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Process and apparatus for making a sheet of aramid fibers using a foamed medium

a technology of aramid fibers and foamed medium, which is applied in the field of foaming, can solve the problems of inefficiency of processes and sheets lacking uniformity, and achieve the effect of improving the integrity of sheets and being effective and efficien

Inactive Publication Date: 2006-01-19
FIBERMARK NORTH AMERICA
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The process achieves excellent uniformity and integrity of the non-woven web, allowing for the effective use of very long aramid fibers with reduced aramid fibrid content, enhancing the web's strength and ease of formation, suitable for various applications including high-temperature insulation and fuel cell diffusion layers.

Problems solved by technology

However, the formed sheets lack uniformly and the processes are inefficient.

Method used

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  • Process and apparatus for making a sheet of aramid fibers using a foamed medium
  • Process and apparatus for making a sheet of aramid fibers using a foamed medium
  • Process and apparatus for making a sheet of aramid fibers using a foamed medium

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Embodiment Construction

[0022] The process of the present invention comprises the steps of first forming a foam furnish by agitating a fiber mixture comprised of up to 100% of aramid fibers, in a foamed medium with the agitation apparatus of the present invention, and then passing the foam furnish onto a screen, e.g., a wire or plastic fabricated screen, and defoaming the furnish. Preferably, the furnish will also contain aramid fibrid. The aramid fibrid is a small irregularly shaped piece of aramid, e.g., Nomex®, polymer that is much larger in two dimensions than it is in the third dimension. It is like a microscopic corn flake in shape. The large dimensions are on the order of 5 to 25 micrometers, while the third and smaller dimension is about 0.01 to 1 micrometer. The fibrid can serve as a bonding agent for the aramid fibers in the final web, and thus greatly enhances the integrity of the final web. The agitating apparatus used in the process is depicted in the Figures of the Drawing, and can be describ...

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Abstract

The present invention relates to a method for forming a non-woven fibrous web comprised of aramid fibers and aramid fibrid which comprises forming a foam furnish by agitating the fibers and fibrid in a foamed medium, and passing the foam furnish onto a screen and defoaming the furnish. In effectively agitating the aramid fibers in the foamed medium, the agitating means is mounted for displacement within the foamed medium and includes a convex leading surface facing in the direction of displacement. The leading surface includes upper and lower portions converging in the direction of displacement to form a generally convex leading surface and driving means for displacing the agitating means in the direction of displacement for dispersing and mutually separating the aramid fibers within the foamed medium.

Description

CROSS REFERENCE TO RELATED APPLICATION [0001] This application claims the benefit of U.S. Provisional Application No. 60 / 409,231, filed on Sep. 10, 2002, the entirety of which is hereby incorporated by reference in its entirety.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to a process for forming a nonwoven sheet of composite aramid fibers, and aramid fibrid, using a foam furnish. More specifically, the present invention relates to an efficient foam process for making a uniform sheet of aramid fibers, also containing aramid fibrid. [0004] 2. Description of the Related Art [0005] The use of foam in a furnish for preparing wet-laid, non-woven fibrous webs is known. See, for example, U.S. Pat. No. 4,443,297, which discloses an apparatus and method for the manufacture of a non-woven fibrous web using foam. The method involves preparing a foam furnish with 55-75% volume air, recirculating a surfactant-water solution through a forming w...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): D21H21/56D21H11/00D21H13/26D21F11/00D21H27/00
CPCD21F11/002D21H27/00D21H13/26
Inventor KINSLEY, HOMAN B. JR.PEART, CHRISTOPHER B.
Owner FIBERMARK NORTH AMERICA
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