Classifications

• • 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
  • D06M11/00—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
  • D06M11/51—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 sulfur, selenium, tellurium, polonium or compounds thereof
  • D06M11/55—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 sulfur, selenium, tellurium, polonium or compounds thereof with sulfur trioxide; with sulfuric acid or thiosulfuric acid or their salts
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
  • B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
  • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
  • B09B—DISPOSAL OF SOLID WASTE NOT OTHERWISE PROVIDED FOR
  • B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
  • B09B3/70—Chemical treatment, e.g. pH adjustment or oxidation
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/06—Fibrous reinforcements only
  • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
  • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/28—Shaping operations therefor
  • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
  • B29C70/32—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core on a rotating mould, former or core
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J11/00—Recovery or working-up of waste materials
  • C08J11/04—Recovery or working-up of waste materials of polymers
  • C08J11/10—Recovery or working-up of waste materials of polymers by chemically breaking down the molecular chains of polymers or breaking of crosslinks, e.g. devulcanisation
  • C08J11/16—Recovery or working-up of waste materials of polymers by chemically breaking down the molecular chains of polymers or breaking of crosslinks, e.g. devulcanisation by treatment with inorganic material
• • 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
  • D06M11/00—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
• • 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
  • D06M11/00—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
  • D06M11/32—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 oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond
  • D06M11/50—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 oxygen, ozone, ozonides, oxides, hydroxides or percompounds; Salts derived from anions with an amphoteric element-oxygen bond with hydrogen peroxide or peroxides of metals; with persulfuric, permanganic, pernitric, percarbonic acids or their salts
• • 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
  • D06M11/00—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
  • D06M11/58—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 nitrogen or compounds thereof, e.g. with nitrides
  • D06M11/64—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 nitrogen or compounds thereof, e.g. with nitrides with nitrogen oxides; with oxyacids of nitrogen or their salts
• • 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
  • D06M10/00—Physical treatment of fibres, threads, yarns, fabrics or fibrous goods made from such materials, e.g. by ultrasonic waves, corona discharge, irradiation, electric currents or magnetic fields; Physical treatment combined with treatment with chemical compounds or elements
• • 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
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
  • Y02W30/00—Technologies for solid waste management
  • Y02W30/20—Waste processing or separation
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
  • Y02W30/00—Technologies for solid waste management
  • Y02W30/50—Reuse, recycling or recovery technologies
  • Y02W30/62—Plastics recycling; Rubber recycling

Definitions

• the present invention relates to a reinforcing material, a method for producing a reinforcing material, a method for producing a composite material, and a composite material.
• Reinforced composite materials are materials that are molded by compounding a base resin with reinforcing materials such as carbon fiber, glass fiber, metal fiber, high-strength organic fiber, inorganic filler, metal filler, carbon nanotubes, and cellulose nanofiber. They are characterized by their high strength and light weight compared to metals such as iron. Taking advantage of these characteristics, reinforced composite materials are beginning to be used in wind turbine blades as well as some automobiles and aircraft as a material that greatly contributes to improving energy efficiency.
• carbon fiber the reinforcing material in carbon fiber reinforced plastic
• carbon fiber reinforced plastic is made by first synthesizing a chemical substance called acrylonitrile from petroleum, which is then spun into acrylic fiber threads. Carbon fiber is then produced by carbonizing it at high temperatures of several thousand degrees. Carbon fiber can be used as is, but it is often processed into various forms such as continuous fiber, nonwoven fabric, and chopped fiber, and is then compounded with various types of resin to be used as carbon fiber reinforced plastic (CFRP), a type of composite reinforcing material.
• CFRP carbon fiber reinforced plastic
• Carbon fiber reinforced plastics have excellent material properties, such as being strong, hard, rust-free, and rot-resistant. However, because of these excellent material properties, disposal methods have become an issue. Ordinary plastics can be easily burned, but carbon fiber is difficult to burn because of its highly graphitized structure. For this reason, in Japan, scraps and waste materials of carbon fiber reinforced plastics are crushed as industrial waste and disposed of in landfills. Crushed carbon fiber disposed of in landfills is not biodegradable and becomes a cause of marine plastic pollution.
• Superheated steam is steam that has a steam temperature equal to or higher than the saturation temperature at a certain pressure by further heating saturated steam. There is a method using this superheated steam to efficiently pyrolyze the resin component, which is the base material, and recover only the carbon fibers (see, for example, Patent Document 2).
• a method has also been proposed in which the resin components are dissolved in a specific organic solvent. This method is characterized by the fact that the processing temperature is low at 100-150°C, and because it is a wet process, no resin remains, so the strength of the recovered carbon fiber does not decrease (for example, see Non-Patent Document 1).
• Non-Patent Document 1 In the regeneration method proposed in Non-Patent Document 1, in which the resin components are dissolved in a specific organic solvent, the functional groups that remain unused during the composite formation are not lost, but since functional groups cannot be imparted to the fiber surface, the amount of functional groups is reduced compared to the original carbon fiber. As described above, in the conventional methods for separating and recovering reinforcing materials from composite reinforcing materials, the amount of functional groups on the surface of the recycled carbon fibers is small, and many of the fibers are short in shape, which makes it difficult to recombine them with resin and reuse them.
• the object of the present invention was therefore made in consideration of the above problems, and is to provide a reinforcing material that has sufficient functional groups on its surface and has excellent surface adhesion so that it can be composited with a resin.
• Another object of the present invention is to provide a method for producing a reinforcing material that can recover a reinforcing material that has sufficient functional groups on its surface from a reinforced composite material.
• a reinforcing material which is a continuous fiber and which is characterized in that the total acidic functional group concentration on the surface of the reinforcing material is 0.4 mmol/g or more and 4.0 mmol/g or less.
• the reinforcing material described in 1 above characterized in that the reinforcing material is a recycled reinforcing material that has been separated and recycled from a reinforced composite material containing a base material and a reinforcing material.
• the reinforcing material according to 1 or 2 characterized in that the acidic functional group is a carboxyl group, a lactone group, or a phenolic hydroxyl group.
• the reinforcing material described in 4 characterized in that the concentration of strong acidic functional groups on the surface of the recycled reinforcing material is 0.2 mmol/g or more and 2.0 mmol/g or less.
• the reinforcing material according to 4 or 5 characterized in that the strongly acidic functional group is a carboxyl group.
• reinforcing material according to any one of 1 to 6 above, characterized in that the reinforcing material is at least one selected from the group consisting of carbon fiber, glass fiber, and metal fiber.
• a method for producing a reinforcing material comprising the steps of: A step of immersing the reinforced composite material in a decomposition solution containing an oxidizing active species derived from sulfuric acid and/or nitric acid; Decomposing the base material or the sizing agent by heating the decomposition solution; removing the acid adhering to the reinforcing material and recovering the reinforcing material by washing with water to obtain the reinforcing material;
• a method for producing a reinforcing material comprising:
• a method for producing a composite material comprising a step of compounding the reinforcing material described in any one of 1 to 8 above with a resin.
• a composite material comprising the reinforcing material described in any one of 1 to 8 above and a resin.
• the present invention can provide a reinforcing material that has sufficient functional groups on its surface and has excellent surface adhesion so that it can be composited with a resin.
• the present invention can also provide a method for producing a reinforcing material that can recover a reinforcing material that has sufficient functional groups on its surface from a reinforced composite material.
• the reinforced composite material of this embodiment is a material whose strength is improved by compounding a reinforcing material, which is a different material such as a fiber or a filler, in a base material such as a resin.
• the compounding method is not particularly limited, and may be a method that utilizes interactions such as hydrogen bonds or intermolecular forces, and may be dispersion, attachment, adhesion, adsorption, support, arrangement, etc.
• the reinforced composite material may include a matrix, a reinforcement, other additives, and the like.
• the reinforcing material in this embodiment refers to a material that is compounded or dispersed in the matrix resin that is the base material of the reinforced composite material, and examples of the reinforcing material include carbon fiber, glass fiber, metal fiber, organic high-strength fiber, inorganic filler, carbon nanotube, cellulose nanofiber, etc., and is preferably at least one selected from the group consisting of carbon fiber, glass fiber, and metal fiber.
• the reinforcing material is more preferably carbon fiber.
• fibrous and particulate There are two types of reinforcing materials: fibrous and particulate. Although the definition is not clear, generally, those with a large aspect ratio (length/width) (for example, an aspect ratio of 100 or more, preferably 200 or more) are called fibrous, and those with a small aspect ratio (length/width) (for example, an aspect ratio of less than 200, preferably less than 100) are called particulate.
• the carbon fiber is a fiber made by carbonizing acrylic fiber or pitch (a by-product of petroleum, coal, coal tar, etc.) at high temperatures.
• the glass fiber is formed by melting and drawing glass into fibers.
• the metal fibers are obtained by processing metals such as stainless steel, aluminum, iron, nickel, copper, etc., into thread form by plastic processing (rolling, etc.), melt spinning, CVD, etc.
• the organic high strength fibers are fibers made from resins such as polyamide, polyester, acrylic, polyparaphenylenebenzobisoxazole, and polyimide.
• the continuous fiber refers to a single fiber that is connected without any cuts and has a length of 30 cm or more. There is no particular upper limit to the length, but it is a length that can be wound around a bobbin and used, and is generally 1000 m to 5000 m.
• the continuous fibers can be used in unidirectional plies, with all the fibers aligned parallel to one another, and can be knitted or woven, or the unidirectional plies can be stacked in various directions to create quasi-isotropic, orthotropic, or anisotropic plates.
• the nonwoven fabric is a sheet-like material made by intertwining fibers without weaving them, and refers to fabric made by bonding or intertwining fibers through thermal, mechanical or chemical action.
• the elements constituting the inorganic filler include, for example, elements in Groups 1 to 16 of the periodic table. Although there is no particular limitation on these elements, elements in Groups 2 to 14 of the periodic table are preferred. Specific examples include Group 2 elements (Mg, Ca, Ba, etc.), Group 3 elements (La, Ce, Eu, Ac, Th, etc.), Group 4 elements (Ti, Zr, Hf, etc.), Group 5 elements (V, Nb, Ta, etc.), Group 6 elements (Cr, Mo, W, etc.), Group 7 elements (Mn, Re, etc.), Group 8 elements (Fe, Ru, Os, etc.), Group 9 elements (Co, Rh, Ir, etc.), Group 10 elements (Ni, Pd, Pt, etc.), Group 11 elements (Cu, Ag, Au, etc.), Group 12 elements (Zn, Cd, etc.), Group 13 elements (Al, Ga, In, etc.), and Group 14 elements (Si, Ge, Sn, Pb, etc.).
• Inorganic compounds containing these elements include, for example, oxides (including complex oxides), halides (fluorides, chlorides, bromides, iodides), oxoacid salts (nitrates, sulfates, phosphates, borates, perchlorates, carbonates, etc.), compounds formed from the above elements and negative elements such as carbon monoxide, carbon dioxide, and carbon disulfide, as well as salts such as hydrocyanic acid, hydrocyanates, cyanates, thiocyanates, and carbides.
• One inorganic filler may contain one or more of the above elements.
• the elements may be present uniformly or unevenly in the particles, and the surface of a particle of a compound of one element may be coated with a compound of another element.
• These inorganic fillers may be used alone or in combination.
• preferred inorganic fillers include, but are not limited to, at least one element selected from the group consisting of silica, zirconia, titanium, zinc, iron, copper, chromium, cadmium, carbon, tungsten, antimony, nickel, and platinum.
• the carbon nanotube is a material in which a six-membered ring network (graphene sheet) made of carbon is formed into a single or multi-layered coaxial tube. It is an allotrope of carbon and is sometimes classified as a type of fullerene.
• the cellulose nanofibers are wood cellulose fibers that have been thinned to a width of about 15 nanometers.
• the content of the reinforcing material in the reinforced composite material is preferably 10 to 80 mass%, with the reinforced composite material being 100 mass%.
• the lower limit is 15 mass% or more and 20 mass% or more, and preferably, the upper limit is 75 mass% or less and 70 mass% or less.
• the concentration of all acidic functional groups on the surface of the reinforcing material is 0.4 mmol/g or more and 4.0 ⁇ mmol/g or less.
• the total acidic functional group concentration on the surface of the reinforcing material is the amount (mmol/g) of all acidic functional groups present near the surface of the reinforcing material.
• the total acidic functional group concentration on the surface of the reinforcing material is measured, for example, by acid-base titration (Boehm method). Specifically, after taking 1 g of sample from the reinforcing material, 30 mL of 0.05 mol/L sodium hydroxide aqueous solution is added, the container is sealed, shaken using a shaker, and then allowed to stand, and 15 mL of the supernatant is titrated with 0.05 mol/L hydrochloric acid, whereby the concentration can be measured. More specifically, the concentration can be measured by the method described in the Examples.
• the acidic functional group examples include a carboxyl group, a lactone group, and a phenolic hydroxyl group.
• the acidic functional group is preferably a strongly acidic functional group (a highly reactive functional group that can react with weakly basic substances or functional groups), and among the strongly acidic functional groups, it is more preferable that the acidic functional group contains at least a carboxyl group, because this can further increase the adhesion to the base material.
• the surface functional group concentration in the reinforcing material of this embodiment is set to 0.4 mmol/g or more from the viewpoint of improving adhesion to the base material, and 4.0 mmol/g or less from the viewpoint of the strength of the composite reinforcing material.
• the higher the total acidic functional group concentration the more sites there are for chemical bonding with the base material, improving adhesion.
• the functional group concentration is set to 4.0 mmol/g or less, the chemical bonds between the fibers do not become larger than necessary, and the fibers can be easily opened when manufacturing the composite reinforcing material.
• the good opening of the fibers allows the reinforcing material to be evenly dispersed in the base material, which tends to increase the strength of the composite material. Therefore, in this embodiment, the total acidic functional group concentration is set to the above numerical range.
• the strongly acidic functional group concentration defined as the amount (mmol/g) of all strongly acidic functional groups present near the surface of the reinforcing material, is preferably 0.1 mmol/g or more from the viewpoint of improving adhesion to the base material, and is preferably 3.0 mmol/g or less from the viewpoint of the strength of the composite reinforcing material due to the openness of the fibers.
• the strongly acidic functional group concentration is more preferably 0.15 mmol/g or more, even more preferably 0.2 mmol/g or more, more preferably 2.5 mmol/g or less, and even more preferably 2.0 mmol/g or less.
• the concentration of the strong acidic functional group is measured, for example, by acid-base titration (Boehm method). Specifically, after taking 1 g of sample from the reinforcing material, 30 mL of 0.05 mol/L aqueous sodium bicarbonate solution is added, the sample is sealed, shaken using a shaker, and then allowed to stand, and 15 mL of the supernatant is titrated with 0.05 mol/L hydrochloric acid. More specifically, the concentration can be measured by the method described in the Examples.
• the method for setting the total acidic functional group concentration on the surface of the reinforcing material of this embodiment to 0.4 mmol/g or more and 4.0 mmol/g or less is not particularly limited.
• adjustment of the acidity and oxidizing power of the acid solution used for treatment, adjustment of the treatment time and treatment temperature, etc. can be mentioned.
• the total acidic functional group concentration can be suitably adjusted by adjusting the time from decomposition of the resin by the acid solution to draining the acid solution and rinsing with water, that is, the time the reinforcing material is in contact with the acid solution.
• the total acidic functional group concentration can be increased by extending the time the reinforcing material is in contact with the acid solution.
• the method for setting the strong acid functional group concentration on the surface of the reinforcing material of this embodiment to 0.2 mmol/g or more and 2.0 mmol/g or less is not particularly limited. Examples include adjustment of the acidity and oxidizing power of the acid solution used for treatment, and adjustment of the treatment time and treatment temperature. The stronger the acidity and oxidizing power of the acid solution, the higher the concentration of the strong acid functional groups tends to be, and the use of electrolytic sulfuric acid can suitably increase the concentration of the strong acid functional groups.
• the strong acid functional group concentration can be suitably adjusted by adjusting the time from decomposition of the resin by the acid solution to draining the acid solution and rinsing with water, that is, the time the reinforcing material is in contact with the acid solution.
• the strong acid functional group concentration can be increased by extending the time the reinforcing material is in contact with the acid solution.
• the reinforcing material in this embodiment is a continuous fiber.
• the openability of the reinforcing material is important for uniformly dispersing the reinforcing material in the base material, and in this case, continuous fibers with a long length are preferable.
• the ends of the fibers tend to become physically entangled with other fibers, reducing the openability.
• the ends of continuous fibers do not become entangled with other fibers, so the openability can be maintained even if the functional group concentration is increased.
• the reinforcing material of this embodiment described above can be appropriately processed to produce an intermediate base material.
• the intermediate substrate in this embodiment may be a continuous fiber or nonwoven fabric containing reinforcement.
• a recycled reinforced composite material can be produced by compounding the aforementioned reinforcing material and the intermediate base material in a base material such as resin.
• the reinforcing material of this embodiment may be a recycled reinforcing material that is separated and recycled from a reinforced composite material containing a base material and a reinforcing material.
• the recycled reinforcement has a strength of 80% or more of the strength of the reinforcement before recycling, and that the shape retention rate of the reinforcement before and after recycling is 90% or more. Furthermore, in this embodiment, it is preferable that the strength of the recycled reinforcement material of the present embodiment described above is 90% or more of the strength of the reinforcement material before recycling, and that the shape retention rate of the reinforcement material before and after recycling is 80% or more.
• the strength of the reinforcing material is measured by the method described in the Examples below.
• the shape retention rate before and after recycling is measured by the method described in the Examples below.
• the strength of the recycled reinforcement of this embodiment described above is 90% or more of the strength of the reinforcement before recycling, and that the shape retention rate of the reinforcement before and after recycling is 90% or more.
• the strength of the reinforced composite material recycled using the recycled reinforcing material is preferably 65% or more, more preferably 70% or more, and even more preferably 75% or more, and is preferably 80% or less, more preferably 90% or less, of the strength of the reinforced composite material prepared using the reinforcing material before recycling.
• the strength of the reinforced composite material is measured by the method described in the Examples below.
• the base material in this embodiment refers to a resin used as a matrix of the reinforced composite material, and a thermoplastic resin or a thermosetting resin is used.
• thermoplastic resin refers to a resin that becomes soft when heated to its glass transition temperature or melting point and can be molded into the desired shape.
• thermoplastic resins are often difficult to machine, such as by cutting or grinding, so injection molding is widely used, in which the resin is heated and softened, then pressed into a mold, cooled, solidified, and made into the final product.
• examples include polyethylene, polypropylene, polystyrene, ABS resin, polyvinyl chloride resin, methyl methacrylate resin, nylon, fluororesin, polycarbonate, polyester resin, etc.
• thermosetting resin refers to a resin that polymerizes when heated, forms a polymer network structure, and hardens and cannot be restored to its original shape.
• a relatively low molecular weight resin with a level of fluidity is shaped into a desired shape, and then reacted and hardened by heating or other means.
• adhesives and putties that use a mixture of liquid A (base) and liquid B (hardener), but these are epoxy resins, a type of thermosetting resin, and a polymerization reaction occurs when they are mixed.
• Thermosetting resins are hard and resistant to heat and solvents. Examples include phenolic resin, epoxy resin, unsaturated polyester resin, and polyurethane.
• the content of the base material in the reinforced composite material is preferably 20 to 90 parts by mass, with the reinforcement being 100 parts by mass.
• the lower limit is 25 parts by mass or more, 30 parts by mass or more, and preferably, the upper limit is 85 parts by mass or less, 80 parts by mass or less.
• the other additives are not particularly limited, and examples thereof include flame retardants, heat stabilizers, antioxidants, light absorbers, release agents, lubricants, various stabilizers, antistatic agents, dyes and pigments, and various reactants used in the above-mentioned compounding.
• the content of the other additives in the reinforced composite material may be 0.01% by mass or less, or 80% by mass or less, based on 100% by mass of the reinforced composite material.
• the method for producing a reinforcing material of this embodiment includes the steps of immersing a reinforced composite material in a decomposition solution containing an oxidizing active species made from sulfuric acid and/or nitric acid as raw materials, heating the solution to decompose the base material, and removing the acid adhering to the reinforcing material and recovering the reinforcing material by washing with water to obtain the reinforcing material.
• the immersion and decomposition step may involve the use of a treatment solution and/or heat, preferably an electrolytic sulfuric acid process.
• the electrolytic sulfuric acid method is a method for treating composite materials, characterized in that a reinforced composite material consisting of a base material and a reinforcing material is immersed in a treatment solution containing oxidizing active species obtained by electrolyzing a sulfuric acid solution, whereby the base material is decomposed into water and carbon dioxide, and the decomposition products are dissolved in the treatment solution, and then the reinforcing material is removed from the treatment solution.
• the oxidizing active species are generated by electrolyzing a sulfuric acid solution at a predetermined current and a predetermined voltage, and specifically include hydroxyl radicals, peroxosulfuric acid, peroxodisulfuric acid, and the like.
• the method for processing the reinforced composite material of this embodiment specifically includes the following steps: A) obtaining a treatment solution containing an oxidizing active species by electrolyzing sulfuric acid; B) immersing the reinforced composite material, which is a scrap material discarded after use or from a manufacturing process, in the treatment solution to decompose and remove the base material; C) washing and drying the reinforcing material from which the base material has been removed, thereby regenerating the reinforcing material; including.
• the sulfuric acid solution is a solution containing sulfuric acid (H 2 SO 4 ) and water (H 2 O).
• the concentration of sulfuric acid contained in the sulfuric acid solution is preferably 30 to 95% by weight, more preferably 50 to 80% by weight. If the concentration of sulfuric acid is less than 30% by weight, the amount of oxidizing active species required to decompose the base material of the reinforced composite material cannot be obtained, and it takes a long time to decompose the base material.
• concentrated sulfuric acid, hydrochloric acid, or nitric acid may be added to the treatment solution containing the electrolyzed oxidizing active species.
• peroxides such as hydrogen peroxide and peroxosulfuric acid may be added to the treatment solution. In this case, the effect of accelerating the decomposition rate of the base material of the reinforced composite material can be obtained.
• Platinum electrodes and carbon electrodes can be used for the electrolysis of sulfuric acid solutions, but for highly concentrated sulfuric acid solutions, so-called diamond electrodes, which are metal plates with a thin diamond coating on the surface, can be used for durability.
• diamond electrodes which are metal plates with a thin diamond coating on the surface, can be used for durability.
• an electrolysis device for sulfuric acid solutions it is preferable to use a diaphragm-type electrolysis cell using diamond electrodes.
• the electrolysis conditions may be a current density of 0.01 to 10 A/cm 2 and a voltage of 0.1 to 100 V, but these may be appropriately changed depending on the type of electrode, the sulfuric acid concentration of the sulfuric acid solution, the amount of the sulfuric acid solution, etc.
• the electrolysis must be performed in a closed system, and is preferably performed while circulating a predetermined amount of sulfuric acid solution in a closed sulfuric acid solution circulation system.
• the circulation method may be a method of passing the solution at a flow rate of 50 mL/min or more in a direction parallel to the electrode surface using a pump or the like, or a method of natural circulation by convection according to the flow of gas generated by electrolysis.
• the processing time for the electrolysis can be changed as appropriate depending on the amount of sulfuric acid solution, sulfuric acid concentration, flow rate of the sulfuric acid solution, current flow conditions, etc., but processing for 0.5 to 10 hours per 1 L of sulfuric acid solution is preferred in terms of efficiently generating oxidizing active species.
• sulfuric acid of different concentrations may be used at both electrodes.
• a sulfuric acid solution containing oxidizing active species obtained by electrolyzing high-concentration sulfuric acid is effective in promoting the decomposition of the base material of the reinforced composite material, so it is preferable to increase the sulfuric acid concentration on the anode side and decrease the sulfuric acid concentration on the cathode side in order to extend the life of the electrodes.
• Electricity can be procured from a variety of possible devices as a power source for electrolyzing the sulfuric acid solution, but it is preferable to use electricity generated from so-called renewable energy sources such as solar cells.
• electricity generated from so-called renewable energy sources such as solar cells.
• the hydrogen (generated from the cathode) and oxygen (generated from the anode) generated by electrolysis can be collected and converted into electricity or heat.
• the method for supplying the obtained sulfuric acid solution containing the oxidizing active species to a treatment tank for decomposing the base material of the reinforced composite material may be either a method in which the solution is continuously supplied to the treatment tank from an electrolytic device using a pump or the like (continuous method), or a method in which the sulfuric acid solution is circulated in a closed system, and a treatment solution is collected from the system after electrolysis and supplied to the treatment tank (batch method).
• the collected treatment solution may also be combined with a device that can heat, cool, or pressurize it.
• the treatment solution used to treat the reinforced composite material can be reused repeatedly, and can be recovered, the concentration adjusted, and reused as a sulfuric acid solution for electrolysis to generate oxidizing active species again.
• the treatment solution containing the oxidizing active species is preferably heated to enhance the decomposition of the matrix of the reinforced composite material.
• the heating temperature depends on the boiling point of the treatment solution, but it is preferable to heat the treatment solution to a temperature of 100° C. or higher in order to efficiently decompose the matrix of the reinforced composite material in a short period of time.
• acids other than sulfuric acid such as hydrochloric acid and nitric acid, may be mixed.
• a method of lining up the edges of a container, piping, cooling pipes, etc., and/or a method of quickly draining and removing the acid solution using a roller or bar are preferably used.
• a system for recovering reinforcing materials from composite materials and using the carbon dioxide generated during the recovery as an industrial raw material The system of this embodiment for recovering reinforcing materials from composite materials and utilizing the carbon dioxide generated during the recovery as an industrial raw material separates neutral gases such as oxygen and nitrogen from the decomposition gas generated during the recovery using a separation membrane or an acidic gas absorption system, and utilizes the carbon dioxide as an industrial raw material.
• reinforced composite materials were produced under the following conditions, and the reinforcing material was then separated and recovered.
• a CFRP pressure tank was used as the composite material.
• the CFRP pressure tank was created by applying epoxy resin to a reinforcing material and winding it around a core material using a filament winder. The pressure tank was then cured at 150°C for 30 minutes to create the pressure tank.
• ⁇ Epoxy resin Epicoat 828 (manufactured by Japan Epoxy Resins Co., Ltd.) 20 parts by weight Epicoat 834 (manufactured by Japan Epoxy Resins Co., Ltd.) 20 parts by weight Epicoat 1001 (manufactured by Japan Epoxy Resins Co., Ltd.) 25 parts by weight Epicoat 154 (manufactured by Japan Epoxy Resins Co., Ltd.) 35 parts by weight Hardener: DICY7 (manufactured by Japan Epoxy Resins Co., Ltd.) 4 parts by weight Hardener: Omicure 24 (manufactured by PTI Japan Co., Ltd.) 5 parts by weight Polyvinyl formal: Vinylec K (manufactured by Chisso Corporation) 5 parts by weight Reinforcement material Carbon fiber: Torayca T700SC-12K-50C (manufactured by Toray Industries, Inc.)
• a blank test was performed in the same manner, and the amount of strongly acidic functional groups was calculated from the difference in the titration amount from the blank test.
• (2) Measurement of Strong Acidic Functional Group Concentration 30 mL of 0.05 mol/L sodium bicarbonate aqueous solution was added to 1 g of sample, and the container was sealed. After shaking for 4 hours using a shaker, the container was left to stand for 8 hours or more. 15 mL of the supernatant was titrated with 0.05 mol/L hydrochloric acid.
• a blank test was performed in the same manner, and the amount of strongly acidic functional groups was calculated from the difference in the titration amount from the blank test.
• the interfacial shear strength was measured by a microdroplet test.
• the fibers were fixed on a dedicated mount, and the fiber diameter was measured using an optical microscope (Keyence Corporation, Digital Microscope V-HX6000).
• the surface treatment method of the reinforcing material was the electrolytic sulfuric acid method 1. Specifically, a diamond electrode with an electrode area of 700 cm2 was used, and a 50% aqueous sulfuric acid solution was electrolyzed in a diaphragm-type electrolysis cell while the electrode was water-cooled to produce a treatment solution containing oxidizing active species. The amount of treatment solution (aqueous sulfuric acid solution) electrolyzed in one run was 10 L. The current was 3-10 A/ cm2 , the voltage was 170-200 V, and the treatment time was 120 minutes. The electric field was applied in a closed system while circulating with a pump.
• the total acidic functional group concentration of the obtained reinforcing material was 1.8 mmol/g, and the strong acidic functional group concentration was 0.8 mmol/g.
• the carbon fibers were obtained in the form of continuous fibers.
• the interfacial shear strength with the epoxy resin was 39 MPa, and cohesive failure of the resin beads occurred, leaving the resin in a fibrous form.
• the opening of the continuous fibers was good. It was not possible to open short fibers obtained by cutting the continuous fibers into 1 cm pieces.
• Example 2 The method for separating and recovering the reinforcing material from the reinforced composite material was the electrolytic sulfuric acid method 2.
• the electrolytic sulfuric acid solution was prepared in the same manner as in Example 1.
• One pressure tank (120 kg) was immersed in 60 L of the prepared electrolytic sulfuric acid solution, and then the reinforced composite material was immersed at 120° C. for 10 hours to decompose the base material of the reinforced composite material.
• the acid solution was quickly drained and removed by passing it through a roller, and the reinforcement was washed with water, dried, and wound around a core as a continuous fiber.
• the time from the start of the immersion treatment to the completion of draining and rinsing was 12 hours.
• the total acidic functional group concentration of the resulting recycled reinforcing material was 1.4 mmol/g, and the strong acidic functional group concentration was 0.6 mmol/g.
• the carbon fibers were recovered in the form of continuous fibers.
• the interfacial shear strength with the epoxy resin was 36 MPa, and cohesive failure of the resin beads occurred, leaving the resin in a fibrous form.
• the opening of the continuous fibers was good. It was not possible to open short fibers obtained by cutting the continuous fibers into 1 cm pieces.
• Example 3 The method for separating and recovering the reinforcing material from the reinforced composite material was the electrolytic sulfuric acid method 3.
• the electrolytic sulfuric acid solution was prepared in the same manner as in Example 1. 10 L of commercially available 30% hydrogen peroxide solution (manufactured by FUJIFILM Wako Pure Chemical Industries, Ltd.) was added to 50 L of the prepared electrolytic sulfuric acid solution, and one pressure tank (120 kg) was immersed in the treatment solution, and then the reinforced composite material was immersed and treated at 120° C. for 5 hours to decompose the base material of the reinforced composite material.
• the acid solution was quickly drained and removed by passing through a roller, and the reinforcement was washed with water, dried, and wound around a core as a continuous fiber.
• the time from the start of the immersion treatment to the completion of draining and rinsing was 12 hours.
• the total acidic functional group concentration of the resulting regenerated reinforcing material was 2.2 mmol/g, and the strong acidic functional group concentration was 1.2 mmol/g.
• the carbon fibers were recovered in the form of continuous fibers.
• the interfacial shear strength with the epoxy resin was 46 MPa, and cohesive failure of the resin beads occurred, leaving the resin in a fibrous form.
• the opening of the continuous fibers was good. It was not possible to open short fibers obtained by cutting the continuous fibers into 1 cm pieces.
• Example 4 The method for separating and recovering the reinforcing material from the reinforced composite material was the electrolytic sulfuric acid method 4.
• the electrolytic sulfuric acid solution was prepared in the same manner as in Example 1. 10 L of commercially available 30% hydrogen peroxide solution (manufactured by FUJIFILM Wako Pure Chemical Industries, Ltd.) was added to 50 L of the prepared electrolytic sulfuric acid solution, and one pressure tank (120 kg) was immersed in the treatment solution, and then the reinforced composite material was immersed and treated at 120° C. for 5 hours to decompose the base material of the reinforced composite material.
• the acid solution was quickly drained and removed by passing through a roller, and the reinforcement was washed with water, dried, and wound around a core as a continuous fiber.
• the time from the start of the immersion treatment to the completion of draining and rinsing was 18 hours.
• the total acidic functional group concentration of the resulting regenerated reinforcing material was 4.0 mmol/g, and the strong acidic functional group concentration was 2.0 mmol/g.
• the carbon fibers were recovered in the form of continuous fibers.
• the interfacial shear strength with the epoxy resin was 49 MPa, and cohesive failure of the resin beads occurred, leaving the resin in a fibrous form.
• the opening of the continuous fibers was good.
• the continuous fibers were cut into short fibers of 1 cm length, but the fibers could not be opened.
• Example 5 The method for separating and recovering the reinforcing material from the reinforced composite material was the concentrated sulfuric acid method 1.
• One pressure tank (120 kg) was immersed in 60 L of commercially available 95% sulfuric acid (manufactured by FUJIFILM Wako Pure Chemical Industries, Ltd.), and the reinforced composite material was then immersed in the treatment at 120° C. for 24 hours to decompose the base material of the reinforced composite material.
• the acid solution was quickly drained and removed by passing through a roller, the reinforcement was washed with water, dried, and wound around a core as a continuous fiber.
• the time from the start of the immersion treatment to the completion of draining and rinsing was 12 hours.
• the total acidic functional group concentration of the resulting regenerated reinforcing material was 0.5 mmol/g, and the strong acidic functional group concentration was 0.3 mmol/g.
• the carbon fibers could be recovered in the form of continuous fibers.
• the interfacial shear strength with the epoxy resin was 26 MPa, and cohesive failure of the resin beads occurred, leaving the resin in a fibrous form.
• the opening of the continuous fibers was good. It was not possible to open short fibers obtained by cutting the continuous fibers into 1 cm pieces.
• Example 6 Concentrated sulfuric acid method 2 was used to separate and recover the reinforcing material from the reinforced composite material. 10 L of commercially available 30% hydrogen peroxide solution (manufactured by FUJIFILM Wako Pure Chemical Industries, Ltd.) was added to 50 L of commercially available 95% sulfuric acid (manufactured by FUJIFILM Wako Pure Chemical Industries, Ltd.), and one pressure tank (120 kg) was immersed in the treatment solution, and then the reinforced composite material was immersed and treated at 120°C for 12 hours to decompose the base material of the reinforced composite material.
• the acid solution was quickly drained and removed by passing it through a roller, and the reinforcement material was washed with water, dried, and wound around a core as a continuous fiber.
• the time from the start of the immersion treatment to the completion of draining and rinsing was 12 hours.
• the total acidic functional group concentration of the resulting regenerated reinforcing material was 0.8 mmol/g, and the strong acidic functional group concentration was 0.4 mmol/g.
• the carbon fibers were recovered in the form of continuous fibers.
• the interfacial shear strength with the epoxy resin was 29 MPa, and cohesive failure of the resin beads occurred, leaving the resin in a fibrous form.
• the opening of the continuous fibers was good. It was not possible to open short fibers obtained by cutting the continuous fibers into 1 cm pieces.
• Example 7 The method for separating and recovering the reinforcing material from the reinforced composite material was a concentrated nitric acid method.
• One pressure tank 120 kg was immersed in 60 L of commercially available 90% nitric acid (manufactured by FUJIFILM Wako Pure Chemical Industries, Ltd.), and the reinforced composite material was then immersed in the treatment at 120° C. for 48 hours to decompose the base material of the reinforced composite material.
• the acid solution was quickly drained and removed by passing through a roller, the reinforcement was washed with water, dried, and wound around a core as a continuous fiber.
• the time from the start of the immersion treatment to the completion of draining and rinsing was 12 hours.
• the total acidic functional group concentration of the resulting regenerated reinforcing material was 0.4 mmol/g, and the strong acidic functional group concentration was 0.2 mmol/g.
• the carbon fibers were recovered in the form of continuous fibers.
• the interfacial shear strength with the epoxy resin was 22 MPa, and cohesive failure of the resin beads occurred, leaving the resin in a fibrous form.
• the opening of the continuous fibers was good. It was not possible to open short fibers obtained by cutting the continuous fibers into 1 cm pieces.
• the carbon fibers became tangled and could not be recovered in the form of continuous fibers.
• the interfacial shear strength with the epoxy resin was 15 MPa, and the resin beads and fibers were peeled off, with no resin remaining in the fibers.
• the short fibers having a length of 1 cm were easily opened.
• the reinforcing material was separated and recovered from the reinforced composite material using an electrolytic sulfuric acid method 5.
• the electrolytic sulfuric acid solution was prepared in the same manner as in Example 1.
• One pressure tank (120 kg) was immersed in the prepared electrolytic sulfuric acid solution (60 L), and then the reinforced composite material was immersed at 120° C. for 10 hours to decompose the base material of the reinforced composite material.
• the acid solution was not quickly drained off and the material was left for one day. Thereafter, the reinforcement was washed with water, dried, and wound around a core as a continuous fiber.
• the time from the start of the immersion treatment to the completion of draining and rinsing was 30 hours.
• the total acidic functional group concentration of the resulting regenerated reinforcing material was 5.0 mmol/g, and the strong acidic functional group concentration was 2.5 mmol/g.
• the carbon fibers were recovered in the form of continuous fibers.
• the interfacial shear strength with the epoxy resin was 46 MPa, and cohesive failure of the resin beads occurred, leaving the resin in a fibrous form. It was not possible to open the continuous fibers. It was not possible to open short fibers obtained by cutting the continuous fibers into 1 cm pieces.
• the reinforcing material was separated and recovered from the reinforced composite material using an electrolytic sulfuric acid method 6.
• the electrolytic sulfuric acid solution was prepared in the same manner as in Example 1.
• One pressure tank (120 kg) was immersed in the prepared electrolytic sulfuric acid solution (60 L), and then the reinforced composite material was immersed at 120° C. for 10 hours to decompose the base material of the reinforced composite material.
• the acid solution was not quickly drained off and the material was left for one day or more. Thereafter, the reinforcement was washed with water, dried, and wound around a core as a continuous fiber.
• the time from the start of the immersion treatment to the completion of draining and rinsing was 3 hours.
• the total acidic functional group concentration of the resulting regenerated reinforcing material was 0.2 mmol/g, and the strong acidic functional group concentration was 0.05 mmol/g.
• the carbon fibers were recovered in the form of continuous fibers.
• the interfacial shear strength with the epoxy resin was 15 MPa, and the resin beads and fibers were peeled off, with no resin remaining in the fibers.
• the opening of the continuous fibers was good. The short fibers having a length of 1 cm were easily opened.
• Anodization was performed for 3 hours at an applied voltage of 4.5 V and a current density of 0.21 A/m2. The distance between the electrodes was 40 mm.
• the electrolyte after anodization was put into a tank equipped with a stirring blade and stirred at high speed to crush the embrittled epoxy resin into small pieces.
• the resulting slurry was filtered through a stainless steel coarse mesh basket and repeatedly washed with water to remove the epoxy resin residue.
• the recovered carbon fibers remaining on the mesh were neutralized and washed, and then dried at 150°C for 2 hours.
• the total acidic functional group concentration of the resulting regenerated reinforcing material was 0.4 mmol/g, and the strong acidic functional group concentration was 0.1 mmol/g.
• the carbon fibers could not be recovered in the form of continuous fibers.
• the interfacial shear strength with the epoxy resin was 18 MPa, and the resin beads and fibers were peeled off, with no resin remaining in the fibers.
• the short fibers having a length of 1 cm were easily opened.
• the surface of the composite material has sufficient functional groups, resulting in high adhesive strength with the resin, and good fiber opening, allowing the reinforcing material to be uniformly dispersed in the base material. This makes it possible to provide a reinforcing material suitable for the production of high-strength reinforced composite materials.

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