiently maintained, and it is difficult to cause lumps, so that excellent homogeneity of the metal fiber nonwoven fabric tends to be obtained.
- the thickness of the metal fiber nonwoven fabric can be adjusted to an arbitrary thickness, but is preferably in the range of 20 ⁇ m to 5 mm, for example.
- the “thickness of the metal fiber nonwoven fabric” means, for example, measurement of an arbitrary number of metal fiber nonwoven fabrics with a terminal drop type film thickness meter (for example, manufactured by Mitutoyo Corporation: Digimatic Indicator ID-C112X). The average value when points are measured.
- the fiber space factor in the metal fiber nonwoven fabric of the present invention is preferably in the range of 5 to 50%, more preferably 15% to 40%. When the fiber space factor is 5% or more, an appropriate homogeneity is obtained because the fiber amount is sufficient. If the fiber space factor is 50% or less, desired flexibility of the metal fiber nonwoven fabric can be obtained in addition to appropriate homogeneity.
- the fiber space factor in the metal fiber nonwoven fabric is the ratio of the portion where the fibers are present to the volume of the metal fiber nonwoven fabric.
- Space factor (%) basis weight of metal fiber nonwoven fabric / (thickness of metal fiber nonwoven fabric ⁇ true density of metal fiber) ⁇ 100
- the space factor can be calculated by adopting a true density value reflecting the composition ratio.
- the coefficient of variation (CV value) of basis weight specified in JIS Z8101 (ISO 3534) per 1 cm 2 is 10% or less.
- the following method is used to determine the basis weight variation coefficient.
- the metal fiber nonwoven fabric to be measured is cut into 1 cm 2 squares to obtain metal fiber nonwoven fabric pieces.
- the individual pieces are weighed with a high-precision analytical balance (for example, product name: BM-252, manufactured by A & I Co., Ltd.) to determine the mass.
- a high-precision analytical balance for example, product name: BM-252, manufactured by A & I Co., Ltd.
- the area of each piece is calculated from the portrait and landscape orientation. 5).
- the basis weight of each piece is calculated by dividing the mass by the area. 6).
- the variation coefficient can be stabilized by measuring, for example, 100 or more pieces. Moreover, what is necessary is just to use the value converted into 1 cm ⁇ 2 > as a coefficient of variation (CV value), when the metal fiber nonwoven fabric of measurement object is less than 1 cm ⁇ 2 >.
- the basis weight is an index representing the weight per unit area
- the fact that the coefficient of variation of the basis weight is a low value below a certain value is a stable value for the space factor, sheet resistance, etc. of each piece. It can be said that there is. That is, when the basis weight variation coefficient is 10% or less, the metal fiber nonwoven fabric has no extreme lumps or voids, and a nonwoven fabric with sufficiently uniform values such as fiber space factor and sheet resistance can be obtained. It can be said that it shows.
- the coefficient of variation (CV value) of basis weight specified in JIS Z8101 (ISO 3534) per 1 cm 2 can be reduced to 10% or less.
- the average fiber length of metal fibers It is important to adjust the average fiber diameter. Specifically, when the metal fiber nonwoven fabric is formed of only metal, the average fiber length is 1 mm to 10 mm, preferably 3 mm to 5 mm, the average fiber diameter is 1 ⁇ m to 30 ⁇ m, and more preferably 2 ⁇ m to 20 ⁇ m. It is preferable to use a certain metal fiber.
- Fabrication of metal fiber nonwoven fabric As a method for obtaining the metal fiber nonwoven fabric of the present invention, a dry method in which a metal fiber or a web mainly composed of metal fiber is compression-molded or a wet papermaking method using a metal fiber or a raw material mainly composed of metal fiber can be employed.
- the metal fiber nonwoven fabric of the present invention is obtained by a dry method
- the metal fiber obtained by the card method, the airlaid method or the like or a web mainly composed of metal fiber is compression-molded.
- a binder may be impregnated between the fibers in order to bind the fibers.
- the binder is not particularly limited.
- organic binders such as acrylic adhesives, epoxy adhesives, and urethane adhesives
- inorganic adhesives such as colloidal silica, water glass, and sodium silicate are used. Can be used.
- the surface of the fiber may be preliminarily coated with a heat-adhesive resin, and the metal fiber or the aggregate mainly composed of the metal fiber may be laminated and then pressed and heated and compressed.
- the metal fiber nonwoven fabric of this invention can also be produced by the wet papermaking method which disperse
- a method for producing a metal fiber nonwoven fabric a process for producing a papermaking slurry by dispersing a fibrous material such as metal fiber in water, a papermaking process for obtaining a wet sheet from the papermaking slurry, a dehydration process for dehydrating the wet sheet, dehydration It comprises at least a drying step of drying the subsequent sheet to obtain a dry sheet, and a binding step of binding metal fibers or the like constituting the dry sheet.
- a slurry of metal fibers or a slurry containing metal fibers and fibrous materials other than metal fibers is prepared using a stirring mixer, and a filler, a dispersant, a thickener, an antifoaming agent, and a paper strength enhancing agent are prepared therein. Further, a sizing agent, a flocculant, a colorant, a fixing agent and the like are appropriately added.
- fibrous materials other than the above metal fibers include polyolefin resins such as polyethylene resin and polypropylene resin, polyethylene terephthalate (PET) resin, polyvinyl alcohol (PVA) resin, polyvinyl chloride resin, aramid resin, nylon, An acrylic resin etc. can be mentioned.
- the fibrous material of these resins can be added to the slurry in order to exhibit binding properties by heating and melting.
- the binding portion is provided between the metal fibers by sintering, it is preferable that there is no organic fiber or the like between the metal fibers because the binding portion is easily provided.
- the basis weight variation coefficient (CV value) specified in JIS Z8101 (ISO 3534) per 1 cm 2 can be kept low.
- CV value the basis weight variation coefficient specified in JIS Z8101 (ISO 3534) per 1 cm 2
- Paper making process Next, the slurry is wet-formed with a paper machine.
- a paper machine As the paper machine, a circular paper machine, a long paper machine, a short paper machine, an inclined paper machine, a combination paper machine in which the same or different kinds of paper machines are combined, and the like can be used.
- Dehydration process Next, the wet paper after paper making is dehydrated. At the time of dehydration, it is preferable to make the water flow rate (dehydrated amount) of dehydration uniform in the plane of the papermaking net, in the width direction, and the like.
- Binding process Next, the metal fibers in the sheet are bound together.
- a binding method a method of sintering a metal fiber nonwoven fabric, a method of binding by chemical etching, a method of laser welding, a method of binding using IH heating, a chemical bond method, a thermal bond method, or the like is used. Can do.
- the metal fibers are fixed and, for example, the basis weight variation coefficient (CV value) is easily stabilized. Preferably used.
- the metal fiber nonwoven fabric In order to sinter the metal fiber nonwoven fabric, it is preferable to include a sintering step of sintering at a temperature below the melting point of the metal fiber in a vacuum or non-oxidizing atmosphere.
- the metal fiber nonwoven fabric that has undergone the sintering process burns away organic matter, and even if it is a nonwoven fabric made only of metal fibers, it is easy to obtain a metal fiber nonwoven fabric with stable homogeneity by binding the contact points between the metal fibers. The effect which becomes.
- a metal fiber nonwoven fabric can be obtained through the above steps.
- the following steps can also be employed.
- a fiber entanglement treatment step of injecting a high-pressure jet water stream onto the wet sheet surface is preferable.
- a plurality of nozzles are arranged in a direction perpendicular to the flow direction of the sheet, and a high-pressure jet water stream is ejected simultaneously from the plurality of nozzles, so that metal fibers or metal fibers are mainly formed over the entire sheet. Can be entangled with each other. After going through the above process, the wet sheet is wound up through a drying process.
- the pressing step can be performed between the dehydration step and the drying step, between the drying step and the binding step, and / or after the binding step.
- the pressing step may be performed with heating or without heating.
- the metal fiber nonwoven fabric contains organic fibers or the like that are heated and melted, heating at or above the melting start temperature is effective.
- only pressurization may be used.
- the pressure may be appropriately set in consideration of the thickness of the metal fiber nonwoven fabric.
- the linear pressure is less than 300 kg / cm, preferably less than 250 kg / cm. It is preferable because it is easy to give homogeneity to the fiber nonwoven fabric.
- the space factor of the metal fiber in a metal fiber nonwoven fabric can also be adjusted by this press process.
- a press (pressurization) process can also be implemented to the metal fiber nonwoven fabric sintered through the binding process.
- the homogeneity can be further enhanced by subjecting the metal fiber nonwoven fabric after the sintering process to a pressing process.
- a metal fiber nonwoven fabric in which fibers are randomly entangled causes a fiber shift not only in the thickness direction but also in the surface direction by being compressed in the thickness direction.
- the resistance value of the metal fiber sintered nonwoven fabric produced in this way can be arbitrarily adjusted by the type, thickness, density, etc. of the metal fiber, but the sheet-like metal fiber obtained by sintering the copper fiber
- the resistance value of the nonwoven fabric is, for example, about 1.3 m ⁇ / ⁇ .
- the metal fiber nonwoven fabric of the present invention can be used in a wide range of applications depending on the type of metal used.
- a windshield for microphones as a total sound transmission material using stainless steel fibers
- an electromagnetic noise countermeasure member used for electronic circuit boards for the purpose of suppressing electromagnetic waves, etc.
- a copper fiber nonwoven fabric used in solder for semiconductor chip bonding as a countermeasure against heat generation of semiconductors
- a heat transfer material etc. can be mentioned.
- it can be widely used for heat dissipation, heating, electromagnetic wave countermeasures, etc. for building materials, vehicles, aircraft, ships, and the like.
- Example 1 Copper fibers having a diameter of 18.5 ⁇ m, an average fiber length of 10 mm, and a substantially circular cross-sectional shape were dispersed in water, and a thickener was appropriately added to obtain a papermaking slurry. Subsequently, the papermaking slurry which removed the part with high copper fiber concentration located in the mixer bottom part of this papermaking slurry was obtained. The obtained papermaking slurry and a basis weight of 300 g / m 2 were put on a papermaking net, and dehydrated and dried to obtain a copper fiber nonwoven fabric.
- Example 1 After pressing the obtained copper fiber nonwoven fabric at a linear pressure of 80 kg / cm at room temperature, it was heated at 1,020 ° C. for 40 minutes in an atmosphere of 75% hydrogen gas and 25% nitrogen gas, and a portion between the copper fibers was partially The copper fiber nonwoven fabric of Example 1 was obtained. The thickness of the obtained copper fiber nonwoven fabric was 310 ⁇ m. Next, the obtained copper fiber nonwoven fabric was cut into 24 cm ⁇ 18 cm, cut into 1 cm 2 at the dotted line portion of the mapping diagram of FIG. 3, and divided into 1 to 24 and A to S (excluding I) for a total of 432 Individual pieces 4 were obtained. The basis weight of each piece 4 was calculated from the mass of the piece 4 and the measured value of the area. The variation coefficient of basis weight calculated from the standard deviation and average value of all pieces 4 was 9.1, and the average space factor of the copper fibers was 11.0%.
- Example 2 Except that the average fiber length of the copper fibers was 5 mm, a piece of copper fiber nonwoven fabric of Example 2 having a thickness of 303 ⁇ m and an average space factor of 12.7% was obtained in the same manner as Example 1. The coefficient of variation of the basis weight calculated by the same method as in Example 1 was 8.8.
- Example 3 Except that the average fiber length of the copper fibers was 3 mm, the copper fiber nonwoven fabric piece of Example 3 having a thickness of 229 ⁇ m and an average space factor of 10.3% was obtained in the same manner as Example 1. The coefficient of variation in basis weight calculated by the same method as in Example 1 was 5.2.
- Example 4 A thickness of 102 ⁇ m and an average space factor of 34 were obtained in the same manner as in Example 2 except that the portion having a high copper fiber concentration at the bottom of the mixer of the papermaking slurry was not removed and pressed at a load of 240 kg / cm in the thickness direction after sintering. 5% of the copper fiber nonwoven fabric pieces of Example 4 were obtained.
- the variation coefficient of basis weight calculated by the same method as in Example 1 was 5.8.
- Example 5 Before cutting the long copper fiber bundle, fully loosen each fiber, and when dewatering, eliminate structures that may interfere with the water flow under the papermaking net, and make papermaking while suppressing turbulence during dewatering. Except having done, it carried out similarly to Example 4, and obtained the copper fiber nonwoven fabric piece of Example 6 of thickness 101 micrometers and average space factor 33.5%. The coefficient of variation of the basis weight calculated by the same method as in Example 1 was 3.9.
- Example 6 Disperse a stainless steel fiber having a fiber diameter of 2 ⁇ m, an average fiber length of 3 mm and an irregular cross-sectional shape and a PVA fiber (trade name: fibril bond VPB105, manufactured by Kuraray Co., Ltd.) in a weight ratio of 98: 2. Then, a thickening agent was appropriately added to obtain a papermaking slurry. Using the papermaking slurry obtained by removing the high stainless fiber concentration portion at the bottom of the mixer of the papermaking slurry, a basis weight of 50 g / m 2 was introduced onto the papermaking net, and a stainless fiber nonwoven fabric was obtained through dehydration and drying.
- a thickening agent was appropriately added to obtain a papermaking slurry.
- the nonwoven fabric was pressed at room temperature with a linear pressure of 80 kg / cm, and then heated at 1,120 ° C. for 60 minutes in an atmosphere of 75% hydrogen gas and 25% nitrogen gas to partially sinter between the stainless steel fibers.
- a stainless fiber nonwoven fabric of Example 6 was obtained.
- the resulting stainless steel nonwoven fabric had a thickness of 152 ⁇ m.
- the obtained stainless fiber nonwoven fabric was cut into 24 cm ⁇ 18 cm, cut into 1 cm 2 at the dotted line portion of the mapping diagram of FIG. 3, and divided into 1 to 24 and A to S (excluding I) for a total of 432 Obtained pieces.
- the basis weight of each piece was calculated from the mass of the piece and the measured value of the area.
- the variation coefficient of the basis weight calculated from the standard deviation and average value of all pieces was 2.3, and the average space factor of the stainless fiber was 4.0%.
- Example 7 Except that the average fiber diameter of the stainless steel fiber was 8 ⁇ m, the individual piece of the stainless steel fiber nonwoven fabric of Example 7 having a thickness of 85 ⁇ m and an average space factor of 7.8% was obtained in the same manner as Example 6. The coefficient of variation in basis weight calculated by the same method as in Example 6 was 3.7.
- Example 8 A thickness of 111 ⁇ m and an average space factor of 33.7% were the same as in Example 7 except that pressing was performed at a load of 240 kg / cm in the thickness direction after sintering and the basis weight was 300 g / m 2.
- the non-woven piece of stainless fiber of Example 8 was obtained.
- the coefficient of variation in basis weight calculated by the same method as in Example 6 was 7.1.
- Basis weight variation coefficient of the piece The basis weight variation coefficient of the total of 432 copper fiber nonwoven fabric pieces obtained in Examples and Comparative Examples is to calculate the basis weight of each piece from the area and mass, and the standard deviation of a total of 432 points is an average value. Calculated by dividing.
- Table 1 shows a list of calculated data
- Table 2 shows the physical properties of metal fibers.
- the variation coefficient of the sheet resistance value of the copper fiber nonwoven fabric piece of Example 2 calculated by this measurement method was 12.2, and the variation coefficient of the copper fiber nonwoven fabric piece of Comparative Example 1 was 23.8.
- FIG. 4 is a photograph taken with a light source arranged on the back surface in order to confirm the homogeneity of the copper fiber nonwoven fabric of Example 3. Compared with the photograph of the copper fiber nonwoven fabric of Comparative Example 1 shown in FIG. 5, the presence of significant lumps 3 cannot be confirmed, and it can be seen that the homogeneity is remarkably improved. In addition, this visual result appears as a difference in coefficient of variation (CV value).
- CV value coefficient of variation
- the copper fiber nonwoven fabrics of Examples 1 to 5 and the stainless fiber nonwoven fabrics of Examples 6 to 8 had a basis weight variation coefficient of 10 or less, and each piece had high homogeneity, but the basis weight variation coefficient was 17. As can be seen from the photograph shown in FIG. 5, in the copper fiber nonwoven fabric of Comparative Example 1 which is 2, spots where the copper fibers of Dama 3 are densely scattered were scattered.
- the metal fiber nonwoven fabric obtained in the examples can be obtained in an industrially sufficient area, and even if processed into an extremely small area form, it is possible to obtain pieces with extremely small quality error, Even if it is used in a relatively large area, the in-plane variation can be kept small.
- the metal fiber nonwoven fabric of the present invention has high density and is homogeneous, it can be used for various applications including members for electronic parts. For example, it can be used widely for windshields of microphones, electromagnetic wave noise countermeasure members, copper fiber nonwoven fabric heat transfer materials used in solder for semiconductor chip bonding, heat radiation, heating, electromagnetic wave countermeasures for building materials, vehicles, aircraft, ships, etc. it can.
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Abstract
Description
また、比較的大きな面積を想定した場合であっても、電気特性、物理特性、透気特性等、面内バラツキを低く抑えた金属繊維不織布が望まれていた。
しかしながら、高い真密度と、塑性変形特性とを有する金属繊維を含む金属繊維不織布を高度に均質化することは非常に困難であった。
また、金属繊維不織布はその可撓性から、狭小箇所への配置性、形状自由度等に優れており、この面からもより均質性の高い金属繊維不織布への要望は高かった。
さらには、金属繊維の平均繊維長、平均繊維径および占積率等を調整することにより、より高い均質性を具備する金属繊維不織布が得られることを見出した。
(1)金属繊維間が結着してなり、1cm2当たりの、JIS Z8101(ISO 3534:2006)に規定する坪量の変動係数(CV値)が10%以下であることを特徴とする金属繊維不織布。
さらに、金属繊維が特定の平均繊維長を有する場合には、金属繊維同士が適度に交絡しやすく、いわゆるダマの生じにくい金属繊維不織布を得ることができる。
金属繊維間が結着しているとは、金属繊維が物理的に固定されている状態を指し、金属繊維が物理的に固定されている部位を結着部という。結着部では、金属繊維同士が直接的に固定されていても良いし、金属繊維の一部同士が金属成分以外の成分を介して間接的に固定されていても良い。
図1は銅繊維を用いて作製した金属繊維不織布のSEM写真であり、参照番号1は銅繊維を示す。また、図2は、図1の拡大SEM写真であり、参照番号2は、銅繊維の結着部を示す。
<1.金属繊維不織布を構成する材料>
金属繊維不織布を構成する前記金属繊維の具体例としては、特に限定されないが、ステンレス、鉄、銅、アルミニウム、青銅、黄銅、ニッケル、クロム、および金、白金、銀、パラジウム、ロジウム、イリジウム、ルテニウム、およびオスミウム等の貴金属であっても良い。この中でも、銅繊維は、剛直性と塑性変形性とのバランスが適度であり、充分な均質性を有する金属繊維不織布を得やすいため好ましい。
さらには、金属繊維に対して結着性および担持性を有する有機物等を結着部に使用することもできる。
本発明で使用する金属繊維の平均繊維径は、不織布の均質性を損なわない範囲で任意に設定可能であるが、好ましくは1μm~30μmであり、さらに好ましくは2μm~20μmである。金属繊維の平均繊維径が1μm以上であれば、金属繊維の適度な剛直性が得られるため、不織布にする際にいわゆるダマが発生しにくい傾向がある。金属繊維の平均繊維径が30μm以下であれば、金属繊維の適度な可撓性が得られるため、繊維が適度に交絡しやすい傾向がある。
なお、金属繊維の平均繊維径は不織布とするのに支障がない範囲内において小さい方が金属繊維不織布の均質性を高め易くなるため好ましい。
また、本明細書における「平均繊維径」とは、顕微鏡で撮像された金属繊維不織布の長手方向に対する任意の垂直断面における、金属繊維の断面積を算出し(例えば、公知ソフトにて算出する。)、当該断面積と同一面積を有する円の直径を算出することにより導かれた面積径の平均値(例えば、20個の繊維の平均値)である。
円形断面の金属繊維は、例えば、角柱断面を有する繊維よりも、応力に対して曲がりが生じやすく、かつ応力を受ける箇所に対して、金属繊維の曲がり度合いに差が生じ難いため、曲がり度合いも均質化する傾向がある。
例えば後述する湿式法で金属繊維不織布を作製した場合、円形断面の金属繊維はスラリー攪拌羽根等との接触により、曲部を生じやすい。曲部を有する金属繊維同士が適度に交絡することで、金属繊維不織布の均質性を高めやすくなる傾向がある。
平均繊維長が1mm~10mmの範囲であると、例えば、抄造によって本発明の金属繊維不織布を作製する場合に、いわゆる金属繊維のダマを生じにくく、金属繊維の分散の度合いを制御しやすくなると共に、金属繊維同士が適度に交絡するため、金属繊維不織布のハンドリング強度向上効果をも発揮しやすくなる。
なお、本明細書における「平均繊維長」とは、顕微鏡で20本を測定し、測定値を平均した値である。
なお、本明細書における「金属繊維不織布の厚み」とは、空気による端子落下方式の膜厚計(例えば、ミツトヨ社製:デジマチックインジケータID-C112X)で例えば、金属繊維不織布の任意の数測定点を測定した場合の平均値をいう。
本明細書における「金属繊維不織布における繊維の占積率」とは、金属繊維不織布の体積に対して繊維が存在する部分の割合である。
単一金属繊維のみから金属繊維不織布が構成される場合、金属繊維不織布の坪量と厚み、及び金属繊維の真密度から以下の式により算出される。
占積率(%)=金属繊維不織布の坪量/(金属繊維不織布の厚み×金属繊維の真密度)×100
なお、金属繊維不織布が、他の金属繊維や金属繊維以外の繊維を含む場合には、組成比率を反映した真密度値を採用することで占積率を算出することができる。
本発明の金属繊維不織布は、1cm2当たりのJIS Z8101(ISO 3534)に規定する坪量の変動係数(CV値)が10%以下である。坪量の変動係数の求め方は、例えば以下の方法による。
2.前記各個片を高精度分析天秤(例えば、エー・アンド・アイ社製、商品名:BM-252)で秤量し、質量を求める。
3.個片が厳密な正方形ではない可能性を考慮して、平行する2辺の中央付近の距離を測定し、その測定値を縦長、横長とする。
4.前記縦長、横長から各個片の面積を算出する。
5.前記質量を、前記面積で割ることによって各個片の坪量を算出する。
6.全個片の坪量の標準偏差を平均値で割り、100を乗じて金属繊維不織布個片の坪量の変動係数(CV値)を算出する。
なお、個片数は例えば100個以上を測定することで変動係数の安定化がはかれる。また、計測対象の金属繊維不織布が1cm2に満たない場合には、1cm2に換算した値を変動係数(CV値)とすればよい。
具体的には、金属繊維不織布を金属のみで形成する場合、平均繊維長が1mm~10mm、好ましくは、3mm~5mmであり、平均繊維径が1μm~30μmであり、さらに好ましくは2μm~20μmである金属繊維を用いることが好ましい。
本発明の金属繊維不織布を得る方法としては、金属繊維または金属繊維を主体としたウェブを圧縮成形する乾式法や、金属繊維または金属繊維を主体とする原料を用いた湿式抄造法を採用できる。
乾式法により、本発明の金属繊維不織布を得る場合には、カード法、エアレイド法等により得られた金属繊維または金属繊維を主体とするウェブを圧縮成形する。この時、繊維同士を結着させるために繊維間にバインダーを含浸させてもよい。
かかるバインダーとしては、特に限定されないが、例えば、アクリル系接着剤、エポキシ系接着剤、ウレタン系接着剤などの有機系バインダーの他に、コロイダルシリカ、水ガラス、ケイ酸ソーダなどの無機質接着剤を用いることができる。
なお、バインダーを含浸させる代わりに、繊維の表面に熱接着性樹脂を予め被覆しておき、金属繊維または金属繊維を主体とする集合体を積層した後に加圧・加熱圧縮しても良い。
また、金属繊維等を水中に分散させて、これを抄き上げる湿式抄造法により本発明の金属繊維不織布を作製することもできる。
金属繊維不織布の製造方法としては、金属繊維等の繊維状物を水中分散等して抄造スラリーを作製する工程、抄造スラリーから湿体シートを得る抄造工程、湿体シートを脱水させる脱水工程、脱水後のシートを乾燥して、乾燥シートを得る乾燥工程、および乾燥シートを構成する金属繊維等を結着させる結着工程を少なくとも具備する。
なお、脱水工程と乾燥工程の間、乾燥工程と結着工程の間、結着工程後にシート状物をプレスするプレス工程を実施しても良い。
以下、工程ごとに説明する。
(スラリー作製工程)
例えば攪拌ミキサーを用いて金属繊維のスラリー、または金属繊維と金属繊維以外の繊維状物とを含有するスラリーを調製し、これに填料、分散剤、増粘剤、消泡剤、紙力増強剤、サイズ剤、凝集剤、着色剤、定着剤等を適宜添加する。
上記金属繊維以外の繊維状物としては、ポリエチレン樹脂およびポリプロピレン樹脂等のポリオレフィン樹脂、ポリエチレンテレフタレ-ト(PET)樹脂、ポリビニルアルコ-ル(PVA)樹脂、ポリ塩化ビニル樹脂、アラミド樹脂、ナイロン、アクリル系樹脂等を挙げることができる。
これら樹脂の繊維状物は、加熱溶融により結着性を発揮するためスラリー中に添加することもできる。
しかしながら、焼結によって金属繊維間に結着部を設ける場合には、金属繊維間に有機繊維等の存在が無い方が、結着部を確実に設けやすいため好ましい。
また、攪拌ミキサー中のスラリーは、真密度の大きな金属繊維がミキサー底面に沈降しやすい傾向にある。このため、金属繊維比率が比較的安定した底面付近を除いたスラリーを抄造スラリーとして用いることが好ましい。
次に前記スラリーを用いて、抄紙機にて湿式抄造する。抄紙機としては、円網抄紙機、長網抄紙機、短網抄紙機、傾斜型抄紙機、これらの中から同種又は異種の抄紙機を組み合わせてなるコンビネーション抄紙機などを用いることができる。
(脱水工程)
次に、抄紙後の湿紙を、脱水する。
脱水時には、脱水の水流量(脱水量)を抄造網の面内、幅方向等で均一化することが好ましい。水流量を一定にすることで、脱水時の乱流等が抑えられ、金属繊維が抄造網へ沈降する速度が均一化されるため、均質性の高い金属繊維不織布を得易くなる。脱水時の水流量を一定にするためには、抄造網下の水流の障害となる可能性のある構造物を排除すればよい。
脱水後、エアードライヤー、シリンダードライヤー、サクションドラムドライヤー、赤外方式ドライヤー等を用いて乾燥する。このような工程を経て金属繊維を含有するシートを得ることができる。
次に、シート中の金属繊維同士を結着させる。結着方法としては、金属繊維不織布を焼結する方法、化学エッチングにより結着する方法、レーザー溶着する方法、IH加熱を利用して結着する方法、ケミカルボンド法、サーマルボンド法等を用いることができる。このような方法の中でも、結着が確実に行われることで、金属繊維間が固定され、例えば坪量の変動係数(CV値)が容易に安定するため、金属繊維不織布を焼結する方法が好適に用いられる。
なお、上記工程以外に、下記工程を採用することもできる。
(繊維交絡処理工程)
抄造工程後の抄造網上の水分を含んだ湿体シートを形成している金属繊維または金属繊維を主体とした繊維を互いに交絡させる繊維交絡処理工程を施してもよい。
ここで、繊維交絡処理工程としては、湿体シート面に高圧ジェット水流を噴射する繊維交絡処理工程が好ましい。具体的には、シートの流れ方向に対して直交する方向に複数のノズルを配列し、この複数のノズルから同時に高圧ジェット水流を噴射することにより、シート全体に亘って金属繊維または金属繊維を主体とする繊維同士を交絡させることが可能である。前記工程を経た後、湿体シートは、乾燥工程を経て巻取り等される。
上述したように、プレス工程は、脱水工程と乾燥工程の間、乾燥工程と結着工程の間、および/または結着工程後に実施することができる。特に、結着工程後にプレス工程を実施することによって、その後の繊維交絡処理工程に於いて金属繊維間に結着部を設けやすい。これにより、金属繊維不織布の均質性をさらに向上させることができるため好ましい。
また、プレスは加熱下で実施しても、非加熱下で実施しても良い。しかしながら、金属繊維不織布が加熱溶融する有機繊維等を含んでいる場合には、その溶融開始温度以上での加熱が有効である。
金属繊維不織布が金属繊維のみで構成される場合には、加圧のみでも良い。圧力は、金属繊維不織布の厚みを考慮して適宜設定すれば良いが、例えば厚み170μm程度の金属繊維不織布の場合、線圧300kg/cm未満、好ましくは250kg/cm未満で実施することで、金属繊維不織布に均質性を与え易くなるため好ましい。また、このプレス工程により、金属繊維不織布における金属繊維の占積率を調整することもできる。
繊維がランダムに交絡した金属繊維不織布は、厚み方向に圧縮されることで厚み方向だけではなく、面方向にも繊維のシフトが生じる。これにより、焼結時には空隙だった場所にも金属繊維が配置しやすくなる効果が期待でき、その状態は金属繊維の有する塑性変形特性によって維持される。
プレス(加圧)時の圧力は、金属繊維不織布の厚みを考慮して適宜設定すれば良い。このようにして作製される金属繊維焼結不織布の抵抗値は、金属繊維の種類、厚み、密度等により任意に調整可能であるが、銅繊維を焼結させて得られたシート状の金属繊維不織布の抵抗値は、例えば1.3mΩ/□程度である。
次に、本発明に係る金属繊維不織布の用途について説明する。
本発明の金属繊維不織布は、用いる金属の種類等により、幅広い用途に使用することができる。例えばステンレス繊維を使用した全音響透過材としてマイクロホンの風防や、電磁波抑制等を目的とした電子回路基板に用いる電磁波ノイズ対策部材、半導体の発熱対策として半導体チップ接合用の半田中に用いる銅繊維不織布伝熱材等を挙げることができる。しかしながら、これら以外にも、建材、車両、航空機、船舶等の放熱、加熱、電磁波対策用途等に幅広く使用することができる。
(実施例1)
直径が18.5μm、平均繊維長が10mm、断面形状が略円環状の銅繊維を水中で分散し、増粘剤を適宜添加して抄造スラリーとした。次いでこの抄造スラリーのミキサー底部に位置する銅繊維濃度の高い部分を取り除いた抄造スラリーを得た。得られた抄造スラリー、坪量300g/m2を抄造網上に投入し、脱水・乾燥を経て銅繊維不織布を得た。
その後、得られた銅繊維不織布を、常温で線圧80kg/cmでプレスした後、水素ガス75%、窒素ガス25%の雰囲気中で1,020℃、40分間加熱して銅繊維間を部分的に焼結させて、実施例1の銅繊維不織布を得た。得られた銅繊維不織布の厚みは310μmであった。
次に、得られた銅繊維不織布を24cm×18cmに裁断し、図3のマッピング図の点線部で1cm2に裁断し、1~24、A~S(Iを除く)で区画される計432個の個片4を得た。この個片4の質量と、面積の測定値から、各個片4の坪量等を算出した。全個片4の標準偏差と平均値から算出した坪量の変動係数は、9.1であり、銅繊維の平均占積率は11.0%であった。
銅繊維の平均繊維長を5mmとしたこと以外は、実施例1と同様にして、厚み303μm、平均占積率12.7%の実施例2の銅繊維不織布個片を得た。実施例1と同様の方法で算出した坪量の変動係数は8.8であった。
銅繊維の平均繊維長を3mmとしたこと以外は、実施例1と同様にして、厚み229μm、平均占積率10.3%の実施例3の銅繊維不織布個片を得た。実施例1と同様の方法で算出した坪量の変動係数は5.2であった。
抄造スラリーのミキサー底部の銅繊維濃度の高い部分を取り除かず、焼結後に厚み方向に240kg/cmの荷重でプレスしたこと以外は、実施例2と同様にして、厚み102μm、平均占積率34.5%の実施例4の銅繊維不織布個片を得た。実施例1と同様の方法で算出した坪量の変動係数は5.8であった。
長銅繊維束を切断する前に、各繊維を充分にほぐし、脱水時に、抄造網下の水流の障害となる可能性のある構造物を排除し、脱水時の乱流を抑制した状態で抄造したこと以外は、実施例4と同様にして、厚み101μm、平均占積率33.5%の実施例6の銅繊維不織布個片を得た。実施例1と同様の方法で算出した坪量の変動係数は3.9であった。
長繊維をほぐさずに束ねて切断した繊維の直径が18.5μm、平均繊維長が10mm、断面形状が略円環状の銅繊維を水中に分散し、増粘剤を適宜添加して抄造スラリーとした。この抄造スラリーを用いて、坪量300g/m2を目安に抄き網上に投入し、脱水・乾燥して、比較例1の銅繊維不織布を得た。その後、同不織布を、常温で線圧80kg/cmでプレス後、水素ガス75%、窒素ガス25%の雰囲気中で1020℃、40分間加熱して金属繊維間を焼結させて、比較例1の銅繊維不織布を得た。得られた銅繊維不織布の厚さは284μmであった。実施例1と同様の方法で算出した坪量の変動係数は17.2、平均占積率は11.9%であった。
繊維の直径が2μm、平均繊維長が3mm、断面形状が不定形のステンレス繊維と、PVA繊維(商品名:フィブリボンドVPB105、クラレ社製)とを、重量比98:2の割合で水中で分散し、増粘剤を適宜添加して抄造スラリーとした。この抄造スラリーのミキサー底部のステンレス繊維濃度の高い部分を取り除いた抄造スラリーを用いて、坪量50g/m2を目安に抄造網上に投入し、脱水・乾燥を経てステンレス繊維不織布を得た。その後、同不織布を、常温で線圧80kg/cmでプレス後、水素ガス75%、窒素ガス25%の雰囲気中で1,120℃、60分間加熱してステンレス繊維間を部分的に焼結させて、実施例6のステンレス繊維不織布を得た。得られたステンレス繊維不織布の厚みは152μmであった。
次に、得られたステンレス繊維不織布を24cm×18cmに裁断し、図3のマッピング図の点線部で1cm2に裁断し、1~24、A~S(Iを除く)で区画される計432個の個片を得た。この個片の質量と、面積の測定値から、各個片の坪量等を算出した。全個片の標準偏差と平均値から算出した坪量の変動係数は、2.3、ステンレス繊維の平均占積率は4.0%であった。
ステンレス繊維の平均繊維径を8μmとしたこと以外は、実施例6と同様にして、厚み85μm、平均占積率7.8%の実施例7のステンレス繊維不織布個片を得た。実施例6と同様の方法で算出した坪量の変動係数は3.7であった。
焼結後に厚み方向に240kg/cmの荷重でプレスを実施し、坪量300g/m2を目安としたこと以外は、実施例7と同様にして、厚み111μm、平均占積率33.7%の実施例8のステンレス繊維不織布個片を得た。実施例6と同様の方法で算出した坪量の変動係数は7.1であった。
実施例、比較例で得られた銅繊維不織布を24cm×18cmに裁断したサンプルの厚みは、ミツトヨ製デジマチックインジケータID-C112Xを用いて、直径15mmの測定端子にて測定した。得られた不織布の厚さを9箇所で測定し、その平均値を厚みとした。
実施例、比較例で得られた計432個の銅繊維不織布個片の寸法は、最小読取値0.05mmのノギスを使用して以下の要領で測定した。個片が厳密な正方形ではない可能性を考慮して、平行する2辺の中央付近の距離を前記ノギスで測定し、その測定値を縦長、横長とし、縦長と横長から各個片の面積を算出した。
実施例、比較例で得られた計432個の銅繊維不織布個片の質量は、高精度分析天秤(エー・アンド・アイ社製、商品名:BM-252)で秤量した。
実施例、比較例で得られた計432個の銅繊維不織布個片の坪量の変動係数は、前記面積と質量から各個片の坪量を算出し、計432点の標準偏差を平均値で割ることで算出した。
実施例、比較例で得られた銅繊維不織布個片の占積率は以下の通り算出した。
占積率(%)=銅繊維不織布の坪量/(銅繊維不織布の厚さ×銅繊維の真密度)×100
計432点の算術平均を、占積率の平均値とした。
図6に示す個片抵抗測定要領にて、各個片の電圧と電流を測定し、下記数1からvan der Pauw法により、シート抵抗値を算出した。なお、図6中、参照番号4は、銅繊維不織布個片を示す。
電源:PA250-0.25A(KENWOOD社製)
電圧計:KEITHLEY DMM7510 7 1/2 DIGIT MULTIMETER(Tektronix社製)
2 結着部
3 ダマ部
4 個片
Claims (5)
- 金属繊維間が結着してなり、
1cm2当たりの、JIS Z8101(ISO 3534)に規定する坪量の変動係数(CV値)が10%以下であることを特徴とする金属繊維不織布。 - 前記金属繊維の平均繊維長が1~10mmであることを特徴とする請求項1に記載の金属繊維不織布。
- 前記金属繊維の占積率の平均値が5%~50%であることを特徴とする請求項1または2に記載の金属繊維不織布。
- 前記金属繊維が銅繊維であることを特徴とする請求項1乃至3いずれか一項に記載の金属繊維不織布。
- 電子部品用部材であることを特徴するする請求項1乃至4いずれか一項に記載の金属繊維不織布。
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WO2024048565A1 (ja) * | 2022-08-30 | 2024-03-07 | 三井金属鉱業株式会社 | 金属不織布及びそれを用いてなる電極 |
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CN110670241B (zh) * | 2019-10-17 | 2024-03-29 | 东华大学 | 电子香烟导液芯用混合纤维无纺毡及其制备方法 |
CN113684608B (zh) * | 2021-09-02 | 2023-03-28 | 前沿新材料研究院(深圳)有限公司 | 非织造布以及电磁屏蔽膜 |
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