Stock material or miscellaneous articles – Web or sheet containing structurally defined element or... – Including interlaminar mechanical fastener
Patent
1991-02-07
1992-09-08
Bell, James J.
Stock material or miscellaneous articles
Web or sheet containing structurally defined element or...
Including interlaminar mechanical fastener
139420A, 139425R, 428225, 428245, 428257, 428258, 428259, 428297, 428367, 428378, 428408, 428413, 428418, 428902, D03D 300
Patent
active
051457342
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
The present invention relates to a woven fabric comprising a high-purity alumina continuous filament, which is used as a reinforcing fibrous substrate of a fiber-reinforced composite material or as a heat-insulating material, a high-purity alumina continuous filament used for the production of this woven fabric, and processes for the production of these woven fabric and continuous filament.
BACKGROUND ART
The alumina content is up to 95% by weight in conventional alumina continuous filament woven fabrics, and this is because a fiber composed of high-purity alumina having an alumina content of at least 95% by weight is very brittle, and thus it is difficult to prepare a continuous filament from this alumina fiber, and even if a high-purity alumina continuous filament is obtained, it is difficult to form a woven fabric from this continuous filament by using a loom.
An alumina continuous filament heretofore used for woven fabrics comprises a silica (SiO.sub.2) component and the like, and generally has an alumina content of 75 to 80% by weight, the alumina content is 95% by weight at highest. This alumina continuous filament generally has a tensile strength of 150 to 200 kg/mm.sup.2 and is less brittle than the high-purity alumina continuous filament having an alumina content of at least 95% by weight, and thus this continuous filament can be woven relatively easily. Nevertheless, the modulus of elasticity of this alumina continuous filament is generally 15 to 20 t/mm.sup.2, and is much lower than 30 to 45 t/mm.sup.2 of the high-purity alumina fiber, and this alumina continuous filament has a disadvantage of a low heat resistance. Accordingly, a woven fabric formed by using an alumina continuous filament having an alumina content lower than 95% by weight has a disadvantage in that only a composite material having a low modulus of elasticity and a low heat resistance is obtained, even if it is used as a reinforcing fibrous substrate of a fiber-reinforced plastic, metal or ceramic material. Thus, a woven fabric formed by using a high-purity alumina continuous filament is highly suitable as a reinforcing fibrous substrate.
It is expected that, if a hybrid woven fabric is obtained by combining a high-purity alumina continuous filament having a very high tensile modulus of elasticity with a high-strength continuous filament having a tensile strength of 200 kg/mm.sup.2 or higher, this woven fabric will have superior physical properties such a high strength, and a high modulus of elasticity will be obtained, and this woven fabric will be very satisfactory as a reinforcing fibrous substrate for a composite material.
As the process for preparing an alumina continuous filament composed mainly of alumina (an alumina content of at least 80% by weight), there can be mentioned, for example, a process in which a spinning solution comprising an aluminum salt, a water-soluble polysiloxane and a water-soluble polymer is spun and then calcined, a process in which a solution comprising an alumina sol, a silica sol and boric acid is spun as the spinning solution, and a process in which a mixture of an inorganic polymer having a polyaluminoxane (--Al--O--) group and a silicic acid ester is spun as the spinning solution. In each of these processes, however, a silica component (SiO.sub.2) is incorporated in an amount of at least 5% by weight, to lessen the brittleness of the alumina fiber.
As the process for preparing a high-purity alumina fiber having an alumina content of at least 95% by weight, there is known a process in which a slurry comprising a-alumina particles having a particle size smaller than 0.5 tm, a small amount of MgCl.sub.2 ;6H.sub.2 O and a basic aluminum salt is dry-spun and the spun filament is calcined at a temperature higher than 1000.degree. C., as proposed in Japanese Unexamined Patent Publication No. 49-35627. Also in the fiber obtained according to this process, the brittleness is generally lessened by a coating of amorphous SiO.sub.2.
An alumina continuous filament woven fabric is prepa
REFERENCES:
patent: 4752515 (1988-06-01), Hosoi et al.
patent: 4812271 (1989-03-01), Hoba et al.
patent: 4929578 (1990-05-01), Sowman
Ito Takashi
Iwasaki Osamu
Ohuchi Akimicu
Otomo Koichiro
Saito Yoshiaki
Bell James J.
Kanebo Limited
Mitsui Mining Company Limited
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