Method of producing inorganic fiber mat and inorganic fiber mat

Patent metadata

Field	Value
Publication number	US-12428763-B2
Application number	US-202318700263-A
Country	US
Kind code	B2
Filing date	Dec 6, 2023
Priority date	Dec 9, 2022
Publication date	Sep 30, 2025
Grant date	Sep 30, 2025

Abstract

Provided is a method of producing an inorganic fiber mat, the method including: a preparing step of preparing a first inorganic fiber molding including an organic binder attached thereto and derived from a needle-punched mat; a defibrating step of defibrating the first inorganic fiber molding to obtain defibrated inorganic fibers; and a papermaking step of forming the inorganic fiber mat by papermaking using a slurry containing the defibrated inorganic fibers.

First claim

The invention claimed is:

1. A method of producing an inorganic fiber mat, the method comprising:
a preparing step of preparing a first inorganic fiber molding including an organic binder attached thereto and derived from a needle-punched mat;
a defibrating step of defibrating the first inorganic fiber molding prepared in the preparing step to obtain defibrated inorganic fibers; and
a papermaking step of forming the inorganic fiber mat by papermaking using a slurry containing the defibrated inorganic fibers.

2. The method of producing an inorganic fiber mat according to claim 1 ,
wherein an average fiber length of inorganic fibers constituting the needle-punched mat is 3.0 to 100 mm.

3. The method of producing an inorganic fiber mat according to claim 1 ,
wherein the defibrating step is performed only by wet defibration.

4. The method of producing an inorganic fiber mat according to claim 1 ,
wherein the needle-punched mat is formed by folding a thin layer sheet of an inorganic fiber precursor multiple times into a layered body with a predetermined width, and firing the layered body.

5. The method of producing an inorganic fiber mat according to claim 1 ,
wherein the slurry further contains new inorganic fibers, and the new inorganic fibers and the defibrated inorganic fibers have the same composition and are alumina-silica fibers containing 60 to 80% by weight of Al2O3.

6. The method of producing an inorganic fiber mat according to claim 1 ,
wherein an inorganic binder and an organic binder are added to the slurry.

7. The method of producing an inorganic fiber mat according to claim 6 ,
wherein the inorganic fiber mat formed by papermaking in the papermaking step is heated and dried at a temperature of 150° C. to 210° C. for five minutes to one hour.

8. A method of producing an inorganic fiber mat, the method comprising:
a preparing step of preparing a first inorganic fiber molding including an organic binder attached thereto and derived from a needle-punched mat;
a defibrating step of defibrating the first inorganic fiber molding to obtain defibrated inorganic fibers; and
a papermaking step of forming the inorganic fiber mat by papermaking using a slurry containing the defibrated inorganic fibers,
wherein a second inorganic fiber molding derived from a papermaking mat is further used, and
wherein the first inorganic fiber molding and the second inorganic fiber molding are each cut before the defibrating step.

9. A method of producing an inorganic fiber mat, the method comprising:
defibrating a first inorganic fiber molding including an organic binder attached thereto and derived from a needle-punched mat to obtain defibrated inorganic fibers; and
forming the inorganic fiber mat by papermaking using a slurry containing the defibrated inorganic fibers.

10. The method of producing an inorganic fiber mat according to claim 9 ,
wherein an average fiber length of inorganic fibers constituting the needle-punched mat is 3.0 to 100 mm.

11. The method of producing an inorganic fiber mat according to claim 9 ,
wherein the defibrating is performed only by wet defibration.

12. The method of producing an inorganic fiber mat according to claim 9 ,
wherein the needle-punched mat is formed by folding a thin layer sheet of an inorganic fiber precursor multiple times into a layered body with a predetermined width, and firing the layered body.

Assignees

• Ibiden Co Ltd

Inventors

• Yamazaki Tomohisa

Classifications

• D21B1/12

  by wet methods, by the use of steam (beaters D21D1/00) · CPC title

• D10B2101/02

  based on oxides or oxide ceramics, e.g. silicates · CPC title

• D04H1/4209 Primary

  Inorganic fibres · CPC title

• D04H1/4274

  Rags; Fabric scraps · CPC title

• D04H1/488

  in combination with bonding agents · CPC title