Inorganic Fiber Sheet Shot Distribution for Coating Adhesion
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Solution Overview
Problem
Inorganic fiber sheets suffer from localized shots that detach with coating agents, leading to poor tackiness and adhesiveness, and existing methods to reduce shot concentration lower production efficiency and yield rates.
Innovation Solution
Inorganic fiber sheets are manufactured with a specific distribution of shots in the sheet thickness direction, controlled by setting the ratio of shot weight to total fiber weight within a defined range, ensuring high workability and adhesiveness without reducing production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If shots are separated in the manufacturing process to reduce shot concentration, then shot localization is reduced, but production efficiency deteriorates and yield rate decreases
Solution Approach 1:
The invention changes the key parameter from shot concentration (total amount) to shot distribution state (spatial arrangement). By controlling the distribution state parameter defined by the ratio of shots in the surface layer to total shots, the patent achieves uniform shot distribution without requiring shot removal processes, thus maintaining production efficiency while improving manufacturing precision.
2Ease of manufacture
If shots are concentrated at the surface, then coating agent application is simplified, but shots detach with the coating agent causing poor adhesiveness
Solution Approach 1:
The invention applies local quality by creating a specific shot distribution pattern where the surface layer contains a controlled proportion of total shots (within 0-30% range). This ensures the surface has sufficient shots for coating agent application while preventing excessive shot concentration that would cause detachment, thus achieving both ease of manufacture and reliability.
3Manufacturing precision
If shot concentration is reduced by centrifuging and filtering, then shot localization is decreased, but production efficiency deteriorates
Solution Approach 1:
Instead of extracting shots from the fiber mixture through centrifuging and filtering, the invention takes out the need for these complex separation processes by directly controlling shot distribution during the papermaking process. The shot distribution state is controlled through parameters such as shot-to-fiber ratio and forming conditions, eliminating the need for additional extraction equipment and steps.
Data Source
AI summary
An inorganic non-woven fiber sheet has a thickness T of 1 mm or more and contains shots derived from inorganic fibers and having a diameter of 45 μm or more. The shots is distributed as represented by “1−Y/X≤0.11.” Wherein X represents “a total weight of the shots in the inorganic fiber sheet per unit area”/“a total weight of the inorganic fiber sheet per unit area”, and Y represents “a weight of the shots per unit area included in the inorganic fiber sheet from which a portion having a thickness t and satisfying 0≤t≤s is removed, 0.10 mm≤s≤0.55 mm, with a wire side surface as a reference surface”/“a weight per unit area of the inorganic fiber sheet from which the portion having the thickness t is removed with the wire side surface as the reference surface”.