Method for producing fiber mat and fiber mat

Abstract

A method for producing a fiber mat that includes: dispersing fibers having a fiber length smaller than a pore diameter of a papermaking wire in a dispersion medium; and matting the dispersed fibers including papermaking the dispersed fibers on a microporous sheet having a pore diameter smaller than that of the papermaking wire and disposed on the papermaking wire.

1 . A method for producing a fiber mat, the method comprising:
 dispersing fibers having a fiber length smaller than a pore diameter of a papermaking wire in a dispersion medium; and   matting the dispersed fibers including papermaking the dispersed fibers on a microporous sheet having a pore diameter smaller than that of the papermaking wire and disposed on the papermaking wire.   
     
     
         2 . The method for producing a fiber mat according to  claim 1 , wherein the fibers are at least a part of a liquid crystal polymer powder. 
     
     
         3 . The method for producing a fiber mat according to  claim 2 , wherein the fibers of the liquid crystal polymer powder have an aspect ratio of the fiber length to a fiber diameter of 10 times or more and 500 times or less, and the fibers of the liquid crystal polymer powder have an average diameter of 2 μm or less. 
     
     
         4 . The method for producing a fiber mat according to  claim 2 , wherein the liquid crystal polymer powder is a thermotropic liquid crystal polymer. 
     
     
         5 . The method for producing a fiber mat according to  claim 2 , wherein a molecule of the liquid crystal polymer powder has a negative thermal expansion coefficient in an axial direction of a molecular axis thereof and a positive thermal expansion coefficient in a radial direction of the molecular axis thereof. 
     
     
         6 . The method for producing a fiber mat according to  claim 2 , wherein the liquid crystal polymer powder does not have an amide bond. 
     
     
         7 . The method for producing a fiber mat according to  claim 1 , further comprising peeling the microporous sheet from the papermaking wire after the matting of the disbursed fibers on the microporous sheet. 
     
     
         8 . The method for producing a fiber mat according to  claim 1 , wherein the microporous sheet is a woven fabric mesh. 
     
     
         9 . The method for producing a fiber mat according to  claim 8 , wherein the pore diameter of the microporous sheet is 100 μm or less. 
     
     
         10 . The method for producing a fiber mat according to  claim 1 , wherein the microporous sheet is a wet nonwoven fabric. 
     
     
         11 . The method for producing a fiber mat according to  claim 1 , wherein the pore diameter of the microporous sheet is 100 μm or less. 
     
     
         12 . The method for producing a fiber mat according to  claim 1 , wherein the pore diameter of the microporous sheet is 5 μm to 50 μm. 
     
     
         13 . A fiber mat comprising fibers and having a formation index of 100 or less as measured by a 3D sheet analyzer. 
     
     
         14 . The fiber mat according to  claim 13 , wherein the formation index is 10 or more. 
     
     
         15 . The fiber mat according to  claim 13 , wherein the fibers are at least a part of a liquid crystal polymer powder. 
     
     
         16 . The fiber mat according to  claim 15 , wherein the fibers of the liquid crystal polymer powder have an aspect ratio of a fiber length to a fiber diameter of 10 times or more and 500 times or less, and the fibers of the liquid crystal polymer powder have an average diameter of 2 μm or less. 
     
     
         17 . The fiber mat according to  claim 15 , wherein a main orientation direction of molecules of the liquid crystal polymer powder is along an in-plane direction of the fiber mat. 
     
     
         18 . The fiber mat according to  claim 15 , wherein the liquid crystal polymer powder is a thermotropic liquid crystal polymer. 
     
     
         19 . The fiber mat according to  claim 15 , wherein a molecule of the liquid crystal polymer powder has a negative thermal expansion coefficient in an axial direction of a molecular axis thereof and a positive thermal expansion coefficient in a radial direction of the molecular axis thereof.