Production of composite structures
First Claim
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1. A process for producing a porous product comprising a network of fibers, comprising:
- producing a preform comprising an unsintered network of fibers and a gasifiable structure forming agent;
in a first step, gasifying, in the presence of oxygen and steam, at least 50% of the structure forming agent by heating and maintaining the preform at a gasification temperature for a time sufficient to gasify at least 50% of the structure forming agent, said gasification temperature being a temperature below the temperature at which the fibers are sintered; and
in a second step, sintering fibers of the preform by maintaining the preform resulting from said first step at a sintering temperature for a period of time sufficient to sinter said fibers at at least a portion of junction points of the fibers, said sintering temperature being higher than said gasification temperature.
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Abstract
A porous composite product comprised of a network of fibers is produced by forming an unsintered preformed network of fibers and a gasifiable structure forming agent, followed by gasification of the structure forming agent prior to sintering of the fibers at appropriate junction points. The preferred structure forming agent is a cellulosic material.
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Citations
12 Claims
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1. A process for producing a porous product comprising a network of fibers, comprising:
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producing a preform comprising an unsintered network of fibers and a gasifiable structure forming agent;
in a first step, gasifying, in the presence of oxygen and steam, at least 50% of the structure forming agent by heating and maintaining the preform at a gasification temperature for a time sufficient to gasify at least 50% of the structure forming agent, said gasification temperature being a temperature below the temperature at which the fibers are sintered; and
in a second step, sintering fibers of the preform by maintaining the preform resulting from said first step at a sintering temperature for a period of time sufficient to sinter said fibers at at least a portion of junction points of the fibers, said sintering temperature being higher than said gasification temperature. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A process for producing a porous product comprising a network of metal fibers, comprising:
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producing a preform comprising an unsintered network of metal fibers and a gasifiable structure forming agent, said structure forming agent being formed of a cellulosic material, and wherein said preform has particles of a catalyst support retained in the interstices of said fiber network, and wherein said catalyst support supports a catalyst or catalyst precursor;
in a first step, gasifying at least 50% of the structure forming agent by heating and maintaining the preform at a gasification temperature for a time sufficient to gasify at least 50% of the structure forming agent, said gasification temperature being a temperature below the temperature at which the fibers are sintered; and
in a second step, sintering fibers of the preform by maintaining the preform resulting from said first step at a sintering temperature for a period of time sufficient to sinter said fibers at at least a portion of junction points of the fibers, said sintering temperature being higher than said gasification temperature. - View Dependent Claims (9, 10, 11, 12)
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Specification