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Wholly aromatic polyamide fiber non-woven sheet and processes for producing the same
| Details |
Inventors: Yoshida, Tsugushi; Sasaki, Hideharu; Sawaki, Toru; Shimada, Keizo;
Assignee: Teijin Limited (Osaka, JP)
Primary Examiner: Kendell; Lorraine T.
Assistant Examiner:
Attorney, Agent or Firm: Burgess, Ryan & Wayne
A wholly aromatic polyamide fiber non-woven sheet having satisfactory density, impregnating property, heat resistance, and surface evenness, comprises mutually, randomly entangled fibers consisting essentially of a wholly aromatic polyamide having 85 molar % or more of at least one type of recurring units selected from those of the formulae (I) and (II): ##STR1## The non-woven sheet is characterized in that the wholly aromatic polyamide fibers have portions thereof having a flattened cross-sectional profile; the aromatic polyamide fibers are fuse-bonded to each other at least at portions thereof intersecting each other; and the sheet includes pores connected to each other, and having a size at the peak of pore size distribution, of 13 microns or less determined by means of a mercury porosimeter, and no voids isolated from each other, and has a porosity of from 5% to 40% and an air permeability rate of from 0.1 to 10,000 sec/100 ml. |
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DETAILED DESCRIPTION An object of the present invention is to provide a wholly aromatic polyamide fiber non-woven sheet having a satisfactory dense structure, impregnating property, and heat resistance and processes for producing the same.
Another object of the present invention is to provide a wholly aromatic polyamide fiber non-woven sheet useful as a core material of lightweight composite articles and resin-impregnated electric insulating materials and processes for producing the same.
The wholly aromatic polyamide fiber non-woven sheet of the present invention comprises wholly aromatic polyamide fibers randomly entangled with each other and consisting essentially of a wholly aromatic polyamide having 85 molar % or more of at least one type of recurring units selected from those of the formulae (I) and (II): ##STR2## which non-woven sheet is characterized in that the wholly aromatic polyamide fibers have portions thereof having a flattened cross-sectional profile; the aromatic polyamide fibers are fuse-bonded to each other at least at portions thereof intersecting each other; and the sheet includes pores connected to each other and having a size at the peak of pore size distribution, of 13 microns or less determined by means of a mercury porosimeter, and no voids isolated from each other, and has a porosity of from 5% to 40% and an air permeability rate of from 0.
1 to 10,000 sec/100 ml.
The above-mentioned wholly aromatic polyamide fiber non-woven sheet can be produced by a process comprising the steps of: providing a precursory non-woven sheet comprising wholly aromatic polyamide fibers randomly entangled with each other and consisting essentially of a wholly aromatic polyamide having 85 molar % or more of at least one type of recurring units selected from those of the formulae (I) and (II): ##STR3## impregnating the precursory non-woven sheet with a plasticizing agent consisting of at least one member selected from the group consisting of polar amide solvents, water, and mixtures of at least one of the polar amide solvents with water, the plasticizing agent being impregnated in an amount, in terms of the polar amide solvent, of from 0
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Manufacturing Materials 
