Sheet-like material, heat-insulating material derived therefrom and methods of manufacturing same
First Claim
1. A sheet-like material comprising 80 to 97% by weight of a non-inflammable fibrous substance, and 3 to 20% by weight of a binder consisting essentially of a thermoplastic resin, said fibrous substance being orientated at an angle of 3°
- to 80°
, said material having an intermediate layer containing at least 2% by weight of said binder and at least 25% of the average quantity of said binder in said material.
1 Assignment
0 Petitions
Accused Products
Abstract
A sheet-like material having excellent fire resistance and bending workability comprises 80 to 97% by weight of a non-flammable fibrous substance, and 3 to 20% by weight of a binder consisting essentially of a thermoplastic resin. The fibrous substance is orientated at an angle of 3° to 80°. The material has an intermediate layer containing at least 2% by weight of the binder and at least 25% of the average quantity of the binder in the material. A heat insulating material comprising such sheet-like materials is also disclosed. The sheet-like material, and the heat insulating material are manufactured by a wet sheet forming process in which a slurry containing the fibrous substance and the binder is fed to a carrier net or sheet at an angle of 5° to 60° thereto, whereby the fibers are orientated. Alternatively, the slurry is fed to the carrier net or sheet at an angle of 20° to 45°, while a fluid is blown into the slurry to create turbulence therein.
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Citations
33 Claims
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1. A sheet-like material comprising 80 to 97% by weight of a non-inflammable fibrous substance, and 3 to 20% by weight of a binder consisting essentially of a thermoplastic resin, said fibrous substance being orientated at an angle of 3°
- to 80°
, said material having an intermediate layer containing at least 2% by weight of said binder and at least 25% of the average quantity of said binder in said material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
- to 80°
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17. A heat insulating material comprising a sheet-like material containing 80 to 97% by weight of a non-inflammable fibrous substance, and 3 to 20% by weight of a binder consisting essentially of a thermoplastic resin, said fibrous substance being orientated at an angle of 3°
- to 80°
, said sheet-like material having an intermediate layer containing at least 2% by weight of said binder and at least 25% of the average quantity of said binder in said sheet-like material. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24, 25)
- to 80°
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26. A method of manufacturing a sheet-like material having excellent fire resistance and bending workability, said material comprising 80 to 97% by weight of a non-inflammable fibrous substance, and 3 to 20% by weight of a binder consisting essentially of a thermoplastic resin, said fibrous substance being orientated at an angle of 3°
- to 30°
, said material having an intermediate layer containing at least 2% by weight of said binder and at least 25% of the average quantity of said binder in said material, said method comprising;dissolving in water a binder consisting essentially of a water-soluble thermoplastic resin or a thermoplastic resin in the form of an emulsion or latex, and a crosslinking agent for said resin or a high polymer coagulant; dispersing a non-inflammable fibrous substance therein to prepare a slurry; feeding said slurry to a traveling or rotating carrier net or porous carrier sheet at an angle of 5°
to 60°
to form a wet mat thereon;dehydrating said mat; and drying said mat. - View Dependent Claims (27, 28, 29)
- to 30°
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30. A method of manufacturing a sheet-like material having excellent fire resistance and bending workability, said material comprising 80 to 97% by weight of a non-inflammable fibrous substance, and 3 to 20% by weight of a binder consisting essentially of a thermoplastic resin, said fibrous substance being orientated at an angle of 31°
- to 80°
, said material having an intermediate layer containing at least 2% by weight of said binder and at least 25% of the average quantity of said binder in said material, said method comprising;dissolving in water a binder consisting essentially of a water-soluble thermoplastic resin or a thermoplastic resin in the form of an emulsion or latex, as well as a crosslinking agent for said resin or a high polymer coagulant; dispersing a non-inflammable fibrous substance therein to prepare a slurry; feeding said slurry to a traveling or rotating carrier net or porous carrier sheet, while blowing a liquid or gas into said slurry to create turbulence therein, to form a wet mat on said carrier net or sheet; dehydrating said mat; and drying said mat. - View Dependent Claims (31, 32, 33)
- to 80°
Specification