Inorganic Fiber Sheet Composition for Stable Corrugation Processing
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Solution Overview
Problem
Existing inorganic fiber sheets face issues with moldability and processability during corrugation processing, leading to decreased yield and productivity due to variations in temperature, pressure, and time, especially when using a corrugation processing device with a gear.
Innovation Solution
An inorganic fiber sheet composed of glass fibers, organic binders with different exothermic peak temperatures, and organic fibers, with specific content ratios and properties to enhance moldability and processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a corrugation processing device having a gear is used to process an inorganic fiber sheet, then the sheet can be formed into a corrugated shape, but the moldability and processability are degraded when temperature, pressure, and time variations are large, leading to decreased yield and productivity
Solution Approach 1:
The patent applies parameter changes by carefully controlling the exothermic peak temperatures of organic binders (T1 and T2 with specific difference range) to optimize the thermal behavior during corrugation processing. This controlled parameter change ensures consistent moldability and processability across variations in temperature, pressure, and time, thereby maintaining high productivity while achieving the desired corrugated shape.
Solution Approach 2:
The patent uses composite materials by combining multiple organic binders with different exothermic peak temperatures in a specific ratio range. This composite binder system provides synergistic effects that simultaneously improve moldability (peeling resistance) and processability (waveform processing suitability), resolving the contradiction between shape formation and productivity.
2Strength
If the content of organic binder is increased to improve moldability, then peeling resistance increases, but the processing suitability for waveform may be affected
Solution Approach 1:
The patent optimizes the content ratio of organic binders (first organic binder: 5-16% by mass, second organic binder: 1-8% by mass) to achieve the right balance between moldability and processability. This precise parameter control ensures that peeling resistance is sufficiently high while maintaining good processing suitability for waveform formation.
Solution Approach 2:
The patent employs a composite organic binder system where multiple binders with different exothermic peak temperatures work together. The first organic binder (higher content) provides peeling resistance, while the second organic binder (lower content) contributes to processing suitability, achieving a balanced performance that neither binder could provide alone.
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 fiber sheet achieves both moldability and processability during corrugation processing, ensuring high yield and productivity by preventing fiber peeling and sticking during corrugation.
Implementation Method 1
an organic binder is composed of two or more kinds of organic binders having different exothermic peak temperatures in differential thermal analysis
Data Source
AI summary
An object of the present invention is to provide an inorganic fiber sheet capable of achieving both moldability and processability during corrugation processing. The present invention provides an inorganic fiber sheet including glass fibers, an organic binder, and organic fibers, in which a content of the organic binder is 8% to 20% by mass, and the organic binder is composed of two or more kinds of organic binders having different exothermic peak temperatures in differential thermal analysis.