Polycrystalline aluminosilicate ceramic filament nonwoven mats, and methods of making the same
Assignee3M Innovative Properties Company
InventorsDavid M. Wilson, William V. Chiu
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Abstract
A nonwoven article includes a plurality of electrospun polycrystalline, aluminosilicate ceramic filaments that form a cohesive nonwoven mat. Each of the aluminosilicate ceramic filaments in the mat have an average diameter of about 200 nm to about 1000 nm as determined with electron microscopy, and the aluminosilicate ceramic filaments have an average crystalline mullite content of about 15 wt % to about 80 wt %.
Claims18
A nonwoven article comprising a plurality of electrospun polycrystalline, aluminosilicate ceramic filaments that form a cohesive nonwoven mat, wherein each of the aluminosilicate ceramic filaments in the mat have an average diameter of about 200 nm to about 1000 nm as determined with electron microscopy, and wherein the aluminosilicate ceramic filaments have an average crystalline mullite content of about 15 wt % to about 80 wt %.
A method for electrospinning a ceramic filament from an aqueous ceramic precursor sol in the presence of an electric field established between a collector surface and a jet supply orifice, the method comprising:
- forming a jet stream of said aqueous ceramic precursor sol to form aluminosilicate ceramic filaments on the collector surface, wherein the sol comprises an alumina to silica ratio in the range of 60:40 to 90:10 by weight, and wherein the sol has a viscosity of less than about 1000 cP and a solids content of less than about 25%;
- collecting the filaments as a green nonwoven web on the collector surface;
- and
- heating the green nonwoven web at a temperature and for a time sufficient to convert the green nonwoven web to a cohesive mat comprising at least one polycrystalline, aluminosilicate ceramic filament comprising about 15 wt % to about 80 wt % crystalline mullite, wherein each of the aluminosilicate ceramic filaments in the cohesive mat has an average diameter of about 200 nm to about 1000 nm as determined using electron microscopy.
Dependencies are inferred from the claim text.