JP2016008371A - 炭素繊維断熱材及びその製造方法 - Google Patents
炭素繊維断熱材及びその製造方法 Download PDFInfo
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Abstract
Description
(炭素繊維断熱材製造用の異種のフェルトの製造方法)
石炭系の高軟化点の等方性ピッチ(軟化点:280℃)を溶融噴射紡糸法により炭素繊維を紡糸した。紡糸されたピッチ系炭素繊維を堆積し、マットを製造した。前記炭素繊維マットを不融化炉及び炭化炉に移送して、0.05g/cm3の炭素繊維マットを製造した。また、前記炭素繊維マットの上部及び下部にポリプロピレンフェルトを積層した後、ニードルパンチングを行い、炭素繊維断熱材製造用の異種のフェルトを製造した。
前記実施例により製造された異種のフェルトをフェノール樹脂に含浸し、6層に積層した後、加圧硬化した。前記加圧硬化された炭素繊維マットを1,000℃の窒素雰囲気で炭化した。炭化された炭素繊維断熱材の見かけ密度は0.16g/cm3であり、ここで、異種のフェルトに含まれたポリプロピレンフェルトは、すべて炭化されて除去された。
実施例とすべての条件を同様にし、ポリプロピレンフェルトのような低炭化率の繊維マットを含むことなく、炭素繊維マットのみを積層して、炭素繊維断熱材を製造した。前記比較例による炭素繊維断熱材は、炭化段階で炭素繊維マット積層体の厚さ方向の繊維が除去されていない状態であった。
前記実施例と比較例により製造された炭素繊維断熱材の熱伝導度を測定するために、厚さが30mmに製造された各炭素繊維断熱材のサンプルを製造した後、それぞれ25℃での熱伝導度を測定した。この際、熱処理温度(800℃及び1,000℃)による熱伝導度の変化もまた確認した。前記熱伝導度測定の結果は、下記の表2に記載されている。
12 炭素繊維マット積層面
13 炭素繊維
21 炭素繊維マット積層体
22 結束された炭素繊維マット積層体
23 炭素繊維断熱材
31 低炭化率の繊維マット
32 低炭化率の繊維
33 結束された異種のフェルト
34 貫通孔
35 炭素繊維断熱材
Claims (17)
- 少なくとも一つの炭素繊維マットが積層された炭素繊維マット積層体と、前記炭素繊維マット積層体の上部及び下部の少なくともいずれか一方に位置する低炭化率の繊維マットと、を含み、前記炭素繊維マット積層体と前記低炭化率の繊維マットが、前記炭素繊維マット積層体の厚さ方向へのニードルパンチングにより結束された状態である異種のフェルトを熱処理して製造される、炭素繊維断熱材。
- 前記低炭化率の繊維マットは、10%以下の炭化率を有することを特徴とする、請求項1に記載の炭素繊維断熱材。
- 前記低炭化率の繊維マットは、ポリプロピレン、ポリエチレンテレフタレート、ポリエチレン及び生分解性樹脂フェルトから選択される少なくともいずれか一つを含むことを特徴とする、請求項2に記載の炭素繊維断熱材。
- 前記低炭化率の繊維マットは、熱処理により除去されることを特徴とする、請求項1に記載の炭素繊維断熱材。
- 前記熱処理は、800〜2,300℃の範囲から選択される温度で行われることを特徴とする、請求項1に記載の炭素繊維断熱材。
- 熱処理後、前記低炭化率の繊維マットの質量残存率が5%未満であることを特徴とする、請求項4に記載の炭素繊維断熱材製造用の炭素繊維断熱材。
- 前記炭素繊維マット積層体と前記低炭化率の繊維マットは、前記炭素繊維マット積層体の厚さ方向にニードルパンチングされた低炭化率の繊維によって結束された状態であることを特徴とする、請求項1に記載の炭素繊維断熱材。
- 前記炭素繊維マット積層体の厚さ方向の低炭化率の繊維は、熱処理により除去されることを特徴とする、請求項7に記載の炭素繊維断熱材。
- 熱処理後、前記炭素繊維マット積層体の厚さ方向の低炭化率の繊維の質量残存率が5%未満であることを特徴とする、請求項8に記載の炭素繊維断熱材。
- 前記炭素繊維断熱材の厚さ方向への熱伝導度は、0.06(W/m・K、25℃)以下であることを特徴とする、請求項1に記載の炭素繊維断熱材。
- (a)少なくとも一つの炭素繊維マットが積層された炭素繊維マット積層体と、前記炭素繊維マット積層体の上部及び下部の少なくともいずれか一方に位置する低炭化率の繊維マットと、を含み、前記炭素繊維マット積層体と前記低炭化率の繊維マットが、前記炭素繊維マット積層体の厚さ方向へのニードルパンチングにより結束された状態である異種のフェルトを準備する段階と、
(b)前記異種のフェルトをバインダー樹脂に含浸した後、硬化する段階と、
(c)前記硬化された異種のフェルトを熱処理して、前記異種のフェルトから前記低炭化率の繊維マットを除去する段階と、を含む、炭素繊維断熱材の製造方法。 - 前記段階(b)において、前記炭素繊維マット積層体と前記低炭化率の繊維マットは、前記炭素繊維マット積層体の厚さ方向にニードルパンチングされた低炭化率の繊維によって結束された状態であることを特徴とする、請求項11に記載の炭素繊維断熱材の製造方法。
- 前記炭素繊維マット積層体の厚さ方向の低炭化率の繊維は、前記段階(c)における熱処理により除去されることを特徴とする、請求項12に記載の炭素繊維断熱材の製造方法。
- 前記バインダー樹脂は、フェノール樹脂、フラン樹脂、エポキシ樹脂、ビニルエステル樹脂、ポリイミド樹脂及び含浸用ピッチから選択される少なくともいずれか一つであることを特徴とする、請求項11に記載の炭素繊維断熱材の製造方法。
- 前記段階(c)における熱処理による前記低炭化率の繊維マットの質量残存率が5%未満であることを特徴とする、請求項11に記載の炭素繊維断熱材の製造方法。
- 前記段階(c)において、800〜1,000℃の範囲から選択される温度での第1熱処理、及び1700〜2300℃の範囲から選択される温度での第2熱処理が、順に行われることを特徴とする、請求項11に記載の炭素繊維断熱材の製造方法。
- 前記炭素繊維断熱材の見かけ密度は、0.1〜0.3g/cm3であることを特徴とする、請求項11に記載の炭素繊維断熱材の製造方法。
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