Methods for producing fiber reinforced microspheres made from dispersed

Abstract

Fiber reinforced hollow microspheres made from dispersed particle film forming compositions including fibers, dispersed particles, a binder, a film stabilizing agent, a dispersing agent and a continuous liquid phase. Porous and non-porous fiber reinforced hollow microspheres can be made. The fiber reinforced hollow microspheres have walls with voids which are interconnected to each other and to the inner and outer wall surfaces, and the fiber reinforced hollow microspheres can be used as membrane substrates in selective separation processes and in biotech processes. The fiber reinforced hollow microspheres can be used as supports for catalysts and as enclosures for catalysts, adsorbents and absorbents. The fiber reinforced hollow microspheres can also be used as filler materials and as proppants for increasing gas recovery from gas wells. The fiber reinforced hollow microspheres are made by a process which includes forming a film of a fiber and dispersed particle film forming composition across a coaxial blowing nozzle, applying a blowing gas at a positive pressure on the inner surface of the fiber and dispersed particle composition film to blow the film and form an elongated cylinder shaped film of the fiber and dispersed particle composition. The cylinder shaped film is initially closed at its outer end, and as the cylinder shaped film progresses away from the coaxial nozzle, the film closes at its inner end, prior to the beginning of the formation of the next cylinder shaped film at the coaxial nozzle. The hollow fiber and dispersed particle composition microspheres are individually formed as they emerge from the coaxial nozzle. The blown microspheres form substantially spherical hardened fiber reinforced hollow green microspheres.