Concave-convex patterned metal fiber, metal fiber yarn and fabric including the same, method for preparing the fabric and use thereof

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to a metal fiber, in which frictional force between metal fibers, entanglement and processability are improved, a metal fiber yarn and a fabric including the same, a method for preparing the fabric and a use thereof, and more particularly, to a metal fiber having concave-convex patterns, in which frictional force between metal fibers, entanglement and processability are improved, a metal fiber yarn and a fabric including the same, a method for preparing the same and a use thereof.

Description of the Related Art

As a filter material and a burner material, a metal fiber fabric has been used in view of durability and heat resistance. Meanwhile, a metal fiber fabric has been prepared using a metal fiber bundle or yarn made of heat-resistant metal fibers or ceramic fibers.

As a conventional art related to a metal fiber yarn, PCT Patent Application No. PCT/EP01/04197 discloses a yarn including a machined metal fiber bundle surrounded by polymer or natural fibers and consolidated with a binding agent, a fabric including the yarn, and a method for manufacturing a gas burner membrane. The method for manufacturing the gas burner membrane includes preparing a fabric and removing a binding agent, polymer or natural fibers from the fabric. As in the case of this PCT patent application, the method for manufacturing the yarn surrounded by the binding agent and the polymer or natural fibers is widely used when preparing a yarn from a machined metal fiber.

PCT Patent Application No. PCT/EP96/03107 also discloses a textile fabric and a gas burner membrane made of the textile fabric. Machined metal filaments having a diameter of 15-150µm are consolidated by a binding agent to form a nearly parallel filament bundle, and the consolidated bundle is woven, knitted or braided to prepare the textile fabric.

U.S. Patent Nos. 4,930,199 and 5,071,713 disclose a yarn which is prepared by surrounding a machined metal fiber with polymer or natural fibers. However, such a yarn cannot be drawn more than the elongation of the polymer. In this regard, there is a limitation on thinning the thickness of the yarn, and it is difficult to manufacture a porous material having finer pores.

Meanwhile, Korean Patent No. 613869 discloses a metal fiber yarn prepared by combing metal fibers which are formed by a melt extraction process and in which orientations are randomly distributed, a fabric prepared from the metal fiber yarn, and a use of the metal fiber yarn as a membrane for a surface combustion burner. According to this patent, the metal fiber yarn is prepared by the entanglement of the metal fibers by means of surface protrusions which are naturally formed on the surfaces of the metal fibers during the process of preparing the metal fibers by the melt extraction process. However, when the metal fibers are prepared by the melt extraction process, there is a limitation on the frictional force of the metal fibers due to the surface protrusions formed on the surfaces of the metal fibers. Therefore, it is difficult to prepare a yarn, one strand of which consists of a smaller number of metal fibers, specifically, less than fifty metal fibers. Moreover, the metal fiber yarn prepared from a large number of metal fibers, such as the above has a problem in that it is difficult to prepare a fabric having lower-density, uniform and fine pores.

SUMMARY OF THE INVENTION

An aspect of the present invention provides a metal fiber, in which frictional force between metal fibers, entanglement and processability are improved, and a metal fiber yarn including the same.

An aspect of the present invention also provides a metal fiber fabric prepared from the metal fabric yarn and having more uniform and finer pores.

An aspect of the present invention also provides a method for preparing a metal fiber fabric using the metal fiber yarn, whereby the metal fiber fabric has more uniform and finer pores.

An aspect of the present invention also provides a filter material and a burner material which are made of the metal fiber fabric.

According to an aspect of the present invention, there is provided a metal fiber having concave-convex patterns formed at intervals of 0.3-50mm in a longitudinal direction of the metal fiber.

According to another aspect of the present invention, there is a metal fiber yarn including a metal fiber having concave-convex patterns formed at intervals of 0.3-50mm in a longitudinal direction of the metal fiber and drawn and the metal fiber yarn has a length of 0.45 m to 10.0m per gram.

According to another aspect of the present invention, there is provided a fabric prepared from the metal fiber yarn.

According to another aspect of the present invention, there is provided a method for preparing a fabric, including: forming concave-convex patterns in a metal fiber at intervals of 0.3-50mm in a longitudinal direction of the metal fiber; forming a metal fiber yarn having a length of 0.45-10.0mm per gram by using the metal fiber in which the concave-convex patterns are formed; and weaving the metal fiber yarn into a fabric.

According to another aspect of the present invention, there are provided a filter material and a burner material made of the fabric.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

FIG. 1 illustrates a method for manufacturing a metal fiber in which concave-convex patterns are formed using a spur gear;

FIG. 2A is a top sectional view of the metal fiber having the concave-convex patterns formed by passing through the spur gear;

FIG. 2B is a side view of the metal fiber having the concave-convex patterns formed by passing through the spur gear;

FIG. 2C is a perspective view of the metal fiber having the concave-convex patterns formed by passing through the spur gear;

FIG. 3 illustrates a method for manufacturing a metal fiber in which concave-convex patterns are formed using a helical gear;

FIG. 4A is a top sectional view of the metal fiber having the concave-convex patterns formed by passing through the helical gear;

FIG. 4B is a side view of the metal fiber having the concave-convex patterns formed by passing through the helical gear;

FIG. 4C is a perspective view of the metal fiber having the concave-convex patterns formed by passing through the helical gear;

FIG. 5 is a SEM image (magnification (X) : 500) showing the surface of a metal fiber manufactured by a cutting process or a drawing process;

FIG. 6 is a SEM image (magnification (X) : 500) showing the side surface of a metal fiber manufactured by a melt extraction process;

FIG. 7A is an image showing a fabric prepared from yarns having 100 strands of fibers with a diameter of 30µm (number of yarns: 20/inch);

FIG. 7B is an image showing a fabric prepared from yarns (FIG. 3B) having 200 strands of fibers with a diameter of 20µm (number of yarns: 20/inch);

FIG. 8 illustrates a metal fiber yarn according to an embodiment of the present invention;

FIG. 9 is an image showing a fabric prepared by weaving the metal fiber yarn according to the embodiment of the present invention;

FIG. 10 is an image showing a fabric prepared by knitting the metal fiber yarn according to the embodiment of the present invention;

FIG. 11A illustrates the bottom surface of a fabric having flame holes according to an embodiment of the present invention;

FIG. 11B illustrates the top surface of the fabric having flame holes according to the embodiment of the present invention;

FIG. 12A illustrates a fabric including metal wires as a part of warp;

FIG. 12B illustrates a fabric including metal wires as a part of weft;

FIG. 13 schematically illustrates a drawing process of a metal fiber;

FIG. 14 is an image showing a surface combustion burner using membranes prepared from yarns of inventive example 12 and comparative example 12;

FIG. 15A is an image showing the lowest load state of the membrane prepared from the yarn of inventive example 12;

FIG. 15B is an image showing the highest load state of the membrane prepared from the yarn of inventive example 12;

FIG. 16A is an image showing the lowest load state of the membrane prepared from the yarn of comparative example 12; and

FIG. 16B is an image showing the highest load state of the membrane prepared from the yarn of comparative example 12.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Exemplary embodiments of the present invention will now be described in detail with reference to the accompanying drawings. The invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, the thicknesses of layers and regions are exaggerated for clarity. Like reference numerals in the drawings denote like elements, and thus their description will be omitted.

An aspect of the present invention provides a metal fiber in which concave-convex patterns are formed in a longitudinal direction of the metal fiber at regular intervals, specifically, at intervals of from 0.3mm to 50mm.

In order to obtain the uniform frictional force between metal fibers and excellent and high porosity in a yarn and a fabric including the metal fibers, it is preferable that the concave-convex patterns are formed at the regular intervals along the longitudinal direction of the metal fiber. That is, the concave-convex patterns may be repeated at intervals of from 0.3mm to 50mm along the longitudinal direction of the metal fiber.

The concave-convex patterns of the metal fiber may be formed at intervals of 0.3 mm -50mm, specifically 0.3 mm -30mm, more specifically 0.5 mm -18mm.

If the concave-convex patterns are formed at intervals of less than 0.3mm, a large number of concave-convex patterns are formed to increase the frictional force between the metal fibers and therefore a stable drawing is impossible. If the concave-convex patterns are formed at intervals of more than 50mm, the frictional force between the metal fibers and the entanglement are insufficient and therefore the metal fibers may be released from the metal fiber yarn.

The concave-convex patterns may be formed by passing a metal fiber bundle through a gear, but the invention is not limited thereto. There is no special limitation on the types of the gear, and the concave-convex patterns may be formed in any kind of metal fibers. Also, there is no special limitation on the number of metal fibers included in the metal fiber bundle which is to be passed through the gear to form the concave-convex patterns thereon in the longitudinal direction of the metal fibers. FIGS. 1 through 4 illustrate a method for forming concave-convex patterns on metal fibers by passing a metal fiber bundle through a gear, and the metal fiber bundle on which the concave-convex patterns are formed.

The concave-convex patterns may be formed on the metal fibers by passing the metal fiber bundle through a spur gear as illustrated in FIG. 1, or by passing the metal fiber bundle through a helical gear as illustrated in FIG. 3, but the invention is not limited thereto. In the case in which the metal fiber bundle 12 is passed through the spur gear 11 as illustrated in FIG. 1, the concave-convex patterns illustrated in FIGS. 2B and 2C are formed on the metal fiber bundle. That is, as illustrated in FIG. 2B which shows the side sectional view of the metal fiber, the concave-convex patterns are formed vertically with respect to the longitudinal direction of the metal fiber. In the case in which the metal fiber bundle 32 is passed through the helical gear 31 as illustrated in FIG. 3, the concave-convex patterns illustrated in FIGS. 4B and 4C are formed on the metal fiber bundle. That is, as illustrated in FIG. 4B which shows the side sectional view of the metal fiber, the concave-convex patterns are formed inclined with respect to vertical line to the longitudinal direction of the metal fiber.

In the metal fiber having the concave-convex patterns according to the embodiment of the present invention, the concave-convex patterns may be different depending on the tooth shape of the gear through which the metal fiber is passed. The shapes of the concave-convex patterns are not specially limited. For example, the concave-convex patterns may have a V-shape, a U-shape, or a U-shape.

The concave-convex patterns may be formed on a metal fiber which is generally known to those skilled in the art, and/or a metal fiber prepared by a method which is generally known to those skilled in the art. In one embodiment, examples of the metal fiber include a metal fiber made of a Fecralloy which is a Fe-Cr-Al alloy. Fecralloy is a generally-known alloy. For example, Fecralloy may include 18-27wt% of chromium (Cr), 3-7wt% of aluminum (Al), specifically 5-7wt%, and the remaining wt% of iron (Fe). Also, an improved Fecralloy which further includes 0.05-0.5wt% of zirconium (Zr) and/or yttrium (Y), specifically 0.1-0.3wt%, may be used. In another embodiment, examples of the metal fiber include a stainless steel metal fiber, specifically, a stainless steel 316L metal fiber.

The concave-convex patterns may be formed on a metal fiber prepared by a cutting process, a drawing process, or a melt extraction process, but the invention is not limited thereto.

As illustrated in FIG. 5, the surfaces of the metal fibers prepared by the machining process such as the cutting process or the drawing process are smooth and without protrusions. Since there is no frictional force between the metal fibers having the smooth surfaces, it is difficult to prepare a yarn from such metal fibers.

Furthermore, as illustrated in FIG. 6, a plurality of protrusions having a height of several micrometers, specifically 1-5µm, are formed on the surfaces of the metal fibers prepared by the melt extraction process. However, since the frictional force between the metal fibers is insufficient, the metal fibers may be released from the metal fiber yarn. Meanwhile, in the case in which the metal fiber yarn is prepared using the metal fibers manufactured by the melt extraction process, the frictional force between the metal fibers is insufficient. Hence, a single strand of the yarn must be prepared from a relatively large number of metal fibers such as 50-100 strands of metal fibers. Even in this case, the metal fibers are released from the metal fiber yarn, and the form of the metal fiber yarn is not maintained.

However, according to the embodiment of the present invention, since the concave-convex patterns are formed on the metal fibers, sufficient friction force and entanglement are provided between the metal fibers prepared by the machining process such as the cutting process or the drawing process and the metal fibers prepared by the melt extraction process. Hence, such metal fibers may be easily processed into the metal fiber yarn, and the metal fibers will not be released from the metal fiber yarn. The number of metal fibers used for forming a single strand of the yarn is not limited. Specifically, the yarn, including any number of metal fibers such as an example, about 10-250 strands or more of metal fiber, may be easily prepared. Furthermore, the metal fiber yarn may be prepared without using an additional binder and/or polymer.

Moreover, the metal fiber yarn prepared from the metal fibers according to the embodiment of the present invention ensures excellent and high porosity because of the concave-convex patterns formed on the metal fibers, and a plurality of very fine and uniform pores are formed in the metal fiber yarn and fabric.

According to the conventional art, the diameter and length of the metal fibers usable when preparing the metal fiber yarn are limited due to weak frictional force, entanglement and processability (specifically, processability of the metal fibers to the metal fiber yarn).

The conventional metal fiber yarn has been prepared using the metal fibers having a diameter of 10 µm -100µm, specifically 30 µm -100µm, and a length of 10 cm -100cm. However, since the metal fibers according to the embodiment of the present invention have the concave-convex patterns, the frictional force between the metal fibers, the entanglement and the processability are increased. Hence, there is no specific limitation on the diameter and length of the metal fibers usable when preparing the metal fiber yarn. That is, the metal fiber yarn may be easily prepared using metal fibers having a diameter of less than 10µm and metal fibers having a diameter of more than 100µm, as well as metal fibers having a diameter of 10 µm -100µm. Also, the metal fiber yarn may be easily prepared using metal fibers having a length of less than 10cm and metal fibers having a length of more than 100cm, as well as the metal fibers having a length of 10 cm -100cm.

In order to form the plurality of excellent, fine and uniform pores in the metal fiber yarn and the fabric prepared from the same, yarn including a large number of thin metal fibers is preferred to yarn including a small number of thick metal fibers under the condition of the same equivalent diameter. For example, in order to form the plurality of fine and uniform pores in the manufacturing of the fabric, yarn having 200 strands of fibers having a diameter of 20µm (yarn diameter: about 0.1mm, FIG. 7B) is preferred to yarn having 100 strands of fibers having a diameter of 30µm (yarn diameter: about 0.1mm, FIG. 7A).

Moreover, the metal fibers according to the embodiment of the present invention have excellent elasticity because of the concave-convex patterns formed on the metal fibers. Due to the elasticity thereof, the metal fibers may be easily processed into the metal fiber yarn and the metal fabric using the same, and the metal fibers may be freely modified in various shapes. Also, the metal fiber yarn and the metal fabric using the same have a soft texture.

The metal fibers having the concave-convex patterns according to the embodiment of the present invention may be drawn and twisted to prepare the metal fiber yarn. Meanwhile, since the conventional metal fiber yarn has insufficient frictional force and entanglement between the metal fibers, it is not processed into a false twist yarn, but into a twisting yarn. However, the metal fibers having the concave-convex patterns according to the embodiment of the present invention can be processed into a false twist yarn as well as a twisting yarn because of the increased frictional force and entanglement between the metal fibers. In the case of the twisting yarn and the false twist yarn prepared from the metal fibers according to the embodiment of the present invention, metal fibers are not released, thereby stably maintaining the form of the yarn.

According to the embodiment of the present invention, since the frictional force between the metal fibers is improved, the metal fibers have excellent entanglement. Thus, when preparing the yarn, the torsion rate is not specifically limited. Meanwhile, as is well known to those skilled in the art, the false twist yarn is prepared by drawing and twisting the metal fibers to manufacture the metal fiber yarn and untwisting the metal fiber yarn.

As described above, when preparing the metal fiber yarn according to the embodiment of the present invention, the torsion rate of the metal fiber is not specially limited. The metal fibers may be twisted to have a porosity and pore distribution suitable for the purpose of the metal fiber fabric prepared from the metal fiber yarn.

As one example, in the case in which the metal fiber fabric used as a burner material is prepared using the metal fiber yarn, the metal fiber yarn including the metal fibers according to the embodiment of the present invention may be processed into a false twist yarn or a twisting yarn, considering the ejection of a gas fuel at pores between the metal fibers, differential pressure, and combustion efficiency. The yarn may be prepared by twisting the metal fibers, e.g., at 3-5 turns/m, but the invention is not limited thereto.

As another example, in the case in which the metal fiber fabric used as a filter material is prepared from the metal fiber yarn, the metal fiber yarn including the metal fibers according to the embodiment of the present invention may be processed into a false twist yarn or a twisting yarn, considering the filtration performance of dust particle/foreign object of the metal fiber fabric and the increase in differential pressure due to the accumulation of dust particles or foreign objects at pores. The yarn may be prepared by twisting the metal fibers, e.g., at 1-15 turns/m, preferably 10-15 turns/m, but the invention is not limited thereto.

As the pores of the metal fiber yarn and/or the fabric are smaller, the fine dust particle/foreign object filtration performance and the combustion efficiency are improved. However, as dust particles and/or foreign objects are accumulated, the differential pressure and the differential pressure rise rate are increased. Thus, in order to obtain excellent filtration performance and combustion efficiency and minimize the differential pressure rise rate, the metal fibers may be processed into a twisting yarn by applying the torsion rate within the above-described range or a false twist yarn according to the intended use of the metal fabric, specifically, the intended use of the metal fabric as a burner material and/or a filter material.

The metal fiber yarn according to the embodiment of the present invention may have a length of 0.45-10.0 m per gram (0.45-10.0 Nm). When the length of the yarn per gram is less than 0.45 m, the yarn becomes thick and thus it is not suitable in view of porosity. When the length of the yarn per gram is more than 10.0 m, the yarn is not prepared.

FIG. 8 illustrates a metal fiber yarn 81 including a plurality of metal fibers 82 according to an embodiment of the present invention. The metal fiber yarn according to the embodiment of the present invention may be prepared by continuing to finely draw and twist the metal fibers in which the concave-convex patterns are formed. Meanwhile, the false twist yarn is prepared by drawing and twisting the metal fibers and untwisting the twisted metal fibers.

In the metal fiber yarn 81 of FIG. 8 prepared from the metal fibers 82 in which the concave-convex patterns are formed, the metal fibers 82 are well entangled together due to the concave-convex patterns. Also, since the frictional force between the metal fibers is increased due to the concave-convex patterns, metal fibers are not released from the yarn, thereby stably maintaining the form of the yarn. Furthermore, due to the concave-convex patterns of the metal fibers constituting the yarn, a plurality of fine and uniform pores are formed between the metal fibers, thereby providing the excellent and high porosity. Moreover, the metal fibers having the concave-convex patterns according to the embodiment of the present invention may be easily processed in a subsequent process and have a soft texture.

Meanwhile, the metal fiber yarn according to the embodiment of the present invention may be woven into a fabric by a general method which is known to those skilled in the art. As one example, a photo of a fabric prepared by a weaving process and a fabric prepared by a knitting process are illustrated in FIGS. 9 and 10, respectively, but the invention is not limited thereto.

As one specific example, although not being limited thereto, the fabric according to the embodiment of the present invention may be prepared from the metal fiber yarn by substantially weaving warp yarn B and weft yarn B' at right angles with relation to one another as illustrated in FIGS. 11A and 11B. The metal fiber fabric may include the metal fiber yarn having 5-30 strands per inch. When the number of the metal fiber yarn in the metal fabric is less than 5 strands/inch, the pore of the fabric is too large, especially when the yarn diameter is small. When the number of the metal fiber yarn is more than 30 strands/inch, the pore is clogged, especially when the yarn diameter is large.

In weaving, the weft yarns and the warp yarns are disposed to be substantially vertical to one another, and flame holes A and A' having sides defined by two parallel warps and two parallel wefts are formed on both sides of the fabric. The flame holes refer to parts which are slightly recessed from the bottom and top of the fabric. The aspect ratio of the flame hole (i.e. the ratio of width : length) is 10:1 or less, specifically, 1:1 to 10:1. When the aspect ratio of the flame hole exceeds 10, the flame hole is formed through the lower yarn of 3-4 strands. Consequently, the structure of the fabric becomes loose. Meanwhile, only if the porosity is not problematic, the fabric may be prepared to have the flame holes whose aspect ratio is 10:1 or less.

As described above, since the metal fiber yarn is prepared using the metal fibers having the concave-convex patterns according to the present invention, there is no limitation on the thickness and/or the length of the metal fiber used in preparing the metal fiber yarn. Hence, metal fibers thinner than the metal fibers which is conventionally used in preparing the conventional metal fiber yarn may be used. Furthermore, metal fiber yarn having a stable form may be prepared, even though a smaller number of metal fibers are used. As such, since the metal fiber yarn is prepared from a small number of metal fibers and/or thin metal fibers, a metal fiber fabric having a low density may be prepared as compared with the conventional art.

In particular, in the case in which the low-density metal fiber fabric is used as a burner material, it has an advantage in that super low load combustion is possible. For example, the density of the fabric may be 4.0kg/m² or less, specifically, 0.1-4.0kg/m², but the invention is not limited thereto. In the case in which the fabric is used as a burner material or a filter material, the lower density of the fabric is favorable in view of the reduction in differential pressure. Therefore, even though the lower limit value for the density of the fabric is not specially limited, if the density of the fabric is less than 0.1kg/m², the interval between the metal fiber yarns constituting the fabric is so wide that the smooth combustion or the dust filtration performance is insufficient. In this regard, it is suitable that the density of the fabric is 0.1kg/m² or more. Meanwhile, if the density of the fabric exceeds 4.0kg/m², the interval between the metal fiber yarns is so narrow that the porosity is lowered and the differential pressure is increased. Thus, it is unsuitable in view of the ejection of fuel gas and the filtration performance. The fabric prepared to have a density of 0.1-4.0kg/m² has a thickness of 0.3-2.5mm. The porosity of the fabric is 75-95%.

The fabric according to the embodiment of the present invention may be used as a filter material and/or a burner material, specifically, as a membrane for a surface combustion burner, a pre-filter for water treatment, and a particulate filter.

Meanwhile, in the case in which the conventional metal fiber fabric is used as a burner material or a filter material, metal meshes are attached to both sides of the metal fiber fabric and then the metal fiber fabric to which the metal meshes are attached is processed, e.g., in a wrinkled shape. However, if the metal meshes attached to both sides of the metal fiber fabric are processed in a fabric form, they are easily damaged.

Therefore, in preparing the metal fiber fabric according to the embodiment of the present invention, metal wires are used instead of the metal fiber yarns used as the warp yarns and/or the weft yarns. The metal fiber yarns and the metal wires may be woven together to prepare the metal fiber fabric including the metal wires. The metal wires may be used as warps and/or wefts. That is, the fabric according to the embodiment of the present invention may be prepared from the metal fiber yarns and the metal wires by using the metal wires as at least one warp, at least one weft, or both of at least one warp and at least one weft among the plurality of warps and wefts. The number of the metal wires usable in preparing the metal fiber fabric is not specially limited. The metal wires may be used at any position of the warps and/or the wefts, at any interval, and/or in any number, considering the physical properties required when used as the burner material or the filter material, for example, combustion performance, filtration performance, and strength. The metal wire which is made of the same kinds of metal with the metal fiber yarn can be used.

Also, the metal wire having a diameter of 0.07 mm to 3mm may be used. If the diameter of the metal wire is less than 0.07mm, the metal wire is thin and thus the tensile strength is weak. In this regard, it is unfavorable because there is no great difference from the metal fiber. If the diameter of the metal wire exceeds 3mm, the metal wire is too thick. Hence, in the case in which the metal fiber fabric including the metal wires is used as the burner material, thermal deformation occurs at high temperature.

The metal fiber fabric prepared using the metal wires includes the metal wires therein. Thus, when the metal fiber fabric is used as a burner material or a filter material, no additional metal meshes are required as compared with the conventional art. Hence, when transforming the metal fiber fabric into the burner material or the filter material, there is no concern about damage to the material due to damage to the metal meshes, thereby improving the moldability into the material. Moreover, the metal wires inside the metal fiber fabric improve its strength, and the dense pores formed inside the metal fiber fabric by the metal wires further improve the combustion efficiency of the burner material and the filtration efficiency of the filter material.

Meanwhile, FIG. 12A illustrates a fabric prepared using metal wires as warps C instead of metal fiber yarns, and FIG. 12B illustrates a fabric prepared using metal wires as wefts C' instead of metal fibers. However, the invention is not limited to the examples of FIGS. 12A and 12B.

Since the metal fiber fabric prepared from the yarn including the metal fibers having the concave-convex patterns according to the embodiment of the present invention includes a plurality of uniform, regular and fine pores, it is suitable for a filter material for filtering fine dust particles and/or foreign objects. Also, since a fuel is finely and regularly ejected through the fine pores, a gas flow rate may be increased between the metal fibers, even in the case that a small amount of fuel is supplied. In this regard, the metal fiber fabric is suitable for the burner material because the fuel is stably burnt. Furthermore, since the fine pores between the metal fibers on which the concave-convex patterns are formed serve as fine flame holes, a wide combustion characteristic is exhibited throughout the high-load and low-load areas, and a more excellent heating effect is exhibited by the uniform flame distribution and the flame splitting effect. Moreover, improved differential pressure performance (reduced differential pressure) is exhibited.

Hereinafter, embodiments of the present invention will be described in detail. It should be noted that the following embodiments are only to aid in understanding the present invention, but the invention is not limited thereto.

Embodiment 1: Preparation and evaluation of yarn using metal fibers prepared by cutting process

A bundle of metal fibers (length: 40cm) having diameters listed in Table 2 below were prepared in a cutting process. Then, by passing the bundle of metal fibers through the spur gear 11 of FIG. 1 or the helical gear 31 of FIG. 3, the V-shaped concave-convex patterns illustrated in FIG. 2C or 4C were formed on the metal fibers at intervals listed in Table 2 below. The metal fiber included 22wt% of chromium (Cr), 5.5wt% of aluminum (Al), and the remaining wt% of iron (Fe).

As illustrated in FIG. 13, the metal fibers of comparative examples 1 to 5 and the metal fibers of embodiments 1 to 6 were drawn by passing them between rollers having different rotating speeds and having a comb shape on the surfaces thereof in a longitudinal direction of the metal fiber. Then, the drawn metal fibers were twisted to prepare yarns, one strand of which had the metal fiber strands and the number of turns listed in Table 2 below. The length of the prepared yarns was 0.55 m per gram. Meanwhile, the false twist yarn was prepared by twisting the metal fibers to manufacture a yarn and untwisting the yarn.

It was evaluated as to whether or not dimensional stability was maintained when metal fiber yarn of about 1m prepared in the above-described manner was pulled by a force of 1 kg.

Roller #1

Roller #2

Roller #3

Roller #4

Rotating speed (rpm)

5.4

5.4

5.4

5.4

Diameter (mm)

80

90

100

110

Surface speed (cm/min)

135.7

152.6

179.0

196.9

Elongation

1.38

Concave-convex pattern/ Interval (mm)

Gear type

Fiber diameter (µm)

Number of fibers/1 strand of yarn

Type of yarn/number of turns (turns/m)

Dimensional stability of yarn

Comparative example 1

None

-

50

30

Twisting yarn/5

Not processed into yarn

Comparative example 2

None

-

50

80

Twisting yarn/8

Not processed into yarn

Comparative example 3

None

-

50

80

False twist yarn/8

Not processed into yarn

Comparative example 4

V pattern/55

Spur gear

50

30

Twisting yarn/8

Metal fibers released from yarn

Inventive example 1

V pattern/10

Spur gear

50

30

Twisting yarn/5

No metal fibers released from yarn

Inventive example 2

V pattern/10

Helical gear

50

30

Twisting yarn/5

No metal fibers released from yarn

Inventive example 3

V pattern/30

Spur gear

50

30

False twist yarn/5

No metal fibers released from yarn

Inventive example 4

V pattern/18

Helical gear

50

30

Twisting yarn/3

No metal fibers released from yarn

Inventive example 5

V pattern/1.0

Helical gear

50

300

Twisting yarn/5

No metal fibers were released from yarn

Inventive example 6

V pattern/0.3

Spur gear

50

20

False twist yarn/3

No metal fibers were released from yarn

Comparative example 5

V pattern/0.2

Spur gear

50

30

Twisting yarn/3

Not drawn

As shown in Table 2 above, in the case of using the metal fibers of comparative examples 1 to 3 in which no concave-convex patterns were formed, the frictional force and entanglement between the metal fibers were insufficient and thus the metal fibers were not made into the yarn. In the case of comparative example 4, the metal fibers were made into the yarn, but the frictional force and entanglement thereof were insufficient due to the concave-convex patterns formed at large intervals. As a result, when the metal fiber yarn was pulled, the metal fibers were released and thus the form of the metal fiber yarn was not maintained. In the case of comparative example 5, the drawing of the metal fibers was impossible due to the concave-convex patterns which were densely formed on the metal fibers. As a result, the metal fibers were not processed into the yarn. In the case of inventive examples 1 to 6, the metal fibers were processed into yarn and false twist yarn. Also, the metal fibers were not released from the prepared yarn.

Embodiment 2: Preparation and evaluation of yarn using metal fibers prepared by drawing process

A bundle of metal fibers (length: 100cm) having diameters listed in Table 3 below were prepared in a drawing process. Then, by passing the bundle of metal fibers through the spur gear 11 of FIG. 1 or the helical gear 31 of FIG. 3, the V-shaped concave-convex patterns illustrated in FIG. 2C or 4C were formed on the metal fibers at intervals listed in Table 3 below. The metal fiber included 22wt% of chromium (Cr), 5.5wt% of aluminum (Al), and the remaining wt% of iron (Fe).

The metal fiber yarns meeting the conditions of Table 3 below were prepared using the metal fibers of comparative examples 6 to 10 and the metal fibers of inventive examples 7 to 12 in the same manner as the embodiment 1. Then, the dimensional stability of the prepared metal fiber yarns was evaluated. The length of the yarns was 1.1 m per gram.

Concave-convex pattern/ Interval (mm)

Gear type

Fiber diameter (µm)

Number of fibers/1 strand of yarn

Type of yarn/number of turns (turns/m)

Dimensional stability of yarn

Comparative example 6

None

-

20

60

Twisting yarn/5

Not processed into yarn

Comparative example 7

None

-

30

50

Twisting yarn/8

Not processed into yarn

Comparative example 8

None

-

40

40

False twist yarn/8

Not processed into yarn

Comparative example 9

V pattern/55

Spur gear

50

40

Twisting yarn/8

Metal fibers released from yarn

Inventive example 7

V pattern/10

Spur gear

40

40

False Twist yarn/3

No metal fibers released from yarn

Inventive example 8

V pattern/10

Helical gear

30

40

Twisting yarn/3

No metal fibers released from yarn

Inventive example 9

V pattern/30

Spur gear

30

40

Twisting yarn/5

No metal fibers released from yarn

Inventive example 10

V pattern/18

Helical gear

30

40

Twisting yarn/1

No metal fibers released from yarn

Inventive example 11

V pattern/1.0

Helical gear

20

20

False twist yarn/5

No metal fibers released from yarn

Inventive example 12

V pattern/0.3

Helical gear

30

40

Twisting yarn/5

No metal fibers released from yarn

Comparative example 10

V pattern/0.2

Spur gear

20

30

Twisting yarn/5

Not drawn

As shown in Table 3 above, in the case of using the metal fibers of comparative examples 6 to 8 in which no concave-convex patterns were formed, the frictional force and entanglement between the metal fibers were insufficient and thus the metal fibers were not processed into yarn. In the case of comparative example 9, the metal fibers were processed into yarn, but the frictional force and entanglement were insufficient due to the concave-convex patterns formed at large intervals. As a result, when the metal fiber yarn was pulled, the metal fibers were released and thus the form of the metal fiber yarn was not maintained. In the case of comparative example 10, the drawing of the metal fibers was impossible due to the concave-convex patterns which were densely formed on the metal fibers. As a result, the metal fibers were not processed into yarn. In the case of inventive examples 7 to 12, the metal fibers were processed into yarn and false twist yarn. Also, the metal fibers were not released from the prepared yarn.

Embodiment 3: Preparation and evaluation of yarn using metal fibers prepared by melt extraction process

A bundle of metal fibers (length: 10-18cm) having diameters listed in Table 4 below were prepared in a melt extraction process. Then, by passing the bundle of metal fibers through the spur gear 11 of FIG. 1 or the helical gear 31 of FIG. 3, the V-shaped concave-convex patterns illustrated in FIG. 2C or 4C were formed on the metal fibers at intervals listed in Table 4 below. The metal fiber included 22wt% of chromium (Cr), 5.5wt% of aluminum (Al), and the remaining wt% of iron (Fe).

The metal fiber yarns meeting the conditions of Table 4 below were prepared using the metal fibers of comparative examples 11 to 15 and the metal fibers of inventive examples 13 to 18 in the same manner as the embodiment 1. Then, the dimensional stability of the prepared metal fiber yarns was evaluated. The length of the yarns was 0.55 m per gram.

Concave-convex pattern/ Interval (mm)

Gear type

Fiber diameter (µm)

Number of fibers/1 strand of yarn

Type of yarn/number of turns (turns/m)

Dimensional stability of yarn

Comparative example 11

None

-

30

50

Twisting yarn/9

Metal fibers released from yarn

Comparative example 12

None

-

30

40

Twisting yarn/5

Metal fibers released from yarn

Comparative example 13

None

-

30

30

Twisting yarn/8

Metal fibers released from yarn

Comparative example 14

V pattern/55

Spur gear

30

40

Twisting yarn/8

Metal fibers released from yarn

Inventive example 13

V pattern/10

Spur gear

30

40

Twisting yarn/8

No metal fibers released from yarn

Inventive example 14

V pattern/10

Helical gear

30

40

Twisting yarn/3

No metal fibers released from yarn

Inventive example 15

V pattern/30

Spur gear

30

40

Twisting yarn/5

No metal fibers released from yarn

Inventive example 16

V pattern/18

Helical gear

30

40

Twisting yarn/7

No metal fibers released from yarn

Inventive example 17

V pattern/1.0

Helical gear

30

30

False twist yarn/5

No metal fibers were released from yarn

Inventive example 18

V pattern/0.3

Spur gear

30

30

False twist yarn/3

No metal fibers were released from yarn

Comparative example 15

V pattern/0.2

Spur gear

30

30

False twist yarn/3

Not drawn

As shown in Table 4 above, in the case of using the metal fibers of comparative examples 11 to 13 in which no concave-convex patterns were formed, the frictional force and entanglement between the metal fibers were insufficient. As a result, when the metal fiber yarn was pulled, the metal fibers were released and thus the form of the metal fiber yarn was not maintained. In the case of comparative example 15, the drawing of the metal fibers was impossible due to the concave-convex patterns which were densely formed on the metal fibers. As a result, the metal fibers were not processed into the yarn. In the case of inventive examples 13 to 18, the metal fibers were processed into yarn and false twist yarn. Also, the metal fibers were not released from the prepared yarn.

Embodiment 4: Air permeability of fabric

(Performance evaluation of differential pressure)

Three fabric samples illustrated in FIG. 9 and

FIG. 11 were woven by using the yarn of inventive example 12 and the yarn of comparative example 12 as the warp yarn and the weft yarn, respectively. The density of the fabric was 1.5kg/m², and the thickness of the fabric was 1.5mm. As illustrated in FIGS. 11A and 11B, flame holes having an aspect ratio (i.e. the ratio of width : length) of 5:1 were formed on both sides of the fabric. The number of the yarns used as the warp yarn and the weft yarn was 20 per inch in the width and length of the fabric, and the porosity of the fabric was 90%.

The minimum pore diameter and the average pore diameter of the fabric were measured using a porosimeter and shown in Table 5 below. Also, the air permeability of each fabric was measured using the KS K 0570-1997 Frazier method and its average was shown in Table 6 below.

Fabric 1

Fabric 2

Fabric 3

Average

Inventive fabric (prepared from yarn of inventive example 12)

Minimum pore diameter (µm)

31.70

13.77

41.07

28.85

Average pore diameter (µm)

44.06

49.88

41.47

45.14

Comparative fabric (prepared from yarn of comparative example 12)

Minimum pore diameter (µm)

22.56

61.98

36.46

40.33

Average pore diameter (µm)

51.08

64.60

53.15

56.28

Inventive fabric

Comparative fabric

Air permeability (cc/min/cm²)

109.86

54.48

As shown in Tables 5 and 6 above, the minimum pore diameter and the average pore diameter of the inventive fabric were smaller than those of the comparative fabric. It can be seen that the metal fiber fabric having finer pores were prepared by using the metal fiber yarn having the metal fibers with the concave-convex patterns according to the embodiment of the present invention. Meanwhile, the inventive fabric had two times the air permeability of the comparative fabric. Hence, it could be confirmed that fine pores were formed in the fabric which was prepared from the metal fiber yarn having the concave-convex pattern according to the embodiment of the present invention, and the air permeability was improved (that is, a small differential pressure was applied).

Embodiment 5: Evaluation of combustion efficiency when fabric is used as burner material

The yarns prepared in inventive example 12 and comparative example 12 were woven to prepare the fabrics of FIGS. 9 and 11 which have the density of 1.5kg/m² and the thickness of 1.5mm. As illustrated in FIGS. 11A and 11B, flame holes having an aspect ratio (i.e. ratio of width : length) of 5:1 were formed on both sides of the fabric. The number of the yarns used as the warps and the wefts was 20 per inch in the width and length of the fabric, and the porosity of the fabric was 90%.

The combustion efficiency was evaluated when the prepared fabrics were used as a membrane in a combustion burner. FIG. 14 is a picture of an inventive fabric prepared from the yarn of inventive example 1 (hereinafter, referred to as an inventive fabric 1) and a comparative fabric prepared from the yarn of comparative example 12 (hereinafter, referred to as a comparative fabric 1) which were applied as a membrane in a surface combustion burner.

A mixture gas of air and fuel gas was injected into the respective fabrics and burnt while changing the mixture ratio thereof to a value of λ which is defined as a ratio of air/fuel gas. First, a mixture gas of air and fuel gas was burnt while changing the mixture ratio λ thereof to 1.05, 1.25, and 1.42. In this case, the lowest heating value of the inventive fabric 1 prepared from the yarn of inventive example 12 was 300 kW/m² (FIG. 15A), and the lowest heating value of the comparative fabric 1 prepared from the yarn of comparative example 12 was 418 kW/m² (FIG. 16A).

Meanwhile, in the case in which the mixture gas of fuel gas and air was burnt while changing its mixture ratio λ to 1.03, 1.22, 1.41, and 1.69, the highest heating value of the inventive fabric 1 was 1,500 kW/m² (FIG. 15B), and the highest heating value of the comparative fabric 1 was 1,063 kW/m² (FIG. 16B).

In the case in which the inventive fabric 1 prepared from the yarn of inventive example 12 was used as a membrane for a surface combustion burner, a lowest combustion load : highest combustion load ratio was 1:5. On the other hand, in the case in which the comparative fabric 1 prepared from the yarn of comparative example 12 was used as a membrane for a surface combustion burner, a lowest combustion load : highest combustion load ratio was 1:2.5. Consequently, the combustion load area of the inventive fabric 1 was two times wider than the combustion load area of the comparative fabric 1. It could be confirmed that the fabric prepared from the yarn including the metal fibers with the concave-convex patterns according to the embodiment of the present invention exhibited the excellent combustion efficiency due to the plurality of fine and uniform pores formed by the concave-convex patterns of the fibers.

Embodiment 6: Evaluation of fabric used as filter material

In this embodiment, The strengths of the inventive fabric 1 which is described in the embodiment 5 prepared by using yarns of inventive example 12 as the weft yarns and the warp yarns; inventive fabric 2 which was prepared using the yarn of the inventive yarn 12 and the metal wire having a diameter of 0.2mm as the wefts and the warps, respectively (the fabric prepared using 20-strand yarns per 1 inch of the fabric as the weft yarn and 8-strand metal wires per 1 inch of the fabric as the warp) ; the comparative fabric 1 which is described in the embodiment 5 prepared using the yarns of comparative example 12 as the weft yarns and the warp yarns; and a complex body, which manufactured by attaching the metal meshes to both sides of the fabric of the inventive fabric 1 were measured and compared with one another.

The metal mesh (porosity: 75%, diameter: 0.2mm) included 22wt% of chromium (Cr), 5.5wt% of aluminum (Al), and the remaining wt% of iron (Fe). The metal wire also included 22wt% of chromium (Cr), 5.5wt% of aluminum (Al), and the remaining wt% of iron (Fe).

The strengths of the fabrics and the complex body were measured using the KS K 0520-1995 ravel strip method and shown in Table 7 below.

Tensile Strength(kgf/cm)

Inventive fabric 1

Weft direction

20

Warp direction

21

Inventive fabric 2

Weft direction

20

Warp direction

250

Comparative fabric 1

Weft direction

13.7

Warp direction

16.6

Complex body

Weft direction

255

Warp direction

263

As shown in Table 7 above, the inventive fabric 1 prepared from the metal fiber yarn according to the embodiment of the present invention exhibited more excellent tensile strength than that of the comparative fabric 1. Also, the inventive fabric 2 prepared using the metal wires as the warp yarn exhibited the warp-direction tensile strength comparable to that of the complex body.

Meanwhile, when the inventive fabric 1 and the comparative fabric 1 were cut with the diameter of 40mm and were used as filters, the collection efficiency of the fabrics was measured three times and the measurement results were shown in Table 8 below. When fume particles were injected into one side of the filter and a vacuum pump was operated, the fume particles were introduced through a connection pipe coupled to the filter and filtered by the filter. The remaining fume particles having passed through the filter were collected in a cassette disposed at the other side of the filter. The collection efficiency were calculated from the following equation and shown in Table 8 below. $$\mathrm{Collection\; Efficiency}\left(\mathrm{\%}\right)\mathrm{=}\frac{\mathrm{A}}{\mathrm{A}\mathrm{+}\mathrm{B}}\mathrm{\times }\mathrm{100}$$

where,

A is weight of fume particles filtered by the filter

B is weight of fume particles passing through the filter

(Weight of fume particles collected in the cassette)

(That is, the sum of A and B is the weight of all fume particles injected into the filter)

No.

Comparative fabric 1

Inventive fabric 1

1

79.1

88.7

2

68.7

85.0

3

61.7

89.8

Average

69.83

87.8

As can be seen from Table 8 above, the inventive fabric 1 exhibited more excellent collection efficiency than that of the comparative fabric 1.

As set forth above, according to exemplary embodiments of the invention, the metal fibers having the concave-convex patterns formed at regular intervals in the longitudinal direction exhibit the improved frictional force between the metal fibers, entanglement, and processability due to the concave-convex patterns on the metal fibers. In particular, the metal fibers exhibit the excellent processability as the metal fiber yarn. Therefore, due to the concave-convex patterns, the metal fiber according to the embodiment of the present invention is well entangled with other metal fibers, and the entangled state between the metal fibers is maintained by the large frictional force between the metal fibers. Also, the fibers are not released from the metal fiber yarn. Therefore, in preparing the metal fiber yarn, no additional binder and/or polymer are/is required.

In addition, by forming the concave-convex patterns at regular intervals in the metal fibers prepared by the metal extraction process or the smooth metal fibers prepared by the machining process such as the cutting process or the drawing process, the metal fiber yarn may be easily prepared using those metal fibers.

Furthermore, the metal fiber having the concave-convex patterns according to the embodiment of the present invention has excellent elasticity due to the concave-convex patterns. Due to the elasticity, the metal fiber yarn may be easily prepared and may be easily processed into the metal fabric. The metal fiber yarn may be processed into any type of fabric. The prepared metal fiber yarn and the metal fabric using the same have a soft texture.

Meanwhile, the metal fiber yarn including the metal fibers having the concave-convex patterns according to the embodiment of the present invention maintains its form stably because metal fibers are not released. Also, the metal fiber yarn has a plurality of uniform and fine pores.

Moreover, due to the easy entanglement and large frictional force between the metal fibers having the concave-convex patterns, there is no limitation on the length and thickness of the metal fiber used in preparing the metal fiber yarn and/or the number of the metal fibers constituting one strand of the yarn. That is, the metal fiber yarn having excellent dimensional stability and air permeability may be prepared using the metal fibers having any length and/or thickness. Furthermore, one strand of the yarn may be formed with any number of metal fibers.

The fabric prepared from the metal fiber yarn according to the embodiment of the present invention also has the more improved porosity. Therefore, when the fabric according to the embodiment of the present invention is used as the filter material, finer dust particles and/or foreign objects may be effectively filtered. Also, when the fabric according to the embodiment of the present invention is used as the burner material, the heating effect is improved by the excellent porosity of the fabric and the excellent flame splitting effect due to the plurality of fine and uniform pores, and the wide combustion area and the high combustion rate are exhibited. Moreover, the fabric according to the embodiment of the present invention exhibits improved differential pressure performance.

While the present invention has been shown and described in connection with the exemplary embodiments, it will be apparent to those skilled in the art that modifications and variations can be made without departing from the spirit and scope of the invention as defined by the appended claims.