WO2010143681A1 - 機械的性能発現に優れた炭素繊維束 - Google Patents
機械的性能発現に優れた炭素繊維束 Download PDFInfo
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- WO2010143681A1 WO2010143681A1 PCT/JP2010/059828 JP2010059828W WO2010143681A1 WO 2010143681 A1 WO2010143681 A1 WO 2010143681A1 JP 2010059828 W JP2010059828 W JP 2010059828W WO 2010143681 A1 WO2010143681 A1 WO 2010143681A1
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- Prior art keywords
- carbon fiber
- fiber
- fiber bundle
- carbon
- strength
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Classifications
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- D—TEXTILES; PAPER
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- D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
- D02J3/00—Modifying the surface
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- D—TEXTILES; PAPER
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- 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
- D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D01F6/18—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polymers of unsaturated nitriles, e.g. polyacrylonitrile, polyvinylidene cyanide
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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
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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
- D01F11/14—Chemical after-treatment of artificial filaments or the like during manufacture of carbon with organic compounds, e.g. macromolecular compounds
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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
- D01F11/16—Chemical after-treatment of artificial filaments or the like during manufacture of carbon by physicochemical methods
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- D—TEXTILES; PAPER
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- D01F9/08—Artificial filaments or the like of other substances; Manufacture thereof; Apparatus specially adapted for the manufacture of carbon filaments of inorganic material
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- 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
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- 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
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- D06M11/73—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with carbon or compounds thereof
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- D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
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- 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
- Y10T428/2918—Rod, strand, filament or fiber including free carbon or carbide or therewith [not as steel]
Definitions
- the present invention relates to a carbon fiber bundle having excellent mechanical properties, particularly for obtaining a fiber reinforced resin having a high toughness and heat resistant resin for use in aircraft as a matrix.
- Patent Document 2 proposes a technique for obtaining a precursor fiber excellent in strength development by paying attention to the pore distribution of the coagulated yarn and drying and densifying the coagulated yarn having a high densified structure.
- the pore distribution obtained by the mercury intrusion method reflects the bulk properties including the inside from the surface of the filament, and is a very excellent method for evaluating the denseness of the overall structure of the fiber. is there.
- High-strength carbon fibers with suppressed defect point formation can be obtained from precursor fiber bundles having an overall denseness level or higher.
- the rupture state of the carbon fiber is observed, there is a very high ratio of the rupture start in the vicinity of the surface layer. This means that a defect point exists in the vicinity of the surface layer. That is, this technique is insufficient for producing a precursor fiber bundle having excellent denseness in the vicinity of the surface layer.
- Patent Document 3 proposes a method for producing an acrylonitrile-based precursor fiber bundle having high denseness as a whole and extremely high density in the surface layer portion.
- Patent Document 4 proposes a technique that suppresses the penetration of the oil agent by focusing on the micro voids in the surface layer portion because the oil agent enters the fiber surface layer portion to inhibit densification.
- both the technology for suppressing the intrusion of oil and the technology for suppressing defect point formation are difficult to put into practical use because they require very complicated processes. For this reason, in the technique currently examined, the effect which suppresses the oil agent penetration
- JP-A-5-5224 JP-A-4-91230 Japanese Patent Publication No. 6-15722 Japanese Patent Laid-Open No. 11-124744
- An object of the present invention is to provide a carbon fiber bundle for obtaining a fiber reinforced resin having high mechanical properties.
- the surface of the single fiber does not have a surface uneven structure having a length of 0.6 ⁇ m or more extending in the longitudinal direction of the fiber, and the height difference (Rp ⁇ v) between the highest and lowest parts of the surface of the single fiber is 5 to 25 nm.
- the carbon fiber has a concavo-convex structure with an average roughness Ra of 2 to 6 nm, and the ratio of the major axis to the minor axis (major axis / minor axis) of the fiber section of the single fiber is 1.00 to 1.01.
- the mass per unit length of a single fiber is in the range of 0.030 to 0.042 mg / m
- the strand strength is 5900 MPa or more
- the strand elastic modulus measured by the ASTM method is 250 to 380 GPa
- the carbon fiber bundle is a carbon fiber having a knot strength of 900 N / mm 2 or more.
- the knot strength is obtained by dividing the tensile breaking stress of a carbon fiber bundle knotted by the cross-sectional area (mass and density per unit length) of the fiber bundle.
- the carbon fiber bundle of the present invention can provide a fiber reinforced resin having high mechanical properties.
- the ipa value obtained by an electrochemical measurement method is 0.05 to 0.25 ⁇ A / cm 2
- the oxygen-containing functionality of the carbon fiber surface obtained by X-ray photoelectron spectroscopy.
- the surface concavo-convex structure extending in the longitudinal direction of the fiber existing on the surface of the carbon fiber and the sizing agent attached to the surface play a very important role in expressing the mechanical properties of the fiber reinforced resin material using the carbon fiber as a reinforcing material. This is because the surface concavo-convex structure and the sizing agent attached to the surface are directly related to the formation of the interfacial phase between the carbon fiber and the resin and the characteristics thereof.
- the mechanical performance of the fiber reinforced resin material is affected by the performance of each of the three elements constituting the fiber, matrix resin, and interfacial phase. If even one of these three elements has poor performance, the fiber-reinforced resin material cannot exhibit excellent mechanical performance.
- the carbon fiber bundle of the present invention has a concavo-convex structure having a smaller size than the concavo-convex structure on the surface of the single fiber.
- the depth of the surface uneven structure existing in the single fiber of the carbon fiber is the difference in height between the highest part and the lowest part of the fiber surface in a range surrounded by a circumferential length of 1.0 ⁇ m and a length in the fiber axis direction of 1.0 ⁇ m. It is defined by (Rp ⁇ v) and average unevenness Ra.
- the (Rp-v) and Ra are obtained by scanning the surface of a single fiber using a scanning atomic force microscope (AFM). It is desirable that the height difference (Rp ⁇ v) is 5 to 25 nm and the average roughness Ra is 2 to 6 nm. More preferably, (Rp-v) is 5 to 18 nm, and Ra is 2 to 5 nm.
- each single fiber constituting the carbon fiber does not have a surface uneven structure having a length of 0.6 ⁇ m or more extending in the longitudinal direction of the fiber on the surface of the single fiber.
- a large-sized surface uneven structure tends to be a stress concentration portion.
- the carbon fiber structure near the concavo-convex structure has low fracture toughness. Therefore, in the surface uneven structure of this size, even in the state where the stress level applied to the composite material is not so high, the vicinity of the uneven structure is likely to be the starting point of interface fracture. As a result, the mechanical performance of the composite material is greatly reduced.
- a more specific aspect of the uneven structure on the surface of each single fiber constituting the carbon fiber of the present invention is as follows.
- the surface of the carbon fiber has a concavo-convex structure that is a ridge-like structure with a length of 0.6 ⁇ m or more extending in the longitudinal direction of the fiber, and a size larger than the concavo-convex structure that is this cocoon-like structure. Is small, and has a fine concavo-convex structure existing in each fibril body itself. That is, the surface of each single fiber constituting the carbon fiber of the present invention does not have an uneven structure with a length of 0.6 ⁇ m or more extending in the longitudinal direction of the fiber, and the size is smaller than such an uneven structure.
- the minute uneven structure has a length of 300 nm or less.
- This concavo-convex structure is indicated by the above (Rp-v) and Ra. That is, the height difference (Rp-v) is 5 to 25 nm and the average roughness Ra is 2 to 6 nm within the range surrounded by the circumferential length of 1.0 ⁇ m and the length in the fiber axis direction of 1.0 ⁇ m. It is undulating.
- (Rp-v) is 5 to 18 nm and Ra is 2 to 5 nm.
- the ratio of the major axis to the minor axis (major axis / minor axis) of the fiber cross section of the single fiber is required to be a single fiber having a perfect circle or a cross section close to a perfect circle. is there. This is because, due to the perfect circle, the structural uniformity in the vicinity of the fiber surface is excellent, so that stress concentration can be reduced. This ratio is preferably 1.00 to 1.005. Further, for the same reason, the mass per unit length of the single fiber is 0.030 to 0.042 mg / m.
- the small mass per unit length of the fiber means that the fiber diameter is small, the non-uniformity of the structure existing in the cross-sectional direction is small, and the mechanical performance in the direction perpendicular to the fiber axis is high. means. Therefore, in the composite material, resistance to stress in a direction perpendicular to the fiber axis is improved, and the mechanical performance as the composite material can be increased.
- the strand strength of the carbon fiber bundle in order to obtain a fiber reinforced resin having excellent mechanical properties, the strand strength of the carbon fiber bundle needs to be 5900 MPa or more.
- the strand strength of the carbon fiber bundle is preferably 6000 MPa or more, more preferably 6100 MPa or more. Higher strand strength is preferable, but 10,000 MPa is sufficient as a composite material in consideration of the balance with compressive strength.
- the strand elastic modulus of the carbon fiber bundle needs to be 250 to 380 GPa as measured by the ASTM method. If the elastic modulus is less than 250 GPa, the elastic modulus as a carbon fiber bundle is insufficient, and sufficient mechanical properties cannot be expressed.
- the elastic modulus exceeds 380 GPa
- the graphite crystal size on the surface and inside of the carbon fiber is increased, and accordingly, the strength in the fiber cross-sectional direction and the compressive strength in the fiber axis direction are lowered, and the tensile and compression performance as a composite material
- the balance is not good and as a result, an excellent composite material cannot be obtained.
- the inactivation progresses due to the enlargement of the graphite crystal size on the surface, and the adhesiveness with the matrix resin decreases, and the tensile strength, interlaminar shear strength, in-plane shear strength and 0 ° of the composite material are reduced. A significant decrease in mechanical performance such as compressive strength appears.
- the knot strength obtained by dividing the tensile breaking stress of the carbon fiber bundles knotted by the cross-sectional area (mass and density per unit length) of the fiber bundle is 900 N / mm 2 or more. . More preferably, it is 1000 N / mm 2 or more, and still more preferably 1100 N / mm 2 or more.
- the knot strength can be an index reflecting the mechanical performance of the fiber bundle other than in the fiber axis direction, and particularly the performance in the direction perpendicular to the fiber axis can be easily seen. In a composite material, a material is often formed by quasi-isotropic lamination, and a complex stress field is formed.
- the carbon fiber bundle of the present invention preferably has a fracture surface generation energy of 30 N / m or more.
- the fracture surface generation energy is determined by forming a hemispherical defect having a size within a predetermined range with a laser on the surface of a single fiber, and breaking the fiber at the hemispherical defect site by a tensile test. Is obtained from the following Griffith equation (1).
- ⁇ (2E / ⁇ C) 1/2 ⁇ (Fracture surface generation energy) 1/2 (1)
- ⁇ is the breaking strength
- E is the ultrasonic elastic modulus of the carbon fiber bundle
- c is the size of the hemispherical defect.
- the fracture surface generation energy is more preferably 31 N / m or more, and even more preferably 32 N / m or more.
- the fracture formation energy is an index of the difficulty of breaking the carbon fiber and represents the substrate strength.
- Carbon fiber is a material that exhibits brittle fracture, and its tensile strength is governed by defect points. When the carbon fiber has the same defect point, the higher the substrate strength, the higher the breaking strength.
- many matrix resins for high-performance composite materials have high adhesion to carbon fibers, and as a result, the critical fiber length that serves as an index of stress transmission is shortened. As a result, the strength of the composite material reflects the strength at a shorter length, and the substrate strength is considered to be an important index.
- the fracture generation energy should be 50 N / m or less.
- the ipa value obtained by an electrochemical measurement method is preferably 0.05 to 0.25 ⁇ A / cm 2 .
- This ipa value is influenced by the number of oxygen-containing functional groups of the carbon fiber, the degree of surface unevenness involved in forming the electric double layer, and the fine graphite structure on the surface of the carbon fiber.
- carbon fibers that have undergone large etching of the surface layer and carbon fibers that form an intercalation compound in which anion ions enter between graphite crystals have large values.
- the interface between carbon fiber and resin is important, especially carbon fiber with a suitable oxygen-containing functional group and a surface that forms a small electric double layer is optimal.
- the ipa value is 0.05 ⁇ A / cm 2 or more, it indicates that sufficient oxygen-containing functional groups are present on the surface, and has sufficient interfacial adhesion.
- the ipa value is 0.25 ⁇ A / cm 2 or less, the surface is not excessively etched, and no intercalation compound is formed. Such a surface can be firmly bonded to the matrix resin, and as a result, has sufficient interfacial adhesion to the resin. More preferably, it is 0.07 to 0.20 ⁇ A / cm 2 , and still more preferably 0.10 to 0.18 ⁇ A / cm 2 .
- the carbon fiber has an oxygen-containing functional group amount (O1S / C1S) on the surface of the carbon fiber determined by X-ray photoelectron spectroscopy in the range of 0.05 to 0.15. This is because it is important to have an appropriate interfacial adhesion with the matrix resin.
- O1S / C1S oxygen-containing functional group amount
- the amount of Si measured by ICP emission analysis is 200 ppm or less.
- a silicone oil-containing oil agent is usually adhered to the precursor fiber bundle. Silicone oil is very excellent in heat resistance and can provide excellent release properties. For this reason, the filament diameter is very small, it has a form of a multifilament bundle formed by aggregating many of these filaments, and is further subjected to processing at a high temperature of 200 ° C. or more for several tens of minutes to several hours. It is considered to be the most suitable for the oil agent of the carbon fiber precursor fiber bundle.
- Precursor fiber bundle and manufacturing method thereof Although there is no restriction
- group precursor fiber (henceforth "precursor fiber” suitably) is preferable from a viewpoint of mechanical performance expression.
- the acrylonitrile copolymer constituting the precursor fiber is obtained from 96% by mass or more of acrylonitrile and several kinds of copolymerizable monomers. More preferably, the composition ratio of acrylonitrile is 97% by mass or more.
- copolymer components other than acrylonitrile include acrylic acid derivatives such as acrylic acid, methacrylic acid, itaconic acid, methyl acrylate, methyl methacrylate, acrylamide, methacrylamide, N-methylol acrylamide, N, N-dimethyl acrylamide, etc. Suitable are acrylamide derivatives and vinyl acetate. These may be used alone or in combination.
- a preferred copolymer is an acrylonitrile-based copolymer obtained by copolymerizing a monomer having one or more carboxyl groups as an essential component.
- a suitable method for copolymerizing the monomer mixture may be, for example, redox polymerization in an aqueous solution or suspension polymerization in a heterogeneous system and emulsion polymerization using a dispersing agent, or any other polymerization method.
- the present invention is not limited by the differences.
- the precursor fiber is preferably prepared by dissolving the acrylonitrile-based polymer described above in an organic solvent such as dimethylacetamide, dimethylsulfoxide, dimethylformamide or the like to prepare a spinning dope. Since these organic solvents do not contain a metal component, the content of the metal component in the obtained carbon fiber bundle can be lowered.
- the solid concentration of the spinning dope is preferably 20% by mass or more, and more preferably 21% by mass or more.
- the spinning method may be either wet spinning or wet and wet spinning. More preferred is dry and wet spinning.
- dry and wet spinning the prepared spinning solution is spun into air from a spinneret with a large number of discharge holes, and then discharged into a coagulation liquid filled with a mixed solution of temperature-controlled organic solvent and water for coagulation.
- the coagulated yarn is taken out and then washed and stretched. Any cleaning method may be used as long as the solvent can be removed.
- a fibril structure can be formed by extending
- the temperature of the drawing tank is preferably in the range of 40 to 80 ° C. If the temperature is less than 40 ° C., the stretchability cannot be ensured and the stretching becomes impossible, and a uniform fibril structure cannot be formed. On the other hand, when the temperature exceeds 80 ° C., the plasticizing action due to heat becomes too large, the solvent removal on the surface of the yarn proceeds rapidly, and the stretching becomes uneven, and the quality of the precursor fiber bundle deteriorates. . A more preferable temperature is 50 to 75 ° C.
- the concentration of the stretching tank is preferably 30 to 60% by mass. If it is less than 30% by mass, stable stretchability cannot be ensured, and if it exceeds 60% by mass, the plasticizing effect becomes too large and the stable stretchability is impaired. A more preferred concentration is 35 to 55% by mass.
- the stretching ratio in this stretching tank is preferably 2 to 4 times. If it is less than 2 times, the stretching is insufficient, and a desired fibril structure cannot be formed. On the other hand, if the stretching exceeds 4 times, the fibril structure itself is broken, resulting in a precursor fiber bundle having a very sparse structural form.
- a more preferable stretching ratio is 2.2 to 3.8 times, and further preferably 2.5 to 3.5 times.
- the stretching is performed 1.1 to 2.0 times in hot water for the purpose of increasing the total stretching ratio and increasing the fiber orientation.
- Dry densification is not particularly limited as long as it is dried and densified by a known drying method.
- a method of passing a plurality of heating rolls is preferable.
- Acrylic fiber bundles after drying and densification may be used in pressurized steam at 130 to 200 ° C., in a dry heat medium at 100 to 200 ° C., between heating rolls at 150 to 220 ° C. or on a heating plate as necessary.
- the film is stretched by 1.8 to 6.0 times, further improved in orientation and densified, and then wound up to obtain a precursor fiber bundle.
- the carbon fiber of the present invention can be produced from the precursor fiber bundle as follows.
- the precursor fiber bundle is passed through a hot air circulation type flameproofing furnace at 220 to 260 ° C. for 30 to 100 minutes to obtain a flameproofed yarn having a flameproofed yarn density of 1.335 to 1.360 g / cm 3 .
- an elongation operation of 0 to 10% is performed.
- the flameproofing reaction includes a cyclization reaction by heat and an oxidation reaction by oxygen, and it is important to balance these two reactions.
- the flameproofing treatment time is preferably 30 to 100 minutes.
- the flame resistant yarn density is less than 1.335 g / cm 3 , the flame resistance becomes insufficient, and a decomposition reaction occurs due to the subsequent heat treatment at a high temperature, and a defect point is formed, so that high strength cannot be obtained.
- the flameproof yarn density exceeds 1.360 g / cm 3 , because the oxygen content of the fiber increases, a reaction in which excess oxygen disappears due to the subsequent heat treatment at a high temperature occurs to form a defect point. High strength cannot be obtained.
- a more preferable range of flame resistant yarn density is 1.340 to 1.350 g / cm 3 .
- Appropriate elongation in the flameproofing furnace is necessary to maintain and improve the orientation of the fibril structure forming the fiber. If the elongation is less than 0%, the orientation of the fibril structure cannot be maintained, the orientation at the fiber axis in the formation of the carbon fiber structure is not sufficient, and excellent mechanical performance cannot be exhibited. On the other hand, if the elongation exceeds 10%, the fibril structure itself breaks, and the subsequent formation of the carbon fiber structure is impaired. Further, the breaking point becomes a defect point, and a high-strength carbon fiber cannot be obtained. A more preferable elongation rate is 3 to 8%.
- the flame-resistant fiber is passed through a first carbonization furnace having a temperature gradient of 300 to 800 ° C. in an inert atmosphere such as nitrogen while applying elongation of 2 to 7%.
- a suitable processing temperature is 300 to 800 ° C., and processing is performed with a linear gradient.
- the starting temperature is preferably 300 ° C. or higher.
- the maximum temperature exceeds 800 ° C., the process yarn becomes very brittle and it is difficult to shift to the next process.
- a more preferred temperature range is 300 to 750 ° C.
- the temperature gradient is not particularly limited, but it is preferable to set a linear gradient.
- the elongation is less than 2%, the orientation of the fibril structure cannot be maintained, the orientation at the fiber axis in the formation of the carbon fiber structure is not sufficient, and excellent mechanical performance cannot be exhibited.
- the elongation exceeds 7%, the fibril structure itself breaks, and the subsequent formation of the carbon fiber structure is impaired, and the break point becomes a defect point, and a high-strength carbon fiber cannot be obtained.
- a more preferable elongation is 3 to 5%.
- the preferred heat treatment time in the first carbonization furnace is 1.0 to 3.0 minutes. In the treatment for less than 1.0 minute, a violent decomposition reaction accompanying a rapid temperature rise occurs, and a high-strength carbon fiber cannot be obtained. If it exceeds 3.0 minutes, the influence of plasticization in the first stage of the process occurs, and the orientation of crystals tends to be lowered, resulting in the deterioration of the mechanical performance of the resulting carbon fiber. A more preferable heat treatment time is 1.2 to 2.5 minutes.
- heat treatment is performed under tension in a second carbonization furnace having a temperature gradient of 1000 to 1600 ° C. in an inert atmosphere such as nitrogen to obtain carbon fibers. Further, if necessary, heat treatment is performed under tension in an inert atmosphere in a third carbonization furnace having an additional desired temperature gradient.
- Carbonization temperature is set according to the desired elastic modulus of the carbon fiber.
- the maximum carbonization temperature is low.
- the elastic modulus can be increased by extending the treatment time, the maximum temperature can be lowered as a result.
- the temperature gradient can be set gently, which is effective in suppressing defect point formation.
- a 2nd carbonization furnace is based also on the temperature setting of a 1st carbonization furnace, what is necessary is just 1000 degreeC or more. Preferably it is 1050 degreeC or more.
- the temperature gradient is not particularly limited, but it is preferable to set a linear gradient.
- the heat treatment time in the second carbonization furnace is preferably 1.3 to 5.0 minutes. More preferably, it is 2.0 to 4.2 minutes. In this heat treatment, since the process fibers are accompanied by a large shrinkage, it is important to perform the heat treatment under tension.
- the elongation is preferably -6.0 to 0.0%. If it is less than -6.0%, the crystal orientation in the fiber axis direction is poor and sufficient performance cannot be obtained. On the other hand, when it exceeds 0.0%, the structure itself that has been formed is destroyed, the formation of defect points becomes remarkable, and the strength is greatly reduced. A more preferred elongation is in the range of -5.0% to -1.0%.
- the carbon fiber bundle is subjected to a surface oxidation treatment.
- the surface treatment method include a known method, that is, an oxidation treatment such as electrolytic oxidation, chemical oxidation, and air oxidation.
- the electrolytic oxidation treatment that is widely practiced industrially is more preferable because stable surface oxidation treatment is possible.
- the simplest method is to use electrolytic oxidation treatment and change the amount of electricity. In this case, even if the amount of electricity is the same, ipa varies greatly depending on the electrolyte used and its concentration.
- the electrolytic oxidation treatment in an alkaline aqueous solution having a pH higher than 7 by using a carbon fiber as an anode and flowing an electric quantity of 10 to 200 coulomb / g.
- ipa can be made 0.05 to 0.25 ⁇ A / cm 2 .
- the electrolyte it is preferable to use ammonium carbonate, ammonium bicarbonate, calcium hydroxide, sodium hydroxide, potassium hydroxide, or the like.
- the carbon fiber bundle of the present invention is subjected to sizing treatment.
- a sizing agent imparts to a carbon fiber bundle a solution dissolved in an organic solvent or an emulsion liquid dispersed in water with an emulsifier or the like by a roller dipping method, a roller contact method or the like.
- the sizing process can be performed by drying this.
- the amount of the sizing agent attached to the surface of the carbon fiber can be adjusted by adjusting the concentration of the sizing agent solution or adjusting the amount of drawing.
- drying can be performed using hot air, a hot plate, a heating roller, various infrared heaters, and the like.
- the most suitable sizing agent composition applied to the surface of the carbon fiber of the present invention is (a) an epoxy resin having a hydroxy group (hereinafter referred to as component (a) as appropriate), (b) a polyhydroxy compound (hereinafter referred to as appropriate ( b) component) and (c) urethane-modified epoxy resins which are reaction products of diisocyanates containing aromatic rings (hereinafter referred to as component (c) where appropriate).
- component (c) urethane-modified epoxy resins which are reaction products of diisocyanates containing aromatic rings
- component (d) a component obtained by using an epoxy resin having no hydroxy group
- component (d) a component obtained by using an epoxy resin having no hydroxy group
- the epoxy group has a very strong interaction with the oxygen-containing functional group on the surface of the carbon fiber, and can firmly adhere the sizing agent component to the surface of the carbon fiber.
- a urethane bond unit produced from a polyhydroxy compound and a diisocyanate containing an aromatic ring, it is possible to impart flexibility and a strong interaction with the carbon fiber surface due to the polarity of the urethane bond and the aromatic ring. Is possible. Therefore, the urethane-modified epoxy resin having an epoxy group and the urethane bond unit in the molecule is a compound that can adhere strongly to the carbon fiber surface and has flexibility. That is, since such a sizing agent composition forms a flexible interface layer firmly bonded to the carbon fiber surface, the mechanical performance of the composite material obtained by impregnating and curing the matrix resin in the carbon fiber is excellent. Can be.
- the component (a) is not particularly limited, and the number of hydroxy groups contained in the component (a) is not limited.
- glycidol, methyl glycidol, bisphenol F type epoxy resin, bisphenol A type epoxy resin, oxycarboxylic acid glycidyl ester epoxy resin and the like can be used.
- Particularly preferred are bisphenol type epoxy resins. Since these have an aromatic ring, the interaction with the carbon fiber surface is strong.
- the matrix resin used for the composite material is often an epoxy resin having an aromatic ring from the viewpoint of heat resistance and rigidity, and is excellent in compatibility with these matrix resins.
- two or more epoxy resins can be used as the component (a).
- the component (b) is preferably composed of any one of bisphenol A alkylene oxide adduct, aliphatic polyhydroxy compound, polyhydroxy monocarboxy compound, or a mixture thereof. This is because these compounds can soften the urethane-modified epoxy resin. Specifically, bisphenol A ethylene oxide 4 mol to 14 mol adduct, bisphenol A propylene oxide 2 to 14 mol adduct, bisphenol A ethylene oxide, propylene oxide block copolymer adduct , Polyethylene glycol, trimethylolpropane, dimethylolpropionic acid and the like.
- component (c) is not particularly limited. Particularly preferred is toluene diisocyanate or xylene diisocyanate.
- the epoxy resin of component (d) is not particularly limited.
- numerator is good. This is because the interaction between the surface of the carbon fiber and the epoxy group is strong, and these compounds adhere firmly to the surface.
- Preferred epoxy resins include bisphenol F type epoxy resin, bisphenol A type epoxy resin, novolac type epoxy resin, dicyclopentadiene type epoxy resin (Epicron HP-7200 series: Dainippon Ink and Chemicals, Inc.), trishydroxyn phenylmethane.
- Type epoxy resin (Epicoat 1032H60, 1032S50: Japan Epoxy Resin Co., Ltd.), DPP novolac type epoxy resin (Epicoat 157S65, 157S70: Japan Epoxy Resin Co., Ltd.), bisphenol A alkylene oxide-added epoxy resin, and the like can be used.
- the component (d) may be added simultaneously with the component (a) when the component (a), the component (b), and the component (c) are reacted. Further, after completion of the urethanization reaction, component (d) may be added.
- aqueous dispersion composed of such a compound include Hydran N320 (manufactured by DIC Corporation).
- the carbon fiber of the present invention has a strand elastic modulus of 250 GPa or more, it is obtained by firing at a relatively high temperature. Therefore, it is advantageous to obtain from precursor fibers containing as little impurities as possible, such as metals. As a result, the metal component contained in the obtained carbon fiber bundle is preferably small.
- the total amount of metal components such as alkali metal, alkaline earth metal, zinc, iron and aluminum is preferably 50 ppm or less. These metals react with carbon at temperatures exceeding 1000 ° C., cause melting or evaporation, and cause the formation of defect points, making it impossible to produce high-strength carbon fibers.
- Measurement of surface uneven structure of single fiber Based on the surface shape, it can be measured as follows. Place several single fibers of a carbon fiber bundle on a sample table, fix both ends, and apply dotite around the sample to make a measurement sample. Using a silicon nitride cantilever with an atomic force microscope (Seiko Instruments Inc., SPI3700 / SPA-300 (trade name)), in the AFM mode, the fiber axis has a range of 1000 nm in the circumferential direction of the single fiber. The scanning is repeated while gradually shifting over a direction length of 1000 nm, and the obtained measurement image is subjected to inverse transformation after the low-frequency component is cut by two-dimensional Fourier transformation.
- Ra ⁇ 1 / (Lx ⁇ Ly) ⁇ ⁇ ⁇ Ly 0 ⁇ LX 0
- Center plane A plane that is parallel to a plane that has a minimum height deviation from the actual surface and that divides the actual surface into two equal parts, that is, a portion that is surrounded by the plane and the actual surface. Planes with equal volumes V1 and V2 on both sides of f (x, y): difference in height between the actual surface and the central surface, Lx, Ly: XY plane size.
- the ratio (major axis / minor axis) of the major axis to the minor axis of the fiber cross section of the single fiber constituting the carbon fiber bundle was determined as follows. A carbon fiber bundle for measurement was passed through a tube made of vinyl chloride resin having an inner diameter of 1 mm, and this was then cut into round pieces with a knife to prepare a sample. Next, the sample was bonded to the SEM sample stage with the fiber cross-section facing upward, and Au was further sputtered to a thickness of about 10 nm, and then scanned with a scanning electron microscope (product name: XL20, manufactured by Philips). The fiber cross section was observed under the conditions of an acceleration voltage of 7.00 kV and a working distance of 31 mm, and the major axis and minor axis of the fiber cross section of the single fiber were measured.
- the nodule strength was measured as follows. A grip part having a length of 25 mm was attached to both ends of a carbon fiber bundle having a length of 150 mm to obtain a test specimen. During the preparation of the test specimen, the carbon fiber bundle was aligned by applying a load of 0.1 ⁇ 10 ⁇ 3 N / denier. A single knot was formed on the test body at almost the center, and the crosshead speed during tension was 100 mm / min. The number of tests was 12 and the minimum and maximum values were removed, and the average value of 10 was used as the measurement value.
- hemispherical defects were formed by irradiating these samples fixed to the mount with a laser.
- the laser interface system used was a micropoint (pulse energy 300 uJ) manufactured by Photonic Instruments.
- An ECLIPSE LV100 manufactured by Nikon Corporation was used as an optical microscope necessary for condensing the laser.
- the aperture stop of the optical microscope was set to the minimum, and the objective lens was set to 100 times. Under this condition, one pulse of a laser beam having a wavelength of 435 nm, which is attenuated by 10% of the laser intensity with an attenuator, is applied to the central portion in the fiber axis direction of the sample and the central portion in the direction perpendicular to the fiber axis. A sample in which a defect was formed was obtained.
- the sample attached to the mount was further sandwiched between films, and the film was filled with a viscous liquid to conduct a tensile test.
- a film having a width of about 5 mm and a length of about 15 mm was prepared, the film was attached to the upper part of both sides of the sample mount with an adhesive, and the entire mount was sandwiched between the films so as to cover the sample.
- the space between the films was filled with a glycerin aqueous solution (a ratio of water 2 to glycerin 1), and then a tensile test was performed at a tensile speed of 0.5 mm / min to measure a breaking load.
- the sample pair divided into two in the tensile test was taken out from the mount, carefully washed with water, and then naturally dried.
- an SEM observation sample was prepared by fixing it to the SEM sample stage with carbon paste so that the fracture surface of the sample was on top.
- the fracture surface of the obtained SEM observation sample was observed by SEM using JSM6060 (acceleration voltage 10 to 15 kV, magnification 10,000 to 15000) manufactured by JEOL.
- the obtained SEM image was taken into a personal computer and image analysis was performed with image analysis software to measure the size of the hemispherical defect and the fiber cross-sectional area.
- breaking load / fiber cross-sectional area breaking strength ( ⁇ ) and hemispherical defect size (C) were plotted, and the slope of the data was calculated.
- the ipa value was measured by the following method.
- the electrolyte is adjusted to pH 3 with a 5% phosphoric acid aqueous solution, and nitrogen is bubbled to eliminate the influence of dissolved oxygen.
- a carbon electrode as a sample is immersed in an electrolytic solution as one electrode, and a platinum electrode having a sufficient surface area is used as a counter electrode.
- an Ag / AgCl electrode was employed as the reference electrode.
- the sample form was 12000 filament tow with a length of 50 mm.
- the scanning range of the potential applied between the carbon fiber electrode and the platinum electrode was ⁇ 0.2 V to +0.8 V, and the scanning speed was 2.0 mV / sec.
- ipa 1 ( ⁇ A) / sample length (cm) ⁇ ⁇ 4 ⁇ ⁇ weight per unit area (g / cm) ⁇ number of filaments / density (g / cm 3 ) ⁇ 1/2 (3)
- the apparent surface area was calculated from the sample length and the sample density determined by the method described in JIS R7601, and the current value i was divided into ipa. This measurement was performed using a cyclic voltametry analyzer model P-1100 manufactured by Yanagimoto Seisakusho.
- Precursor fiber bundle production examples 1 to 7 Precursor fiber (1) An acrylonitrile polymer having a composition of 98% by mass of acrylonitrile and 2% by mass of methacrylic acid was dissolved in dimethylformamide to prepare a spinning stock solution of 23.5% by mass. This spinning dope was spun from a spinneret having a discharge hole having a diameter of 0.15 mm and several thousands, and was subjected to dry and wet spinning. That is, it was spun into air and passed through a space of about 5 mm, and then coagulated in a coagulation liquid filled with an aqueous solution containing 79.0% by mass dimethylformamide adjusted to 10 ° C., and the coagulated yarn was taken up. .
- the film was stretched 1.1 times in air, and then stretched 2.5 times in a stretching tank filled with an aqueous solution containing 35 mass% dimethylformamide adjusted to 60 ° C.
- the process fiber bundle containing the solvent was washed with clean water, and then stretched 1.4 times in 95 ° C. hot water.
- an oil agent containing amino-modified silicone as a main component was applied to the fiber bundle so as to be 1.1% by mass, followed by drying and densification.
- the fiber bundle after drying and densification was stretched 2.6 times between heated rolls, and after further improving the orientation and densification, it was wound up to obtain an acrylonitrile-based precursor fiber bundle.
- the fineness of this fiber was 0.77 dtex.
- Precursor fiber (2) The precursor fiber bundle (2) under the same conditions as the precursor fiber bundle (1) except that the draw ratio before the water washing treatment was 2.9 times and the draw ratio in the hot water after washing was 1.2 times. Got.
- Precursor fiber (3) A precursor fiber bundle (3) was obtained under the same conditions as the precursor fiber bundle (2) except that the fineness of the precursor fiber was 0.67 dtex.
- Precursor fiber (4) A precursor fiber bundle (4) was obtained under the same conditions as the precursor fiber bundle (2) except that the fineness of the precursor fiber was 0.90 dtex.
- Precursor fiber (5) The precursor fiber bundle (1) except that the draw ratio before washing with water was 4.1 times, the draw ratio in hot water after washing was 0.99 times, and the drawing ratio was 2.4 times between heating rolls. A precursor fiber bundle (5) was obtained under the same conditions.
- Precursor fiber (6) The precursor fiber bundle (6) under the same conditions as the precursor fiber bundle (1) except that the draw ratio before the water washing treatment was 1.9 times and the draw ratio in the hot water after washing was 2.0 times. Got.
- Precursor fiber (7) A precursor fiber bundle (7) was obtained under the same conditions as the precursor fiber bundle (2) except that the fineness of the precursor fiber was 1.0 dtex.
- the production conditions of the precursor fiber bundles (1) to (7) are shown in Table 1.
- Examples 1 to 7, Comparative Examples 1 to 4 Preparation of carbon fiber bundle
- a plurality of precursor fiber bundles (1), (2), (3), (4), (5), (6) or (7) are introduced into a flameproofing furnace in a state where they are aligned in parallel, 220 to 280
- the precursor fiber bundle was flameproofed by blowing air heated to 0 ° C. onto the precursor fiber bundle to obtain a flameproof fiber bundle having a density of 1.345 g / cm 3 .
- the elongation rate was 6%, and the flameproofing treatment time was 70 minutes.
- the flame-resistant fiber bundle was passed through a first carbonization furnace having a temperature gradient of 300 to 700 ° C. in nitrogen with an elongation of 4.5%.
- the temperature gradient was set to be linear.
- the processing time was 2.0 minutes.
- heat treatment was performed at a predetermined temperature shown in Table 2 or Table 3 using a second carbonization furnace capable of setting a temperature gradient of 1000 to 1600 ° C. in a nitrogen atmosphere.
- heat treatment was performed at a predetermined temperature shown in Table 2 or Table 3 using a third carbonization furnace capable of setting a temperature gradient of 1200 to 2400 ° C. in a nitrogen atmosphere to obtain a carbon fiber bundle.
- the elongation ratio of the second carbonization furnace and the third carbonization furnace was -4.0%, and the treatment time was 3.5 minutes. Subsequently, it was run in an aqueous solution of 10% by weight of ammonium bicarbonate, and with the carbon fiber bundle as the anode, an electric current treatment was carried out with the counter electrode so that the amount of electricity was 40 coulombs per 1 g of carbon fiber to be treated. And then dried. Next, 0.5% by mass of hydran N320 (hereinafter referred to as “sizing agent 1”) was adhered and wound around a bobbin to obtain a carbon fiber bundle.
- sizing agent 1 0.5% by mass of hydran N320
- 156 carbon fiber bundles unwound from a bobbin are arranged on a release paper coated with B-staged epoxy resin # 410 (180 ° C curing type) (Mitsubishi Rayon Co., Ltd.), and thermocompression bonded.
- the epoxy resin was impregnated through a roller.
- a protective film was laminated thereon to produce a unidirectionally aligned prepreg (hereinafter referred to as “UD prepreg”) having a resin content of about 33% by mass, a carbon fiber basis weight of 125 g / m 2 , and a width of 500 mm.
- Precursor fiber bundle production example 8 Using the spinning stock solution prepared in the same manner as in Production Example 1, spinning was performed from a spinneret in which discharge holes having a diameter of 0.13 mm and several 2,000 were arranged, and dry and wet spinning was performed. That is, it was spun into air and passed through a space of about 5 mm, and then coagulated in a coagulation liquid filled with an aqueous solution containing 77.0% by mass dimethylformamide adjusted to 5 ° C., and the coagulated yarn was taken up. It was. Next, the film was stretched 1.3 times in air and then stretched 2.0 times in a stretching tank filled with an aqueous solution adjusted to 60 ° C.
- the process fiber bundle was washed with clean water, and then stretched 2.0 times in 95 ° C. hot water. Subsequently, an oil agent containing amino-modified silicone as a main component was applied to the fiber bundle so as to be 1.0% by mass, followed by drying and densification.
- the fiber bundle after drying and densification was drawn 1.9 times between heating rolls, and after further improving the orientation and densification, it was wound up to obtain a precursor fiber bundle. The fineness of this fiber was 0.77 dtex.
- Example 8 A carbon fiber bundle was produced under the same firing conditions as in Example 5 except that the third carbonization furnace was not used. Moreover, the laminated board was produced similarly and mechanical performance evaluation was implemented and the result of Table 2 was obtained. In addition, there was no surface uneven structure with a length of 0.6 ⁇ m or more extending in the longitudinal direction of the fiber on the surface of the single fiber, and a minute uneven structure with a length of 300 nm or less was confirmed.
- Example 9 to 11 Comparative Examples 6 to 8
- a carbon fiber bundle was obtained in the same manner as in Example 2 except that the firing conditions were changed.
- the evaluation results are shown in Table 4. In any of the examples, there was no surface uneven structure having a length of 0.6 ⁇ m or more extending in the longitudinal direction of the fiber on the surface of the single fiber, and a minute size uneven structure having a length of 300 nm or less was confirmed.
- Example 12 A carbon fiber bundle was obtained in the same manner as in Example 5 except that the surface treatment conditions were changed.
- the evaluation results are shown in Table 5.
- Example 14 to 16 A carbon fiber bundle was obtained in the same manner as in Example 5 except that the type of sizing agent and the amount of adhesion were changed. The evaluation results are shown in Table 5. In any of the examples, there was no surface uneven structure having a length of 0.6 ⁇ m or more extending in the longitudinal direction of the fiber on the surface of the single fiber, and a minute size uneven structure having a length of 300 nm or less was confirmed. Sizing agent 2, sizing 3 and sizing 4 were prepared as follows.
- Size agent 2 80 parts by mass of “Epicoat 828” manufactured by Japan Epoxy Resin Co., Ltd. as the main agent and 20 parts by mass of “Pluronic F88” manufactured by Asahi Denka Co., Ltd. as the emulsifier were mixed, and an aqueous dispersion was prepared by phase inversion emulsification.
- the carbon fiber bundle of the present invention can be used as a structural material for aircraft, high-speed moving bodies, and the like.
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Abstract
Description
本発明は、単繊維の表面に繊維の長手方向に延びる長さ0.6μm以上の表面凹凸構造が無く、単繊維の表面の最高部と最低部の高低差(Rp-v)が5~25nmで平均凹凸度Raが2~6nmの凹凸構造を有し、かつ単繊維の繊維断面の長径と短径との比(長径/短径)が1.00~1.01である炭素繊維の単繊維からなり、単繊維の単位長さ当たりの質量が0.030~0.042mg/mの範囲にあり、ストランド強度が5900MPa以上、ASTM法で測定されるストランド弾性率が250~380GPaであり、結節強さが900N/mm2以上の炭素繊維である炭素繊維束である。
なお、結節強さは、炭素繊維束を結節したものの引張破断応力を繊維束の断面積(単位長さ当たりの質量と密度)で除して求められる。
炭素繊維束の一般的な製造方法から、通常の炭素繊維には繊維軸方向にほぼ平行な表面凹凸構造が存在する。この凹凸構造は、繊維軸とほぼ平行で、繊維軸方向に伸びたうねり構造を有している。凹凸の深さは、通常50nm~数百nm程度であり、その長さは通常0.6μm~数μm程度で、場合により数十μmである。この表面凹凸構造は、通常、表面皺と称されている。
本発明の炭素繊維束は、単繊維の表面に繊維の長手方向に延びる長さ0.6μm以上の表面凹凸構造を有していないものである。
通常炭素繊維表面には、数個のフィブリルの集合体を単位とする繊維の長手方向に伸びる長さ0.6μm以上の皺状構造である凹凸構造とこの皺状構造である凹凸構造よりもサイズが小さく、各フィブリル体の自体に存在する微小な凹凸構造を有する。
即ち、本発明の炭素繊維を構成する各単繊維の表面には、繊維の長手方向に延びる長さ0.6μm以上の凹凸構造が存在せず、このような凹凸構造よりもよりもサイズが小さい、各フィブリル体の自体に存在する微小な凹凸構造のみが存在するものである。さらに、その微小な凹凸構造は、長さ300nm以下のものとなっている。この凹凸構造は前記の(Rp-v)及びRaによって表示される。即ち、単繊維の表面の円周長さ1.0μm、繊維軸方向長さ1.0μmで囲まれる範囲で、高低差(Rp-v)が5~25nm、平均凹凸度Raが2~6nmの起伏である。好ましくは、(Rp-v)は5~18nm、Raは2~5nmである。この微小サイズの凹凸構造の方向には特に限定はなく、繊維軸方向に平行、あるいは垂直、あるいはある角度を有する。
また、単繊維の繊維断面の長径と短径との比(長径/短径)は1.00~1.01である、真円或いは真円に近い断面を有する単繊維であることが必要である。真円であることにより、繊維表面近傍の構造均一性が優れているために、応力集中を低減させることができるからである。この比は好ましくは1.00~1.005である。さらに、同様な理由から、単繊維の単位長さ当たりの質量は、0.030~0.042mg/mである。繊維の単位長さ当たりの質量(単繊維目付け)が小さいことは、繊維径が小さく、断面方向に存在する構造の不均一性が小さく、繊維軸と垂直な方向の機械的性能が高いことを意味する。したがって、複合材料において、繊維軸に垂直な方向の応力に対する耐性が向上し、複合材料としての機械的性能を高くすることができる。
本発明において、優れた機械物性を有する繊維強化樹脂を得るには、炭素繊維束のストランド強度は5900MPa以上であることが必要である。炭素繊維束のストランド強度は、好ましくは6000MPa以上、より好ましくは6100MPa以上である。ストランド強度は高い方が好ましいが、複合材料として、圧縮強度とのバランスを考えると、10000MPaあれば十分である。また、本発明において、優れた機械物性を有する繊維強化樹脂を得るには、炭素繊維束のストランド弾性率はASTM法で測定される数値で250~380GPaであることが必要である。弾性率が250GPa未満では、炭素繊維束としての弾性率が不足し、十分な機械物性を発現させることができない。一方、弾性率が380GPaを超えると、炭素繊維の表面及び内部の黒鉛結晶サイズが大きくなり、それに伴い繊維断面方向強度および繊維軸方向の圧縮強度が低下し、複合材料としての引張と圧縮の性能バランスがうまく付かず、その結果として、優れた複合材料を得ることができなくなる。さらに、表面の黒鉛結晶サイズの拡大により不活性化が進み、マトリックス樹脂との接着性が低下することになり、複合材料の90°方向の引張強度、層間剪断強度、面内剪断強度や0°圧縮強度などの機械的性能の低下が顕著に現れる。
ここで、σは破断強度、Eは炭素繊維束の超音波弾性率、cは半球状欠陥の大きさである。破壊表面生成エネルギーは、より好ましくは、31N/m以上、さらに好ましくは32N/m以上である。
本発明の炭素繊維束を得る出発原料としては特に制限はないが、機械的性能発現の観点で、アクリロニトリル系前駆体繊維(以下適宜「前駆体繊維」という)から得られるものが好ましい。
この前駆体繊維を構成するアクリロニトリル系共重合体は96質量%以上のアクリロニトリルと数種の共重合可能なモノマーより得られるものである。より好ましくはアクリロニトリルの組成比は97質量%以上である。アクリロニトリル以外の共重合成分としては例えばアクリル酸、メタクリル酸、イタコン酸、アクリル酸メチル、メタクリル酸メチル等のアクリル酸誘導体、アクリルアミド、メタクリルアミド、N-メチロ-ルアクリルアミド、N、N-ジメチルアクリルアミド等のアクリルアミド誘導体、酢酸ビニルなどが適する。これらは単独でも組合せでも良い。好ましい共重合体は、一つ以上のカルボキシル基有するモノマーを必須成分として共重合させたアクリロニトリル系共重合体である。
乾燥緻密化後のアクリル繊維束は、必要に応じて130~200℃の加圧スチームや、100~200℃の乾熱熱媒中、あるいは、150~220℃の加熱ロール間や加熱板上で1.8~6.0倍延伸して、更なる配向の向上と緻密化を行った後に巻き取って前駆体繊維束を得る。
さらに、ヒドロキシ基を有しないエポキシ樹脂(以下適宜(d)成分という)を使用して得られる、ウレタン変性エポキシ樹脂と(d)成分との混合物が挙げられる。また更に、ウレタン変性エポキシ樹脂、(a)成分と(d)成分との混合物が挙げられる。
(a)成分として2種以上のエポキシ樹脂を用いることもできる。
表面形状を基に、以下のようにして計測できる。
炭素繊維束の単繊維を数本、試料台上にのせ、両端を固定し、さらに周囲にドータイトを塗り、測定サンプルとする。原子間力顕微鏡(セイコーインスツルメンツ(株)製、SPI3700/SPA-300(商品名))によりシリコンナイトライド製のカンチレバーを使用し、AFMモードにて単繊維の円周方向に1000nmの範囲を繊維軸方向長さ1000nmに渡り少しずつづらしながら繰り返し走査し、得られた測定画像を二次元フーリエ変換にて低周波成分をカットしたのち逆変換を行う。そうして得られた単繊維の曲率を除去した断面の平面画像より、円周長さ1.0μm、繊維軸方向長さ1.0μmで囲まれる範囲での最高部と最低部の高低差を読み取り、さらに下記式(2)で算出されるRaを測定する。
中央面:実表面との高さの偏差が最小となる平面に平行で、かつ実表面を等しい体積で2分割する平面、即ち、その平面と実表面で囲まれた部分であって、その平面の両側の部分の体積V1とV2が等しい平面、
f(x,y):実表面と中央面との高低差、
Lx、Ly:XY平面の大きさ。
炭素繊維束を構成する単繊維の繊維断面の長径と短径との比(長径/短径)は、以下のようにして決定した。
内径1mmの塩化ビニル樹脂製のチューブ内に測定用の炭素繊維束を通した後、これをナイフで輪切りにして試料を準備した。ついで、前記試料を繊維断面が上を向くようにしてSEM試料台に接着し、さらにAuを約10nmの厚さにスパッタリングしてから、走査型電子顕微鏡(フィリップス社製、製品名:XL20)により、加速電圧7.00kV、作動距離31mmの条件で繊維断面を観察し、単繊維の繊維断面の長径及び短径を測定した。
樹脂含浸炭素繊維束のストランド試験体の調製および強度の測定は、JIS R7601に準拠し測定し評価した。ただし、弾性率の算出はASTMに準じたひずみ範囲を用いて実施した。
結節強さの測定は以下のように実施した。
150mm長の炭素繊維束の両端に長さ25mmの掴み部を取り付け試験体とした。試験体の作製の際、0.1×10-3N/デニールの荷重を掛けて炭素繊維束の引き揃えを行った。この試験体に結び目を1つ、ほぼ中央部に形成し、引張時のクロスヘッド速度は100mm/minで実施した。試験数は12本で実施し、最小と最大値を取り除き、10本の平均値で測定値とした。
炭素繊維の単繊維を20cmに切断し、この単繊維の中央部をJIS R7606に示される試料長10mm用の単繊維引張試験の台紙に貼り付け固定し、台紙からはみ出た余分な部分を切断して取り除いたサンプルを作製した。
式(1)より、算出した傾きと炭素繊維束の超音波弾性率(E)により破壊表面生成エネルギーを求めた。
ipa値は次の方法により測定した。
電解液は5%りん酸水溶液でpH3とし、窒素をバブリングさせ溶存酸素の影響を除く。試料である炭素繊維を一方の電極として電解液に浸漬し、対極として充分な表面積を有する白金電極を用いる。ここで、参照電極としてはAg/AgCl電極を採用した。試料形態は長さ50mmの12000フイラメントトウとした。炭素繊維電極と白金電極の間にかける電位の走査範囲は-0.2Vから+0.8Vとし、走査速度は2.0mV/secとした。X-Yレコーダーにより電流-電圧曲線を描き、3回以上掃引させ曲線が安定した段階で、Ag/AgCl参照電極に対して+0.4Vでの電位を基準電位として電流値iを読み取り、次式(3)に従ってipaを算出した。
炭素繊維束の試料を風袋既知の白金るつぼに入れ600~700℃マッフル炉で灰化し、その質量を測定して灰分を求めた。次に炭酸ナトリウムを規定量加え、バーナーで溶融し、脱イオン水で溶解しながら50mlポリメスフラスコに定容した。本試料をICP発光分析法によりSiを定量した。
前駆体繊維(1)
組成がアクリロニトリル98質量%、メタクリル酸2質量%のアクリロニトリル系重合体をジメチルホルムアミドに溶解し23.5質量%の紡糸原液を調製した。
この紡糸原液を直径0.15mm、数2000の吐出孔を配置した紡糸口金から紡出させて乾湿式紡糸した。即ち空気中に紡出させて約5mmの空間を通過させた後、10℃に調温した79.0質量%ジメチルホルムアミドを含有する水溶液を満たした凝固液中で凝固させ、凝固糸を引き取った。次いで空気中で1.1倍延伸した後、60℃に調温した35質量%ジメチルホルムアミドを含有する水溶液を満たした延伸槽中にて2.5倍延伸した。延伸後、溶剤を含有している工程繊維束を清浄な水で洗浄し、次に、95℃の熱水中で1.4倍の延伸を行った。引き続き、繊維束にアミノ変性シリコーンを主成分とする油剤を1.1質量%となるよう付与し乾燥緻密化した。乾燥緻密化後の繊維束を、加熱ロール間で2.6倍延伸して、更なる配向の向上と緻密化を行った後に巻き取ってアクリロニトリル系前駆体繊維束を得た。この繊維の繊度は、0.77dtexであった。
水洗浄処理前の延伸倍率を2.9倍、洗浄後の熱水中の延伸倍率を1.2倍にした以外は、前駆体繊維束(1)と同じ条件で前駆体繊維束(2)を得た。
前駆体繊維の繊度を0.67dtexとした以外は、前駆体繊維束(2)と同じ条件で前駆体繊維束(3)を得た。
前駆体繊維の繊度を0.90dtexとした以外は、前駆体繊維束(2)と同じ条件で前駆体繊維束(4)を得た。
水洗浄処理前の延伸倍率を4.1倍、洗浄後の熱水中の延伸倍率を0.99倍、加熱ロール間で2.4倍延伸にした以外は、前駆体繊維束(1)と同じ条件で前駆体繊維束(5)を得た。
水洗浄処理前の延伸倍率を1.9倍、洗浄後の熱水中の延伸倍率を2.0倍にした以外は、前駆体繊維束(1)と同じ条件で前駆体繊維束(6)を得た。
前駆体繊維の繊度を1.0dtexとした以外は、前駆体繊維束(2)と同じ条件で前駆体繊維束(7)を得た。
前駆体繊維束(1)~(7)の製造条件を表1に示した。
(炭素繊維束の調製)
複数の前駆体繊維束(1)、(2)、(3)、(4)、(5)、(6)または(7)を平行に揃えた状態で耐炎化炉に導入し、220~280℃に加熱された空気を前駆体繊維束に吹き付けることによって、前駆体繊維束を耐炎化処理して密度1.345g/cm3の耐炎化繊維束を得た。伸長率は6%とし、耐炎化処理時間は70分とした。
更に窒素雰囲気中で1000~1600℃の温度勾配を設定可能な第二炭素化炉を用いて、表2または表3に示した所定の温度にて熱処理した。引き続き、窒素雰囲気中1200~2400℃の温度勾配の設定可能な第三炭素化炉を用いて、表2または表3に示した所定の温度にて熱処理を行い、炭素繊維束を得た。第二炭素化炉および第三炭素化炉を合わせた伸長率は、-4.0%、処理時間は3.5分とした。
引き続いて、重炭酸アンモニウム10質量%水溶液中を走行せしめ、炭素繊維束を陽極として、被処理炭素繊維1g当たり40クーロンの電気量となる様に対極との間で通電処理を行い、温水90℃で洗浄した後、乾燥した。
次に、ハイドランN320(以下「サイジング剤1」という)を0.5質量%付着させ、ボビンに巻きとり、炭素繊維束を得た。
Bステージ化したエポキシ樹脂#410(180℃硬化タイプ)(三菱レイヨン株式会社製)を塗布した離型紙上に、ボビンから巻き出した炭素繊維束の156本を引き揃えて配置して、加熱圧着ローラーを通して、このエポキシ樹脂を含浸した。その上に保護フィルムを積層して、樹脂含有量約33質量%、炭素繊維目付125g/m2 、幅500mmの一方向引揃えプリプレグ(以下「UDプリプレグ」という)を作製した。
前記UDプリプレグを使用して積層板を成形し、積層板の0°引張強度をASTM D3039に準拠した評価法により測定した。
炭素繊維束の製造条件と評価結果を表2及び表3に示した。
尚、いずれの実施例においても、単繊維の表面に繊維の長手方向に延びる長さ0.6μm以上の表面凹凸構造は無く、長さ300nm以下の微小サイズの凹凸構造が確認された。
製造例1と同様に調製した紡糸原液を用いて、直径0.13mm、数2000の吐出孔を配置した紡糸口金から紡出させて乾湿式紡糸した。即ち空気中に紡出させて約5mmの空間を通過させた後、5℃に調温した77.0質量%ジメチルホルムアミドを含有する水溶液を満たした凝固液中で凝固させ、凝固糸を引取った。次いで空気中で1.3倍延伸した後、60℃に調温した水溶液を満たした延伸槽中にて2.0倍延伸した。延伸後、工程繊維束を清浄な水で洗浄し、次に、95℃の熱水中で2.0倍の延伸を行った。引き続き、繊維束にアミノ変性シリコーンを主成分とする油剤を1.0質量%となるよう付与し乾燥緻密化した。乾燥緻密化後の繊維束を、加熱ロール間で1.9倍延伸して、更なる配向の向上と緻密化を行った後に巻き取って前駆体繊維束を得た。この繊維の繊度は、0.77dtexであった。
第3炭素化炉を用いなかったことを除いて、実施例5と同様な焼成条件にて炭素繊維束を作製した。また、同様に積層板を作製し、機械的性能評価を実施し、表2の結果を得た。尚、単繊維の表面に繊維の長手方向に延びる長さ0.6μm以上の表面凹凸構造は無く、長さ300nm以下の微小サイズの凹凸構造が確認された。
焼成条件を変更したこと以外は実施例2と同様にして炭素繊維束を得た。評価結果を表4に示した。尚、いずれの実施例においても、単繊維の表面に繊維の長手方向に延びる長さ0.6μm以上の表面凹凸構造は無く、長さ300nm以下の微小サイズの凹凸構造が確認された。
表面処理条件を変更したこと以外は実施例5と同様にして炭素繊維束を得た。評価結果を表5に示した。尚、いずれの実施例においても、単繊維の表面に繊維の長手方向に延びる長さ0.6μm以上の表面凹凸構造は無く、長さ300nm以下の微小サイズの凹凸構造が確認された。
サイジング剤の種類と付着量を変更したこと以外は実施例5と同様にして炭素繊維束を得た。評価結果を表5に示した。いずれの実施例においても、単繊維の表面に繊維の長手方向に延びる長さ0.6μm以上の表面凹凸構造は無く、長さ300nm以下の微小サイズの凹凸構造が確認された。
尚、サイジング剤2、サイジング3及びサイジング4は、以下のように調製した。
主剤として、ジャパンエポキシレジン(株)製「エピコート828」を80質量部、乳化剤として旭電化(株)製「プルロニックF88」20質量部を混合し、転相乳化により水分散液を調製した。
フラスコにビスフェノールAのプロピレンオキサイド8モル付加物1.8モル、トリメチロールプロパン0.8モル、ジメチロールプロピオン酸0.6モルよりなるポリオール3.2モルを投入し、さらに、反応禁止剤として2,6-ジ(t-ブチル)4-メチルフェノール(BHT)0.5g、反応触媒としてジブチルスズジラウレート0.2gを添加しこれら混合物が均一になるまで撹拌した。ここで、必要に応じて粘度調整剤としてメチルエチルケトンを加えた。均一に溶解した混合物にメタキシレンジイソシアネート3.4モルを滴下して加え、攪拌をしながら反応温度50℃、反応時間2時間でウレタンプレポリマーの重合を実施した。次にエピコート834(JER(株)製)を0.25モル加え、ウレタンプレポリマーの末端にあるイソシアネート基を反応させることによりエポキシ変性ウレタン樹脂を得た。
このエポキシ変性ウレタン樹脂90質量部と乳化剤として旭電化(株)製「プルロニックF88」10質量部を混合し、水分散液を調製した。
フラスコにポリエチレングリコール400を2.5モル、エピコート834(JER(株)製)0.7モルを投入し、さらに、反応禁止剤として2,6-ジ(t-ブチル)4-メチルフェノール(BHT)0.25g、反応触媒としてジブチルスズジラウレート0.1gを添加しこれら混合物が均一になるまで撹拌した。ここで、必要に応じて粘度調整剤としてメチルエチルケトンを加えた。均一に溶解した混合物にメタキシレンジイソシアネート2.7モルを滴下して加え、攪拌をしながら反応温度40℃、反応時間2時間でエポキシ変性ウレタン樹脂を得た。
このエポキシ変性ウレタン樹脂80質量部と乳化剤として旭電化(株)製「プルロニックF88」20質量部を混合し、水分散液を調製した。
Claims (10)
- 単繊維の表面に繊維の長手方向に延びる長さ0.6μm以上の表面凹凸構造が無く、単繊維の表面の最高部と最低部の高低差(Rp-v)が5~25nmで平均凹凸度Raが2~6nmの凹凸構造を有し、かつ単繊維の繊維断面の長径と短径との比(長径/短径)が1.00~1.01である炭素繊維の単繊維からなり、単繊維の単位長さ当たりの質量が0.030~0.042mg/mの範囲にあり、ストランド強度が5900MPa以上、ASTM法で測定されるストランド弾性率が250~380GPaであり、結節強さが900N/mm2以上の炭素繊維である炭素繊維束。
- 単繊維の表面に、繊維の長手方向に延びる長さ0.6μm以上の凹凸構造が無く、長さ300nm以下の凹凸構造であって、単繊維の表面の最高部と最低部の高低差(Rp-v)が5~25nm、平均凹凸度Raが2~6nmの凹凸構造を有し、かつ単繊維の繊維断面の長径と短径との比(長径/短径)が1.00~1.01である炭素繊維の単繊維からなり、単繊維の単位長さ当たりの質量が0.030~0.042mg/mの範囲にあり、ストランド強度が5900MPa以上、ASTM法で測定されるストランド弾性率が250~380GPaであり、結節強さが900N/mm2以上の炭素繊維である炭素繊維束。
- 単繊維表面にレーザーにて所定範囲の大きさを有する半球状欠陥を形成し、前記繊維を引張試験により前記半球状欠陥部位で破断させ、前記繊維の破断強度と半球状欠陥の大きさからグリフィス式(1)より求められる破壊表面生成エネルギーが、30N/m以上である請求項1または2に記載の炭素繊維束。
σ=(2E/πC)1/2×(破壊表面生成エネルギー)1/2 ・・・(1)
ここで、σは破断強度、Eは炭素繊維束の超音波弾性率、cは半球状欠陥の大きさである。 - 電気化学的測定法(サイクリック・ボルタ・メトリー)により求められるipa値が0.05~0.25μA/cm2であり、X線光電子分光法により求められる炭素繊維表面の酸素含有官能基量(O1S/C1S)が0.05~0.15の範囲にある請求項1~3のいずれかに記載の炭素繊維束。
- ICP発光分析法によって測定されるSi量が、200ppm以下である請求項1~4のいずれかに記載の炭素繊維束。
- (a)ヒドロキシ基を有するエポキシ樹脂、(b)ポリヒドロキシ化合物及び(c)芳香環を含むジイソシアネ-トの反応生成物であるウレタン変性エポキシ樹脂を含むサイジング剤組成物、または、該ウレタン変性エポキシ樹脂と(a)ヒドロキシ基を有するエポキシ樹脂及び又は(d)ヒドロキシ基を有しないエポキシ樹脂との混合物を含むサイジング剤組成物でサイジングされた請求項1~5のいずれかに記載の炭素繊維束。
- (a)ヒドロキシ基を有するエポキシ樹脂が、ビスフェノール型エポキシ樹脂である請求項6に記載の炭素繊維束。
- (b)ポリヒドロキシ化合物が、ビスフエノ-ルAのアルキレンオキサイド付加物、脂肪族ポリヒドロキシ化合物、及びポリヒドロキシモノカルボキシ化合物のいずれか、又はこれら混合物である請求項6または7に記載の炭素繊維束。
- (c)芳香環を含むジイソシアネ-トが、トルエンジイソシアネートあるいはキシレンジイソシアネートである請求項6~8のいずれかに記載の炭素繊維束。
- アルカリ金属、アルカリ土類金属、亜鉛、鉄、アルミニウムを含む金属が総量として含有する量が50ppm以下である請求項1~9のいずれかに記載の炭素繊維束。
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EP10786212.0A EP2441866B1 (en) | 2009-06-10 | 2010-06-10 | Carbon fiber bundle that develops excellent mechanical performance |
CA2764662A CA2764662C (en) | 2009-06-10 | 2010-06-10 | Carbon fiber bundle that develops high mechanical performance |
CN2010800251194A CN102459728B (zh) | 2009-06-10 | 2010-06-10 | 机械性能表现优异的碳纤维束 |
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JP2010524014A JP4908636B2 (ja) | 2009-06-10 | 2010-06-10 | 機械的性能発現に優れた炭素繊維束 |
US13/377,289 US20120088103A1 (en) | 2009-06-10 | 2010-06-10 | Carbon fiber bundle that develops high mechanical performance |
ES10786212.0T ES2534650T3 (es) | 2009-06-10 | 2010-06-10 | Haz de fibras de carbono que desarrolla un rendimiento mecánico excelente |
BRPI1012996A BRPI1012996A2 (pt) | 2009-06-10 | 2010-06-10 | feixe de fibras de carbono que desenvolve alto desempenho mecanico |
US16/158,646 US20190040549A1 (en) | 2009-06-10 | 2018-10-12 | Carbon fiber bundle that develops high mechanical performance |
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US13/377,289 A-371-Of-International US20120088103A1 (en) | 2009-06-10 | 2010-06-10 | Carbon fiber bundle that develops high mechanical performance |
US16/158,646 Continuation US20190040549A1 (en) | 2009-06-10 | 2018-10-12 | Carbon fiber bundle that develops high mechanical performance |
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EP (1) | EP2441866B1 (ja) |
JP (1) | JP4908636B2 (ja) |
KR (1) | KR101340225B1 (ja) |
CN (1) | CN102459728B (ja) |
BR (1) | BRPI1012996A2 (ja) |
CA (1) | CA2764662C (ja) |
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Also Published As
Publication number | Publication date |
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JP4908636B2 (ja) | 2012-04-04 |
US20120088103A1 (en) | 2012-04-12 |
TW201107547A (en) | 2011-03-01 |
CN102459728A (zh) | 2012-05-16 |
KR20120024954A (ko) | 2012-03-14 |
EP2441866B1 (en) | 2015-02-18 |
US20190040549A1 (en) | 2019-02-07 |
ES2534650T3 (es) | 2015-04-27 |
EP2441866A1 (en) | 2012-04-18 |
JPWO2010143681A1 (ja) | 2012-11-29 |
TWI396786B (zh) | 2013-05-21 |
EP2441866A4 (en) | 2013-05-22 |
CN102459728B (zh) | 2013-09-18 |
CA2764662A1 (en) | 2010-12-16 |
CA2764662C (en) | 2013-07-30 |
BRPI1012996A2 (pt) | 2018-01-16 |
KR101340225B1 (ko) | 2013-12-10 |
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