초록 ▼

Fiber reinforced hollow microspheres made from dispersed particle film forming compositions including fibers, dispersed particles, a binder, a film stabilizing agent, a dispersing agent and a continuous liquid phase. Porous and non-porous fiber reinforced hollow microspheres can be made. The fiber r

Fiber reinforced hollow microspheres made from dispersed particle film forming compositions including fibers, dispersed particles, a binder, a film stabilizing agent, a dispersing agent and a continuous liquid phase. Porous and non-porous fiber reinforced hollow microspheres can be made. The fiber reinforced hollow microspheres have walls with voids which are interconnected to each other and to the inner and outer wall surfaces, and the fiber reinforced hollow microspheres can be used as membrane substrates in selective separation processes and in biotech processes. The fiber reinforced hollow microspheres can be used as supports for catalysts and as enclosures for catalysts, adsorbents and absorbents. The fiber reinforced hollow microspheres can also be used as filler materials and as proppants for increasing gas recovery from gas wells. The fiber reinforced hollow microspheres are made by a process which includes forming a film of a fiber and dispersed particle film forming composition across a coaxial blowing nozzle, applying a blowing gas at a positive pressure on the inner surface of the fiber and dispersed particle composition film to blow the film and form an elongated cylinder shaped film of the fiber and dispersed particle composition. The cylinder shaped film is initially closed at its outer end, and as the cylinder shaped film progresses away from the coaxial nozzle, the film closes at its inner end, prior to the beginning of the formation of the next cylinder shaped film at the coaxial nozzle. The hollow fiber and dispersed particle composition microspheres are individually formed as they emerge from the coaxial nozzle. The blown microspheres form substantially spherical hardened fiber reinforced hollow green microspheres.

대표청구항 ▼

A method for making fiber reinforced hollow porous microspheres of 200 to 10,000 microns diameter and of 1 to 1000 microns wall thickness from a stable dispersion of a fiber and dispersed particle film forming composition, said composition comprising fibers and dispersed particles in a continuous li

A method for making fiber reinforced hollow porous microspheres of 200 to 10,000 microns diameter and of 1 to 1000 microns wall thickness from a stable dispersion of a fiber and dispersed particle film forming composition, said composition comprising fibers and dispersed particles in a continuous liquid phase, wherein said fibers have a diameter of 0.5 to 10 microns and a length of 2 to 500 microns and the ratio of fiber diameter to length is 1:3 to 1:100 said method comprising feeding said fibers and dispersed particle composition and a blowing gas to a coaxial blowing nozzle, said coaxial blowing nozzle having an inner coaxial nozzle for said blowing gas and an outer coaxial nozzle for said fiber and dispersed particle composition and a coaxial blowing nozzle orifice, feeding said blowing gas to said inner nozzle, feeding said fiber and dispersed particle composition to said outer nozzle to blow and form, in the region of said coaxial blowing nozzle orifice, hollow fiber and dispersed particle composition microspheres having stable film walls, removing said hollow microspheres from the region of said coaxial blowing nozzle orifice, surface tension forces acting on said hollow microspheres to cause said hollow microspheres to form a spherical shape, treating said removed hollow microspheres to bring the fibers and dispersed particles into point to point contact and to harden them to obtain fiber reinforced hollow green microspheres, wherein said fibers are evenly distributed and are deposited between the dispersed particles to form a mat of fibers; and subjecting said fiber reinforced hollow green microspheres to a sufficiently high temperature for a sufficient period of time to remove the continuous liquid phase from the hollow green microspheres and to sinter or otherwise bond the fibers to each other and to the particles and to sinter the dispersed particles at their points of contact and to form within the walls of said hollow microspheres interconnecting voids that are continuous from the outer wall surface to the inner wall surface of the hollow microspheres, and to obtain fiber reinforced hollow porous microspheres having substantially uniform distribution of fibers in the walls, substantially uniform void content and substantially uniform distribution of the voids in the walls of the microspheres.