Inorganic Fiber Mat Papermaking for Density and Thickness Control

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Solution Overview

Problem

Existing methods for producing inorganic fiber mats face challenges in formability, particularly in controlling density and thickness, and achieving resilience and wrapability.

Innovation Solution

A method involving the use of inorganic fibers derived from needle-punched and papermaking mats, combined through defibration and papermaking, allowing for the production of an inorganic fiber mat with controlled density and thickness, and enhanced resilience and wrapability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If inorganic fiber moldings are used as raw material, then waste reduction is achieved, but formability into product is insufficient

Engineering Contradiction:

Improvewaste reductionVSAvoidformability

Core Design Contradiction:

Loss of substanceVSEase of manufacture

Solution Approach 1:

The inorganic fiber moldings are cut into smaller pieces before defibration, creating segments that can be more effectively processed. This segmentation allows the fibers to be more uniformly separated and redistributed in the slurry, improving formability while utilizing waste materials.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the physical state and properties of the inorganic fiber moldings through defibration processing, transforming them from a molded solid form into individual fibers suspended in slurry. This parameter change enables the waste materials to be reformed with controlled density and thickness, resolving the formability issue.

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If defibration is performed to obtain individual fibers, then fiber distribution is improved, but fiber length is reduced

Engineering Contradiction:

Improvefiber distributionVSAvoidfiber length

Core Design Contradiction:

Stability of the object's compositionVSLength of moving object

Solution Approach 1:

The defibration process is controlled to achieve partial separation of fibers rather than complete individualization. This partial action maintains longer fiber lengths while still improving distribution, balancing both requirements through controlled processing intensity.

Inventive Principle:

Principle #16Partial or excessive action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method enables the production of an inorganic fiber mat with improved formability, resilience, and wrapability, utilizing fibers from both types of mats to achieve uniform distribution and desired properties.

Implementation Method 1

a defibrating step of defibrating the first inorganic fiber molding and the second inorganic fiber molding to obtain defibrated inorganic fibers

Methodology Applied

Scientific EffectMechanical disintegration: Mechanical Force

Implementation Method 2

a papermaking step of forming the inorganic fiber mat by papermaking using a slurry containing the defibrated inorganic fibers

Methodology Applied

Scientific EffectFiber deposition: Deposition (physical)

Data Source

PatentEP4403695B1Inorganic fiber mat production method

Publication Date: 2025.10.08 IBIDEN CO LTD

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Figure 2~3B
Figure 3C

AI summary

Provided is a method of producing an inorganic fiber mat the method including: a preparing step of preparing a first inorganic fiber molding derived from a needle-punched mat and a second inorganic fiber molding derived from a papermaking mat; a defibrating step of defibrating the first inorganic fiber molding and the second 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.