Composite Inorganic Fiber Sheet for Honeycomb Filter Formability
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Solution Overview
Problem
Conventional inorganic fiber sheets are not suitable as substrates for honeycomb filters due to insufficient supporting properties and shape processability.
Innovation Solution
An inorganic fiber sheet composed of first and second inorganic fibers with different average diameters and an organic substance, where the second fiber is an artificial crystalline fiber, and the organic substance has a melting point of 150°C or less, is used to enhance strength and processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional inorganic fiber sheets are used as substrate, then heat resistance is maintained, but supporting properties and shape processability are insufficient
Solution Approach 1:
The patent uses a composite fiber structure combining coarse inorganic fibers (3-15 μm diameter, 50% or more) as the primary load-bearing component with fine inorganic fibers as filler, creating a composite material that simultaneously achieves high strength/supporting properties and improved shape processability through the synergistic effect of different fiber diameters
Solution Approach 2:
The patent optimizes specific parameters including the fiber diameter distribution (50% or more of 3-15 μm fibers), the ratio of coarse to fine fiber content (M1/M2 = 1.50 to 10.00), and pore area (500-2000 μm²) to balance supporting properties and shape processability
2Strength
If fine inorganic fibers are used to improve supporting properties, then strength increases, but shape processability deteriorates
Solution Approach 1:
The patent applies local quality by using fibers with different diameters in different proportions - coarse fibers (3-15 μm) comprising 50% or more provide the primary supporting structure and shape processability, while fine fibers fill the spaces to enhance supporting properties, creating a heterogeneous structure with optimized local functions
Solution Approach 2:
The patent creates a composite fiber system where coarse inorganic fibers serve as the matrix providing shape processability and fine inorganic fibers act as reinforcement enhancing supporting properties, achieving both requirements through material composition rather than using a single fiber type
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 resulting inorganic fiber sheet exhibits excellent strength, toughness, and processability, making it suitable as a substrate for honeycomb filters with enhanced adsorption capabilities.
Implementation Method 1
an organic substance... (a) a binder having a melting point of 150°C or less or a hot-water dissolution temperature of 100°C or less
Implementation Method 2
a fibrillated organic fiber... The beating degree of the fibrillated organic fiber is preferably 200 CSF or less in terms of freeness
Data Source
AI summary
Provided is an inorganic fiber sheet having excellent performance. One embodiment of the present invention is an inorganic fiber sheet including: a first inorganic fiber; a second inorganic fiber; and an organic substance, wherein an average fiber diameter of the first inorganic fiber is larger than an average fiber diameter of the second inorganic fiber, the second inorganic fiber is an artificial crystalline fiber, and the organic substance is (a) a binder having a melting point of 150°C or less or a hot-water dissolution temperature of 100°C or less, and/or (b) a fibrillated organic fiber.