Metal fiber laminate

Abstract

Provided is a metal fiber laminate which can be made into a non-woven fabric even with fine metal fibers, and which has excellent texture (surface morphology), interlaced state, high density, smoothness, and air permeability. The metal fiber laminate is characterized in that the metal fiber laminate comprises at least three layers including a double metal fiber layer (A) having a fiber diameter of 6 [mu] m or more and a metal fiber layer (B) located between the double metal fiber layers (A) and having a fiber diameter of less than 6 [mu] m, the metal fiber laminate is laminated and integrated by a water jet, and the outer surface of the metal fiber laminate has an uneven structure.

Description

Technical Field

[0001] The present utility model relates to a metal fiber laminate that requires high strength, heat resistance, and corrosion resistance. Background Art

[0002] Conventionally, metal fiber non-woven fabrics have high strength, heat resistance, and corrosion resistance, and can be subjected to machining such as rolling and welding, and can be processed into various shapes and structures. Therefore, they are widely used in heat-resistant buffer materials, heat insulation materials, sound absorption materials, abrasives for glass, etc.

[0003] The metal fiber non-woven fabric can, according to required characteristics such as heat resistance, pressure resistance, and corrosion resistance, select corrosion-resistant metal fibers such as stainless steel wires, nickel alloy wires, and tungsten wires, and set specifications such as fiber diameter, weight per unit area, and forming thickness in a form that maintains specified pore characteristics. Especially when using a sheet-shaped filter medium with a thickness of about 5 mm or less, each metal fiber is oriented in a direction perpendicular to the flow of the fluid to be treated, and the fibers are firmly sintered at their contact portions. Thus, there is also an advantage, for example, that gel-like substances caused by segregation or the like generated in the fluid to be treated can be finely divided, and this advantage is also one of the reasons for using the metal fiber non-woven fabric.

[0004] Patent Document 1 proposes: using a ceramic fabric as a base fabric, and winding an aggregate of metal fibers manufactured by a cutting method on its surface by needling, and laminating it into a double-layer structure or a triple-layer structure, and using a metal non-woven fabric coated with a ceramic coating after this lamination as a bag filter as needed. Patent Document 2 proposes: a filter using a metal fiber sintered body obtained by dispersing and sintering metal fibers in a non-woven fabric form, and being a metal fiber sintered filter in which the change rate caused by pressure treatment of the air permeability resistance of the filter medium is 2 to 70%. Patent Document 3 proposes: a precision filter that controls the pores of a filter by electroplating or vapor deposition of metals such as gold and nickel with a thickness of about 5 μm on the surface of a stainless steel fiber sintered filter with a wire diameter of 1 μm, and changing the surface processing thickness and wire diameter by thickening the wire diameter.

[0005] Prior Art Documents:

[0006] Patent Documents:

[0007] Patent Document 1: Japanese Patent Laid-Open No. 2003-181225;

[0008] Patent Document 2: Japanese Patent Laid-Open No. 2002-119811;

[0009] Patent Document 3: Japanese Patent Laid-Open No. 10-314521. Summary of the Utility Model

[0010] Problems to be Solved by the Utility Model:

[0011] However, when laminating metal fibers with a relatively thin fiber diameter by needling, the fine fibers are exposed on the surface of the non-woven fabric as granular masses, resulting in a problem of poor texture (surface morphology). In addition, tough metal fibers also have problems such as difficulty in interlacing during needling, difficulty in achieving high density, inability to smooth the surface, and inability to reduce air permeability.

[0012] The present utility model aims to solve the above-mentioned existing problems, and can provide a metal fiber laminate with good texture (surface morphology), good interlacing state, high density, smoothness, and good air permeability even for relatively thin metal fibers.

[0013] Means for solving the problem:

[0014] The metal fiber laminate of the present utility model is composed of a metal fiber layer (A) with a fiber diameter of 6 μm or more and a metal fiber layer (B) with a fiber diameter less than 6 μm, and is a metal fiber laminate with at least three layers in which the metal fiber layer (B) is clamped by the metal fiber layer (A). The at least three-layer metal fiber laminate is integrated by water jet lamination, and the outer surface has an uneven structure.

[0015] Effect of the utility model:

[0016] The metal fiber laminate of the present utility model is composed of a metal fiber layer (A) with a fiber diameter of 6 μm or more and a metal fiber layer (B) with a fiber diameter less than 6 μm, and is a metal fiber laminate with at least three layers in which the metal fiber layer (B) is clamped by the metal fiber layer (A). The at least three-layer metal fiber laminate is integrated by water jet lamination, so that even for relatively thin metal fibers, a metal fiber laminate with good texture (surface morphology), good interlacing state, high density, smoothness, and good air permeability can be provided. Description of the drawings

[0017] Figure 1 is a schematic cross-sectional view of a metal fiber laminate according to an embodiment of the present utility model;

[0018] Figure 2 is a schematic cross-sectional view of a metal fiber laminate according to another embodiment of the present utility model;

[0019] Symbol description:

[0020] 1, 4 Metal fiber laminate

[0021] 2a, 2b Metal fiber layer (A)

[0022] 3 Metal fiber layer (B)

[0023] 5 Reinforcing metal fabric (woven fabric)

[0024] 7 metal long fiber bundles. Detailed implementation mode

[0025] The metal fiber laminate of the present utility model is composed of a metal fiber layer (A) with a fiber diameter of 6 μm or more and a metal fiber layer (B) with a fiber diameter of less than 6 μm, and the at least three-layer metal fiber laminate in which the metal fiber layer (B) is clamped by the metal fiber layer (A), and the at least three-layer metal fiber laminate is integrated by water jet lamination. By including the metal fiber layer (B) with an average fiber diameter of less than 6 μm, the metal fiber laminate can be densified and the air permeability can be reduced. By arranging the metal fiber layer (B) in the inner layer, the texture (surface morphology) can be made good. Through water jet lamination integration, the interweaving state of the fibers between the metal fiber layers can be densified and smoothed.

[0026] The diameter of the metal fiber constituting the metal fiber layer (A) is preferably 7 to 15 μm, more preferably 8 to 12 μm. Also, the diameter of the metal fiber constituting the metal fiber layer (B) is preferably 1 to 5 μm, more preferably 2 to 4 μm.

[0027] The average fiber length of the metal fiber constituting the metal fiber layer (A) is preferably longer than the average fiber length of the metal fiber constituting the metal fiber layer (B). The average fiber length of the metal fiber constituting the metal fiber layer (A) is preferably more than twice as long as the average fiber length of the metal fiber constituting the metal fiber layer (B), more preferably more than three times as long. Thus, the metal fiber laminate can prevent the shedding fibers of the metal fiber layer (B) disposed in the inner layer.

[0028] The metal fiber laminate may further include a reinforcing metal fabric. When there is a reinforcing metal fabric, the laminate can be strengthened. The reinforcing metal fabric is preferably woven from metal long fibers with an average fiber diameter of 6 μm or more.

[0029] The metal fiber constituting the metal fiber laminate is preferably a corrosion-resistant metal fiber such as a stainless steel wire, a nickel alloy wire, or a tungsten wire. Among them, stainless steel fibers with low cost are preferred.

[0030] The mass per unit area (unit area weight) of the metal fiber laminate is preferably 100 to 3000 g / m 2 , more preferably 300 g / m 2 ~1500 g / m 2 . If the metal fiber laminate has this unit area weight, it can be applied to various uses.

[0031] The lamination integration of the metal fiber laminate of the present utility model includes the following processes:

[0032] The metal fiber layer (B) is disposed on the inner side, and the metal fiber layer (A) is disposed on the outer side. The entire laminate is integrally laminated by water jet machining from the surface of the metal fiber layer (A). Water jet machining is a machining method in which pressurized water is ejected from a nozzle to entangle the fibers of the laminate with each other for integration. The nozzle diameter is preferably 0.01 to 5.0 mm, and more preferably 0.01 to 2.0 mm. The water pressure is preferably 1 to 50 Pa, and more preferably 1 to 20 Pa. Through water jet machining, a metal fiber laminate with good texture (surface morphology), good intertwining state, high density, smoothness and air permeability is obtained.

[0033] Next, an explanation will be given using the drawings. In the following drawings, the same reference numerals denote the same structures. Figure 1 It is a cross-sectional view of the metal fiber laminate 1 according to an embodiment of the present invention. In the metal fiber laminate 1, metal fiber layers (A) 2a, 2b having an average fiber diameter of 6 μm or more are disposed on both outer surfaces, and a metal fiber layer (B) 3 having an average fiber diameter of less than 6 μm is disposed on the inner layer. The three-layer metal fiber laminate is integrally laminated by water jet machining.

[0034] Figure 2 It is a cross-sectional view of the metal fiber laminate 4 according to another embodiment of the present invention. In the metal fiber laminate 4, a metal fiber layer (A) 2a having an average fiber diameter of 6 μm or more is disposed on one outer surface, a metal fiber layer (B) 3 having an average fiber diameter of less than 6 μm is disposed on the inner layer, and a reinforcing metal fabric (woven fabric) 5 is disposed thereunder. A metal fiber layer (A) 2b having an average fiber diameter of 6 μm or more is disposed on the other outer surface, and the laminate is integrally laminated by water jet machining from the side of the metal fiber layer (A) 2a or 2b.

[0035]

Examples

[0036] Hereinafter, further details will be described using examples and comparative examples. In addition, the present invention is not limited to the following examples:

[0037] <Measurement methods and evaluations>

[0038] The measurement methods and evaluations of the following examples and comparative examples are carried out as follows:

[0039] (1) Weight per unit area

[0040] It is obtained based on the method described in 6.2 of JIS L1913;

[0041] (2) Thickness

[0042] It is obtained based on the method described in 6.1A of JIS L1906;

[0043] (3) Air permeability

[0044] Obtained based on the method (Vladimir method) described in 6.8.1 of JIS L1913;

[0045] (4) Texture

[0046] Visually confirm the granular masses of fibers on the surface of the non-woven fabric;

[0047] A: Less than 10 per 5 cm × 5 cm

[0048] B: 10 to less than 20 per 5 cm × 5 cm

[0049] C: 20 or more per 5 cm × 5 cm.

[0050] <Raw materials used and common conditions>

[0051] (1) Metal fiber layer (A)

[0052] * Use a stainless steel fiber mesh with a fiber diameter of 8 μm and an average fiber length of 20 mm, and a unit area weight of 100 g / m 2 ;

[0053] * Use a stainless steel fiber mesh with a fiber diameter of 12 μm and an average fiber length of 20 mm, and a unit area weight of 100 g / m 2 ;

[0054] (2) Metal fiber layer (B)

[0055] Use a stainless steel fiber mesh with a fiber diameter of 4 μm and an average fiber length of 20 mm, and a unit area weight of 100 g / m 2 ;

[0056] (3) Reinforcing metal fabric

[0057] Use a stainless steel long fiber fabric (unit area weight 715 g / m 2 , fabric structure: plain weave). The filament fineness of the warp and weft of the fabric: 180 decitex, and the number of filament structures: 48 (hereinafter referred to as 180 dtex - 48 f).

[0058] (4) Water jet processing conditions

[0059] Nozzle diameter: 0.2 mm, water pressure: 10 Pa, processing speed: 5.0 m / min.

[0060] (Example 1)

[0061] (1) For the metal fiber layer (A), use a stainless steel fiber mesh with an average fiber diameter of 8 μm and an average fiber length of 20 mm,

[0062] (2) A stainless steel fiber mesh with an average fiber diameter of 4 μm and an average fiber length of 2 mm is used for the metal fiber layer (B).

[0063] (3) A stainless steel fiber mesh with an average fiber diameter of 8 μm and an average fiber length of 20 mm is used for the metal fiber layer (A). The above layers are laminated in this order to an A4 (210 mm × 297 mm) size and formed by water jet machining. Figure 1 The obtained three-layer structure (A / B / A) has a unit area weight of 300 g / m². 2 .

[0064] (Example 2)

[0065] Except that a stainless steel fiber mesh with an average fiber diameter of 12 μm and an average fiber length of 20 mm is used for the metal fiber layer (A), the same procedure as in Example 1 is carried out. The obtained three-layer structure (A / B / A) has a unit area weight of 300 g / m². 2 .

[0066] (Example 3)

[0067] (1) A stainless steel fiber mesh with an average fiber diameter of 8 μm and an average fiber length of 20 mm is used for the metal fiber layer (A).

[0068] (2) A woven fabric of stainless steel fibers.

[0069] (3) A stainless steel fiber mesh with an average fiber diameter of 4 μm and an average fiber length of 2 mm is used for the metal fiber layer (B).

[0070] (4) A stainless steel fiber mesh with an average fiber diameter of 8 μm and an average fiber length of 20 mm is used for the metal fiber layer (A). The above layers are laminated in this order to an A4 (210 mm × 297 mm) size and formed by water jet machining. Figure 2 The obtained four-layer structure (A / B / woven fabric / A) has a unit area weight of 1200 g / m² (including the woven fabric). 2 (including the woven fabric).

[0071] Regarding the respective stainless steel fiber nonwoven fabric structures obtained in Examples 1 to 3, for comparing their properties, workability, air permeability, and texture are shown in Table 1.

[0072]

Table 1

[0073]

[0074] Examples 1 to 3 use a stainless steel fiber mesh with an average fiber diameter of 4 μm and an average fiber length of 2 mm as the intermediate layer for the metal fiber layer (B), so that granular masses of fine fibers are not formed on the surface of the non-woven fabric. Also, the non-woven fabric can be densified, and the air permeability can be reduced.

[0075] (Comparative Example 1)

[0076] The metal fiber layer (A) uses a stainless steel fiber mesh with an average fiber diameter of 8 μm and an average fiber length of 20 mm, which is laminated to an A4 (210 mm × 297 mm) size, and a structure is formed by water jet machining. The unit area weight of this structure is 300 g / m 2 。

[0077] (Comparative Example 2)

[0078] The metal fiber layer (B) uses a stainless steel fiber mesh with an average fiber diameter of 4 μm and an average fiber length of 20 mm, which is laminated to an A4 (210 mm × 297 mm) size, and a structure is formed by water jet machining. However, a non-woven fabric cannot be formed.

[0079] (Comparative Example 3)

[0080] The metal fiber layer (B) uses a stainless steel fiber mesh with an average fiber diameter of 4 μm and an average fiber length of 2 mm, and the metal fiber layer (A) uses a stainless steel fiber mesh with an average fiber diameter of 8 μm and an average fiber length of 20 mm. The above are laminated in this order to an A4 (210 mm × 297 mm) size, and a double-layer structure is formed by water jet machining. The unit area weight of this double-layer structure is 1200 g / m 2 (including woven fabric).

[0081] (Comparative Example 4)

[0082] The metal fiber layer (A) uses a stainless steel fiber mesh with an average fiber diameter of 8 μm and an average fiber length of 20 mm, and the metal fiber layer (B) uses a stainless steel fiber mesh with an average fiber diameter of 4 μm and an average fiber length of 2 mm. The above are laminated in this order to an A4 (210 mm × 297 mm) size, and a double-layer structure is formed by water jet machining. The unit area weight of this double-layer structure is 300 g / m 2 。

[0083] (Comparative Example 5)

[0084] For the metal fiber layer (B), use stainless steel fiber mesh with an average fiber diameter of 4 μm and an average fiber length of 2 mm. For the metal fiber layer (A), use stainless steel fiber mesh with an average fiber diameter of 8 μm and an average fiber length of 20 mm. For the metal fiber layer (B), use stainless steel fiber mesh with an average fiber diameter of 4 μm and an average fiber length of 2 mm. Laminate the above in this order to an A4 (210 mm × 297 mm) size, and form a three-layer structure by water jet machining. The weight per unit area of this three-layer structure is 300 g / m 2 .

[0085] Regarding each stainless steel fiber non-woven fabric structure obtained in Comparative Examples 1 to 5, for comparing their properties, the workability, air permeability, and texture are shown in Table 2.

[0086]

Table 2

[0087]

[0088] In one layer of the 4-μm stainless steel fiber mesh of Comparative Example 2, the fibers cannot be entangled by needling and cannot be made into a non-woven fabric. In Comparative Examples 1, 3 to 4, they can be made into a non-woven fabric by needling, but since the 4-μm stainless steel fiber mesh is arranged in the upper layer or the lower layer, granular masses of fine fibers are likely to form on the surface of the non-woven fabric, and the texture is poor. Also, since the 4-μm stainless steel fibers are difficult to be entangled by needling and cannot be made dense, the air permeability cannot be reduced.

[0089] Industrial applicability:

[0090] The metal fiber laminate of the present utility model is of high strength, has heat resistance and corrosion resistance, and can be formed into various shapes and structures, so it can be widely applied to heat-resistant cushioning materials, heat insulation materials, sound absorption materials, abrasives for glass, filter components, etc.

Claims

1. A metal fiber laminate, characterized in that: The invention is a metal fiber laminate of at least three layers, comprising a double-layer metal fiber layer A with a fiber diameter of more than 6 μm and a metal fiber layer B with a fiber diameter of less than 6 μm located between the double-layer metal fiber layers A. The laminate is integrated by water jet and has a concave-convex structure on the outer surface.

2. The metal fiber laminate according to claim 1, characterized in that: The average fiber length of the metal fibers constituting the metal fiber layer A is longer than the average fiber length of the metal fibers constituting the metal fiber layer B.

3. The metal fiber laminate according to claim 1 or 2, characterized in that: The metal fiber laminate further comprises a reinforcing metal fabric.

4. The metal fiber laminate according to claim 1 or 2, characterized in that: The metal fibers constituting the metal fiber laminate are stainless steel fibers.

5. The metal fiber laminate according to claim 1 or 2, characterized in that: The mass per unit area of ​​the metal fiber laminate is 100 to 3000 g / m 2 .

6. The metal fiber laminate according to claim 1 or 2, characterized in that: The thickness of the metal fiber laminate is 1 to 20 mm.

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