Inorganic fiber and process for manufacturing same

Patent metadata

Field	Value
Publication number	US-9302947-B2
Application number	US-201314374135-A
Country	US
Kind code	B2
Filing date	Jan 21, 2013
Priority date	Jan 31, 2012
Publication date	Apr 5, 2016
Grant date	Apr 5, 2016

Abstract

Provided is a method for producing inorganic fiber including: preparing a spinning raw material liquid which comprises an aluminum source, a calcium source, a silicon source and a spinning auxiliary, in which the content of the spinning auxiliary is, in terms of solid matter, 3 parts by mass or more relative to 100 parts by mass of the total of the aluminum source, the calcium source and the silicon source; spinning the spinning raw material liquid by a sol-gel method to obtain crude inorganic fiber; and firing the crude inorganic fiber to produce inorganic fiber that comprises 35 mass % to 88 mass % of Al 2 O 3 , 3 mass % to 45 mass % of CaO and 5 mass % to 40 mass % of SiO 2 in which the total of Al 2 O 3 , CaO and SiO 2 is 97 mass % or more of the entire fiber.

First claim

The invention claimed is:

1. A method for producing inorganic fiber, the method comprising the steps of:
preparing a spinning raw material liquid that comprises an aluminum source, a calcium source, a silicon source and a spinning auxiliary, wherein the content of the spinning auxiliary is, in terms of solid matter, 3 parts by mass or more relative to 100 parts by mass of the total of the aluminum source, the calcium source and the silicon source;
spinning the spinning raw material liquid by a sol-gel method to obtain crude inorganic fiber; and
firing the crude inorganic fiber to produce inorganic fiber that comprises 35 mass % to 88 mass % of Al 2 O 3 , 3 mass % to 45 mass % of CaO and 5 mass % to 40 mass % of SiO 2 in which the total of Al 2 O 3 , CaO and SiO 2 is 97 mass % or more of the entire fiber.

2. The method for producing inorganic fiber according to claim 1 , wherein the inorganic fiber obtained does not have fine pores.

3. The method for producing the inorganic fiber according to claim 1 , wherein the aluminum source is a water-soluble aluminum compound, the calcium source is a water-soluble calcium compound, the silicon source is a water-soluble or water-dispersible silicon compound, and the spinning raw material liquid is an aqueous solution of spinning raw materials.

4. The method for producing inorganic fiber according to claim 1 , wherein the aluminum source is basic aluminum chloride.

5. Inorganic fiber produced by preparing a spinning raw material liquid that comprises an aluminum source, a calcium source, a silicon source and a spinning auxiliary;
spinning the spinning raw material liquid by a sol-gel method to obtain crude inorganic fiber; and
firing the crude inorganic fiber;
wherein the inorganic fiber comprises 35 mass % to 88 mass % of Al 2 O 3 , 3 mass % to 45 mass % of CaO and 5 mass % to 40 mass % of SiO 2 in which the total of Al 2 O 3 , CaO and SiO 2 is 97 mass % or more of the entire fiber, and the inorganic fiber does not have fine pores.

Assignees

• Nichias Corp

Inventors

• Tomosue Nobuya
• Isomura Kazutoshi
• Murayama Kazutaka
• Sato Kiyoshi

Classifications

• D01F1/08

  for forming hollow filaments · CPC title

• C04B35/624

  Sol-gel processing · CPC title

• C04B2235/5454

  nanometer sized, i.e. below 100 nm · CPC title

• C04B2235/5264

  characterised by the diameter of the fibers · CPC title

• C04B2235/3217

  Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina · CPC title