WO2009125857A1 - 炭素繊維及びその製造方法 - Google Patents
炭素繊維及びその製造方法 Download PDFInfo
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- WO2009125857A1 WO2009125857A1 PCT/JP2009/057406 JP2009057406W WO2009125857A1 WO 2009125857 A1 WO2009125857 A1 WO 2009125857A1 JP 2009057406 W JP2009057406 W JP 2009057406W WO 2009125857 A1 WO2009125857 A1 WO 2009125857A1
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- precursor
- carbon
- fiber
- thermoplastic
- thermoplastic resin
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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
- D01F9/14—Carbon filaments; Apparatus specially adapted for the manufacture thereof by decomposition of organic filaments
- D01F9/145—Carbon filaments; Apparatus specially adapted for the manufacture thereof by decomposition of organic filaments from pitch or distillation residues
-
- 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
- D01F9/14—Carbon filaments; Apparatus specially adapted for the manufacture thereof by decomposition of organic filaments
-
- 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
- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
- D01F6/44—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds
-
- 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
- D01F9/14—Carbon filaments; Apparatus specially adapted for the manufacture thereof by decomposition of organic filaments
- D01F9/20—Carbon filaments; Apparatus specially adapted for the manufacture thereof by decomposition of organic filaments from polyaddition, polycondensation or polymerisation products
- D01F9/21—Carbon filaments; Apparatus specially adapted for the manufacture thereof by decomposition of organic filaments from polyaddition, polycondensation or polymerisation products from macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D01F9/22—Carbon filaments; Apparatus specially adapted for the manufacture thereof by decomposition of organic filaments from polyaddition, polycondensation or polymerisation products from macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyacrylonitriles
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
- D06C7/00—Heating or cooling textile fabrics
- D06C7/04—Carbonising or oxidising
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2101/00—Inorganic fibres
- D10B2101/10—Inorganic fibres based on non-oxides other than metals
- D10B2101/12—Carbon; Pitch
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2913—Rod, strand, filament or fiber
- Y10T428/298—Physical dimension
Definitions
- the present invention relates to a carbon fiber and a method for producing the same. More specifically, the present invention relates to an ultrafine carbon fiber having both high crystallinity and high conductivity and having no branched structure.
- Carbon fibers have excellent properties such as high crystallinity, high conductivity, high strength, high elastic modulus, and light weight.
- ultrafine carbon fibers are used as nanofillers for high-performance composite materials. in use. Its application is not limited to the conventional nano fillers for reinforcing the mechanical strength, but by making use of the high electrical conductivity of carbon materials, it can be used as an electrode additive material for various batteries and as an electrode additive for capacitors. It is expected to be used as a material, electromagnetic wave shielding material, conductive resin nanofilament for antistatic materials, or nanofilament for electrostatic coatings on resin. Utilizing the characteristics of chemical stability, thermal stability and fine structure as carbon materials, it is also expected to be used as field electron emission materials such as flat displays.
- an organic compound such as benzene is used as a raw material, and an organic transition metal compound such as pheptene is introduced as a catalyst together with a carrier gas into a high-temperature reactor to be generated on a substrate.
- a method for example, see Patent Document 1), a method for generating VGCF in a floating state (for example, see Patent Document 2), or a method for growing on a reactor wall (for example, see Patent Document 3) Disclosed Yes.
- the ultrafine carbon fiber obtained by these methods has high strength and high elastic modulus, it has many problems of fiber branching and has a problem that its performance as a reinforcing filler is low. There was also the problem of high costs due to productivity. More
- Patent Document 1 Japanese Patent Application Laid-Open No. Sho 6 0-2 7 700 (Publication No. 2-3)
- Patent Document 2 Japanese Patent Application Laid-Open No. 60-0 5 4 9 98 (Publication No. 11-2)
- Patent Document 3 Japanese Patent No. 2 7 7 8 4 3 4 (Publication No. 1-12)
- Patent Document 4 Japanese Patent Application Laid-Open Publication No. 2 00 1-7 3 2 2 6 (Publication No. 3-4) Disclosure of the Invention Problems to be Solved by the Invention
- An object of the present invention is to solve the above-mentioned problems of the prior art and to provide an ultrafine carbon fiber having a high crystallinity / high conductivity without a branched structure. Furthermore, the other object of this invention is to provide the manufacturing method of the said carbon fiber.
- X-ray diffraction measurement ⁇ Evaluated lattice spacing (d 002) is in the range of 0.336 nm to 0.338 nm
- crystallite size (Lc 002) force is in the range of 50 nm to l 50 nm Yes
- thermoplastic resin From 100 parts by mass of thermoplastic resin and from 1 to 150 parts by mass of at least one thermoplastic carbon precursor selected from the group consisting of pitch, polyacrylonitrile, polycarpositimide, polyimide, polybenzazole and aramid Forming precursor fibers from the mixture comprising,
- thermoplastic resin from the stabilized resin composition under reduced pressure to form a fibrous carbon precursor
- thermoplastic resin is represented by the following formula (I).
- RR 2 , R 3 , and R 4 are each independently a hydrogen atom, carbon number It is selected from the group consisting of an alkyl group having 1 to 15 carbon atoms, a cycloalkyl group having 5 to 10 carbon atoms, an aryl group having 6 to 12 carbon atoms and an aralkyl group having 7 to 12 carbon atoms.
- n represents an integer of 20 or more
- thermoplastic resin is 3 5 0 and has a melt viscosity of 5 to 100 Pa ⁇ s as measured in 60 0 s "" 1 ; Production method.
- thermoplastic resin is polyethylene
- thermoplastic carbon precursor is at least one selected from the group consisting of mesophase pitch and polyacrylonitrile.
- thermoplastic resin is polyethylene with a melt viscosity of 5 to 100 Pa ⁇ s as measured at 3500, 600 s — 1 , and the thermoplastic carbon precursor is mesophase pitch. 5.
- the carbon fiber of the present invention has excellent properties as a reinforcing nanofiller because there is no branched structure that has been a problem with conventionally known ultrafine carbon fibers.
- the highly crystalline carbon material because of the high conductivity of the highly crystalline carbon material, it can be used as an electrode additive material for various batteries, an electrode additive material for capacitors, an electromagnetic shielding material, and a conductive resin nanofilament for antistatic materials. Or excellent properties as a nanofiller for electrostatic coatings on resins.
- it provides superior mechanical properties compared to carbon fibers obtained from composite fibers of phenol resin and polyethylene.
- Fig. 1 shows a photograph of the nonwoven fabric surface obtained by the operation of Example 1 taken with a scanning electron microscope ("S-2 4 0 0" manufactured by Hitachi, Ltd.) (magnification magnification 2, 0 0 0 times) )
- Figure 2 shows the surface of the nonwoven fabric obtained by the operation of Comparative Example 2 using a scanning electron microscope It is a photograph (photographing magnification 6,000 times) taken by Hitachi, Ltd. FE-SEM, S-4800).
- the carbon fiber of the present invention has a lattice spacing (d 002) measured and evaluated by X-ray diffraction method in the range of 0.336 nm to 0.338 nm and a crystallite size (L c 002) of 50 nm.
- the volume resistivity (ER) measured using a 4-probe type electrode unit is in the range of ⁇ 008 ⁇ ⁇ ⁇ : ⁇ to 0.015 ⁇ ⁇ cm, and the fiber diameter Is a carbon fiber having a branched structure in the range of 10 nm to 500 nm.
- the fiber diameter is an average fiber diameter calculated from the values obtained by measuring the fiber diameters of a plurality of carbon fibers from an electron micrograph of the carbon fibers.
- Lattice spacing (d 002) when the lattice spacing (d 002) deviates from the range of 0.336 nm to 0.338 nm, or the crystallite size (Lc 002) deviates from the range of 50 nm to 150 nm. Not only does the volume resistivity (ER) fall outside the range of 0.008 Q * cm to 0.015 ⁇ ⁇ cm, the electrical conductivity decreases, but the mechanical properties of the carbon fiber also decrease. Highly crystalline carbon fiber with high conductivity is more preferable.
- Lattice spacing (d 002) is in the range of 0.336 nm to 0.3375 nm and crystallite size (L c 002) is 55 nm.
- the carbon fiber of the present invention that is in the range of ⁇ 150 nm needs to have a volume resistivity (ER) in the range of 0.008 ⁇ ⁇ cm to 0.015 ⁇ ⁇ cm.
- ER volume resistivity
- the fiber diameter is larger than 500 nm, the performance as a highly conductive composite material filler is significantly reduced.
- the fiber diameter is less than 1 O nm, the bulk density of the obtained carbon fiber aggregate becomes very small and the handling becomes inferior.
- the ultrafine carbon fiber in the present invention does not have a branched structure.
- having no branched structure is a mode in which a plurality of carbon fibers extend, and does not have a granular portion that bonds the carbon fibers to each other, that is, a so-called branch-like shape from the main carbon fiber. This means that no fiber is formed, but this does not exclude a fiber having a branched structure within the range in which the performance as a filler for high conductivity targeted by the present invention is maintained.
- thermoplastic resin 100 parts by mass of a thermoplastic resin and at least one thermoplastic carbon precursor selected from the group consisting of pitch, polyacrylonitrile, polycarbopositimide, polyimide, polybenzazole and aramid, and a precursor comprising a mixture of 1 to 150 parts by mass Forming a body fiber,
- thermoplastic resin from the stabilized resin composition under reduced pressure to form a fibrous carbon precursor
- thermoplastic resin used in the present invention (i) a thermoplastic carbon precursor will be described, and then (iii) from the thermoplastic resin and the thermoplastic carbon precursor.
- the method will be described in detail in the order of a method for producing a mixture, U v) a method for producing carbon fiber from the mixture.
- thermoplastic resin used in the present invention needs to be easily removed after the production of the stabilized precursor fiber. For this reason, by holding for 5 hours at an oxygen or inert gas atmosphere at a temperature of not less than 3500 and not more than 60.00, it is 15% by mass or less of the initial mass, more preferably 10% by mass or less. It is preferable to use a thermoplastic resin that decomposes to 5% by mass or less. In addition, heat that decomposes to 10% by mass or less of the initial weight, more preferably 5% by mass or less by holding at a temperature not lower than 45 ° C. and less than 60 ° C. for 2 hours in an oxygen or inert gas atmosphere. It is more preferable to use a plastic resin.
- thermoplastic resins polyacrylate polymers such as polyolefin, polymethacrylate, and polymethyl methacrylate, polystyrene, polycarbonate, polyarylate, polyester carbonate, polysulfone, polyimide, polyetherimide, and the like are preferably used.
- a polyolefin-based thermoplastic resin represented by the following formula (I) is preferably used as the thermoplastic resin that has high gas permeability and can be easily thermally decomposed.
- RR 2 , R 3 , and R 4 are each independently a hydrogen atom, an alkyl group having 1 to 15 carbon atoms, a cycloalkyl group having 5 to 10 carbon atoms, or 6 to 6 carbon atoms. Selected from the group consisting of an aryl group of 1 2 and an aralkyl group having 7 to 12 carbon atoms, n represents an integer of 20 or more)
- Specific examples of the compound represented by the above formula (I) include copolymers of poly-4-methylpentene-1 and poly-4-methylpentene-1, such as poly-4-methylpentene-1, vinyl.
- Polymers such as copolymerized monomers and polyester
- polyethylene include high-pressure low-density polyethylene, medium-density polyethylene, high-density polyethylene, and linear low-density polyethylene.
- Polymers Ethylene / vinyl acetate copolymers and other copolymers of ethylene and other vinyl monomers.
- vinyl monomers include, for example, vinyl esters such as vinyl acetate; (meth) acrylic acid, (meth) methyl acrylate, (meth) ethyl acrylate, (meth) acrylic acid n-butyl ( And (meth) acrylic acid and its alkyl esters.
- thermoplastic resin used in the production method of the present invention can be easily melt-kneaded with the thermoplastic carbon precursor, so that the glass transition temperature is 2500 or less in the case of amorphous, the case of being crystalline, it is preferred crystalline melting point is not more than 3 0 0 Further, the thermoplastic resin used in the present invention, 3 5 0, the melt viscosity of 5 to 1 OOP a ⁇ when measured at 6 0 0 s-1 What is s is preferable. The detailed reason is unknown, but when the melt viscosity is less than 5 Pa ⁇ s, the volume resistivity increases, which is not preferable.
- melt viscosity exceeds 100 Pa ⁇ s, it is difficult to obtain a precursor fiber by spinning a mixture for producing a carbon fiber, which is not preferable. More preferably, it is 7 to 100 Pa * s, and further preferably 5 to 100 Pa * s.
- thermoplastic carbon precursor used in the production method of the present invention is maintained at 20.00 or more and less than 3500 for 2 to 30 hours in an oxygen gas atmosphere or a halogen gas atmosphere, and then inert. It is preferable to use a thermoplastic carbon precursor in which 80% by mass or more of the initial mass remains when held at a temperature of 35 ° C. or more and less than 50 ° C. for 5 hours in a gas atmosphere. Under the above conditions, if the residual amount is less than 80% of the initial mass, It is not preferable because carbon fibers cannot be obtained from the plastic carbon precursor with a sufficient carbonization rate.
- thermoplastic carbon precursor that satisfies the above conditions include rayon, pitch, polyacrylonitrile, poly ⁇ -chloroacrylonitrile, polycarboimide, polyimide, polyetherimide, polybenzoazole, and amide. Of these, pitch, polyacrylonitrile, and polycarbopositimide are preferable, and pitch is more preferable.
- mesophase pitches that are generally expected to have high crystallinity, high conductivity, high strength, and high elastic modulus are preferred.
- the mesophase pitch refers to a compound that can form an optically anisotropic phase (liquid crystal phase) in a molten state.
- petroleum residue oil is hydrogenated ⁇
- Heat treatment ⁇ A method mainly consisting of solvent extraction
- Hydrogenation of petroleum mesophase pitch and coal tar bitch ⁇ Mainly heat treatment Or hydrogenation, heat treatment, coal-based mesophase pitch obtained by solvent extraction, and aromatic hydrocarbons such as naphthenic, alkylnaphthalene, anthracene, etc.
- HF super raw acids
- BF 3 super raw acids
- synthetic liquid crystal pitches using aromatic hydrocarbons such as naphthalenes as raw materials are particularly preferable in terms of stabilization, carbonization or graphitization.
- thermoplastic resin (i i ⁇ )
- thermoplastic precursor (i i ⁇ )
- the amount of the thermoplastic carbon precursor used is 1 to 1550 parts by mass, preferably 5 to 100 parts by mass with respect to 100 parts by mass of the thermoplastic resin. If the amount of the thermoplastic carbon precursor used exceeds 150 parts by mass, precursor fibers having a desired dispersion diameter cannot be obtained, and if it is less than 1 part by mass, ultrafine carbon fibers cannot be produced at low cost. This is not preferable because of such problems.
- the mixture used in the production method of the present invention comprises a thermoplastic carbon precursor for producing carbon fibers having a maximum fiber diameter of less than 2 / ⁇ m and an average fiber diameter of 10 nm to 500 nm. It is preferable that the dispersion diameter in the thermoplastic resin is from 0.01 to 50 xm.
- the thermoplastic carbon precursor forms an island phase and becomes spherical or elliptical.
- the dispersion diameter referred to here means the spherical diameter of the thermoplastic carbon precursor contained in the mixture or the major axis diameter of the ellipsoid.
- thermoplastic carbon precursor in the thermoplastic resin when the dispersion diameter of the thermoplastic carbon precursor in the thermoplastic resin deviates from the range of 0.0 l to 50 / m, it is difficult to produce carbon fibers for high-performance composite materials. May be.
- a more preferable range of the dispersion diameter of the thermoplastic carbon precursor is 0.01 to 30 ⁇ m.
- the dispersion diameter of the thermoplastic carbon precursor in the thermoplastic resin is 0.001 to 50 m. Preferably there is.
- thermoplastic carbon precursor aggregates over time.
- the degree of agglomeration rate of the thermoplastic carbon precursor varies depending on the type of the thermoplastic resin and the thermoplastic carbon precursor used, but is more preferably 300 for 5 minutes or more, more preferably 30. It is preferable that the dispersion diameter of 0.1 to 50 / m is maintained at 0 for 10 minutes or more.
- thermoplastic resin and a thermoplastic carbon precursor As a method for producing the above mixture from a thermoplastic resin and a thermoplastic carbon precursor, kneading in a molten state is preferable.
- a known method can be used as necessary.
- a co-rotating twin-screw melt kneading extruder is preferably used for the purpose of well-dispersing the thermoplastic carbon precursor in the thermoplastic resin.
- the melt kneading temperature is preferably from 100 to ⁇ 40 Ot :. Melting and kneading temperature If the degree is less than 100, the thermoplastic carbon precursor is not in a molten state, and micro-dispersion with the thermoplastic resin is difficult, which is not preferable. On the other hand, if it exceeds 400, neither decomposition is preferred because the decomposition of the thermoplastic resin and the thermoplastic carbon precursor proceeds.
- a more preferable range of the melt kneading temperature is 1 5 0 t: to 3 ⁇ 0.
- the melt kneading time is 0.5 to 20 minutes, preferably 1 to 15 minutes.
- melt kneading time is less than 0.5 minutes, it is not preferable because micro dispersion of the thermoplastic carbon precursor is difficult. On the other hand, if it exceeds 20 minutes, the productivity of carbon fiber is remarkably lowered, which is not preferable.
- thermoplastic carbon precursor used in the present invention reacts with oxygen to be modified and infusible at the time of melt kneading, and may inhibit the dispersion of the mixture in the thermoplastic resin. For this reason, it is preferable to perform melt-kneading while circulating an inert gas to reduce the oxygen gas content as much as possible.
- the oxygen gas content during melt kneading is more preferably less than 5% by volume, and even less than 1% by volume.
- the carbon fiber of this invention can be manufactured from the mixture which consists of the above-mentioned thermoplastic resin and a thermoplastic carbon precursor. That is, the carbon fiber of the present invention comprises (1) a step of forming a precursor fiber from a mixture comprising a thermoplastic resin and a thermoplastic carbon precursor,
- thermoplastic resin It is preferably produced by a production method through a step of forming a fibrous carbon precursor by removing and (4) a step of carbonizing or graphitizing the fibrous carbon precursor. Each step will be described in detail below.
- Precursor fibers are formed from a mixture of thermoplastic resin and thermoplastic carbon precursor. Process to be completed
- precursor fibers are formed from the mixture obtained by melt-kneading a thermoplastic resin and a thermoplastic carbon precursor.
- the method for producing the precursor fiber include a method obtained by melt spinning a mixture of a thermoplastic resin and a thermoplastic carbon precursor from a spinneret.
- the melt-spinning temperature at the time of melt spinning is 1550 T: ⁇ 400, preferably 1800 ⁇ : ⁇ 400, and more preferably 2300: ⁇ 400.
- the spinning take-up speed is preferably 1 mZ min to 200 m / min, and more preferably 1 O mZ min to 200 O mZ min. Deviating from the above range is not preferable because a desired precursor fiber cannot be obtained.
- thermoplastic resin and a thermoplastic carbon precursor When a mixture obtained by melt-kneading a thermoplastic resin and a thermoplastic carbon precursor is melt-spun from a spinneret, it is preferable to send the liquid in a molten state and melt-spin from the spinneret.
- the transfer time from the melt kneading of the thermoplastic resin and the thermoplastic carbon precursor to the spinneret is preferably within 10 minutes.
- Another example is a method of forming precursor fibers by a melt blow method from a mixture obtained by melt-kneading a thermoplastic resin and a thermoplastic carbon precursor.
- the melt blow conditions are preferably those in which the discharge die temperature is 1550 to 400 and the gas temperature is 1550 to 400.
- the gas blowing speed of the melt blow affects the fiber diameter of the precursor fiber, but the gas blowing speed is usually from 100 to 2 OOO mZ s, more preferably from 200 to 100 O mZ s. .
- a precursor obtained by forming a mixture of a thermoplastic resin and a thermoplastic carbon precursor into a film under an atmosphere of 10 Ot: ⁇ 400.
- the film form refers to a sheet form having a thickness of 1; u m to 500 / m.
- the precursor film is obtained from the above mixture, for example, the mixture is sandwiched between two plates and only one plate is rotated, or the two plates are rotated in different directions, or A shear-fed film is created by rotating at different speeds in the same direction.
- a method for producing a film a method for producing a film to which a shear is imparted by abruptly applying stress to the mixture by a compression press, a method for producing a film to which a shear is imparted by a rotating roller, etc. Can do.
- thermoplastic carbon precursor contained therein by stretching the precursor fiber or precursor film in the molten state or the softened state as described above. These treatments are preferably carried out at 1 00 to ⁇ 400, more preferably at 1 550: to 380.
- the precursor film is also used in addition to the step (1 ′) shown below, which is the step of making the precursor fiber into a non-woven fabric and holding it with a support substrate. Can be applied.
- the precursor fiber a non-woven fabric with a basis weight of 100 g Zm 2 or less and hold it with a support base material having a heat resistance of 60 0 or more.
- a support base material having a heat resistance of 60 0 or more.
- the basis weight of the precursor fiber non-woven fabric is 100 g Zm 2 or less. If the basis weight of the precursor fiber nonwoven fabric is more than 100 g / m 2 , the heat treatment in the stabilization process increases the amount of precursor fibers that aggregate at the contact portion with the support substrate. It is not preferable because a portion where it is difficult to maintain air permeability between the precursor fibers is generated. On the other hand, when the basis weight is reduced, it is possible to suppress the degree of aggregation of the precursor fibers at the contact portion with the support base material, but it is preferable because the amount of precursor fibers that can be processed at a time is reduced. Absent. A more preferable weight of the precursor fiber is 10 to 50 g Zm 2 .
- Methods for producing precursor fiber nonwoven fabrics include known nonwoven fabric production methods such as wet methods, dry methods, melt blow methods, spun pond methods, thermal bond methods, It can be selected as appropriate from the micarbide method, needle punch method, hydroentanglement method (spun lace method), stitch bond method, etc.
- short fibers are dispersed in a solvent such as water, and paper is made to produce a nonwoven fabric.
- the wet method is preferable in that the weight per unit area (mass per unit area) can be easily adjusted, and it is not necessary to use a substance that may adversely affect the subsequent process.
- a desired supporting substrate can be used as long as the aggregation of the precursor fibers due to the heat treatment in the stabilization process can be suppressed.
- deformation / corrosion is caused by heating in air. It is necessary not to receive.
- As the heat resistance temperature it is necessary to prevent deformation according to the processing temperature of “the step of removing the thermoplastic resin from the stabilized resin composition to form a fibrous carbon precursor”. Heat resistance is necessary. Examples of such materials include metal materials such as stainless steel and ceramics such as alumina and silica, but metal materials are preferable in terms of strength. It should be noted that the higher the heat resistance, the better, but the metal material generally used in industrial equipment and machines has the highest heat resistance of 1 2 0 0.
- the corner is grasped with something like a pinch cock and hung in a curtain shape, or the laundry is hung on a bar or string that hangs horizontally
- Various methods can be used such as fixing both sides and holding them on a stretcher, or placing them on a plate-like material, but the effect of maintaining the air permeability between the precursor fibers in the stabilization process is required. Therefore, it is preferable to place a nonwoven fabric of precursor fibers on a supporting substrate having a breathable shape in the direction perpendicular to the surface.
- the mesh opening is preferably 0.1 mm to 5 mm.
- the mesh opening is larger than 5 mm, the degree of aggregation of the precursor fibers on the mesh line is increased by the heat treatment in the stabilization process, and the thermoplastic carbon precursor is not sufficiently stabilized. This is not preferable because it is possible.
- the mesh opening is 0.1 mm Is also not preferable, since the air permeability of the support base material may be reduced due to a decrease in the porosity of the support base material.
- the precursor fiber nonwoven fabric is placed on the support base material having the above-described network structure, it is also preferable that the precursor fiber nonwoven fabric is stacked several times and the precursor fiber nonwoven fabric is sandwiched and held by the support base material.
- the spacing between the supporting substrates is not limited as long as the air permeability between the precursor fibers can be maintained, but it is more preferable that the spacing is 1 mm or more.
- the precursor fiber prepared above is subjected to a stabilization treatment (also referred to as an infusibilization treatment) to stabilize and stabilize the thermoplastic carbon precursor in the precursor fiber.
- a stabilization treatment also referred to as an infusibilization treatment
- a fluorinated resin composition is formed. Stabilization of the thermoplastic carbon precursor is a process necessary to obtain carbonized or graphitized carbon fibers. If this is not carried out and the thermoplastic resin, which is the next process, is removed, the thermoplastic carbon Problems such as thermal decomposition and fusion of the carbon precursor occur.
- a stabilization method it can be carried out by a known method such as gas treatment of air, oxygen, ozone, nitrogen dioxide, halogen, etc., solution treatment of acidic aqueous solution, etc. Stabilization is preferred.
- the gas component to be used is preferably air or oxygen alone or a mixed gas containing these from the viewpoint of ease of handling, and air is particularly preferred from the viewpoint of cost.
- the oxygen gas concentration used is preferably in the range of 10 to 100% by volume of the total gas composition. If the oxygen gas concentration is less than 10% by volume of the total gas composition, it takes a long time to stabilize the thermoplastic carbon precursor, which is not preferable.
- the treatment temperature is preferably 50 to 35, more preferably 60 to 30, and 100 to 300. More preferably, it is very preferably in the range of 200 to 300.
- Stabilization processing time is 1 0 to 120 minutes are preferable, 10 to 60 minutes are more preferable, 30 to 30 minutes are more preferable, and 60 to 20 minutes are extremely preferable.
- the softening point of the thermoplastic carbon precursor contained in the precursor fiber is significantly increased by the above stabilization, it is preferable that the softening point is 400 or more for the purpose of obtaining a desired ultrafine carbon fiber. And more preferably 5 0 0 or more.
- thermoplastic carbon precursor in the precursor fiber is stabilized while maintaining its shape, while the thermoplastic resin is softened and melted, so that the fiber before stabilization treatment is obtained.
- a stabilized resin composition that does not maintain a fibrous shape can be obtained.
- the third step in the production method of the present invention is to remove the thermoplastic resin contained in the stabilized resin composition by pyrolysis. Specifically, the thermoplastic resin contained in the stabilized resin composition is removed. Only the fibrous carbon precursor that has been removed and stabilized is separated to form a fibrous carbon precursor. In this step, it is necessary to suppress thermal decomposition of the fibrous carbon precursor as much as possible, decompose and remove the thermoplastic resin, and separate only the fibrous carbon precursor.
- the thermoplastic resin is removed under reduced pressure.
- the process under reduced pressure it is possible to efficiently remove the thermoplastic resin and form the fibrous carbon precursor.
- a carbon fiber with extremely little fusion can be produced.
- the lower the atmospheric pressure when removing the thermoplastic resin the better. It is preferably 0 to 50 kPa, but since complete vacuum is difficult to achieve, more preferably 0.01 to 3 0 k Pa, and more preferably 0.0 1 to 1 0? More preferably, it is 0.01 to 5 kPa.
- gas may be introduced as long as the above atmospheric pressure is maintained.
- the decomposition product of the thermoplastic resin can be efficiently removed out of the system.
- the gas to be introduced is preferably an inert gas such as carbon dioxide, nitrogen, or argon from the viewpoint of suppressing fusion due to thermal degradation of the thermoplastic resin.
- the heat treatment is preferably performed at a temperature of 3 50 or more and less than 60 0.
- the heat treatment time is preferably 0.5 to 10 hours.
- the fibrous carbon precursors obtained by the stabilization treatment it is preferable to pass a step of dispersing the fibrous carbon precursors obtained by the stabilization treatment, if necessary. By passing through this step, it becomes possible to produce carbon fibers with better dispersibility.
- a method for dispersing the fibrous carbon precursor any method can be used as long as the fibrous carbon precursors can be physically separated from each other.
- the fibrous carbon precursor is mechanically added to a solvent. Examples thereof include a method of dispersing by stirring or vibrating the solvent with an ultrasonic oscillator or the like, and a method of dispersing the fibrous carbon precursor with a pulverizer such as a jet mill or a bead mill.
- a method of dispersing the fibrous carbon fiber precursor added in the solvent by vibration generated by an ultrasonic oscillator or the like is preferable because the fibrous carbon fiber precursor can be dispersed while maintaining the fiber shape of the fibrous carbon fiber precursor.
- the time for the dispersion treatment is not particularly limited, but a treatment of 0.5 to 60 minutes is preferable from the viewpoint of productivity.
- the temperature at which the dispersion treatment is performed need not be particularly heated or cooled, and may be room temperature (usually 5 to 4 Ot in Japan). If the liquid temperature rises due to the dispersion treatment, the temperature is appropriately cooled. You may do it.
- the fifth step in the production method of the present invention is to produce carbon fibers by carbonizing or graphitizing the fibrous carbon precursor excluding the thermoplastic resin in an inert gas atmosphere.
- the fibrous carbon precursor is carbonized or graphitized by high-temperature treatment under an inert gas atmosphere to obtain desired carbon fibers.
- the minimum value and the maximum value are preferably in the range of 0.01 m (lnm) to 2, and the average fiber diameter is 0.0 lm to 0.001.
- m (10 nm to 500 nm) is more preferable, and 0.01 m to 0.3 um (10 nm to 300 nm) is even more preferable.
- the carbonization or graphitization treatment (heat treatment) of the fibrous carbon precursor can be performed by a known method.
- the inert gas used include nitrogen and argon, and the treatment temperature is preferably 500 to 3500, more preferably 800 to 3000.
- the graphitization temperature is preferably 2000 to 3500, more preferably 2600 to 3000.
- the treatment time is preferably from 0.:! To 24 hours, more preferably from 0.2 to 10 hours, and even more preferably from 0.5 to 8 hours.
- the oxygen concentration during carbonization or graphitization is preferably 20 volume ppm or less, more preferably 10 volume ppm or less.
- the carbon fiber of the present invention can be obtained in a state where the fusion between the carbon fibers is extremely small.
- the dispersion particle diameter of the thermoplastic carbon precursor in the thermoplastic resin, the fiber diameter of the carbon fiber, and the degree of fusion of the carbon fiber were determined using a scanning electron microscope (S-2400 or S-4800 manufactured by Hitachi, Ltd.) FE-SEM)) and obtained by photographic images.
- the volume resistivity (ER) is the volume resistivity (ER) when the packing density is 0.8 gZc m 3 from the relationship diagram of volume resistivity ( ⁇ ⁇ cm) with the change of the packing density (g / cm 3 ). The value of was used as the volume resistivity of the sample.
- melt viscosity was measured with a 25 mm parallel plate at a gap interval of 2 mm.
- thermoplastic resin manufactured by Prime Polymer Co., Ltd., Hi-Zex 5000 SR; melt viscosity 14 Pa ⁇ s at 350, 600 s 1
- thermoplastic carbon precursor Mitsubishi A mixture was prepared by melt-kneading 10 parts of Gas Chemical Co., Ltd. with a twin screw extruder (TEM-26 SS, manufactured by Toshiba Machine Co., Ltd., barrel temperature 310, under nitrogen stream).
- the dispersion diameter of the mixture obtained under these conditions into the thermoplastic carbon precursor in the thermoplastic resin was 0.05 to 2 ⁇ m.
- the mixture was kept at 300 for 10 minutes, but no aggregation of the thermoplastic carbon precursor was observed, and the dispersion diameter was 0.05 to 2 / m.
- long fibers having a fiber diameter of 100 / xm were produced from the above mixture by a cylinder type single-hole spinning machine under conditions at a spinning temperature of 390.
- a short fiber of about 5 cm in length is produced from this precursor fiber, and the basis weight of the short fiber is 30 gZm 2 on a wire mesh with an opening of 1.4 mm and a wire diameter of 0.35 mm. It was arranged in a nonwoven fabric shape.
- the nonwoven fabric made of this precursor fiber was held in a hot air dryer at 215 for 3 hours to prepare a stabilized resin composition.
- the pressure was reduced to 1 kPa, and heating from this state produced a nonwoven fabric made of a fibrous carbon precursor.
- the heating condition was that the temperature was raised to 500 in Z minutes at a heating rate of 5, and then held at that temperature for 60 minutes.
- the fibrous carbon precursor was dispersed in the solvent by adding the nonwoven fabric made of the fibrous carbon precursor to an ethanol solvent and applying vibration for 30 minutes with an ultrasonic vibrator. By filtering the fibrous carbon precursor dispersed in the solvent, a nonwoven fabric in which the fibrous carbon precursor was dispersed was produced.
- the nonwoven fabric in which the fibrous carbon precursor was dispersed was heated to 1000 in 5 minutes in a vacuum gas replacement furnace and heated at the same temperature for 0.5 hours, and then cooled to room temperature. Furthermore, this non-woven fabric is placed in a graphite crucible and is heated in a vacuum using an ultra-high temperature furnace (manufactured by Kurata Giken Co., Ltd., SCC—U—80 / 150 type, soaking section 80 mm (diameter) X 150 mm (height)). The temperature was raised from room temperature to 2000 in 1 OtZ minutes.
- the fiber diameter of the carbon fiber obtained through the blackening treatment is 300 to 600 nm (average fiber diameter 298 nm), and there is almost no fiber aggregate in which a few fibers are fused.
- the carbon fiber was extremely excellent in dispersibility.
- the lattice spacing (d 002) of the carbon fiber obtained above was 0.3373 nm, and the commercial product VGCF (manufactured by Showa Denko KK, carbon nanometer using the vapor phase method)
- the fiber was found to be considerably lower than 0.3386 nm.
- the crystallite size (Lc 002) of the carbon fiber is 69 nm, which is considerably larger than 30 nm of the commercial product VGCF, and is extremely highly crystalline.
- the volume resistivity, which shows the conductive properties was 0.013 ⁇ ⁇ cm, lower than the commercially available VGCF of 0.016 ⁇ ⁇ cm, indicating high conductivity. Comparative Example 1
- Example 1 except that polymethylpentene (TPX RT 18, manufactured by Mitsui Chemicals, Inc .; 350, 600 s- 1 melt viscosity 0.005 Pa ⁇ s) was used as the thermoplastic resin.
- a mixture was made.
- the dispersion diameter of the thermoplastic carbon precursor in the thermoplastic resin obtained under these conditions was 0.05 / xm to 2 ttm.
- the mixture was kept at 300 for 10 minutes, but no aggregation of the thermoplastic carbon precursor was observed, and the dispersion diameter was 0.05 / m-2 / m. When this was spun from a spinneret at 390 with a cylinder type single-hole spinning machine, the yarn was cut frequently and stable fibers could not be obtained.
- Comparative Example 2 Comparative Example 2
- a mixture obtained by the same method as in Comparative Example 1 was spun from a spinneret at 350 with a cylinder type single-hole spinning machine to produce a precursor fiber.
- the fiber diameter of this precursor fiber was 200 // m.
- the step of forming a fibrous carbon precursor by removing the thermoplastic resin from the stabilized resin composition in the precursor fiber is performed in a vacuum gas replacement furnace under a normal pressure nitrogen stream without reducing the pressure.
- a nonwoven fabric in which a fibrous carbon precursor was dispersed was produced by the same treatment as in Example 1 except that. This nonwoven fabric of fibrous carbon precursor was heat-treated in the same manner as in Example 1 to obtain carbon fibers.
- the obtained carbon fiber had an average fiber diameter of 300 nm and an average fiber length of 10 m.
- the lattice spacing (d 002) was 0.3811 nm and the crystallite size (Lc 002) was 4 ⁇ nm.
- the volume resistivity exhibiting the conductive properties was 0.027 ⁇ ⁇ cm.
- the carbon fiber of the present invention is excellent in high crystallinity, high conductivity, high strength, high elastic modulus, light weight, etc. Therefore, it can be used as a nanofiller for high-performance composite materials in various applications such as electrode additive materials for various batteries.
Abstract
Description
Claims
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JP2010507294A JP5451595B2 (ja) | 2008-04-08 | 2009-04-06 | 炭素繊維及びその製造方法 |
US12/936,799 US9376765B2 (en) | 2008-04-08 | 2009-04-06 | Carbon fiber and method for producing the same |
KR1020107024412A KR101529747B1 (ko) | 2008-04-08 | 2009-04-06 | 탄소 섬유 및 그 제조 방법 |
CN2009801214448A CN102057086B (zh) | 2008-04-08 | 2009-04-06 | 碳纤维及其制造方法 |
EP09730139A EP2264233A4 (en) | 2008-04-08 | 2009-04-06 | CARBON FIBER AND METHOD FOR MANUFACTURING THE SAME |
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JP (1) | JP5451595B2 (ja) |
KR (1) | KR101529747B1 (ja) |
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JP7402631B2 (ja) | 2018-08-27 | 2023-12-21 | 帝人株式会社 | 極細炭素繊維混合物、その製造方法、及び炭素系導電助剤 |
WO2022050211A1 (ja) | 2020-09-01 | 2022-03-10 | 帝人株式会社 | 樹脂結合繊維、並びにこれを用いる活物質層、電極、及び非水電解質二次電池 |
WO2022255307A1 (ja) | 2021-05-31 | 2022-12-08 | 帝人株式会社 | リチウムイオン二次電池用電極シート |
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KR20100129332A (ko) | 2010-12-08 |
JP5451595B2 (ja) | 2014-03-26 |
CN102057086B (zh) | 2013-05-29 |
EP2264233A4 (en) | 2011-06-22 |
US9376765B2 (en) | 2016-06-28 |
TW201005146A (en) | 2010-02-01 |
KR101529747B1 (ko) | 2015-06-17 |
TWI479056B (zh) | 2015-04-01 |
EP2264233A1 (en) | 2010-12-22 |
JPWO2009125857A1 (ja) | 2011-08-04 |
CN102057086A (zh) | 2011-05-11 |
US20110033705A1 (en) | 2011-02-10 |
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