JP5079819B2 - カーボン・ナノチューブを浸出したファイバとその製造方法 - Google Patents
カーボン・ナノチューブを浸出したファイバとその製造方法 Download PDFInfo
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- JP5079819B2 JP5079819B2 JP2009544866A JP2009544866A JP5079819B2 JP 5079819 B2 JP5079819 B2 JP 5079819B2 JP 2009544866 A JP2009544866 A JP 2009544866A JP 2009544866 A JP2009544866 A JP 2009544866A JP 5079819 B2 JP5079819 B2 JP 5079819B2
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Images
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B82—NANOTECHNOLOGY
- B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F9/00—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments
- D01F9/08—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments of inorganic material
- D01F9/12—Carbon filaments; Apparatus specially adapted for the manufacture thereof
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B32/00—Carbon; Compounds thereof
- C01B32/15—Nano-sized carbon materials
- C01B32/158—Carbon nanotubes
- C01B32/16—Preparation
- C01B32/162—Preparation characterised by catalysts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
- B01J23/74—Iron group metals
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
- B01J23/74—Iron group metals
- B01J23/745—Iron
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
- B01J23/74—Iron group metals
- B01J23/75—Cobalt
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
- B01J23/74—Iron group metals
- B01J23/755—Nickel
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/08—Heat treatment
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B32/00—Carbon; Compounds thereof
- C01B32/15—Nano-sized carbon materials
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- C01B32/16—Preparation
- C01B32/164—Preparation involving continuous processes
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F11/00—Chemical after-treatment of artificial filaments or the like during manufacture
- D01F11/10—Chemical after-treatment of artificial filaments or the like during manufacture of carbon
- D01F11/12—Chemical after-treatment of artificial filaments or the like during manufacture of carbon with inorganic substances ; Intercalation
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D01F9/00—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments
- D01F9/08—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments of inorganic material
- D01F9/12—Carbon filaments; Apparatus specially adapted for the manufacture thereof
- D01F9/127—Carbon filaments; Apparatus specially adapted for the manufacture thereof by thermal decomposition of hydrocarbon gases or vapours or other carbon-containing compounds in the form of gas or vapour, e.g. carbon monoxide, alcohols
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B82—NANOTECHNOLOGY
- B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- B82Y40/00—Manufacture or treatment of nanostructures
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- Nanotechnology (AREA)
- Chemical Kinetics & Catalysis (AREA)
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- Inorganic Chemistry (AREA)
- Condensed Matter Physics & Semiconductors (AREA)
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- General Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Textile Engineering (AREA)
- General Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Composite Materials (AREA)
- Chemical Or Physical Treatment Of Fibers (AREA)
- Carbon And Carbon Compounds (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Inorganic Fibers (AREA)
- Reinforced Plastic Materials (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
- Artificial Filaments (AREA)
Description
(A) 母材であるファイバからサイジングを除去するステップと、
(B) カーボン・ナノチューブを形成する触媒を母材であるファイバに適用(例塗布)するステップと、
(C) ファイバをナノチューブが合成できる温度に加熱するステップと、
(D) カーボン・プラズマを、触媒担持した母材であるファイバ(catalyst-laden parent fiber)に噴霧するステップと
を有する。
カーボン・ナノチューブを形成する方法と技術は、特許文献1に開示されており、同文献に開示したプロセスを本発明に適用可能である。本発明の一実施例においては、アセチレンガスをイオン化して、冷却カーボン・プラズマのジェットを作り出す。このプラズマを、触媒を含んだ母材であるファイバ(catalyst-bearing parent fiber)の方向に向ける。
1.カーディング(Carding):ファイバを開き平たいフィルム状にするプロセス。
2.カーディド・ファイバ(Carded Fibers):カーディングされ開かれた状態のファイバ。
3.クロス(Cloth):ファイバ・ヤーン(糸)のストランドを織って形成した強化材料。
4.連続フィラメント・ストランド(Continuous Filament Strand):多くのフィラメントからなるファイバの一束。ガン・ロービング(gun roving)について用いる時には、糸状のファイバあるいはヤーンを集めた物で、噴霧プロセスのチョッパー・ガン(Chopper gun)を通して供給される。
5.連続ストランド・ロービング(Continuous Strand Roving):噴霧プロセスでチョッパー・ガンを通して供給されるフィラメントの一束。
6.ファブリック(Fabric):ヤーン、ファイバ、フィラメントを織り合わせることにより生成された平面のテキスタイル構造物。
7.ファイバ(Fiber):天然物あるいは人工物のユニットで、ファブリックと他のテキスタイル構造の基本要素。
8.ファイバ配向(Fiber orientation):不織あるいはマット状の積層した状態のファイバの整合物。ファイバの大部分が同一方向にあり、その方向により高い強度を示す。
9.ファイバ・パターン(Fiber Pattern):ラミネートあるいはモールディングされた物の表面上の可視ファイバ;糸のサイズとガラス製クロスの織り方。
10.フィラメント(Filament):無限あるいは極端に長い一本のファイバで、天然(シルク)あるいは人工物である。通常、直径はミクロンレベルであり、人工ファイバは、フィラメント上に伸ばされて、フィラメントのヤーン、ステープル、トウに変換される。
11.フィラメント巻き上げ(Filament Winding):ガラス製フィラメントにレジンを飽和したストランドを回転するマンドレルの周囲に巻くプロセス。
13.浸出(Infuse):化学結合を形成すること。
14.メール・モールド(Male Mold):部品の凹状表面をモールド表面で正確に規定する凸状モールド。
15.マトリックス(matrix):合生物あるいは積層物の液状成分
16.マンドレル(Mandrel):紙あるいは繊維あるいはレジンを含浸したファイバが巻かれるコアを意味し、これによりパイプ、チューブ、容器を形成し、押し出す場合にはパイプあるいはチューブのダイの中央フィンガ。
17.引き抜き(Pultrusion):「押し出しextrusion」の逆のプロセスで、ロッド、チューブ、永久断面の構造形状を製造する際にレジンを含有したロービングを引き抜くステップ。ロービングとは、レジンを浸したタンクを通した後、ダイを通して引き抜き、所望の断面を形成すること。
18.レジン(Resin):触媒作用させた時に、固体状態に固化する液状ポリマ。
19.ロービング(Roving):ねじられ細くされカーディングされたファイバの軟らかいストランドで、スピニングの準備段階としての異物の供給。
21.スプレー・アップ(Spray-up):ファイバ、レジン、触媒を同時に噴霧してチョッパー・ガンを用いてモールドにするステップ。
22.ストランド(Strands):ねじらずに1個のコンパクトなユニットに結合された連続するフィラメント/スライバ(Slivers)の主要な一束。これらのフィラメント(通常、51、102あるいは204)は、形成操作の間一体にされる。
23.テープ(Tape):幅の狭い強化繊維あるいはマット。
24.トウ(Tow):ねじらない状態のフィラメントのルーズなストランド。
25.ねじれ(Twist):製造プロセスの間、2個のヤーンが回転する方向と、その回転数に使用される用語。
26.ウォーブン・ロービング・ファブリック(Woven Roving Fabric):ロービング形態で連続するフィラメントから織った重い繊維、通常1平方ヤード当たり18−30オンスの間の重量である。
27.ヤーン(Yarn):テキスタイル、ファイバ、フィラメントあるいはニッティング、ウィービング、ブレイディングあるいはインタートゥワイニングに適した形態の材料の連続するストランドに使用される一般的な用語。
プロセス102:ナノチューブを形成する触媒を母材であるファイバに適用するステップ
プロセス104:母材であるファイバをカーボン・ナノチューブの合成に十分な温度にまで加熱するステップ。
プロセス106:カーボン・プラズマを、触媒を担持した母材であるファイバ(catalyst-laden parent fiber)に噴霧するステップ。
102:ナノチューブを形成する触媒を母材であるファイバに適用する
104:母材であるファイバをカーボン・ナノチューブの合成に十分な温度に加熱する
106:カーボン・プラズマを、触媒を担持した母材であるファイバに噴霧する
200 システム
201 ファイバ
202 ファイバ送出引っ張りステーション
204 送出ボビン
205 サイジングのないファイバ
206 引っ張り機
207 触媒担持ファイバ
208 ファイバ・延展ステーション
209 カーボン・ナノチューブを浸出したファイバ
210 サイジング除去ステーション
212 カーボン・ナノチューブ浸出ステーション
214 触媒付与ステーション
216 ファイバ前加熱ステーション
218 プラズマ・スプレイ・ステーション
220 ファイバ加熱器
222 ファイバ結束ステーション
224 ファイバ巻き上げボビン
226 カーボン・ナノチューブ浸出セクション
300 フィラメント巻き上げステーション
302 ファイバ巻糸軸架
303 トウ
307 カーボン・ナノチューブを浸出したトウ
307 カーボン・ナノチューブを浸出したファイバ・トウ
328 レジン・バス
330 シリンダ
332 フィラメント巻き上げマンドレル
Claims (11)
- (x)母材であるファイバを延展するステップと、
(a)カーボン・ナノチューブを形成する触媒を、前記母材であるファイバの表面上に配置し、触媒担持ファイバを形成するステップと、
(b)前記触媒担持ファイバを、ナノチューブを合成する温度まで加熱するステップと、
(c)前記触媒担持ファイバを、大気圧でカーボン・プラズマ中を移動させながら、前記カーボン・ナノチューブを前記触媒担持ファイバ上に直接合成するステップと、
(d)前記(c)ステップの後に、前記(x)ステップで延展した前記母材であるファイバを再度束ねるステップと
を有する
ことを特徴とするカーボン・ナノチューブを浸出したファイバを形成する方法。 - 前記(a)ステップの前に、
(y) サイジング材料を前記母材であるファイバから除去するステップ
をさらに有する
ことを特徴とする請求項1記載の方法。 - 前記触媒は、遷移金属触媒である
ことを特徴とする請求項1記載の方法。 - 前記(a)ステップは、
(a1) 前記触媒の溶液を液状にするステップと、
(a2) 前記触媒の溶液を前記母材であるファイバ上に噴霧するステップと、
を有する
ことを特徴とする請求項1記載の方法。 - 前記(b)ステップは、前記触媒担持ファイバを、その軟化温度まで加熱する
ことを特徴とする請求項1記載の方法。 - 前記(b)ステップは、前記触媒担持ファイバを、500℃と1000℃の間の温度まで加熱する
ことを特徴とする請求項1記載の方法。 - 前記母材であるファイバは、カーボン・ファイバであり、
前記(b)ステップは、前記触媒担持ファイバを、800℃まで加熱する
ことを特徴とする請求項1記載の方法。 - (e)レジンを前記カーボン・ナノチューブを浸出したファイバに添加するステップをさらに有する
ことを特徴とする請求項1記載の方法。 - 前記(e)ステップの後に、
(f)前記カーボン・ナノチューブを浸出したファイバを、マンドレルの周囲に巻きつけるステップをさらに有する
ことを特徴とする請求項8記載の方法。 - 前記母材であるファイバは、グラファイト・トウとグラス・ロービングからなるグループから選択される
ことを特徴とする請求項1記載の方法。 - サイジング材料を有する母材であるファイバにカーボン・ナノチューブを浸出する方法において、
(a)サイジング材料を母材であるファイバから除去するステップと、
(b)カーボン・ナノチューブを形成する触媒を前記母材であるファイバに適用して、触媒担持ファイバを形成するステップと、
(c)前記触媒担持ファイバを500℃以上に加熱するステップと、
(d)前記触媒担持ファイバを移動させながら、カーボン・ナノチューブを前記触媒担持ファイバ上に合成するステップと、
を有する
ことを特徴とするサイジング材料を有する母材であるファイバ上にカーボン・ナノチューブを浸出する方法。
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US20100276072A1 (en) | 2010-11-04 |
AU2007342249A1 (en) | 2008-07-17 |
JP2010531934A (ja) | 2010-09-30 |
ES2392558T3 (es) | 2012-12-11 |
US20120065300A1 (en) | 2012-03-15 |
AU2007342249B2 (en) | 2012-08-23 |
CA2673891C (en) | 2014-08-19 |
ATE557118T1 (de) | 2012-05-15 |
JP2015110859A (ja) | 2015-06-18 |
ES2387950T3 (es) | 2012-10-04 |
ZA200904640B (en) | 2010-04-28 |
EP2290139A1 (en) | 2011-03-02 |
EP2115191B1 (en) | 2012-10-03 |
EP2115191A1 (en) | 2009-11-11 |
EP2261404B1 (en) | 2012-08-22 |
JP2012193105A (ja) | 2012-10-11 |
DK2261404T3 (da) | 2012-09-17 |
DK2290139T3 (da) | 2012-07-23 |
DK2115191T3 (da) | 2012-10-22 |
KR20090086277A (ko) | 2009-08-11 |
KR101218487B1 (ko) | 2013-01-04 |
JP6066584B2 (ja) | 2017-01-25 |
WO2008085634A1 (en) | 2008-07-17 |
EP2261404A1 (en) | 2010-12-15 |
US8158217B2 (en) | 2012-04-17 |
EP2290139B1 (en) | 2012-05-09 |
CA2673891A1 (en) | 2008-07-17 |
JP6113769B2 (ja) | 2017-04-12 |
ES2389402T3 (es) | 2012-10-25 |
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