JP2000080547A - Method for producing laminated sheet comprising alumina fiber precursor - Google Patents
Method for producing laminated sheet comprising alumina fiber precursorInfo
- Publication number
- JP2000080547A JP2000080547A JP19147899A JP19147899A JP2000080547A JP 2000080547 A JP2000080547 A JP 2000080547A JP 19147899 A JP19147899 A JP 19147899A JP 19147899 A JP19147899 A JP 19147899A JP 2000080547 A JP2000080547 A JP 2000080547A
- Authority
- JP
- Japan
- Prior art keywords
- alumina fiber
- sheet
- fiber precursor
- laminated sheet
- spinning
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000000835 fiber Substances 0.000 title claims abstract description 100
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 title claims abstract description 95
- 239000002243 precursor Substances 0.000 title claims abstract description 61
- 238000004519 manufacturing process Methods 0.000 title claims description 18
- 238000009987 spinning Methods 0.000 claims abstract description 44
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 11
- -1 aluminum compound Chemical class 0.000 claims abstract description 9
- 238000000034 method Methods 0.000 claims description 18
- 238000010304 firing Methods 0.000 claims description 9
- 239000000463 material Substances 0.000 claims description 8
- 239000000203 mixture Substances 0.000 claims description 5
- 229910018072 Al 2 O 3 Inorganic materials 0.000 claims description 4
- 239000000243 solution Substances 0.000 description 18
- 238000007664 blowing Methods 0.000 description 7
- VSCWAEJMTAWNJL-UHFFFAOYSA-K aluminium trichloride Chemical compound Cl[Al](Cl)Cl VSCWAEJMTAWNJL-UHFFFAOYSA-K 0.000 description 6
- 239000003054 catalyst Substances 0.000 description 6
- 230000000052 comparative effect Effects 0.000 description 5
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 4
- 238000007796 conventional method Methods 0.000 description 4
- 239000004372 Polyvinyl alcohol Substances 0.000 description 3
- 229910004298 SiO 2 Inorganic materials 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 239000007864 aqueous solution Substances 0.000 description 3
- 230000007423 decrease Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 229920002451 polyvinyl alcohol Polymers 0.000 description 3
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 238000010030 laminating Methods 0.000 description 2
- 229910052710 silicon Inorganic materials 0.000 description 2
- 239000010703 silicon Substances 0.000 description 2
- 239000002202 Polyethylene glycol Substances 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 235000014113 dietary fatty acids Nutrition 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 229930195729 fatty acid Natural products 0.000 description 1
- 230000009970 fire resistant effect Effects 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000012774 insulation material Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 150000002736 metal compounds Chemical class 0.000 description 1
- 239000002480 mineral oil Substances 0.000 description 1
- 235000010446 mineral oil Nutrition 0.000 description 1
- 229920000620 organic polymer Polymers 0.000 description 1
- 229920001223 polyethylene glycol Polymers 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000000746 purification Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 229920003169 water-soluble polymer Polymers 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Landscapes
- Nonwoven Fabrics (AREA)
Abstract
(57)【要約】
【課題】 全体に亘って均一な目付け量を有するアルミ
ナ繊維前駆体から成る積層シートを提供する。
【解決手段】 アルミニウム化合物を主体とする溶液を
紡糸して得たアルミナ繊維前駆体を、集積装置上に降り
積らせてアルミナ繊維前駆体の薄層シートを形成し、こ
の薄層シートを集積装置から連続的に引出し、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。
(57) Abstract: Provided is a laminated sheet comprising an alumina fiber precursor having a uniform basis weight throughout. SOLUTION: An alumina fiber precursor obtained by spinning a solution mainly containing an aluminum compound is dropped on an accumulating device to form a thin sheet of the alumina fiber precursor, and this thin sheet is accumulated. It is continuously pulled out from the device, folded to a predetermined width, and continuously moved in a direction perpendicular to the folding direction while being stacked.
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、アルミニウム化合
物を含む紡糸液を紡糸して得たアルミナ繊維前駆体より
なる積層シートの製造方法に関する。詳しくは本発明
は、全体に亘って均一な目付け量を有するアルミナ繊維
前駆体よりなる積層シートの製造方法に関する。この積
層シートを焼成して得られるアルミナ繊維シートは、高
温においても優れた耐火断熱性、機械的強度、化学的安
定性を有し、高温耐火断熱材、高温クッション材などと
して使用される。The present invention relates to a method for producing a laminated sheet comprising an alumina fiber precursor obtained by spinning a spinning solution containing an aluminum compound. More specifically, the present invention relates to a method for producing a laminated sheet made of an alumina fiber precursor having a uniform basis weight throughout. An alumina fiber sheet obtained by firing this laminated sheet has excellent fire insulation properties, mechanical strength, and chemical stability even at high temperatures, and is used as a high-temperature fire-resistant insulation material, a high-temperature cushioning material, and the like.
【０００２】[0002]
【従来の技術】アルミニウム化合物を含む紡糸液を紡糸
してアルミナ繊維前駆体を形成し、これを焼成してアル
ミナ繊維とする方法は公知である。この方法は、溶融繊
維化法が困難であるアルミナ含有量が約６５重量％を越
えるようなアルミナ繊維の製造に特に好適である。紡糸
液としては、アルミニウム化合物を主体とし、これに種
々の補助成分を含有させたものが用いられている。補助
成分には、金属化合物のように最終的に得られるアルミ
ナ繊維の構成要素となるものと、水溶性高分子化合物の
ように紡糸液の性状を調整するためのものとがある。例
えば、塩酸にアルミニウムを溶解して得られる塩基性塩
化アルミニウム水溶液に、シリカゾルとポリビニルアル
コールとを添加して調製した紡糸液が用いられる。2. Description of the Related Art It is known that an alumina fiber precursor is formed by spinning a spinning solution containing an aluminum compound, and the precursor is calcined to obtain alumina fibers. This method is particularly suitable for the production of alumina fibers having an alumina content of more than about 65% by weight, which is difficult to melt and fibrillate. As the spinning solution, a solution mainly containing an aluminum compound and containing various auxiliary components is used. Auxiliary components include those that are components of alumina fibers finally obtained, such as metal compounds, and those that adjust the properties of the spinning solution, such as water-soluble polymer compounds. For example, a spinning solution prepared by adding silica sol and polyvinyl alcohol to a basic aluminum chloride aqueous solution obtained by dissolving aluminum in hydrochloric acid is used.
【０００３】紡糸液からアルミナ繊維前駆体を紡糸する
方法としては、ブローイング法や遠心力を用いるスピン
ドル法が知られているが、一般にはブローイング法が用
いられている。このブローイング法では、高速の紡糸気
流中にノズルから紡糸液を供給する。紡糸液は紡糸気流
中で引伸ばされ、かつ、水分を失って固化してアルミナ
繊維前駆体となる。[0003] As a method of spinning an alumina fiber precursor from a spinning solution, a blowing method and a spindle method using centrifugal force are known, but the blowing method is generally used. In this blowing method, a spinning solution is supplied from a nozzle into a high-speed spinning airflow. The spinning solution is stretched in a spinning air flow, and loses moisture to solidify to form an alumina fiber precursor.
【０００４】形成されたアルミナ繊維前駆体は集積し
て、所定の目付け量、すなわち単位面積当りの重量を有
するアルミナ繊維前駆体シートとする。この前駆体シー
トそのものは、それを構成するアルミナ繊維前駆体は柔
軟性を有するが、繊維強度が低く、また、繊維中に構造
水や原料添加物が含まれ不安定であるため、通常、その
まま商品になりうるものではない。そこで、アルミナ繊
維前駆体シートを焼成して、安定な酸化物状態で結晶性
の高いアルミナ繊維シートとする必要がある。また、焼
成前に前駆体シートにニードリングを施すことにより、
機械的強度に優れたアルミナ繊維シートが得られる（特
公平１−３８９０１、特公平６−６７７８０等参照）。The formed alumina fiber precursor is accumulated to form an alumina fiber precursor sheet having a predetermined basis weight, that is, a weight per unit area. This precursor sheet itself has flexibility of the alumina fiber precursor constituting it, but has a low fiber strength and is unstable since structural water and raw material additives are contained in the fiber. It cannot be a product. Therefore, it is necessary to sinter the alumina fiber precursor sheet to obtain a highly oxidized alumina fiber sheet in a stable oxide state. Also, by needling the precursor sheet before firing,
An alumina fiber sheet having excellent mechanical strength can be obtained (see Japanese Patent Publication No. 1-38901, Japanese Patent Publication No. 6-67780).
【０００５】アルミナ繊維前駆体を集積して所定の目付
け量（単位面積当たりの繊維重量）を有するアルミナ繊
維前駆体シートを製造する方法としては、紡糸気流中の
アルミナ繊維前駆体を、所定の目付け量のシートが形成
されるまで集積装置上に降り積らせる方法がある。例え
ば、無端ベルトを回転させつつその上にアルミナ繊維前
駆体を降り積らせる。次に、降り積もって形成されたア
ルミナ繊維前駆体シートを、無端ベルト上から順次引出
す。As a method of manufacturing an alumina fiber precursor sheet having a predetermined basis weight (fiber weight per unit area) by accumulating the alumina fiber precursor, the alumina fiber precursor in a spinning air stream is subjected to a predetermined basis weight. There is a method of landing on an accumulation device until a quantity of sheets is formed. For example, an endless belt is rotated while an alumina fiber precursor is deposited thereon. Next, the alumina fiber precursor sheets formed by stacking are sequentially pulled out from the endless belt.
【０００６】また、別の方法としては紡糸気流中のアル
ミナ繊維前駆体を集積装置上に所定の目付け量のシート
よりも著しく薄い薄層シートとして降り積らせ、この薄
層シートを次工程でドラムなどの回転体上に所定の目付
け量のシートが形成されるまで何重にも巻回する方法が
ある。その代表的な方法では、金網製など易通気性の無
端ベルトを回転させつつ、これにアルミナ繊維前駆体を
含む紡糸気流をほぼ直角に衝突させる。紡糸気流は無端
ベルトを通過するが、アルミナ繊維前駆体は無端ベルト
上に捕集されて薄層シートを形成する。この薄層シート
を無端ベルト上から引出し、回転体上に所定の目付け量
のシートが形成されるまで何層にも巻付ける。その後、
回転体に巻き付けた積層シートのロールを切り出して展
開し、次の焼成等の工程にかける。[0006] As another method, the alumina fiber precursor in the spinning air stream is deposited on an accumulator as a thin sheet much thinner than a sheet having a predetermined basis weight, and this thin sheet is used in the next step. There is a method of winding multiple times until a sheet having a predetermined basis weight is formed on a rotating body such as a drum. In a typical method, a spinning airflow containing an alumina fiber precursor is caused to collide with the endless belt made of a wire mesh at substantially right angles while rotating the endless belt. While the spinning air stream passes through the endless belt, the alumina fiber precursor is collected on the endless belt to form a thin sheet. The thin sheet is pulled out from the endless belt, and wound in multiple layers until a sheet having a predetermined basis weight is formed on the rotating body. afterwards,
The roll of the laminated sheet wound around the rotating body is cut out and developed, and is subjected to the next step such as firing.
【０００７】[0007]
【発明が解決しようとする課題】上記の方法によれば紡
糸気流からのアルミナ繊維前駆体の捕集が容易である
が、シートの形成操作が回分式となって煩雑であり、か
つ、シートの長さも回転体の外周の長さにより定まるの
で、任意の長さのシートを形成することはできない。ま
た、以上の従来法の問題点の一つとして、形成されたア
ルミナ繊維前駆体シートの目付け量がその幅方向におい
て不均一であり、特に両端部においては目付け量が小さ
いことが挙げられる。これは紡糸気流中から集積装置上
にアルミナ繊維前駆体を降り積らせる際に、集積装置の
幅全体に亘って均一に降り積らず、特に幅方向の両端部
に降り積る量が相対的に少ないためである。According to the above-mentioned method, the alumina fiber precursor can be easily collected from the spinning air stream, but the operation for forming the sheet is a batch type, and the operation is complicated. Since the length is also determined by the length of the outer periphery of the rotating body, a sheet of an arbitrary length cannot be formed. One of the problems of the above conventional method is that the basis weight of the formed alumina fiber precursor sheet is not uniform in the width direction, and the basis weight is particularly small at both ends. This is because when the alumina fiber precursor is deposited on the accumulator from the spinning air stream, it does not fall uniformly over the entire width of the accumulator. It is because there is little.
【０００８】アルミナ繊維前駆体シートの目付け量が幅
方向で不均一であり、特にその両端部において小さいこ
とは、これを焼成して得られるアルミナ繊維シートの幅
方向の目付け量も同様に変動していることを意味する。
ところで、商品としてのアルミナ繊維シートは全体が均
一な目付け量であることが要求されるので、目付け量が
所定値より小さい幅方向の両端部分は、かなり多目に切
除せざるを得ず、アルミナ繊維シートの歩留り低下をも
たらす。また、両端部を切除しても、目付け量が規定の
範囲外の部分が存在するものは、規格外品として処分し
なければならない。The fact that the basis weight of the alumina fiber precursor sheet is non-uniform in the width direction and particularly small at both ends thereof means that the basis weight in the width direction of the alumina fiber sheet obtained by firing this sheet also fluctuates. Means that.
By the way, since the alumina fiber sheet as a product is required to have a uniform basis weight as a whole, both ends in the width direction in which the basis weight is smaller than a predetermined value have to be considerably cut off. The yield of the fiber sheet is reduced. Further, even if both ends are cut off, if there is a portion where the basis weight is outside the specified range, it must be disposed of as a nonstandard product.
【０００９】特に、近年においては、アルミナ繊維シー
トを排ガス浄化装置用把持材や耐熱性フィルターなどの
用途への使用が注目されており、かかる用途においては
従来の用途以上にシートの厚み精度の向上が求められ
る。例えば、内燃機関では排ガス処理のために、排ガス
の流露に触媒ケーシング内にハニカム型触媒を収容した
浄化装置を設置している。このハニカム型触媒を触媒ケ
ーシング内に把持するには、ハニカム触媒の全周に把持
材をできるだけ均一な厚さに巻き付けて触媒ケーシング
内に収容し、把持材の復元力によりケーシング内壁に密
着固定される必要がある。かかる把持材としては、高温
おいても繊維の脆化が起こらず、適当な面圧を維持でき
るものが望ましく、特開平７ー２８６５１４号では、ア
ルミナ繊維シートの中でも、特に、組成がＡｌ2 Ｏ3：
ＳｉＯ2 ＝７０〜７４：３０〜２６（重量比）のアルミ
ナ繊維を積層してニードリングが施されたシートが望ま
しい旨が開示されている。In particular, in recent years, attention has been focused on the use of alumina fiber sheets for applications such as gripping materials for exhaust gas purification devices and heat resistant filters. In such applications, the sheet thickness accuracy is improved more than conventional applications. Is required. For example, in an internal combustion engine, for exhaust gas treatment, a purifying device in which a honeycomb type catalyst is accommodated in a catalyst casing for the flow of exhaust gas is installed. In order to hold the honeycomb catalyst in the catalyst casing, the holding material is wound around the entire circumference of the honeycomb catalyst to a thickness as uniform as possible, and is accommodated in the catalyst casing. Need to be Such gripping member, also keep a high temperature does not occur embrittlement of the fiber, is desirable as it can maintain a suitable surface pressure, in Japanese Patent Laid-Open 7-2 No. 286,514, among alumina fiber sheet, in particular, composition Al 2 O 3 :
It is disclosed that a sheet which is obtained by laminating alumina fibers of SiO 2 = 70 to 74:30 to 26 (weight ratio) and subjected to needling is desirable.
【００１０】[0010]
【課題を解決するための手段】従って、本発明は幅方向
の全体に亘って均一な目付け量のアルミナ繊維前駆体シ
ートの製造方法を提供しようとするものである。そし
て、本発明は、アルミニウム化合物を主体とする溶液を
紡糸して得たアルミナ繊維前駆体を、集積装置上に降り
積らせてアルミナ繊維前駆体の薄層シートを形成し、こ
の薄層シートを集積装置から連続的に引出して折り畳み
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を
特徴とするアルミナ繊維前駆体よりなる積層シートの製
造方法に関する。SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a method for producing an alumina fiber precursor sheet having a uniform weight per unit area in the width direction. Further, the present invention provides an alumina fiber precursor obtained by spinning a solution mainly containing an aluminum compound, and deposits the alumina fiber precursor on an accumulator to form a thin sheet of the alumina fiber precursor. Is continuously pulled out from the accumulating device and sent to the folding device, and while being folded and stacked to a predetermined width, continuously moved in a direction perpendicular to the folding direction. It relates to a manufacturing method.
【００１１】[0011]
【発明の実施の形態】以下、発明を詳細に説明する。本
発明においては、紡糸液の調製及び紡糸液からのアルミ
ナ繊維前駆体の製造は、常法に従って行うことができ
る。紡糸液としては、例えば、塩酸にアルミニウムを溶
解して調製した塩基性塩化アルミニウム水溶液に、最終
的に得られるアルミナ繊維の組成が、Ａｌ2Ｏ3：ＳｉＯ
2（重量比）として、好ましくは６５〜９８：３５〜
２、特に好ましくは７０〜９７：３５〜３の範囲となる
ようにシリカゾルを添加する。珪素成分が多すぎると繊
維化は容易となるが耐熱性が著しく低下し、一方、珪素
成分が少なすぎると繊維が脆化しやすくなるからであ
る。更に、紡糸性を向上させるために、好ましくは、ポ
リビニルアルコール、ポリエチレングリコール、澱粉、
セルロース誘導体等の水溶性有機重合体を加え、場合に
よっては適宜濃縮操作を行い、粘度を通常１０〜１００
ポイズに調整したものが用いられる。DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail. In the present invention, preparation of a spinning solution and production of an alumina fiber precursor from the spinning solution can be performed according to a conventional method. As a spinning solution, for example, a basic aluminum chloride aqueous solution prepared by dissolving aluminum in hydrochloric acid is mixed with a final alumina fiber composition of Al 2 O 3 : SiO 2.
2 (weight ratio), preferably 65-98: 35-
2, particularly preferably, silica sol is added in a range of 70 to 97:35 to 3. If the silicon content is too large, fiberization becomes easy, but the heat resistance is remarkably reduced. On the other hand, if the silicon content is too small, the fibers tend to be brittle. Further, in order to improve spinnability, preferably, polyvinyl alcohol, polyethylene glycol, starch,
A water-soluble organic polymer such as a cellulose derivative is added, and in some cases, an appropriate concentration operation is performed, and the viscosity is usually 10 to 100.
The one adjusted to poise is used.
【００１２】紡糸液からのアルミナ繊維前駆体の形成
は、高速の紡糸気流中に紡糸液を供給するブローイング
法によるのが好ましい。なお、ブローイング法のノズル
には、紡糸気流を発生する気流ノズル中に紡糸液ノズル
を内装したものと、紡糸気流の外から紡糸液を供給する
ように紡糸液ノズルを設置したものとがあるが、いずれ
を用いることもできる。上述のブローイング法により紡
糸した場合には、金網製の無端ベルトを、紡糸気流に対
してほぼ直角となるように設置し、これを回転させつ
つ、これに形成されたアルミナ繊維前駆体を含む紡糸気
流を衝突させる方法によるのが好ましい。この紡糸によ
り形成されたアルミナ繊維前駆体は、その太さが通常数
μｍであり、長さが数十ｍｍ〜数百ｍｍである。The formation of the alumina fiber precursor from the spinning solution is preferably performed by a blowing method in which the spinning solution is supplied into a high-speed spinning air stream. There are two types of blowing method nozzles: a spinning nozzle that is provided inside a spinning nozzle that generates a spinning airflow, and a spinning nozzle that is installed to supply a spinning liquid from outside the spinning airflow. And any of them can be used. In the case of spinning by the above-described blowing method, an endless belt made of wire mesh is installed so as to be substantially perpendicular to the spinning airflow, and while spinning, the spinning including the alumina fiber precursor formed thereon is performed. It is preferable to use a method of impinging an air current. The alumina fiber precursor formed by this spinning has a thickness of usually several μm and a length of several tens mm to several hundred mm.
【００１３】集積装置上に形成されたアルミナ繊維前駆
体の薄層シートは、集積装置から連続的に引出して折り
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。
言い換えれば、薄層シートは集積装置から連続的に引出
し、薄層シートの進行方向に折り畳んで積み重ねつつ、
折り畳み方向に対して横方向に連続的に移動させる。従
って、折り畳む幅は形成しようとする積層シートの幅と
等しくなる。これにより薄層シートの幅方向の両端部は
形成される積層シート内に分散されるので、積層シート
の目付け量は積層シート全体に亘って均一となる。[0013] The thin sheet of alumina fiber precursor formed on the accumulating device is continuously pulled out from the accumulating device, sent to a folding device, folded to a predetermined width, and stacked.
Move continuously in the direction perpendicular to the folding direction.
In other words, the thin sheet is continuously pulled out from the stacking device, and folded and stacked in the traveling direction of the thin sheet,
Move continuously in the transverse direction to the folding direction. Therefore, the folding width is equal to the width of the laminated sheet to be formed. As a result, both ends of the thin sheet in the width direction are dispersed in the laminated sheet to be formed, so that the basis weight of the laminated sheet is uniform over the entire laminated sheet.
【００１４】上記における薄層シートの目付量は、薄層
シートが最低限形成される必要があり、通常１０〜２０
０ｇ／ｍ2、好ましくは３０〜１００ｇ／ｍ2である。ま
た、この薄層シートはその幅方向及び長さ方向のいずれ
においても必ずしも均一ではないので、積層シートとし
ては、少なくとも５層以上、好ましくは８層以上、特に
好ましくは１０〜８０層の薄層シートを積み重ねて形成
する。これにより薄層シートの部分的な不均一が相殺さ
れて、全体に亘って均一な目付け量を有する積層シート
を得ることができる。なお、積層数の上限は特に制限は
ないが、シートが厚くなりすぎると、後工程で通常実施
されるニードリングによる厚み方向の剥離強度向上が不
十分になったり、あるいは、シートの生産性も低下する
のであまり好ましくない。The basis weight of the above-mentioned thin sheet is required to be at least as small as the thin sheet, and is usually from 10 to 20.
0 g / m 2, preferably from 30 to 100 g / m 2. In addition, since the thin sheet is not necessarily uniform in any of the width direction and the length direction, the laminated sheet has at least five or more layers, preferably eight or more layers, and particularly preferably 10 to 80 thin layers. The sheets are formed by stacking. Thereby, partial unevenness of the thin sheet is offset, and a laminated sheet having a uniform basis weight can be obtained throughout. The upper limit of the number of layers is not particularly limited, but when the sheet is too thick, the peel strength in the thickness direction due to needling usually performed in a subsequent step is insufficiently improved, or the productivity of the sheet also increases. It is not so preferable because it lowers.
【００１５】薄層シートを折り畳んで積み重ねて積層シ
ートとするには、薄層シートを集積装置から連続的に引
出して折り畳み装置に送り、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
動させるようにする。例えば、集積装置においては、回
転している金網状の無端ベルト上にアルミナ繊維前駆体
を積らせて薄層シートを形成させた後、この薄層シート
を無端ベルト上から引き出して折り畳み装置に送る。こ
の折り畳み装置においては、折り畳み方向に対してほぼ
直角方向に回転している無端ベルト上に所定の幅に折り
畳んで積み重ねていけばよい。なお、積層シートの積層
数は該無端ベルトの移動速度で決定され、遅くするほど
積層数が大きくなり、速くするほど積層数が小さくな
る。In order to fold the thin sheets and stack them into a laminated sheet, the thin sheets are continuously pulled out from the stacking device, sent to a folding device, folded into a predetermined width and stacked, and at right angles to the folding direction. Move continuously in the direction. For example, in an accumulator, a thin layer sheet is formed by laminating an alumina fiber precursor on a rotating wire mesh endless belt, and then the thin layer sheet is pulled out from the endless belt and fed to a folding device. send. In this folding device, it is sufficient that the folding device is folded to a predetermined width and stacked on an endless belt rotating in a direction substantially perpendicular to the folding direction. The number of stacked sheets is determined by the moving speed of the endless belt. The number of stacked sheets increases as the speed decreases, and the number of stacks decreases as the speed increases.
【００１６】図１はこのような本発明を実施するフロー
シートの１例を示す概念図である。薄層シート２を運搬
するための薄層シート搬送用無端ベルト１と、この無端
ベルトの後端部に、この無端ベルトよりも低い位置に且
つこの無端ベルトに対して横方向に設けた積層シート搬
送用無端ベルト５と、薄層シート用無端ベルトの後端部
から垂下する薄層シートを折り畳んで積層シート搬送用
無端ベルト５の上に積み重ねる折り畳み手段とを備えた
折り畳み装置３を用いる。この折り畳み装置３では図１
の矢印のように左右に可動し、その可動幅により積層シ
ートの幅が決定される。このような折り畳み装置を用い
れば、連続的に送られてくる薄層シートから、任意の幅
の積層シート４を連続的に製造することができる。ま
た、折り畳み装置の構造は図1のものに限定されるもの
ではなく、例えば、図２のような水平運動による縦型の
折り畳み装置も使用することができる。FIG. 1 is a conceptual diagram showing an example of such a flow sheet embodying the present invention. An endless belt 1 for transporting a thin sheet 2 for transporting a thin sheet 2, and a laminated sheet provided at a rear end of the endless belt at a position lower than the endless belt and in a lateral direction with respect to the endless belt. A folding device 3 including a transport endless belt 5 and folding means for folding a thin sheet hanging down from the rear end of the thin sheet endless belt and stacking the thin sheet on the laminated sheet transport endless belt 5 is used. In this folding device 3, FIG.
And the width of the laminated sheet is determined by its movable width. If such a folding device is used, a laminated sheet 4 having an arbitrary width can be continuously manufactured from a continuously fed thin layer sheet. Further, the structure of the folding device is not limited to that shown in FIG. 1, and for example, a vertical folding device by horizontal movement as shown in FIG. 2 can be used.
【００１７】このようにして製造されたアルミナ繊維前
駆体の積層シートは、常法により焼成することによりア
ルミナ繊維シートに転換される。焼成は、通常５００℃
以上、好ましくは１０００〜１３００℃で行われる。ま
た、焼成に先立ち、積層シートにニードリングを施す
と、アルミナ繊維がシートの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シートとすることができ
る。ニードリングの打数は通常１〜５０打／ｃｍ2であ
り、一般に打数が多いほど得られるアルミナ繊維シート
の嵩密度と剥離強度が大きくなる。The laminate sheet of the alumina fiber precursor thus produced is converted into an alumina fiber sheet by firing in a conventional manner. Baking is usually 500 ° C
As mentioned above, it is preferably carried out at 1000 to 1300 ° C. In addition, if needling is performed on the laminated sheet before firing, an alumina fiber sheet having high mechanical strength in which alumina fibers are oriented also in the thickness direction of the sheet can be obtained. The number of shots of needling is usually 1 to 50 shots / cm 2 , and the larger the number of shots, the larger the bulk density and peel strength of the obtained alumina fiber sheet.
【００１８】[0018]
【実施例】実施例１ 塩基性塩化アルミニウム（アルミニウム含有量７０ｇ／
ｌ、Ａｌ／Ｃｌ＝１．８（原子比））水溶液に、シリカ
ゾルを最終的に得られるアルミナ繊維の組成がＡｌ2 Ｏ
3 ：ＳｉＯ2 ＝７２：２８（重量比）となるように加
え、更に、ポリビニルアルコールを加えた後、濃縮し
て、粘度４０ポイズ、アルミナ・シリカ含量約３０重量
％の紡糸液を調製し、該紡糸液を用いてブローイング法
で紡糸した。形成されたアルミナ繊維前駆体を含む紡糸
気流を金網製の無端ベルトに衝突させてアルミナ繊維前
駆体を捕集し、目付約４０ｇ／ｍ2 の比較的不均一で、
かつアルミナ繊維前駆体が面内でランダムに配列してい
る幅１０５０ｍｍ薄層シートを得た。EXAMPLES Example 1 Basic aluminum chloride (aluminum content 70 g /
1, Al / Cl = 1.8 (atomic ratio) aqueous solution, the composition of alumina fiber which finally obtains silica sol is Al 2 O
3 : SiO 2 = 72: 28 (weight ratio), polyvinyl alcohol was further added, and the mixture was concentrated to prepare a spinning solution having a viscosity of 40 poise and an alumina / silica content of about 30% by weight. The spinning solution was spun by a blowing method. The formed spinning airflow containing the alumina fiber precursor was collided with an endless belt made of wire mesh to collect the alumina fiber precursor, and was relatively non-uniform with a basis weight of about 40 g / m 2 ,
In addition, a 1050 mm-wide thin sheet in which alumina fiber precursors were randomly arranged in the plane was obtained.
【００１９】この薄層シートを図１に示すような構造の
折り畳み装置を用いて折り畳んで積み重ね、幅９５０ｍ
ｍで６３層の薄層シートから成るアルミナ繊維前駆体の
連続する積層シートを製造した。これを、３００℃で２
時間保持し、次に、３００〜５５０℃で２℃／分、５５
０〜１２５０℃で５℃／分で逐次昇温し、１２５０℃で
３０分保持するように焼成して、厚さ約２５ｍｍ、幅約
６５０ｍｍの連続アルミナ繊維シートとした。このアル
ミナ繊維シートを幅６００ｍｍに切断して折り返し部か
らなる両端部を除去した。このアルミナ繊維シートの長
さ２０００ｍｍの部分につき、幅方向に６等分、長さ方
向に２０等分して、各部分の目付け量を測定した。長さ
方向に２０等分した各部分につき、幅方向の目付け量の
平均値に対する標準偏差の３倍値（［３σ／目付け量］
×１００）を求め、これを長さ方向の２０点を平均して
求めたバラツキ値は７．７％であった。The thin sheets are folded and stacked using a folding apparatus having a structure as shown in FIG.
A continuous laminated sheet of alumina fiber precursor consisting of 63 thin sheets at m was produced. This at 300 ° C for 2
Hold at 300-550 ° C., 2 ° C./min, 55
The temperature was sequentially increased at 0 to 1250 ° C. at 5 ° C./min, and calcined at 1250 ° C. for 30 minutes to obtain a continuous alumina fiber sheet having a thickness of about 25 mm and a width of about 650 mm. This alumina fiber sheet was cut into a width of 600 mm to remove both end portions formed of folded portions. The 2000 mm length portion of the alumina fiber sheet was divided into 6 equal parts in the width direction and 20 equal parts in the length direction, and the basis weight of each part was measured. For each portion divided into 20 equal parts in the length direction, three times the standard deviation of the average value of the weight per unit area in the width direction ([3σ / weight per unit area])
× 100) was obtained and averaged over 20 points in the length direction, and the variation value was 7.7%.
【００２０】比較例１ 実施例１と同様な方法で得た薄層シートを真円の回転体
上に巻きつけて６３層の薄層シートからなる幅１０５０
ｍｍのアルミナ繊維前駆体の積層シートを製造し、これ
を焼成して、厚さ約４０ｍｍ、幅約７４０ｍｍのアルミ
ナ繊維シートを幅６００ｍｍに切断したものについて同
様に試験を行ったところ、実施例１と同様な方法で求め
たバラツキ値は１７．４％であった。Comparative Example 1 A thin sheet obtained in the same manner as in Example 1 was wound around a circular rotating body, and had a width of 1050 consisting of 63 thin sheets.
A laminated sheet of an alumina fiber precursor having a thickness of about 40 mm and a thickness of about 740 mm was cut into an alumina fiber sheet having a thickness of about 740 mm. The variation value determined by the same method as in Example 1 was 17.4%.
【００２１】実施例２ 実施例１と同様の方法で得た目付約４０ｇ／ｍ2 、幅１
０５０ｍｍの薄層シートは、実施例１よりも積層シート
その引き出し速度を速めることで、幅９５０ｍｍで３０
層の薄層シートから成るアルミナ繊維前駆体の連続する
積層シートを製造した。該積層シートに、減摩剤として
１０重量％高級脂肪酸エステルミネラルオイル溶液３０
ｍｌ／ｋｇを吹き付け、次いで、５打／ｃｍ2のニード
リングを行った後、実施例１と同様の方法で焼成して、
厚さ約１０ｍｍ、幅約６５０ｍｍの連続アルミナ繊維シ
ートとした。このアルミナ繊維シートについて、実施例
１と同様な方法で評価したところ、バラツキ値は６．７
％であった。また、上記で得られたアルミナ繊維シート
の排ガス浄化装置用把持材としての適性を評価するため
に、シートの幅方向に５０ｍｍ×５０ｍｍ角の試料を等
間隔で５枚採取し、圧縮試験機で室温で厚さ方向に厚さ
４ｍｍｍに圧縮して面圧を測定し、次いで開放するとい
う圧縮開放操作を１枚の試料につき５回繰り返した。ま
た、同様に、５枚の試料を厚さ３ｍｍｍに圧縮して面圧
を測定し、次いで開放する圧縮開放操作も１枚の試料に
つき５回繰り返した。以上の結果を表−１に示す。Example 2 A unit weight of about 40 g / m 2 and a width of 1 obtained in the same manner as in Example 1
The thin sheet of 050 mm has a width of 950 mm and a thickness of 30 mm by increasing the drawing speed of the laminated sheet compared to Example 1.
A continuous laminated sheet of alumina fiber precursor consisting of a thin sheet of layers was produced. A 10% by weight higher fatty acid ester mineral oil solution 30 as a lubricant was added to the laminated sheet.
After spraying ml / kg, and then performing needling of 5 strokes / cm 2 , firing was performed in the same manner as in Example 1,
A continuous alumina fiber sheet having a thickness of about 10 mm and a width of about 650 mm was obtained. When the alumina fiber sheet was evaluated in the same manner as in Example 1, the variation value was 6.7.
%Met. In addition, in order to evaluate the suitability of the alumina fiber sheet obtained above as a holding material for an exhaust gas purifying apparatus, five samples of 50 mm × 50 mm square in the width direction of the sheet were sampled at equal intervals, and a compression tester was used. The compression and release operation of compressing the sample to a thickness of 4 mm in the thickness direction at room temperature, measuring the surface pressure, and then releasing the sample was repeated five times for each sample. Similarly, the operation of compressing and releasing the five samples to a thickness of 3 mm, measuring the surface pressure, and then releasing the sample was repeated five times for each sample. Table 1 shows the above results.
【００２２】比較例２ 比較例１と同様なよう方法で得た薄層シートを真円の回
転体上に巻きつけて３０層の薄層シートからなる幅１０
５０ｍｍのアルミナ繊維前駆体の積層シートを製造し、
これを実施例２と同様にニードリング及び焼成を行い、
厚さ約１０ｍｍ、幅約７４０ｍｍのアルミナ繊維シート
のバラツキ値は１６．８％であった。また、実施例２と
同様に、得られたアルミナ繊維シートの排ガス浄化装置
用把持材としての適性を評価した結果を表−１に示す。
実施例２と比較例２を比較すると、両者とも面圧が高
く、かつ、厚さ変更を繰返しても面圧の低下が少なく、
繊維の復元力が高く、把持材として適していることがわ
かる。但し、実施例２の方が比較例２よりも、各シート
間での面圧特性のばらつきが少なく、把持材原料として
特に好適であることがわかる。COMPARATIVE EXAMPLE 2 A thin sheet obtained in the same manner as in Comparative Example 1 was wound on a perfect circular rotating body and had a width of 10
Producing a laminated sheet of 50 mm alumina fiber precursor,
This is needled and fired in the same manner as in Example 2,
The variation value of the alumina fiber sheet having a thickness of about 10 mm and a width of about 740 mm was 16.8%. Also, as in Example 2, the results of evaluating the suitability of the obtained alumina fiber sheet as a holding material for an exhaust gas purifying apparatus are shown in Table 1.
When Example 2 and Comparative Example 2 are compared, both have a high surface pressure, and even if the thickness change is repeated, the decrease in the surface pressure is small,
It can be seen that the restoring force of the fiber is high and is suitable as a gripping material. However, it can be seen that Example 2 has less variation in surface pressure characteristics among the sheets than Comparative Example 2 and is particularly suitable as a gripping material.
【００２３】[0023]
【表１】 [Table 1]
【００２４】[0024]
【発明の効果】本発明によれば、全体に亘って均一な目
付け量を有するアルミナ繊維前駆体よりなる積層シート
を製造することができる。そして、この積層シートを、
所望によりニードリングを施した後、常法により焼成す
ることにより、全体に亘って均一な目付け量を有するア
ルミナ繊維シートを得ることができる。また、本発明に
よれば、任意の長さのアルミナ繊維シートを連続生産す
ることが容易であり、従来法よりも生産効率の向上が顕
著である。According to the present invention, a laminated sheet made of an alumina fiber precursor having a uniform basis weight can be manufactured. And this laminated sheet,
After needling is performed, if necessary, firing is performed by a conventional method, whereby an alumina fiber sheet having a uniform basis weight can be obtained. Further, according to the present invention, it is easy to continuously produce an alumina fiber sheet having an arbitrary length, and the production efficiency is remarkably improved as compared with the conventional method.
【図面の簡単な説明】[Brief description of the drawings]
【図１】本発明を実施するフローシートの１例を示す概
念図であるFIG. 1 is a conceptual diagram showing an example of a flow sheet for implementing the present invention.
【図２】本発明の実施に用いることができる折り畳み装
置の１例を示す概念図であるFIG. 2 is a conceptual diagram showing an example of a folding device that can be used for carrying out the present invention.
１．アルミナ繊維前駆体薄層シート搬送用無端ベルト ２．アルミナ繊維前駆体薄層シート ３．折り畳み装置 ４．積層シート ５．積層シート搬送用無端ベルト 1. Endless belt for conveying alumina fiber precursor thin layer sheet 2. 2. Alumina fiber precursor thin layer sheet 3. Folding device Laminated sheet 5. Endless belt for conveying laminated sheets
Claims (8)
紡糸して得たアルミナ繊維前駆体を、集積装置上に降り
積らせてアルミナ繊維前駆体の薄層シートを形成し、こ
の薄層シートを集積装置から連続的に引出して折り畳み
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を
特徴とするアルミナ繊維前駆体よりなる積層シートの製
造方法。An alumina fiber precursor obtained by spinning a solution mainly containing an aluminum compound is deposited on an accumulator to form a thin sheet of the alumina fiber precursor. Manufacturing a laminated sheet made of an alumina fiber precursor, wherein the sheet is continuously drawn in a direction perpendicular to the folding direction while being continuously pulled out from the accumulating device, sent to the folding device, folded and stacked to a predetermined width, and stacked. Method.
紡糸して得たアルミナ繊維前駆体を、集積装置の回転し
ている無端ベルト上に降り積らせてアルミナ繊維前駆体
の薄層シートを形成し、この薄層シートを集積装置の無
端ベルト上から引き出して折り畳み装置に送り、折り畳
み方向に対して直角方向に回転している無端ベルト上に
所定の幅に折り畳んで積み重ねることを特徴とする請求
項１のアルミナ繊維前駆体よりなる積層シートの製造方
法。2. An alumina fiber precursor obtained by spinning a solution containing an aluminum compound as a main component is deposited on a rotating endless belt of an accumulator to form a thin sheet of the alumina fiber precursor. The thin sheet is pulled out from the endless belt of the stacking device, sent to the folding device, and folded and stacked to a predetermined width on the endless belt rotating in the direction perpendicular to the folding direction. Item 10. A method for producing a laminated sheet comprising the alumina fiber precursor according to Item 1.
2 である請求項１又は２のアルミナ繊維前駆体よりなる
積層シートの製造方法。3. A thin sheet having a basis weight of 10 to 200 g / m.
3. A method for producing a laminated sheet comprising the alumina fiber precursor according to claim 1 or 2.
成ることを特徴とする請求項１〜３のいずれかのアルミ
ナ繊維前駆体よりなる積層シートの製造方法。4. The method for producing a laminated sheet comprising an alumina fiber precursor according to claim 1, wherein the laminated sheet comprises eight or more thin-layer sheets.
られたアルミナ繊維前駆体よりなる積層シートを焼成し
てアルミナ繊維シートとするアルミナ繊維シートの製造
方法。5. A method for producing an alumina fiber sheet, wherein the laminated sheet comprising the alumina fiber precursor obtained by the production method according to claim 1 is fired to obtain an alumina fiber sheet.
られた積層シートにニードリングを施した後、焼成して
アルミナ繊維シートとする請求項５のアルミナ繊維シー
トの製造方法。6. The method for producing an alumina fiber sheet according to claim 5, wherein the laminated sheet obtained by the production method according to any one of claims 1 to 4 is subjected to needling and then fired to obtain an alumina fiber sheet.
2＝６５〜９８：３５〜２（重量比）である請求項５又
は６のアルミナ繊維シートの製造方法。7. The composition of the alumina fiber is Al 2 O 3 : SiO.
7. The method for producing an alumina fiber sheet according to claim 5, wherein 2 = 65 to 98:35 to 2 (weight ratio).
紡糸して得たアルミナ繊維前駆体を、集積装置上に降り
積らせてアルミナ繊維前駆体の薄層シートを形成し、こ
の薄層シートを集積装置から連続的に引出して折り畳み
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を
特徴とするアルミナ繊維前駆体よりなる積層シートにニ
ードリングをした後、焼成してなるアルミナ繊維シート
で構成されることを特徴とする排ガス浄化装置用把持
材。8. An alumina fiber precursor obtained by spinning a solution containing an aluminum compound as a main component is deposited on an accumulator to form a thin sheet of the alumina fiber precursor. Needle to a laminated sheet made of an alumina fiber precursor, which is continuously pulled out from the accumulating device, sent to the folding device, folded and stacked to a predetermined width, and continuously moved in a direction perpendicular to the folding direction. A holding material for an exhaust gas purifying device, comprising an alumina fiber sheet formed by firing after forming a ring.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP19147899A JP2000080547A (en) | 1998-07-07 | 1999-07-06 | Method for producing laminated sheet comprising alumina fiber precursor |
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP19154498 | 1998-07-07 | ||
| JP10-191544 | 1998-07-07 | ||
| JP19147899A JP2000080547A (en) | 1998-07-07 | 1999-07-06 | Method for producing laminated sheet comprising alumina fiber precursor |
Related Child Applications (3)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2003118424A Division JP2004027464A (en) | 1998-07-07 | 2003-04-23 | Alumina fiber continuous sheet |
| JP2003433955A Division JP2004197752A (en) | 1998-07-07 | 2003-12-26 | Grasping material for exhaust gas purification equipment |
| JP2006218845A Division JP2006342486A (en) | 1998-07-07 | 2006-08-10 | Alumina fiber sheet |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JP2000080547A true JP2000080547A (en) | 2000-03-21 |
Family
ID=26506716
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP19147899A Pending JP2000080547A (en) | 1998-07-07 | 1999-07-06 | Method for producing laminated sheet comprising alumina fiber precursor |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP2000080547A (en) |
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