US4454189A
Expired / Lapsed
US
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Sheet of polyphenylene sulfide filaments and process for producing the same
Assignee: Toray Industries Inc
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Filing: 1981-06-24
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Granted: 1984-06-12
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Expires: 2001-06-24
Abstract
Abstract This invention relates to a sheet which is formed by randomly dispersing and accumulating polyphenylene sulfide (PPS) filaments and to a process for producing the same. The filaments drawn by a high-velocity air stream are formed directly into a sheet. The sheet is useful as industrial filters, heat insulating materials, electrical insulating materials, etc. because of its outstanding chemical resistance, heat resistance, and electrical insulating properties.
Inventors
- 👤 Shunsuke Fukata
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 12:05
CPC Classifications
D; D04; D04H; D04H3/00; D04H3/08; D04H3/12; Y; Y10; Y10T; Y10T428/00; Y10T428/26; Y10T428/269; Y10T428/27; Y10T428/29; Y10T428/2913; Y10T428/2922; Y10T428/298
Claims Analysis
Total Claims: 23
Claim 1
Independent Claim
85 words
A sheet of polyphenylene sulifide filaments which comprises randomly dispersed and accumulated polyphenylene sulfide filaments, each having a fineness of 0.1 to 15 denier, a dry heat shrinkage of about 5-50% at 140° C. and a strength greater than 1.5 g/d, wherein said filaments are made of a linear polymer having a degree of crosslinking and branching as defined by the non-Newtonian constant n of 0.9<n<2.0 as defined by the formula ##EQU2## wherein r is shear rate, T is shear force and μ is viscosity.
Claim 2
Dependent Claim
85 words
A sheet of polyphenylene sulifide filaments which comprises randomly dispersed and accumulated polyphenylene sulfide filaments, each having a fineness of 0.1 to 15 denier, a dry heat shrinkage of about 5-50% at 140° C. and a strength greater than 1.5 g/d, wherein said filaments are made of a linear polymer having a degree of crosslinking and branching as defined by the non-Newtonian constant n of 0.9<n<2.0 as defined by the formula ##EQU2## wherein r is shear rate, T is shear force and μ is viscosity.
Claim 3
Dependent Claim
45 words
A sheet of polyphenylene sulfide filaments as claimed in claim 1, wherein said p-phenylene sulfide is copolymerized with a comonomer selected from the group consisting of m-dichlorobenzene, 1,2,4-trichlorobenzene, compounds having a diphenylether group, compounds having a diphenyl sulphone groups and compounds having a naphthalene nucleus.
Claim 4
Dependent Claim
25 words
A sheet of polyphenylene sulfide filaments as claimed in claim 1, wherein said PPS filaments have a shrinkage of 5 to 40% at 140° C.
Claim 5
Dependent Claim
38 words
A sheet of polyphenylene sulfide filaments as claimed in claim 1, wherein said polyphenylene sulfide filaments are bonded with at least one thermosetting resin selected from the group consisting of polyimide, polyamide-imide, aromatic polyamide, polybenzimidazole, and polyarylene sulfide.
Claim 6
Dependent Claim
30 words
A sheet of polyphenylene sulfide filaments as claimed in claim 4, wherein the quantity of said thermosetting resin is 5 to 90 wt% based on the quantity of the filaments.
Claim 7
Dependent Claim
18 words
A sheet of polyphenylene sulfide filaments as claimed in claim 1, wherein said filaments are felted by interlocking.
Claim 8
Dependent Claim
101 words
A web of polyphenylene sulfide filaments to be bonded or interlocked comprising randomly dispersed and accumulated polyphenylene sulfide filaments, wherein said filaments are 0.5 to 5 denier, said web has an area shrinkage of 5 to 80% and, said filaments have a dry heat shrinkage of about 5-40% at 140° C. and a strength greater than 1.5 g/d, said filaments are made of a linear polymer having a degree of cross-linking and branching as defined by the non-Newtonian constant n of 0.9<n<2.0 as defined by the formula ##EQU3## wherein r is shear rate, T is shear force and μ is viscosity.
Claim 9
Dependent Claim
101 words
A web of polyphenylene sulfide filaments to be bonded or interlocked comprising randomly dispersed and accumulated polyphenylene sulfide filaments, wherein said filaments are 0.5 to 5 denier, said web has an area shrinkage of 5 to 80% and, said filaments have a dry heat shrinkage of about 5-40% at 140° C. and a strength greater than 1.5 g/d, said filaments are made of a linear polymer having a degree of cross-linking and branching as defined by the non-Newtonian constant n of 0.9<n<2.0 as defined by the formula ##EQU3## wherein r is shear rate, T is shear force and μ is viscosity.
Claim 10
Dependent Claim
21 words
A web of polyphenylene sulfide filaments as claimed in claim 7, wherein said web weighs 10 to 600 g/m 2 .
Claim 11
Dependent Claim
22 words
A web of polyphenylene sulfide filaments as claimed in claim 7, wherein said web has an area shrinkage of 10 to 60%.
Claim 12
Dependent Claim
22 words
A web of polyphenylene sulfide filaments as claimed in claim 7, wherein said web has an area shrinkage of 15 to 40%.
Claim 13
Dependent Claim
21 words
A web of polyphenylene sulfide filaments as claimed in claim 7, wherein said web weighs 20 to 300 g/m 2 .
Claim 14
Dependent Claim
85 words
A process for producing a sheet of polyphenylene sulfide filaments which comprises extruding a polyphenylene sulfide polymer from a plurality of small holes at a temperature 20° to 85° C. higher than the melting point of the polyphenylene sulfide polymer, drawing apart the extrudate from the small holes at a rate greater than 1300 m/min by a high-velocity air stream, simultaneously causing the resulting filaments to be opened by electrostatic charge, collecting the opened filaments on a plane, and bonding or interlocking the collected filaments.
Claim 15
Dependent Claim
85 words
A process for producing a sheet of polyphenylene sulfide filaments which comprises extruding a polyphenylene sulfide polymer from a plurality of small holes at a temperature 20° to 85° C. higher than the melting point of the polyphenylene sulfide polymer, drawing apart the extrudate from the small holes at a rate greater than 1300 m/min by a high-velocity air stream, simultaneously causing the resulting filaments to be opened by electrostatic charge, collecting the opened filaments on a plane, and bonding or interlocking the collected filaments.
Claim 16
Dependent Claim
46 words
A process for producing a sheet of polyphenylene sulfide filaments as claimed in claim 12, wherein said PPS polymer is composed of more than 90 mol% of p-phenylene sulfide units and has "n" which is represented by 0.9<n<3.0 (where n is as defined in the specification).
Claim 17
Dependent Claim
27 words
A process for producing a sheet of polyphenylene sulfide filaments as claimed in claim 13, wherein said polyphenylene sulfide polymer has "n" which is represented by 0.9<n<2.0.
Claim 18
Dependent Claim
40 words
A process for producing a sheet of polyphenylene sulfide filaments as claimed in claim 12, wherein said polyphenylene sulfide polymer has a melt viscosity of 300 to 100,000 poise at a shear rate of 200 sec -1 at 300° C.
Claim 19
Dependent Claim
37 words
A process for producing a sheet of polyphenylene sulfide filaments as claimed in claim 12, wherein the extrudate is drawn apart from the small holes at a rate greater than 1300 m/min by a high-velocity air stream.
Claim 20
Dependent Claim
34 words
A process for producing a sheet of polyphenylene sulfide filaments as claimed in claim 12, wherein the extrusion temperature is 30° to 60° C. higher than the melting point of the polyphenylene sulfide polymer.
Claim 21
Dependent Claim
23 words
A process for producing a sheet of polyphenylene sulfide filaments as claimed in claim 12, wherein the interlocking is performed by needle punching.
Claim 22
Dependent Claim
23 words
A process for producing a sheet of polyphenylene sulfide filaments as claimed in claim 12, wherein the interlocking is performed by water jet.
Claim 23
Dependent Claim
31 words
A process for producing a sheet of polyphenylene sulfide filaments as claimed in claim 12, wherein a heat bonding process and a compacting process using a hot calendering machine are added.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1987-06-12 | 1987-12-12 | 1988-06-12 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-06-12 | 1991-12-12 | 1992-06-12 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-06-12 | 1995-12-12 | 1996-06-12 | $7700.00 | Window Closed / Lapsed |