GB2212148A - Treatment of inorganic fibres - Google Patents

Treatment of inorganic fibres Download PDF

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Publication number
GB2212148A
GB2212148A GB8829345A GB8829345A GB2212148A GB 2212148 A GB2212148 A GB 2212148A GB 8829345 A GB8829345 A GB 8829345A GB 8829345 A GB8829345 A GB 8829345A GB 2212148 A GB2212148 A GB 2212148A
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United Kingdom
Prior art keywords
fibres
islands
web
carbon
metal
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB8829345A
Other versions
GB8829345D0 (en
Inventor
Colin Moore
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BOC Group Ltd
Original Assignee
BOC Group Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by BOC Group Ltd filed Critical BOC Group Ltd
Publication of GB8829345D0 publication Critical patent/GB8829345D0/en
Publication of GB2212148A publication Critical patent/GB2212148A/en
Withdrawn legal-status Critical Current

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Classifications

    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01FCHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F11/00Chemical after-treatment of artificial filaments or the like during manufacture
    • D01F11/10Chemical after-treatment of artificial filaments or the like during manufacture of carbon
    • D01F11/12Chemical after-treatment of artificial filaments or the like during manufacture of carbon with inorganic substances ; Intercalation
    • D01F11/126Carbides
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01FCHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F11/00Chemical after-treatment of artificial filaments or the like during manufacture
    • D01F11/10Chemical after-treatment of artificial filaments or the like during manufacture of carbon
    • D01F11/12Chemical after-treatment of artificial filaments or the like during manufacture of carbon with inorganic substances ; Intercalation
    • D01F11/123Oxides
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01FCHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F11/00Chemical after-treatment of artificial filaments or the like during manufacture
    • D01F11/10Chemical after-treatment of artificial filaments or the like during manufacture of carbon
    • D01F11/12Chemical after-treatment of artificial filaments or the like during manufacture of carbon with inorganic substances ; Intercalation
    • D01F11/127Metals
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01FCHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F11/00Chemical after-treatment of artificial filaments or the like during manufacture
    • D01F11/10Chemical after-treatment of artificial filaments or the like during manufacture of carbon
    • D01F11/12Chemical after-treatment of artificial filaments or the like during manufacture of carbon with inorganic substances ; Intercalation
    • D01F11/128Nitrides, nitrogen carbides

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  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

Discrete islands 82 of a substance, eg a metal, metal oxide, metal nitride or metal carbide are deposited eg by magnetron sputtering on a web of fibres 80. The islands 82 enhance bonding of the fibres 80 to a body 84 eg of plastics that the fibres 80 are intended to strengthen. Fibres may be carbon, glass or a ceramic eg. silica, aluminium oxide, zirconia, boron nitride, silicon carbide or silicon nitride. <IMAGE>

Description

TREATMENT OF INORGANIC MATERIAL DESCRIPTION This invention relates to the treatment of inorganic material. In particular, it relates to the surface treatment of fibres of inorganic material. The term "fibres of inorganic material" includes within its scope carbon fibres even though such carbon fibres may be formed from precursor fibres of organic material such as polyacrylonitrile.
Carbon fibres are forms of carbon having a carbon content typically in excess of 92% by weight and are characterised in having excellent mechanical properties such as high strength and a high Young's modulus. There are typically also flexible, chemically inert, except to oxidation, and have good refractoriness. The fibres are therefore employed commercially in plastics and metals as strengtheners. One well recognised problem in the art is that there can be inadequate bonding between the fibres and the material in which the fibres are embedded with the result that premature failure of the materials can take place. Accordingly, in order to ameliorate this problem, carbon fibres are generally given a surface treatment, typically be anodic oxidation, although other forms of oxidative etching in air, or nitric acid or other oxidising liquids are known.Such surface treated carbon fibres are currently used commercially in, for example, major flight-critical structures.
There is nonetheless still a recognition in the art that improvements to the surface treatment so as to gain superior bonds between the fibres and the material in which they are embedded are desirable, and it is an aim of the invention to provide a novel form of surface treatment which will be at least satisfactory as methods currently practised. The method according to the invention is not limited to the treatment of carbon fibres and may also be employed to treat fibres of other inorganic material, particularly ceramic materials, which may have properties comparable to carbon fibres.
According to the present invention there is provided a method of treating fibres of inorganic material comprising the step of depositing discrete islands of a substance, on a web of said fibres.
The invention also provides fibres of inorganic material bearing deposits of a substance in the form of discrete islands.
The said islands are preferably deposited by magnetron sputtering or ion plating and are preferably of a substance other than elemental carbon. Ion plating is a technique in which a DC potential or radio frequency applied to or in front of the substrate (ie the web of fibres) and a DC or radio frequency glow discharge (or plasma) is struck in an atmosphere of inert gas, for example, argon about the substrate such that the substrate is subject to continual inert gas ion bombardment. The source of the coating is desirably a planar magnetron sputtering source which itself is subject to a discharge.
It is possible however to use other kinds of source, particularly those that rely on bombardment of a target by charged or energetic particles (eg an electron beam). Evaporative sources are however are not preferred. The ion plating source typically comprise a metal such as aluminium, zinc, tin, nickel, or chromium or a non-metallic element such as silicon. The islands may comprise a metal or silicon, or may comprise a compound of such metal or silicon. Preferably the compound is an oxide, nitride or carbide and is prepared by reactive ion plating. In reactive ion plating there is a partial pressure of a chemically active gas or ionic species in the vicinity of a substrate such that there is reaction between the metal sputtering source and the chemically active species at the surface of the substrate.With some sources, for example, indium it is possible to deposit a coating by a sputtering method (and preferably a planar magnetron sputtering method) without striking a DC or radio frequency glow discharge (or plasma) about the substrate. Although such a method can be referred to as an ion plating method, it is not so described herein but is instead referred to as a (planar magnetron) sputtering method. The term "ion plating" is reserved for processes in which a DC or radio frequency discharge is struck in a suitable atmosphere about the substrate.
Conventionally, ion plating or magnetron sputtering is employed to deposit continuous uniform coatings rather than discrete islands of material.
However, islands can be readily deposited employing magnetron sputtering sources by appropriately selecting the sputtering voltage and sputtering current. Suitable sputtering voltages and sputtering currents can be selected by simple experiment according to the desired proportion of the surface area of the web that is to be covered by the islands. Tyically, the sputtering voltage and sputtering current will be less than the values used when depositing a continuous coating.
Preferably, each island has a maximum radial thickness in the range 10 to 1000 Angstroms. Preferably, islands are deposited on both sides of the web, the web being advanced through a first and then a second deposition station.
Although the fibrous material of choice is typically carbon, the invention can be used to deposit islands on ceramic fibres. Known ceramic fibres include silica, aluminium oxide, zirconia, boron nitride, silicon carbide, and silicon nitride (Si3 N4).
The invention may also be used to deposit islands on glass fibres.
The invention also includes a structural member comprising a body of plastics or metal having embedded therein fibres treated in accordance with the invention The invention will now be described by way of example with reference to the accompanying drawings, in which Figure 1 is a schematic diagram of a plant for making carbon fibres, and Figure 2 is a schematic drawing of part of a plant of depositing ions of substance other than carbon on carbon fibres, the apparatus being suitable for use in the plant shown in Figure 1.
Figure 3 is a schematic section of a fragment of a prepeg including fibres in accordance with the invention.
The e drawings are not to scale.
Referring to Figure 1 of the drawings, a multiplicity of polyacrylonitrle (PAN) fibres are fed to a creel unit 2 and are doffed upon creels forming part of the unit and formed into a parallel web over textile guides and tensioning rolls (not shown). The web is then drawn through a first oxidation oven 4 and a second oxidation oven 6 in which under controlled conditions of stretch, shrinkage, air flow and temperature, the fibres are reacted with atmospheric oxygen. This treatment converts the polyacrylonitrle to a thermally stable, non-flamable, carbonisable fibre of complex chemical composition. The gases evolved from the polyacrylonitrle fibres are burnt in catalytic incinerators 8 associated with the ovens 4 and 6 so as to ensure that no toxic vapours are emitted to the atmosphere.
The web of fibres is then passed through first and second carbonisation furnaces 10 and 12 respectively. The first furnace 10 is operated at a lower temperature than the second furnace 12 and is effective to remove vaporisable by-products including tar from the fibres so as to increase their carbon content to approximately 90% by weight. Further heat treatment in the higher temperature furnace 12 anneals the web and drives off most of the residual non-carbonaceous elements. After carbonisation, the web of fibres are passed through a further furnace 14 which is operated at a temperature in excess of 2,0000C. The e purpose of this treatment is to ensure that micro-crystallites in the fibres develop into an ordered texture. Some hydrogen is also evolved during this step. The e web of fibres is then passed through a cooler 16 and into a surface treatment apparatus 18 which is operated in accordance with the invention. The resulting carbon fibres are then typically sized in a sizer 20 and passed to a collection unit 22.
It is to be appreciated that all the units described with reference to Figure 1 are well known in the art with the exception of the apparatus 18.
One part of the apparatus 18 is shown in Figure 2. It comprises a vacuum chamber 32. In the chamber 32 there is provided a set of rollers, including a roller 34 on to which the web is fed in use. During deposition of the islands of material other than carbon on the web, the web is fed from the roller 4 around a main water cooled roller 36 to a roller 38. Rollers 34, 36 and 38 each have full electronic motor control to ensure the correct winding of the web during operation of the apparatus.
In addition, pinch rollers 40 and 42 co-operate with the roller 36 to prevent the web from slipping on the surface of the roller 36. The rollers 34 and 38 act as tensioned unwind and rewind rollers respectively. The rollers 34, 36, 38, 40 and 42 are all located in an inner cage 44 which is in turn located within an outer cage 45. The cages 44 and 45 have contiguous openings 46 facing forwards to permit deposition of a coating on the web as it passes along the opening in operation of the rollers.
The cage 44 is provided with a water-cooled aluminium platten 48 in a rearward position and in electrically-conductive relationship with the cage 44. The platten 48 is insulated from earth by an insulator 50. The drives (not shown) to the rollers 34, 36, 38 are also insulated. A radio frequency generator 52 is adapted to apply a radio frequency potential to the platten 46 through connectors 54. The connectors 54 are water-cooled. The cage 45 is connected to earth and in effect functions is a second electrode.
All the rollers, the cage 44, which acts a RF cage, the cage 45 which is earthed and the platten 48 and insulator 50 are all located as a demountable assembly within the evacuable chamber or housing 32. The chamber 32 has a port 58 connectible to a vacuum pump (not shown) and a port 60 connectible to a Pirani gauge (not shown) or other vacuum measuring device.
A planar magnetron sputtering source 62 is provided within the chamber 56 opposite to the opening 46 and the cage 45. The planar magnetron sputtering source 62 has associated therewith an earthed shield 64, and water-cooled arc supression means 66. The planar magnetron sputtering source is its own potential supply (not shown). A combination of motor generator and electronic supply (not shown) may be used to supply the DC potential as the sputtering source 62. An annular gas distributor 68 is located near to the planar magnetron sputtering source 62 and a similar distributor 70 is located about the opening 46 and the cage 45.A gas distributor 68 is connectible to a source (not shown) of argon under pressure and in operation distributes the argon generally radially inwards, and the gas distributor 70 is connectible to a source (not shown) of reactive gas under pressure and is adapted to distribute the reactive gas radially inwards. The reactive gas, for example oxygen, may be employed to react with the source material at the surface of the web.
In operation, the chamber 32 is continously evacuated, an RF potential is applied to the platten 48 and the planar magnetron sputtering source 62 is activated. The web is fed from the roller 34 to the roller 38 and passes along the opening 46, and argon and oxygen are passed into the chamber 32 from their respective distributors. The planar magnetron confines magnetically a toroidal plasma of argon ions about the source to be sputtered. Atoms of the source material thus emitted from the source in the direction of the opening 46 and the cage 45. The RF potential creats a glow discharge about the web to be coated, which glow discharge is confined to the region of the main roller 36. As the impinging atoms of the source material come into contact with oxygen the exposed surface of the web for the time being along side the opening 46.The sputtering voltage and current is controlled so that discrete islands of metal oxide are deposited on to the exposed surface of the web.
If desired, the apparatus shown in Figure 2 may be operated purely as a planar magnetron sputtering apparatus, in which instance no potential is applied to the electrode 48.
Typically, in the surface treater 18 shown in Figure 1, two apparatuses of the kind shown in Figure 2 may be employed, one apparatus being used to deposit islands of metal oxide on one side of the web and the other apparatus being employed to deposit islands of metal oxide on the other side of the web.
Alternatively, a system of rollers and two sputtering sources may be employed in a single chamber such that islands of chosen material may be deposited on both sides of the web of carbon fibres.
If desired, the finished web may be converted into any conventional form for use in making prepegs or other structural members. Such prepegs are typically formed by embedding the fibres, sometimes woven into suitable shape, in a chosen plastics resin. The presence of the islands of metal oxide or other substance on the carbon fibres facilitates good bonding between the plastics and the carbon fibres. It is to be appreciated that carbon fibres according to the invention may also be used in strengthing metal members.
A plastics prepeg in accordance with the invention is illustrated in Figure 3 of the drawings. Fibres 80 bearing deposited islands 82 are embedded in a plastics body or matrix 84.

Claims (1)

1. A method of treating fibres of inorganic material comprising the step of depositing discrete islands of a substance on a web of said fibres.
2. A method as claimed in claim 1 in which the islands are deposited by magnetron sputtering or ion plating.
3. A method as claimed in claim 1 or claim 2 in which the islands comprise a metal or silicon.
4. A method as claimed in claim 1 or claim 2, in which the islands comprise a compound of a metal or silicon, said compound being an oxide, nitride or carbide.
5. A method as claimed in claim 4, in which the islands are prepared by reactive ion plating.
6. A method as claimed in any one of the preceding claims, in which each island has a maximum radial thickness in the range 10 to 1000 Angstroms.
7. A method as claimed in any one of the preceding claims, in which islands are deposited on both sides of the web.
8. A method as claimed in any one of the preceding claims, in which the web is of carbon fibres.
9. A method as claimed in any one of claims 1 to 7, in which the web is of ceramic fibres.
10. A method as claimed in claim 9, in which the ceramic fibres are selected from fibres of silica, aluminium oxide, zirconia, boron nitride, silicon carbide, or silicon nitride.
11. A method as claimed in any one of claims 1 to 7, in which the fibres are of glass.
12. A method of treating carbon fibres, substantially as herein described with reference to the accompanying drawings.
13. Fibres of inorganic material bearing deposits of a substance in the form of discrete islands.
14. Fibres as claimed in claim 13, in which each island has a maximum radial thickness in the range 10 to 1000 Angstrorrs.
15. Fibres as claimed in claim 13 or 14, being of carbon.
16. Fibres as claimed in claim 13 or 14, being of ceramic material.
17. Fibres as claimed in claim 16, in which the ceramic material comprises silica, aluminium oxide, zirconia, boron nitride, silicon carbide, and silicon nitride.
18. Fibres as claimed in claim 12 or claim 13, being of glass.
20. Fibres whenever prepared by a method as claimed in any one of claims 1 to 12.
21. A structural member comprising a body of plastics or metal having embedded therein fibres as claimed in any one of claims 13 to 20.
GB8829345A 1987-12-23 1988-12-16 Treatment of inorganic fibres Withdrawn GB2212148A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB878729955A GB8729955D0 (en) 1987-12-23 1987-12-23 Treatment of inorganic material

Publications (2)

Publication Number Publication Date
GB8829345D0 GB8829345D0 (en) 1989-02-01
GB2212148A true GB2212148A (en) 1989-07-19

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GB878729955A Pending GB8729955D0 (en) 1987-12-23 1987-12-23 Treatment of inorganic material
GB8829345A Withdrawn GB2212148A (en) 1987-12-23 1988-12-16 Treatment of inorganic fibres

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1485896A (en) * 1975-09-15 1977-09-14 Fiber Materials Fibre/metal composite materials
GB1593246A (en) * 1976-09-06 1981-07-15 Romaniec C Process for producing passivley inert fibrous material
GB2044737B (en) * 1978-12-30 1982-10-27 Kernforschungsz Karlsruhe Supercondutors
EP0167254A1 (en) * 1984-06-06 1986-01-08 Imperial Chemical Industries Plc Fibrous composite materials and the production and use thereof
WO1987007559A1 (en) * 1986-06-06 1987-12-17 Hyperion Catalysis International, Inc. Novel carbon fibrils, method for producing same, and compositions containing same

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1485896A (en) * 1975-09-15 1977-09-14 Fiber Materials Fibre/metal composite materials
GB1593246A (en) * 1976-09-06 1981-07-15 Romaniec C Process for producing passivley inert fibrous material
GB2044737B (en) * 1978-12-30 1982-10-27 Kernforschungsz Karlsruhe Supercondutors
EP0167254A1 (en) * 1984-06-06 1986-01-08 Imperial Chemical Industries Plc Fibrous composite materials and the production and use thereof
WO1987007559A1 (en) * 1986-06-06 1987-12-17 Hyperion Catalysis International, Inc. Novel carbon fibrils, method for producing same, and compositions containing same

Also Published As

Publication number Publication date
GB8729955D0 (en) 1988-02-03
GB8829345D0 (en) 1989-02-01

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