WO2016068034A1 - 炭素繊維束およびその製造方法 - Google Patents
炭素繊維束およびその製造方法 Download PDFInfo
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- WO2016068034A1 WO2016068034A1 PCT/JP2015/079932 JP2015079932W WO2016068034A1 WO 2016068034 A1 WO2016068034 A1 WO 2016068034A1 JP 2015079932 W JP2015079932 W JP 2015079932W WO 2016068034 A1 WO2016068034 A1 WO 2016068034A1
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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
- D01F9/20—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
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
- 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
- D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06M15/31—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated nitriles
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
- D06M2101/40—Fibres of carbon
Definitions
- the present invention relates to a carbon fiber bundle for a carbon fiber composite material and a method for producing the same.
- Carbon fiber is used as a reinforcing fiber for composite materials, and its use is expanded in various fields, and further enhancement of performance is strongly demanded.
- Increasing the tensile strength of the carbon fiber contributes to reducing the weight of the member such as a pressure vessel. Therefore, further increasing the tensile strength is an important issue.
- the tensile strength of the carbon fiber can be increased by reducing the defect size of the carbon fiber or increasing the fracture toughness value of the carbon fiber according to the Griffith equation.
- the improvement in the fracture toughness value of carbon fibers is effective in that the tensile strength of the carbon fibers can be increased without depending on the state of the defect size of the carbon fibers (Patent Document 1).
- the improvement in the fracture toughness value of the carbon fiber is also effective in that the tensile strength of the carbon fiber composite material obtained using the carbon fiber can be efficiently increased.
- Patent Documents 7 to 9 Furthermore, a technique for increasing the torsional modulus of carbon fiber in order to improve the compressive strength of the carbon fiber is known (Patent Documents 7 to 9). Until now, when investigating the compressive strength of a single fiber, the loop method of the carbon fiber single fiber has been used (Patent Documents 7 and 10). In Patent Document 10, a high compressive fracture strain is obtained using a carbon fiber having a low elastic modulus, and in Patent Document 7, although the compressive strength of the carbon fiber is increased using an ion implantation technique, the tensile strength of the carbon fiber is increased. Can not be raised enough.
- Patent Documents 11 and 12 In order to improve the tensile elastic modulus and the perforated plate tensile strength of the carbon fiber composite material, a method of controlling the single fiber strength distribution in the short test length region of the carbon fiber is known (Patent Documents 11 and 12).
- Patent Document 1 is only intended to improve the physical properties by controlling the surface defect or fine structure distribution by controlling the silicone oil agent, the single fiber fineness and the inner / outer structure difference, but not the fine structure itself. It was.
- the number of temperature control regions in the flameproofing process is set to 2 to 3, and processing is performed at as high a temperature as possible in each region, but the processing time takes 44 to 60 minutes. .
- the number of temperature control regions in the flame-proofing process is set to 2 to 3, and the heat treatment time in the high-temperature region is lengthened so that the flame-proofing is performed in a short time. The conversion time was long.
- the proposal of Patent Document 4 is to set a plurality of stages of extension in the flameproofing furnace or to require 3 to 6 furnaces for shortening the flameproofing time. Control has not been reached.
- the proposal of Patent Document 5 is to heat-treat at 280 to 400 ° C.
- Patent Document 6 is to control the specific gravity of the flameproof yarn after the first flameproofing furnace to 1.27 or more, and has not yet achieved satisfactory microstructure control.
- Patent Documents 7 to 9 Although it is difficult to compare the torsional elastic modulus of carbon fibers in the proposals of Patent Documents 7 to 9 with a shear elastic modulus described later, the following can be said.
- the proposals in Patent Documents 7 and 8 use ion implantation or electron beam irradiation to increase the torsional elastic modulus of the carbon fiber. Since the resulting carbon fiber contains lattice defects because the covalent bonds are broken and rearranged, the shear modulus of the carbon fiber is not satisfactory, and the relationship with the tensile strength of the carbon fiber is not satisfactory. Not considered.
- the proposal of Patent Document 9 discloses that even if the single yarn fineness is large, the same physical properties as those of the normal single yarn fineness carbon fiber are expressed. Specifically, a carbon fiber having a shear modulus of 4 GPa or more is disclosed. However, it has not reached a satisfactory level.
- Patent Documents 7 and 10 are not intended to increase the tensile strength of carbon fiber, and are not actually high in tensile strength of carbon fiber judged from the loop shape.
- an object of the present invention is to provide a carbon fiber (carbon fiber bundle) capable of obtaining a carbon fiber composite material having a high tensile strength, and a method for producing the same.
- the carbon fiber bundle of the present invention has the following characteristics.
- the first aspect of the carbon fiber bundle of the present invention is that the coefficient A obtained from the approximate expression (1) of the nonlinearity of the stress ⁇ -strain ⁇ curve in the resin-impregnated strand tensile test and the crystal orientation in the wide-angle X-ray diffraction measurement It is a carbon fiber bundle in which the relationship of ⁇ (%) satisfies the following formula (2) and the tensile strength is 7.5 GPa or more.
- ⁇ A ⁇ 2 + B ⁇ + C (1) (0.0000832 ⁇ 2 ⁇ 0.0184 ⁇ + 1.00) / A ⁇ ⁇ 395 (2)
- ⁇ indicates the degree of crystal orientation (%) in the X-ray diffraction measurement.
- the second embodiment of the carbon fiber bundle of the present invention has a tensile elastic modulus of 240 to 440 GPa in a resin impregnated strand tensile test, and a single fiber diameter d and a loop width W immediately before break evaluated by a single fiber loop method.
- This is a carbon fiber bundle in which the product E ⁇ d / W of the ratio d / W and the strand elastic modulus E is 14.6 GPa or more.
- the single fiber apparent stress when the number of fiber breaks by the single fiber fragmentation method of the single fiber composite of carbon fiber is 0.30 pieces / mm is 8.5 GPa or more
- the number of fiber breaks by a single fiber fragmentation method of a carbon fiber single fiber composite is 0.30 / mm
- the number of fiber breaks by a double fiber fragmentation method of a carbon fiber single fiber composite is 0.24 to 0.42. It is a carbon fiber bundle that is / mm.
- a carbonization step is performed in which the flame-resistant fiber bundle is carbonized in an inert atmosphere at 1000 to 3000 ° C. It is a method of manufacturing a carbon fiber bundle.
- a carbon fiber bundle capable of obtaining a high performance carbon fiber reinforced composite material that exhibits excellent tensile strength can be obtained.
- the inventors have found that when the nonlinearity of the stress-strain curve obtained by a tensile test of a resin-impregnated strand of carbon fiber bundle (hereinafter simply abbreviated as a strand) is small and the change in tensile elastic modulus with respect to tensile strain is small, carbon It has been found that the fracture toughness value of the fiber is high and the tensile strength tends to be high.
- the strand tensile test is a simple test method for evaluating the characteristics of a carbon fiber bundle.
- the stress-strain curve of a carbon fiber bundle generally shows a downwardly convex curve when the stress is on the vertical axis and the strain is on the horizontal axis.
- a stress ⁇ -strain ⁇ curve obtained by measuring the carbon fiber bundle by a resin-impregnated strand tensile test is expressed by the following nonlinear equation ( The value of the coefficient A obtained by introducing into 1) satisfies the following equation (2).
- ⁇ A ⁇ 2 + B ⁇ + C (1) (0.0000832 ⁇ 2 ⁇ 0.0184 ⁇ + 1.00) / A ⁇ ⁇ 395 (2)
- ⁇ indicates the degree of crystal orientation (%) obtained by measuring the carbon fiber bundle by wide-angle X-ray diffraction measurement.
- the coefficient A indicates the nonlinearity of the stress-strain curve.
- the coefficient A is obtained by fitting a stress ⁇ (GPa) -strain ⁇ ( ⁇ ) curve obtained by measuring a carbon fiber bundle by a resin-impregnated strand tensile test to an approximate expression (1) in a stress range of 0 to 3 GPa. Is required.
- the stress-strain curve of the carbon fiber bundle generally shows a downwardly convex curve when the stress is on the vertical axis and the strain is on the horizontal axis, and therefore the coefficient obtained from the approximate expression (1) A takes a negative value. That is, the closer the coefficient A is to 0, the smaller the nonlinearity.
- the inventors have also found that the correlation with the shear modulus of carbon fiber is not always sufficient only by the nonlinearity of the stress-strain curve.
- theories related to stress and deformation in carbon fibers are described in, for example, “Carbon” (Netherlands), Elsevier, 1991, Vol. 29, No. 8, p. 1267-1279. ing. However, this is an academic study, and is difficult to use for practical studies for improving the strength of carbon fibers.
- the inventors have obtained the above equation (1) derived from the crystal orientation degree ⁇ which is relatively easy to measure from a practical viewpoint and the coefficient A of the above approximate equation (1). It was found that the value (0.0000832 ⁇ 2 ⁇ 0.0184 ⁇ + 1.00) / A on the left side of 2) has a very high correlation with the shear modulus of carbon fiber.
- the value on the left side of the equation (2) takes a negative value.
- the shear modulus of the carbon fiber tends to increase as the absolute value of the value on the left side of the formula (2) increases.
- the value on the left side of the formula (2) is ⁇ 395 or less, preferably ⁇ 436 or less, and more preferably ⁇ 445 or less.
- the value on the left side of the formula (2) is larger than ⁇ 395, the tensile strength of the carbon fiber is lowered.
- the range of the coefficient A is preferably ⁇ 1.20 ⁇ 10 ⁇ 4 or more, more preferably ⁇ 9.8 ⁇ 10 ⁇ 5 or more, and more preferably ⁇ 9.5 ⁇ . 10 ⁇ 5 or more, more preferably ⁇ 9.3 ⁇ 10 ⁇ 5 or more.
- the coefficient A increases as the nonlinearity of the stress-strain curve becomes weaker, and approaches zero. The closer the coefficient A is to 0, the higher the shear modulus of the carbon fiber bundle and the higher the fracture toughness value. In order to reduce the nonlinearity of the stress-strain curve, it is preferable to use the carbon fiber bundle manufacturing method of the present invention described later.
- the tensile strength is 7.5 GPa or more, preferably 7.7 GPa, more preferably 7.9 GPa.
- the tensile strength is a value evaluated by a resin-impregnated strand tensile test of the carbon fiber bundle.
- the tensile strength is 7.5 GPa or more, there are few defects contained in the carbon fiber, so the fracture toughness value of the carbon fiber is dominant in the tensile strength. If there are many defects contained in the carbon fiber, the tensile strength may not be improved even if the fracture toughness value of the carbon fiber is increased.
- There is no particular upper limit on the tensile strength but it is empirically about 10 GPa.
- the carbon fiber bundle manufacturing method of the present invention described later may be used.
- the product E ⁇ d / W of the single fiber diameter d and the ratio d / W of the loop width W just before break evaluated by the single fiber loop method and the strand elastic modulus E Is 14.6 GPa or more, preferably 15.0 GPa or more, more preferably 15.2 GPa or more.
- the single fiber loop method is a method for examining the relationship between strain applied to a single fiber by deforming the single fiber into a loop shape and fracture behavior such as single fiber breakage and buckling. When a single fiber is deformed in a loop shape, compressive strain is applied to the inside of the single fiber, and tensile strain is applied to the outside.
- the single fiber loop method has often been used as a test method for the single fiber compressive strength of carbon fibers because compression buckling occurs before tensile failure.
- a value that can be said to be the reachable tensile strength of the carbon fiber can be evaluated. That is, d / W is a value proportional to the tensile strain, and the product of this value and the strand elastic modulus E (details will be described later) can be said to be a value corresponding to the tensile strength. Even if the strand strength of the carbon fiber is simply increased, the tensile strength of the carbon fiber composite material may not be increased.
- the tensile strength of the carbon fiber composite material can be effectively increased by increasing the Ex ⁇ d / W. .
- the tensile strength of the carbon fiber composite material is significantly increased by setting the E ⁇ d / W to 14.6 GPa or more (see Table 4- below). 1 and 6).
- the upper limit of E ⁇ d / W is not particularly limited, but it is sufficient that 19.0 GPa is set as the upper limit of E ⁇ d / W.
- this parameter can be controlled by using the manufacturing method of the carbon fiber bundle of this invention mentioned later.
- the tensile modulus in the resin-impregnated strand tensile test (simply abbreviated as simply the strand modulus) is 240 to 440 GPa, preferably 280 to 400 GPa, more preferably Is 310 to 400 GPa.
- a tensile modulus of 240 to 440 GPa is preferable because of excellent balance between tensile modulus and tensile strength.
- the tensile modulus can be determined by the method described in ⁇ Carbon Fiber Strand Tensile Test> described later. At this time, the strain range is 0.1 to 0.6%.
- the tensile elastic modulus of the carbon fiber bundle can be controlled mainly by applying tension to the fiber bundle in any one of the heat treatment steps in the production process of the carbon fiber bundle or changing the carbonization temperature.
- the Weibull shape factor m in the Weibull plot of the value of E ⁇ d / W evaluated for 20 single fibers is preferably 12 or more.
- the Weibull plot is a widely used method for evaluating the intensity distribution, and the spread of the distribution can be known from the Weibull shape factor m.
- the Weibull plot is numbered as 1,..., I,... 20 from the smallest value of E.times.d / W, and the vertical axis is represented by ln (-ln (1- (i-0. 5) / 20)), and the horizontal axis is drawn as ln (E ⁇ d / W).
- ln means a natural logarithm.
- the Weibull shape factor m is obtained as the slope.
- the Weibull shape factor m of tensile strength evaluated by a single fiber tensile test often takes a value in the vicinity of 5. This is interpreted to be derived from the size distribution of large defects.
- the Weibull shape factor m of E ⁇ d / W is significantly larger than around 5.
- the Weibull shape factor m is 12 or more, it is preferable that there are sufficiently few defects in the carbon fiber.
- the single fiber apparent stress when the number of fiber breaks by the single fiber fragmentation method of the single fiber composite of carbon fiber is 0.30 pieces / mm is 8.5 GPa or more
- the number of fiber breaks of a single-fiber fragmentation method of a carbon fiber single fiber fragmentation is 0.30 pieces / mm
- the number of fiber breaks of a single-fiber composite of carbon fibers is 0.24 to 0.42 Pieces / mm, preferably 0.24 to 0.37 pieces / mm, and more preferably 0.24 to 0.32 pieces / mm.
- the single fiber fragmentation method for single fiber composites is to measure the number of fiber breaks at each strain while giving strain to the composite with one carbon fiber single fiber embedded in the resin. This is a technique for examining the distribution.
- the measurement of the single fiber strength of the carbon fiber by the single fiber fragmentation method of the single fiber composite is described in “Advanced Composite Materials” (Japan), 2014, 23, 5-6, p. 535-550 and the like.
- the single fiber composite double fiber fragmentation method is a stepwise method of applying a strain to a composite in which two carbon fiber single fibers are embedded in parallel at intervals of 0.5 ⁇ m or more and an average single fiber diameter or less. This is a technique for examining the single fiber strength distribution in a particularly high strength region of the carbon fiber by counting the number of breaks. It is known that when a fiber breaks in a composite, a stress several tens of percent higher is applied to a portion adjacent to the broken portion, and the adjacent fiber is selectively broken.
- the single fiber strength distribution of the carbon fiber in a very high stress state that cannot be loaded by the single fiber fragmentation method can be examined. . If the distance between the two single fibers of the carbon fiber exceeds the average single fiber diameter, it becomes difficult to be influenced by adjacent fibers, so that high stress cannot be applied. If the distance between the two single fibers of the carbon fiber is less than 0.5 ⁇ m, it is difficult to determine the fiber breakage. Therefore, the interval between two single fibers of carbon fiber is set to 0.5 ⁇ m or more and an average single fiber diameter or less.
- the apparent single fiber stress is 8.5 GPa or more when the number of fiber breaks by a single fiber fragmentation method of a single fiber composite of carbon fibers is 0.30 pieces / mm.
- Single fiber apparent stress refers to the product of single fiber composite strain and single fiber elastic modulus of carbon fiber.
- the number of fiber breaks of 0.30 / mm is preferably used as an index.
- the single fiber apparent stress is 8.5 GPa or more when the number of fiber breaks by the single fiber fragmentation method is 0.30 / mm
- the single fiber strength distribution in the region of 3 to 10 mm in the length of the carbon fiber is substantially high. This means that the carbon fiber strand strength can be significantly increased.
- the carbon fiber composite can be effectively reduced by reducing fiber breakage in the double fiber fragmentation method described above.
- the tensile strength of the material can be increased.
- the number of fiber breaks by the single fiber fragmentation method is 0.30 / mm
- the number of fiber breaks by the double fiber fragmentation method is 0.30 / mm when not affected by adjacent fibers. Considering variation, it is 0.24 piece / mm or more.
- the number of fiber breaks by the double fiber fragmentation method exceeds 0.42 / mm when the number of fiber breaks by the single fiber fragmentation method is 0.30 / mm, the single fiber strength distribution in the high-strength region is low, resulting in high stress.
- the fiber is loaded, adjacent fibers are liable to break. That is, since the single fiber breakage causes cluster breakage and the tensile strength of the carbon fiber composite material does not increase, the number of such fiber breaks is 0.42 pieces / mm or less, preferably 0.37 pieces / mm or less, More preferably, it is 0.32 piece / mm or less.
- this parameter can be controlled by using the manufacturing method of the carbon fiber bundle of this invention mentioned later.
- the number of fiber breaks when the single fiber apparent stress is 15.3 GPa by the single fiber fragmentation method of the single fiber composite of carbon fibers is preferably 2.0 pieces / mm or more. More preferably, it is 2.1 pieces / mm or more.
- the carbon fiber composite material cannot be subjected to stress when the number of fiber breaks increases due to a decrease in the interfacial adhesion between the carbon fiber and the matrix resin. The strength may decrease.
- the fiber stress is difficult to increase.
- the number of fiber breaks is saturated. Therefore, the actual fiber stress is smaller than the single fiber apparent stress. If the single fiber elastic modulus of the carbon fiber is low, the single fiber composite may break before loading the single fiber apparent stress to 15.3 GPa, but if the fiber breakage is saturated, that breakage is substituted. can do.
- saturation means when the increase in the number of fiber breaks is ⁇ 0.2 pieces / mm or less when the change in strain of the single fiber composite is ⁇ 1%.
- the preferable degree of crystal orientation of the carbon fiber bundle is 82% or more, more preferably 83% or more, and still more preferably 85% or more.
- the upper limit of the degree of crystal orientation is 100% in principle. As the crystal orientation increases under stress, the stress-strain curve of the carbon fiber bundle exhibits nonlinearity. The higher the degree of crystal orientation of the carbon fiber bundle before stress loading, the better because the crystallite bears stress and the tensile strength is likely to increase.
- the crystal orientation degree of the carbon fiber bundle can be determined by the method described in ⁇ Crystal orientation degree of carbon fiber> described later.
- the degree of crystal orientation of the carbon fiber bundle can be increased mainly by applying tension to the carbon fiber bundle during the heat treatment process or by increasing the carbonization temperature.
- the preferred single fiber diameter of the carbon fiber bundle is 4.5 to 7.5 ⁇ m, more preferably 5.0 to 7.0 ⁇ m.
- the single fiber diameter can be calculated from the mass per unit length of the carbon fiber bundle and the specific gravity.
- the initial tensile modulus in the resin-impregnated strand tensile test of the carbon fiber bundle is preferably 280 GPa or more, more preferably 300 GPa or more, and further preferably 320 GPa or more. Normally, it is known that the tensile strength decreases as the initial tensile elastic modulus increases. If the initial tensile elastic modulus is 280 GPa or more and any of the first to third aspects of the present invention is satisfied, it is preferable because the balance between the tensile elastic modulus and the tensile strength is excellent.
- the initial tensile elastic modulus is calculated by 1 / B from the approximate expression (1) of nonlinearity of the stress-strain curve obtained by tensile testing the resin-impregnated strand.
- the initial tensile modulus is often about 90% of the tensile modulus as shown in the catalog value.
- the initial tensile elastic modulus of the carbon fiber bundle can be controlled mainly by applying tension to the fiber bundle in any one of the heat treatment steps in the production process of the carbon fiber bundle or changing the carbonization temperature.
- the crystallinity in the wide-angle X-ray diffraction measurement of the carbon fiber bundle is preferably 40 to 60%, more preferably 43 to 60%, and further preferably 45 to 60%.
- the higher the shear modulus of the amorphous part in the carbon fiber the higher the tensile strength of the carbon fiber.
- the higher the shear modulus of carbon fiber and the higher the crystallinity the higher the shear modulus of the amorphous part.
- the crystallinity indicates the volume fraction of the crystallites of the carbon fiber, and often exhibits a satisfactory shear modulus of the amorphous part when the crystallinity is 40 to 60%.
- the evaluation of the crystallinity is obtained based on the diffraction intensity of artificial graphite from the wide-angle X-ray diffraction measurement of the powdered carbon fiber bundle (details are described in ⁇ Carbon Fiber Crystallinity> described later).
- the crystallinity can be controlled by the carbonization temperature.
- the carbon fiber bundle is obtained by subjecting the carbon fiber precursor fiber bundle to a flameproofing step, a preliminary carbonization step, and a carbonization step.
- the obtained flameproofed fiber has a peak intensity of 1370 cm ⁇ 1 in the infrared spectrum. for a range ratio of 0.70 to 0.75 of the peak intensity of 1453cm -1, and the ratio of the peak intensity of 1254cm -1 to the peak intensity of 1370 cm -1 in the infrared spectra of 0.50 to 0.65 It is necessary to control the range.
- the peak at 1453 cm ⁇ 1 in the infrared spectrum is derived from an alkene and decreases with the progress of flame resistance.
- the peak at 1370 cm ⁇ 1 and the peak at 1254 cm ⁇ 1 are peaks derived from a flame-resistant structure (respectively considered to be a naphthyridine ring and a hydrogenated naphthyridine ring structure), and increase with the progress of flame resistance. If the specific gravity of the obtained oxidized fiber is 1.35, the ratio of the peak intensity of 1453cm -1 to the peak intensity of 1370 cm -1 is about 0.63 to 0.69.
- the conditions of the flameproofing process are such that many alkenes are left behind. Set. It is considered that there is an effect of increasing the shear elastic modulus of the obtained carbon fiber bundle by subjecting the flame resistant fiber having such a structure to the preliminary carbonization step. Furthermore, it is important the ratio of the peak intensity of 1254cm -1 to the peak intensity of 1370 cm -1 is set flame conditions such that 0.50 to 0.65.
- a peak at 1254 cm ⁇ 1 is often observed in a portion where flame resistance is insufficient, and if this structure is large, it is considered that the shear elastic modulus of the obtained carbon fiber is lowered.
- the peak intensity ratio decreases with the progress of flame resistance, and the initial decrease is particularly large. However, depending on the flame resistance conditions, the peak intensity ratio may not be 0.65 or less even if the time is increased.
- the amount of the copolymer component contained in the polyacrylonitrile polymer constituting the carbon fiber precursor fiber bundle is small, Conditions may be set mainly focusing on the fact that the degree of crystal orientation of the fiber precursor fiber bundle is high, the fineness of the carbon fiber precursor fiber bundle is reduced, and the flameproofing temperature is increased in the latter half.
- the ratio of the peak intensity of 1453cm -1 to the peak intensity of 1370 cm -1 in the infrared spectra were heat treated to a range of from 0.98 to 1.10 (first oxidation step), followed by the first oxidation step at a temperature higher than the ratio range of 0.70 to 0.75 of the peak intensity of 1453cm -1 to the peak intensity of 1370 cm -1 in the infrared spectrum and,, 1254Cm to the peak intensity of 1370 cm -1 in the infrared spectrum It is preferable to perform heat treatment (second flameproofing step) with a flameproofing time of 5 to 14 minutes, preferably 5 to 10 minutes, until the ratio of ⁇ 1 peak intensity is in the range of 0.50 to 0.65.
- the flameproofing temperature may be adjusted high, but the appropriate flameproofing temperature depends on the characteristics of the polyacrylonitrile precursor fiber bundle.
- the carbon fiber bundle center temperature is preferably 280 to 310 ° C., more preferably 280 to 300 ° C., and even more preferably 285 to 295 ° C., in order to control the above infrared spectrum range.
- the flameproof temperature does not need to be constant, and may be set at multiple stages.
- the flameproofing temperature is high and the flameproofing time is shortened.
- the flameproofing time is preferably 8 to 25 minutes, more preferably 8 to 15 minutes, and flameproofing is preferably performed at a flameproofing temperature within the above range.
- the flameproofing time mentioned here means the time during which the fiber bundle stays in the flameproofing furnace, and the flameproofing fiber bundle means the fiber bundle after the flameproofing process and before the preliminary carbonization process.
- the peak intensity described here is the absorbance at each wavelength after baseline correction of the spectrum obtained by sampling a small amount of flame-resistant fiber and measuring the infrared spectrum. Not performed. Further, the sample concentration is measured by diluting with KBr so as to be 0.67% by mass. In this way, the infrared spectrum is measured each time the flameproofing condition setting is changed, and the conditions may be examined in accordance with a preferable manufacturing method described later.
- the amount of the copolymer component contained in the polyacrylonitrile-based polymer is preferably 0.1 to 2% by mass, more preferably 0.1 to 1% by mass. Addition of a copolymer component has an effect of promoting the flame resistance reaction, but the effect is difficult to obtain when the copolymerization amount is less than 0.1% by mass. Further, if the copolymerization amount exceeds 2% by mass, the flame resistance of the single fiber surface layer is preferentially promoted, and the flame resistance inside the flame resistant yarn becomes insufficient, so the above infrared spectrum peak intensity ratio range is not satisfied. There are many cases.
- the flameproofing step means that the carbon fiber precursor fiber bundle is heat-treated at 200 to 400 ° C. at an oxygen atmosphere concentration in air of ⁇ 5 mass%.
- the total treatment time of the flameproofing step can be appropriately selected within a range of preferably 13 to 20 minutes.
- the specific gravity of the obtained flame-resistant fiber bundle is preferably 1.28 to 1.32, more preferably 1.30 to 1.32.
- Set the flameproofing treatment time as follows. More preferable treatment time of the flameproofing process depends on the flameproofing temperature. If the specific gravity of the flameproof fiber bundle is not greater than 1.28, the tensile strength of the carbon fiber bundle may decrease. If the specific gravity of the flameproof fiber bundle is 1.32 or less, the shear elastic modulus can be increased. The specific gravity of the flameproof fiber bundle is controlled by the treatment time and flameproofing temperature of the flameproofing process.
- the timing for switching from the first flameproofing process to the second flameproofing process is preferably such that the specific gravity of the fiber bundle is in the range of 1.21 to 1.23.
- the conditions of the flameproofing process are controlled giving priority to satisfying the range of the infrared spectrum intensity ratio.
- the preferable range of the flameproofing treatment time and flameproofing temperature varies depending on the properties of the carbon fiber precursor fiber bundle and the copolymer composition of the polyacrylonitrile polymer.
- the integrated value of the amount of heat given to the fiber during the heat treatment at a specific gravity of the carbon fiber precursor fiber bundle of 1.22 or more and 220 ° C. or more is preferably 50 to 150 J ⁇ h. / G, more preferably 70 to 100 J ⁇ h / g.
- the integrated value of heat quantity is calculated by the following equation using the flameproofing temperature T (K), the residence time t (h) of the flameproofing furnace, and the heat capacity of the polyacrylonitrile-based precursor fiber bundle: 1.507 J / g ⁇ ° C. This is the calculated value.
- Integrated value of heat (J ⁇ h / g) T ⁇ t ⁇ 1.507
- the heat amount may be calculated from the residence time at each temperature and integrated.
- the polyacrylonitrile-based polymer means a polymer in which at least acrylonitrile is a main component of the polymer skeleton.
- the main component refers to a component that usually occupies 90 to 100 mol% of the polymer skeleton.
- the polyacrylonitrile-based polymer contains a copolymer component from the viewpoint of improving the yarn-making property and efficiently performing the flameproofing treatment.
- a monomer that can be used as a copolymerization component a monomer containing at least one carboxylic acid group or amide group is preferably used from the viewpoint of promoting flame resistance.
- examples of the monomer containing a carboxylic acid group include acrylic acid, methacrylic acid, itaconic acid and their alkali metal salts, and ammonium salts.
- acrylamide etc. are mentioned as a monomer containing an amide group.
- the production method of the polyacrylonitrile-based polymer can be selected from known polymerization methods.
- a dry-wet spinning method or a wet-spinning method may be used as a spinning method, but a dry-wet spinning method that is advantageous for the tensile strength of the obtained carbon fiber bundle is used.
- the spinning process is obtained by a spinning process in which a spinning stock solution is discharged from a spinneret into a coagulation bath by a wet and wet spinning method, spinning, a water washing process in which fibers obtained in the spinning process are washed in a water bath, and the water washing process.
- a water bath stretching process in which the fibers are stretched in a water bath
- a dry heat treatment process in which the fibers obtained in the water bath stretching process are dry heat-treated.
- the fibers obtained in the dry heat treatment process are steam-stretched. It is preferable to include a steam stretching step.
- the spinning dope is obtained by dissolving the polyacrylonitrile-based polymer described above in a solvent in which polyacrylonitrile such as dimethyl sulfoxide, dimethylformamide, dimethylacetamide or the like is soluble.
- the coagulation bath preferably contains a solvent such as dimethyl sulfoxide, dimethylformamide and dimethylacetamide used as a solvent for the spinning dope and a so-called coagulation promoting component.
- a solvent such as dimethyl sulfoxide, dimethylformamide and dimethylacetamide used as a solvent for the spinning dope
- a so-called coagulation promoting component As the coagulation accelerating component, a component that does not dissolve the polyacrylonitrile polymer and is compatible with the solvent used in the spinning solution can be used. Specifically, it is preferable to use water as a coagulation promoting component.
- a rinsing bath in the rinsing step it is preferable to use a rinsing bath comprising a plurality of stages having a temperature of 30 to 98 ° C.
- the draw ratio in the water bath drawing step is preferably 2 to 6 times, and more preferably 2 to 4 times.
- an oil agent made of silicone or the like to the yarn for the purpose of preventing adhesion between single fibers.
- a silicone oil agent it is preferable to use a modified silicone, and it is preferable to use one containing an amino-modified silicone having high heat resistance.
- the drying temperature is 100 to 200 ° C.
- a carbon fiber precursor fiber bundle suitable for obtaining the carbon fiber bundle of the present invention is obtained by performing steam stretching as necessary after the above-described water washing step, water bath stretching step, oil agent application step, and drying heat treatment step. It is done.
- the steam stretching is preferably performed in the pressurized steam at least twice or more, more preferably 4 times or more, and further preferably 5 times or more.
- the preliminary carbonization step it is preferable to heat-treat the obtained flame-resistant fiber in an inert atmosphere at a maximum temperature of 500 to 1200 ° C. until the specific gravity becomes 1.5 to 1.8.
- the temperature of the carbonization step is preferably higher from the viewpoint of increasing the strand elastic modulus of the carbon fiber to be obtained, but if it is too high, the strength of the high strength region may decrease, and it is set in consideration of both. Is good.
- a more preferable temperature range is 1200 to 2000 ° C., and a further preferable temperature range is 1200 to 1600 ° C.
- the carbon fiber bundle obtained as described above is subjected to an oxidation treatment and oxygen-containing functional groups are introduced in order to improve adhesion with the matrix resin.
- oxidation treatment method gas phase oxidation, liquid phase oxidation and liquid phase electrolytic oxidation are used. From the viewpoint of high productivity and uniform processing, liquid phase electrolytic oxidation is preferably used.
- the method for liquid phase electrolytic oxidation is not particularly limited, and may be performed by a known method.
- a sizing agent can also be added to give the obtained carbon fiber bundle a focusing property.
- a sizing agent having good compatibility with the matrix resin can be appropriately selected according to the type of the matrix resin used in the composite material.
- the measuring method of various physical property values used in the present invention is as follows.
- ⁇ Single fiber loop test> Place a single fiber of about 10 cm in length on a glass slide, add 1 or 2 drops of glycerin at the center, and lightly twist both ends of the single fiber in the fiber circumferential direction to create a loop at the center of the single fiber. Put the cover glass on. This is set on the stage of the microscope, and moving image shooting is started under the condition that the total magnification is 100 times and the frame rate is 15 frames / second. While adjusting the stage so that the loop does not deviate from the field of view, both ends of the looped fiber are pressed in the direction of the slide glass with fingers and pulled at a constant speed in the opposite direction, thereby straining until the single fiber breaks.
- the frame immediately before the break is specified by frame advance, and the horizontal width W of the loop immediately before the break is measured by image analysis.
- the fiber diameter d is divided by W to calculate d / W.
- the n number of the test is 20, and E ⁇ d / W is obtained by multiplying the average value of d / W by the strand elastic modulus.
- a perforated mount with monofilaments fixed thereon is placed on the spacer, and a glass plate on which a film is similarly attached is set on the spacer with the surface on which the film is attached facing downward.
- a tape having a thickness of about 70 ⁇ m is attached to both ends of the film.
- the strain ⁇ c of the final single fiber composite is expressed by the following equation from the gauge factor ⁇ of the strain gauge, the fiber embedding depth e ( ⁇ m) measured by the above procedure (d), and the residual strain 0.14 (%). calculate.
- Measurement of the number of fiber breaks by the double fiber fragmentation method is performed by the following procedures (f) to (j).
- n number of a test shall be 20 and it tests about 40 single fibers.
- the single fiber elastic modulus of the carbon fiber is determined as follows based on JIS R7606 (2000). First, a bundle of carbon fibers having a length of about 20 cm is divided into approximately four equal parts, and single yarns are sampled sequentially from the four bundles, and the whole bundle is sampled as evenly as possible. The sampled single yarn is fixed to the perforated mount using an adhesive. A base sheet on which a single yarn is fixed is attached to a tensile tester, and the tensile strength is measured by a tensile test with a gauge length of 50 mm, a strain rate of 2 mm / min, and the number of samples of 20.
- the elastic modulus is defined by the following formula.
- Elastic modulus (obtained strength) / (cross-sectional area of single fiber ⁇ obtained elongation)
- the mass per unit length (g / m) is divided by the density (g / m 3 ) and further divided by the number of filaments to determine the single fiber cross-sectional area.
- the density is measured by the Archimedes method using o-dichloroethylene as a specific gravity liquid.
- strand modulus E The resin-impregnated strand tensile modulus (strand modulus E), tensile strength, and stress-strain curve of carbon fiber are determined in accordance with JIS R7608 (2008) “Resin-impregnated strand test method”.
- the strand elastic modulus E is measured in the strain range of 0.1 to 0.6%, and the initial elastic modulus is obtained from the slope of the stress-strain curve at zero strain.
- a test piece impregnates the following resin composition in a carbon fiber bundle, and produces it on the hardening conditions of the heat processing for 35 minutes at the temperature of 130 degreeC.
- the number of strands to be measured is 6, and the arithmetic average value of the measurement results is the strand tensile modulus and tensile strength of the carbon fiber.
- the above 3,4-epoxycyclohexylmethyl-3,4-epoxy-cyclohexane-carboxylate “BAKELITE (registered trademark)” ERL- manufactured by Union Carbide Co., Ltd. 4221 was used. Strain is measured using an extensometer.
- ⁇ is the specific gravity of ethanol.
- ⁇ Crystallinity of carbon fiber> The carbon fiber used for the measurement is cut to a length of 2 to 3 mm with scissors and then pulverized with an agate mortar for 10 to 20 minutes until the fiber shape disappears.
- a sample for wide-angle X-ray diffraction measurement is prepared by mixing 180 mg of the carbon fiber powder thus obtained with 300 mg of silica gel powder and 20 mg of silicone powder (100 mesh). The prepared measurement sample is measured under the following conditions using a wide-angle X-ray diffractometer.
- -X-ray source CuK ⁇ ray (tube voltage 40 kV, tube current 30 mA)
- Detector Goniometer + Monochromator + Scintillation counter
- Scanning range: 2 ⁇ 10-40 °
- Scan mode Step scan, step unit 0.01 °, counting time 1 second.
- ⁇ Crystal orientation degree of carbon fiber bundles> By aligning the carbon fiber bundles used for measurement and solidifying them with a collodion / alcohol solution, a square column measurement sample having a length of 4 cm and a side length of 1 mm is prepared. The prepared measurement sample is measured under the following conditions using a wide-angle X-ray diffractometer.
- -X-ray source CuK ⁇ ray (tube voltage 40 kV, tube current 30 mA)
- XRD-6100 manufactured by Shimadzu Corporation is used.
- a f (g / m) and specific gravity B f (g / cm 3 ) per unit length are determined for a carbon fiber bundle composed of a large number of carbon filaments to be measured.
- the number of filaments of the carbon fiber bundle from C f to values and measurements obtained A f and B f, the average carbon fiber monofilament diameter ([mu] m), is calculated by the following equation.
- Average single fiber diameter ( ⁇ m) of carbon fiber ((A f / B f / C f ) / ⁇ ) (1/2) ⁇ 2 ⁇ 10 3 .
- Flame-resistant fiber to be used for measurement is collected by freeze-grinding and weighing 2 mg, mixing it well with KBr 300 mg, placing it in a molding jig, and pressurizing at 40 MPa for 2 minutes using a press.
- Make a tablet The tablet is set in a Fourier transform infrared spectrophotometer, and the spectrum is measured in the range of 1000 to 2000 cm ⁇ 1 .
- the background correction is performed by subtracting the minimum value from each intensity so that the minimum value in the range of 1700 to 2000 cm ⁇ 1 becomes zero.
- the Fourier transform infrared spectrophotometer Parakin 1000 manufactured by PerkinElmer was used.
- the fiber direction of the unidirectional fiber reinforced composite material is defined as the axial direction
- the axial direction is defined as the 0 ° axis
- the axial orthogonal direction is defined as the 90 ° axis.
- the unidirectional reinforcing material is cut into a width of 12.7 mm and a length of 230 mm, and tabs made of glass fiber reinforced plastic having a length of 1.2 mm and a length of 50 mm are bonded to both ends to obtain a test piece.
- the test piece thus obtained is subjected to a tensile test at a crosshead speed of 1.27 mm / min using an Instron universal testing machine to obtain a 0 ° tensile strength.
- Examples 1 to 8 and Comparative Examples 1 to 10 A copolymer composed of 99.0% by mass of acrylonitrile and 1.0% by mass of itaconic acid (in Comparative Example 8, a copolymer composed of 97.0% by mass of acrylonitrile and 3.0% by mass of itaconic acid) Polymerization was performed by a solution polymerization method using sulfoxide as a solvent to obtain a spinning solution containing a polyacrylonitrile-based copolymer.
- the obtained spinning solution was once discharged from the spinneret into the air, and a coagulated yarn was obtained by a dry and wet spinning method in which the spinning solution was introduced into a coagulation bath made of an aqueous solution of dimethyl sulfoxide.
- the coagulated yarn was washed with water by a conventional method, and then stretched 3.5 times in two warm water baths. Subsequently, an amino-modified silicone-based silicone oil was applied to the fiber bundle after stretching in the water bath, and a dry densification treatment was performed using a 160 ° C. heating roller. After the number of single fibers is 12,000, the yarn is stretched 3.7 times in pressurized steam, so that the total draw ratio of the yarn is 13 times, and then the entanglement treatment is performed to obtain a crystal orientation degree of 93% and a single fiber number of 12,000. A carbon fiber precursor fiber bundle was obtained. The single fiber fineness of the carbon fiber precursor fiber bundle was 0.7 dtex.
- Comparative Example 10 had a single fiber fineness of 0.5 dtex.
- Table 1 the conditions of flameproofing temperature and flameproofing time shown in Table 1 for Examples 1 to 7 and Comparative Examples 1 to 8, 10 and Table 2 for Example 8 and Table 3 for Comparative Example 9 are shown in Table 1.
- the carbon fiber precursor fiber bundle was subjected to flame resistance treatment while being stretched at a draw ratio of 1 in an oven in an air atmosphere to obtain flame resistant fiber bundles shown in Tables 1 to 3, respectively.
- the process of making flame resistant in the “first furnace” corresponds to the first flame resistant process
- “second furnace” however, in Comparative Example 4, “second furnace” and “third furnace”
- the process for making flame resistant corresponds to the second flame resistant process.
- the process of making flame resistant in the “first furnace”, “second furnace”, “third furnace”, and “fourth furnace” corresponds to the first flameproofing process
- “fifth furnace” “sixth furnace” The process for making flame resistant corresponds to the second flame resistant process.
- the number of flameproofing furnaces for performing the first flameproofing process and the second flameproofing process is not limited.
- flame resistance was performed at 250 ° C. for 11 minutes in the “first furnace” and flame resistance was performed for 6 minutes at 285 ° C. in the “second furnace”.
- the first flame resistance was achieved.
- Flame resistance was achieved by a 6 furnace configuration in which the process was performed in 4 furnaces and the second flame resistance process was performed in 2 furnaces.
- the pre-carbonized fiber bundle was obtained by subjecting the obtained flame-resistant fiber bundle to a pre-carbonization treatment while drawing at a draw ratio of 1.15 in a nitrogen atmosphere at a temperature of 300 to 800 ° C.
- the obtained preliminary carbonized fiber bundle was carbonized at a maximum temperature of 1500 ° C. and a tension of 14 mN / dTex in a nitrogen atmosphere.
- Tables 4-1 to 4-3 show the physical properties of the obtained carbon fiber bundles which were subjected to surface treatment and sizing agent coating treatment to obtain final carbon fiber bundles.
- Comparative Example 1 is Example 4 of Japanese Patent Application Laid-Open No. 2012-082541
- Comparative Example 2 is Example 1 of Japanese Patent Application Laid-Open No.
- Comparative Example 3 is Example 1 of Japanese Patent Application Laid-Open No. 2012-082541. Comparative Example 4 was carried out in accordance with the flameproofing conditions of Example 3 of JP2012-082541, and Comparative Example 5 was carried out in accordance with the flameproofing conditions of Example 7 of JP2012-082541A.
- carbon fiber composite material evaluation was implemented in the following procedures about the carbon fiber bundle of Example 1 and Comparative Example 10.
- Comparative Example 10 flame resistance and carbonization were performed under the same conditions as in Comparative Example 3, but the tensile strength was higher than that of Comparative Example 3 due to a reduction in surface defects due to a decrease in single fiber fineness.
- a carbon fiber bundle was subjected to electrolytic surface treatment with an aqueous solution of ammonium hydrogen carbonate having a concentration of 0.1 mol / l as an electrolytic solution at an electric quantity of 80 coulomb per gram of carbon fiber.
- the carbon fiber subjected to the electrolytic surface treatment was washed with water and dried in heated air at a temperature of 150 ° C. to obtain an electrolytically treated carbon fiber bundle.
- a sizing agent adhesion treatment was performed with a sizing solution containing “Denacol (registered trademark)” EX-521 (manufactured by Nagase ChemteX Corporation) to obtain a sizing agent-coated carbon fiber bundle.
- a prepreg was produced by the following procedure.
- Example 1 A carbon fiber composite material was produced using such a prepreg, and the 0 ° tensile strength was evaluated. The results are shown in Table 4-3. In Example 1 and Comparative Example 10, although the tensile strength of the carbon fiber bundle was equal to 7.6, the carbon fiber composite material 0 ° tensile strength was superior to that of Comparative Example 10 in Example 1.
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Abstract
Description
ε=Aσ2+Bσ+C ・・・(1)
(0.0000832Π2-0.0184Π+1.00)/A≦-395 ・・・(2)
ここで、ΠはX線回折測定における結晶配向度(%)を示す。
ε=Aσ2+Bσ+C ・・・(1)
(0.0000832Π2-0.0184Π+1.00)/A≦-395 ・・・(2)
ここで、Πは、炭素繊維束を広角X線回折測定により測定することにより求められる結晶配向度(%)を示す。
熱量の積算値(J・h/g)=T×t×1.507
ここで耐炎化工程に温度条件が複数ある場合には、各温度での滞留時間から熱量を計算して、積算すればよい。
長さ約10cmの単繊維をスライドガラス上に置き、中央部にグリセリンを1~2滴たらして単繊維両端部を繊維周方向に軽くねじることで単繊維中央部にループを作り、その上にカバーガラスを置く。これを顕微鏡のステージに設置し、トータル倍率が100倍、フレームレートが15フレーム/秒の条件で動画撮影を開始する。ループが視野から外れないようにステージを都度調節しながら、ループさせた繊維の両端を指でスライドガラス方向に押しつけつつ逆方向に一定速度で引っ張ることで、単繊維が破断するまで歪をかける。コマ送りにより破断直前のフレームを特定し、画像解析により破断直前のループの横幅Wを測定する。繊維直径dをWで除してd/Wを算出する。試験のn数は20とし、d/Wの平均値にストランド弾性率をかけ算することによりE×d/Wを求める。
シングルファイバーフラグメンテーション法による繊維破断数の測定は、次の(a)~(e)の手順で行う。
ビスフェノールA型エポキシ樹脂化合物“エポトート(登録商標)YD-128”(新日鐵化学(株)製)190質量部とジエチレントリアミン(和光純薬工業(株)製)20.7質量部を容器に入れてスパチュラでかき混ぜ、自動真空脱泡装置を用いて脱泡する。
20cm程度の長さの炭素繊維束をほぼ4等分し、4つの束から順番に単繊維をサンプリングした。このとき、束全体からできるだけまんべんなくサンプリングする。次に、穴あき台紙の両端に両面テープを貼り、サンプリングした単繊維に一定張力を与えた状態で穴あき台紙に単繊維を固定する。次に、ポリエステルフィルム“ルミラー(登録商標)”(東レ(株)製)を貼り付けたガラス板を用意して、試験片の厚さを調整するための2mm厚のスペーサーをフィルム上に固定する。そのスペーサー上に単繊維を固定した穴あき台紙を置き、さらにその上に、同様にフィルムを貼り付けたガラス板をフィルムが貼り付いた面を下向きにセットする。このときに繊維の埋め込み深さを制御するために、厚み70μm程度のテープをフィルムの両端に貼り付ける。
上記(b)の手順で得られたモールド(スペーサーとフィルムに囲まれた空間)内に上記(a)の手順で調整した樹脂を流し込む。樹脂を流し込んだモールドを、あらかじめ50℃に昇温させたオーブンを用いて5時間加熱後、降温速度2.5℃/分で30℃の温度まで降温する。その後、脱型、カットをして2cm×7.5cm×0.2cmの試験片を得る。このとき、試験片幅の中央0.5cm幅内に単繊維が位置するように試験片をカットする。
上記(c)の手順で得られた試験片に対して、レーザーラマン分光光度計(日本分光 NRS-3000)のレーザーと532nmノッチフィルターを用いて繊維の埋め込み深さ測定を行う。まず、単繊維表面にレーザーを当て、レーザーのビーム径が最も小さくなるようにステージ高さを調整し、そのときの高さをA(μm)とする。次に試験片表面にレーザーを当て、レーザーのビーム径が最も小さくなるようにステージ高さを調整し、そのときの高さをB(μm)とする。このようにして得られた高さA、Bと、上記レーザーを使用して測定した樹脂の屈折率1.732から、以下の式により、繊維の埋め込み深さe(μm)を計算する。
上記(c)の手順で得られた試験片に対して、図1に示すように外側圧子50mm間隔、内側圧子20mm間隔の治具を用いて4点曲げで引張り歪みを負荷する。ステップワイズに0.1%毎に歪みを与え、偏光顕微鏡により試験片を観察し、試験片長手方向の中心部10mmの範囲における単繊維の破断数を測定する。測定した破断数を10で除した値を繊維破断数(個/mm)とする。また、試験片の中心から幅方向に約5mm離れた位置に貼り付けた歪みゲージを用いて歪みε1(%)を測定した。試験のn数は40とし、測定結果の算術平均値をε1(%)の値とする。最終的な単繊維コンポジットの歪みεcは、歪みゲージのゲージファクターκ、上記(d)の手順で測定した繊維埋め込み深さe(μm)、残留歪み0.14(%)から以下の式で計算する。
ダブルファイバーフラグメンテーション法による繊維破断数の測定は、次の(f)~(j)の手順で行う。
前記(a)と同様に行う。
20cm程度の長さの炭素繊維束をほぼ4等分し、4つの束から2本の単繊維をサンプリングし、穴あき台紙の両端に両面テープを貼り、サンプリングした単繊維に一定張力を与えた状態で2本の単繊維の間隔が0.5μm以上、平均単繊維径以内となり、かつ平行となるように固定する以外は前記(b)と同様に行う。
前記(c)と同様に行う。
前記(d)と同様に繊維埋め込み深さを測定した後、光学顕微鏡で単繊維間隔を測定する。単繊維間隔が0.5μm以上、平均単繊維径以下で平行に埋め込まれたコンポジットのみ試験に用いる。
前記(e)と同様に行う。なお、試験のn数は20とし、40本の単繊維について試験を行う。
炭素繊維の単繊維弾性率は、JIS R7606(2000年)に基づいて、以下の通りにして求める。まず、20cm程度の長さの炭素繊維の束をほぼ4等分し、4つの束から順番に単糸をサンプリングして束全体からできるだけまんべんなくサンプリングする。サンプリングした単糸は、穴あき台紙に接着剤を用いて固定する。単糸を固定した台紙を引張試験機に取り付け、ゲージ長50mm、歪速度2mm/分、試料数20で引張試験により引張強力を測定し、測定結果の算術平均値を強力の値とする。弾性率は以下の式で定義される。
弾性率=(得られる強力)/(単繊維の断面積×得られる伸度)
測定する繊維束について、単位長さ当たりの質量(g/m)を密度(g/m3)で除して、さらにフィラメント数で除して単繊維断面積を求める。密度は、比重液としてo-ジクロロエチレンを用いてアルキメデス法で測定する。
炭素繊維の樹脂含浸ストランド引張弾性率(ストランド弾性率E)、引張強度および応力-ひずみ曲線は、JIS R7608(2008)「樹脂含浸ストランド試験法」に従って求める。ストランド弾性率Eは歪み範囲0.1~0.6%の範囲で測定し、初期弾性率は歪み0における応力-ひずみ曲線の傾きから求める。なお、試験片は、次の樹脂組成物を炭素繊維束に含浸し、130℃の温度で35分間熱処理の硬化条件により作製する。
・3,4-エポキシシクロヘキシルメチル-3,4-エポキシ-シクロヘキサン-カルボキシレート(100質量部)
・3フッ化ホウ素モノエチルアミン(3質量部)
・アセトン(4質量部)。
1.0~3.0gの繊維を採取し、120℃で2時間絶乾する。絶乾質量W1(g)を測定した後、エタノールに含浸させ十分脱泡してから、エタノール浴中での繊維質量W2(g)を測定し、繊維比重=(W1×ρ)/(W1-W2)により繊維比重を求める。ここで、ρはエタノールの比重である。
測定に供する炭素繊維をハサミで2~3mmの長さに切断した後、めのう乳鉢を用いて繊維形状がなくなるまで10~20分間粉砕する。そのようにして得られた炭素繊維粉末180mgに対し、シリカゲル粉末300mgとシリコーン粉末(100メッシュ)20mgを混合することで広角X線回折測定用試料を用意する。用意された測定試料について、広角X線回折装置を用いて、次の条件により測定を行う。
・X線源:CuKα線(管電圧40kV、管電流30mA)
・検出器:ゴニオメーター+モノクロメーター+シンチレーションカウンター
・走査範囲:2θ=10~40°
・走査モード:ステップスキャン、ステップ単位0.01°、計数時間1秒。
A1=X1×B100/(B1×X100)×100
なお、後述の実施例および比較例においては、上記広角X線回折装置として、島津製作所製XRD-6100を用いた。
測定に供する炭素繊維束を引き揃え、コロジオン・アルコール溶液を用いて固めることにより、長さ4cm、1辺の長さが1mmの四角柱の測定試料を用意する。用意された測定試料について、広角X線回折装置を用いて、次の条件により測定を行う。
・X線源:CuKα線(管電圧40kV、管電流30mA)
・検出器:ゴニオメーター+モノクロメーター+シンチレーションカウンター
2θ=25~26°付近に現れるピークを円周方向にスキャンして得られる回折強度分布の半価幅H(°)から次式を用いて結晶配向度Π(%)を求める。
結晶配向度Π(%)=[(180-H)/180]×100
なお、上記広角X線回折装置として、島津製作所製XRD-6100を用いる。
測定する多数本の炭素フィラメントからなる炭素繊維束について、単位長さ当たりの質量Af(g/m)および比重Bf(g/cm3)を求める。求めたAfおよびBfの値ならびに測定する炭素繊維束のフィラメント数をCfから、炭素繊維の平均単繊維径(μm)を、下記式で算出する。
測定に供する耐炎化繊維を、凍結粉砕後に2mgを精秤して採取し、それをKBr300mgと良く混合して、成形用治具に入れ、プレス機を用いて40MPaで2分間加圧することで測定用錠剤を作製する。この錠剤をフーリエ変換赤外分光光度計にセットし、1000~2000cm-1の範囲でスペクトルを測定する。なお、バックグラウンド補正は、1700~2000cm-1の範囲における最小値が0になるようにその最小値を各強度から差し引くことで行う。なお、上記フーリエ変換赤外分光光度計として、パーキンエルマー製Paragon1000を用いた。
JIS K7017(1999)に記載されているとおり、一方向繊維強化複合材料の繊維方向を軸方向として、その軸方向を0°軸、軸直交方向を90°軸と定め、作成後24時間以内の一方向プリプレグを所定の大きさにカットし、これを一方向に6枚積層した後、真空バッグ法により、オートクレーブを用いて、温度180℃、圧力6kg/cm2、2時間で硬化させ、一方向強化材(炭素繊維複合材料)を得る。この一方向強化材を幅12.7mm、長さ230mmにカットし、両端に1.2mm、長さ50mmのガラス繊維強化プラスチック製のタブを接着し試験片を得る。このようにして得られた試験片について、インストロン社製万能試験機を用いてクロスヘッドスピード1.27mm/分で引張試験を行い、0°引張強度を求める。
アクリロニトリル99.0質量%とイタコン酸1.0質量%からなる共重合体(ただし、比較例8では、アクリロニトリル97.0質量%とイタコン酸3.0質量%からなる共重合体)を、ジメチルスルホキシドを溶媒として溶液重合法により重合させ、ポリアクリロニトリル系共重合体を含む紡糸溶液を得た。得られた紡糸溶液を、紡糸口金から一旦空気中に吐出し、ジメチルスルホキシドの水溶液からなる凝固浴に導入する乾湿式紡糸法により凝固糸条を得た。
Claims (13)
- 樹脂含浸ストランド引張試験における応力σ-ひずみε曲線の非線形性の近似式(1)から求まる係数Aと広角X線回折測定における結晶配向度Π(%)の関係が式(2)を満足し、かつ引張強度が7.5GPa以上の炭素繊維束;
ε=Aσ2+Bσ+C ・・・(1)
(0.0000832Π2-0.0184Π+1.00)/A≦-395 ・・・(2)
ここで、A、B、Cは応力σとひずみεの2次関数の係数である。 - 広角X線回折測定における結晶配向度Π(%)が82%以上である、請求項1に記載の炭素繊維束。
- 樹脂含浸ストランド引張試験における引張弾性率が240~440GPaであり、かつ単繊維直径dと単繊維ループ法で評価される破断直前のループ幅Wの比d/Wとストランド弾性率Eとの積E×d/Wが14.6GPa以上である炭素繊維束。
- 単繊維20本に対して評価したE×d/Wのワイブルプロットにおけるワイブル形状係数mが12以上である、請求項3に記載の炭素繊維束。
- 炭素繊維の単繊維コンポジットのシングルファイバーフラグメンテーション法による繊維破断数が0.30個/mmのときの単繊維見掛け応力が8.5GPa以上であり、かつ炭素繊維の単繊維コンポジットのシングルファイバーフラグメンテーション法による繊維破断数が0.30個/mmのときの炭素繊維の単繊維コンポジットのダブルファイバーフラグメンテーション法による繊維破断数が0.24~0.42個/mmである炭素繊維束。
- 炭素繊維の単繊維コンポジットのシングルファイバーフラグメンテーション法による、単繊維見掛け応力が15.3GPaのときの繊維破断数が2.0個/mm以上である、請求項5に記載の炭素繊維束。
- 樹脂含浸ストランド引張試験における初期引張弾性率が280GPa以上である、請求項1~6のいずれかに記載の炭素繊維束。
- 広角X線回折測定における結晶化度が40~60%である、請求項1~7のいずれかに記載の炭素繊維束。
- ポリアクリロニトリル系炭素繊維前駆体繊維束を、赤外スペクトルにおける1370cm-1のピーク強度に対する1453cm-1のピーク強度の比が0.98~1.10の範囲となるまで8~25分間耐炎化する第1耐炎化工程を行い、さらに、赤外スペクトルにおける1370cm-1のピーク強度に対する1453cm-1のピーク強度の比が0.70~0.75の範囲、かつ、赤外スペクトルにおける1370cm-1のピーク強度に対する1254cm-1のピーク強度の比が0.50~0.65の範囲となるまで5~14分間耐炎化する第2耐炎化工程を行って耐炎化繊維束を得て、その後、耐炎化繊維束を1000~3000℃の不活性雰囲気中で炭素化する炭素化工程を行う炭素繊維束の製造方法。
- 耐炎化工程におけるトータルの処理時間を13~20分の範囲とする、請求項9に記載の炭素繊維束の製造方法。
- 耐炎化工程における繊維の比重が1.22であって、かつ、220℃以上で熱処理される間に与えられる熱量の積算値が50~150J・h/gの範囲内となるように耐炎化する、請求項9または10に記載の炭素繊維束の製造方法。
- 得られる耐炎化繊維束の比重が1.28~1.32の範囲となるように耐炎化する、請求項9~11のいずれかに記載の炭素繊維束の製造方法。
- ポリアクリロニトリル系炭素繊維前駆体繊維束において、アクリロニトリルに共重合成分をモノマー成分全体の0.1~2質量%共重合させる、請求項9~12のいずれかに記載の炭素繊維束の製造方法。
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