Ceramic filters formed from photocurable pre-ceramic polymers
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B01D-039/06
B01D-024/00
B01D-039/14
C08G-079/08
C08G-077/56
C08F-012/30
출원번호
UP-0738631
(2003-12-16)
등록번호
US-7658778
(2010-04-02)
발명자
/ 주소
Pope, Edward J. A.
Hepp, Jozsef
Kratsch, Kenneth M.
출원인 / 주소
Global Strategic Materials, LLC
대리인 / 주소
Connolly Bove Lodge & Hutz LLP
인용정보
피인용 횟수 :
1인용 특허 :
66
초록▼
A method for making high temperature filter media includes the steps of melt-spinning a plurality of fibers of pre-ceramic thermoplastic polymer to form a non-woven textile web of the fibers, curing and cross-linking the thermoplastic polymer to a thermo-set polymer and thermally decomposing the the
A method for making high temperature filter media includes the steps of melt-spinning a plurality of fibers of pre-ceramic thermoplastic polymer to form a non-woven textile web of the fibers, curing and cross-linking the thermoplastic polymer to a thermo-set polymer and thermally decomposing the thermo-set polymer to ceramic.
대표청구항▼
What is claimed is: 1. A method for making high temperature filter media comprising: producing a pre-ceramic thermoplastic polymer by reacting sodium acetylide with an organochlorosilane to generate an organo(ethynyl)chlorosilane product, and condensing the organic(ethynyl)chlorosilane product with
What is claimed is: 1. A method for making high temperature filter media comprising: producing a pre-ceramic thermoplastic polymer by reacting sodium acetylide with an organochlorosilane to generate an organo(ethynyl)chlorosilane product, and condensing the organic(ethynyl)chlorosilane product with an excess of an alkali metal; melt-spinning a plurality of fibers of the pre-ceramic thermoplastic polymer to form a non-woven textile web of the fibers; cross-linking the thermoplastic polymer to a thermo-set polymer; and thermally decomposing the thermo-set polymer to ceramic to form a ceramic filter media. 2. The method of claim 1, further comprising bonding the plurality of fibers of pre-ceramic thermoplastic polymer to form a first planar sheet and a second pleated sheet. 3. The method of claim 2, further comprising placing the first planar sheet against the second pleated sheet to form channels between the first and second sheets. 4. The method of claim 3, further comprising rolling the first and second sheets together to form a cylindrical filter media wherein the channels are oriented axially from end-to-end thereof. 5. The method of claim 1, wherein the alkali metal is sodium. 6. The method of claim 1, wherein the organochlorosilane is selected from the group consisting of dichlorodimethylsilane, trifunctional trichlorophenylsilane, and methyltrichlorosilane. 7. The method of claim 1, further comprising heat-treating the ceramic filter media after thermally decomposing the thermo-set polymer to ceramic. 8. The method of claim 1, wherein the pre-ceramic thermoplastic polymer after being cured and thermally decomposed yields the ceramic comprising silicon carbide. 9. The method of claim 1, wherein thermally decomposing the thermo-set polymer to ceramic comprises pyrolyzing the thermo-set polymer in a non-oxidizing atmosphere. 10. A method for making high temperature filter media comprising: producing a pre-ceramic thermoplastic polymer by reacting a sub-stoichiometric amount of an alkali metal with an organochlorosilane to form a partially polymerized polyorganochlorosilane, and reacting the partially polymerized polyorganochlorosilane with sodium acetylide; melt-spinning a plurality of fibers of the pre-ceramic thermoplastic polymer to form a non-woven textile web of the fibers; cross-linking the thermoplastic polymer to a thermo-set polymer; and thermally decomposing the thermo-set polymer to ceramic to form a ceramic filter media. 11. The method of claim 10, further comprising bonding the plurality of fibers of pre-ceramic thermoplastic polymer to form a first planar sheet and a second pleated sheet. 12. The method of claim 11, further comprising placing the first planar sheet against the second pleated sheet to form channels between the first and second sheets. 13. The method of claim 12, further comprising rolling the first and second sheets together to form a cylindrical filter media wherein the channels are oriented axially from end-to-end thereof. 14. The method of claim 10, wherein the alkali metal is sodium. 15. The method of claim 10, wherein the organochlorosilane is selected from the group consisting of dichlorodimethylsilane, trifunctional trichlorophenylsilane, and methyltrichlorosilane. 16. The method of claim 10, further comprising heat-treating the ceramic filter media after thermally decomposing the thermo-set polymer to ceramic. 17. The method of claim 10, wherein thermally decomposing the thermo-set polymer to ceramic comprises pyrolyzing the thermo-set polymer in a non-oxidizing atmosphere. 18. A method for making high temperature filter media comprising: producing a pre-ceramic thermoplastic polymer by reacting sodium acetylide with an organochlorosilane to generate an organo(ethynyl)chlorosilane product, and condensing the organic(ethynyl)chlorosilane product with ammonia; melt-spinning a plurality of fibers of the pre-ceramic thermoplastic polymer to form a non-woven textile web of the fibers; cross-linking the thermoplastic polymer to a thermo-set polymer; and thermally decomposing the thermo-set polymer to ceramic to form a ceramic filter media. 19. The method of claim 18, further comprising bonding the plurality of fibers of pre-ceramic thermoplastic polymer to form a first planar sheet and a second pleated sheet. 20. The method of claim 19, further comprising placing the first planar sheet against the second pleated sheet to form channels between the first and second sheets. 21. The method of claim 20, further comprising rolling the first and second sheets together to form a cylindrical filter media wherein the channels are oriented axially from end-to-end thereof. 22. The method of claim 18, wherein the organochlorosilane is selected from the group consisting of dichlorodimethylsilane, trifunctional trichlorophenylsilane, and methyltrichlorosilane. 23. The method of claim 18, further comprising heat-treating the ceramic filter media after thermally decomposing the thermo-set polymer to ceramic. 24. The method of claim 18, wherein thermally decomposing the thermo-set polymer to ceramic comprises pyrolyzing the thermo-set polymer in a non-oxidizing atmosphere. 25. The method of claim 18, wherein the pre-ceramic thermoplastic polymer after being cured and thermally decomposed yields the ceramic comprising silicon nitride. 26. A method for making high temperature filter media comprising: producing a pre-ceramic thermoplastic polymer by reacting a sub-stoichiometric amount of ammonia with an organochlorosilane to form a partially polymerized polyorganochlorosilazane, and reacting the partially polymerized polyorganochlorosilazane with sodium acetylide; melt-spinning a plurality of fibers of the pre-ceramic thermoplastic polymer to form a non-woven textile web of the fibers; cross-linking the thermoplastic polymer to a thermo-set polymer; and thermally decomposing the thermo-set polymer to ceramic to form a ceramic filter media. 27. The method of claim 26, further comprising bonding the plurality of fibers of pre-ceramic thermoplastic polymer to form a first planar sheet and a second pleated sheet. 28. The method of claim 27, further comprising placing the first planar sheet against the second pleated sheet to form channels between the first and second sheets. 29. The method of claim 28, further comprising rolling the first and second sheets together to form a cylindrical filter media wherein the channels are oriented axially from end-to-end thereof. 30. The method of claim 26, wherein the organochlorosilane is selected from the group consisting of dichlorodimethylsilane, trifunctional trichlorophenylsilane, and methyltrichlorosilane. 31. The method of claim 26, further comprising heat-treating the ceramic filter media after thermally decomposing the thermo-set polymer to ceramic. 32. The method of claim 26, wherein thermally decomposing the thermo-set polymer to ceramic comprises pyrolyzing the thermo-set polymer in a non-oxidizing atmosphere. 33. The method of claim 26, wherein the pre-ceramic thermoplastic polymer after being cured and thermally decomposed yields the ceramic comprising silicon nitride.
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