An ultrahigh strength carbon fiber having a surface layer having a crystalline completeness which is substantially the same as or higher than that of the central region of the fiber, and a functional group amount ratio (Ols /Cls) (O1s /C1s) of 0.1 to 0.4 as detected in the fiber surface by X-ray photoelectron spectroscopy, the surface layer preferably having an ultrathin outermost layer having a lower crystalline completeness than the central region of the fiber.
|
1. A process for producing an ultrahigh strength carbon fiber, which comprises the steps of:
electrochemically oxidizing an acrylic precursor based carbon fiber in an electrolyte solution comprising nitrate ions as the indispensable component and maintained at a temperature of at least 40°C with an anode being said acrylic precursor based carbon fiber with a quantity of electricity of about 100 50 to 600 coulomb per gram of said fiber, followed by water washing and drying; heating the electrochemically oxidized carbon fiber in an inert or reductive atmosphere of about 600° to 1,000°C to remove functional groups from said electrochemically oxidized carbon fiber.
2. A process for producing an ultrahigh strength carbon fiber as set forth in claim 12 1, wherein said acrylic precursor based on carbon fiber has an average filament strength of at least about 380 400 kg/mm2.
3. A process for producing an ultrahigh strength carbon fiber as set forth in
4. A process for producing an ultrahigh strength carbon fiber as set forth in
5. A process for producing an ultrahigh strength carbon fiber as set forth in
|
|||||||||||||||||||||||||||||||||||||||
This (Ols /Cls) (O1s /C1s) detected by X-ray photoelectron spectroscopy is 0.1 to 0.4, preferably 0.15 to 0.3, more preferably 0.20 to 0.25, while the amount of heat-decomposable organic components being 0.05 to 0.5% by weight, preferably 0.1 to 0.4% by weight, more preferably 0.15 to 0.30% by weight. Also, the carbon fiber of this invention should preferably have an average filament strength of at least 480 kg/mm2, preferably 500 kg/mm2 or more, more preferably 530 kg/mm2 or more. When these requirements are satisfied, there appears an advantageous feature that, not only the mechanical strength of the carbon fibers is largely reflected on an improvement in the strength of the composite material prepared therefrom, but also the strength of the composite material does not vary depending on the kind of a matrix resin constituting the composite material, namely the composite material has little resin dependency.
The term "crystalline completeness" as used herein refers to a property indicative of crystallinity as determined in terms of the size of crystallites constituting the carbon fiber and regularity of arrangement of graphite basal planes. It is said that, as the crystalline completeness is higher, crystals are larger in size and higher in regularity of arrangement of carbon network.
The carbon fiber of this invention "with a surface layer region having substantially the same level of crystalline completeness as the central region of the fiber and an ultrathin outermost layer lower in the crystalline completeness than that in the above-mentioned central region of the fiber" is of a novel structural feature provided, for the first time, by a novel process for producing a carbon fiber according to the present invention but neither by the conventionally known electrolysis treatment nor by the conventionally known combination of the etching treatment with a conc. inorganic acid and the heat treatment in an inert atmosphere.
More specifically, the usual electrolysis treatment only generates functional groups on the surface of a carbon fiber to substantially improve the ILSS, but never forms a fiber structure "with the surface layer region having substantially the same level of the crystalline completeness as the central region of the fiber and an ultrathin outermost layer lower in the crystalline completeness than that in the above-mentioned central region of the fiber" as found in the carbon fiber of this invention. Accordingly, this treatment can improve neither the tensile strength of the carbon fiber itself nor the tensile strength of a composite material prepared therefrom. Additionally stated, when such severe conditions of the electrolysis treatment as will provide poorer crystalline completeness for the ultrathin surface layer region of a carbon fiber than that in the central region of the carbon fiber, for example, use of an extremely large quantity of electricity, is adopted, the amount of functional groups as detected in the surface of the carbon fiber obtained by X-ray photoelectron spectroscopy becomes large, the translation of the carbon fiber strength in a composite material prepared from the carbon fiber largely lowers, and the resin dependency increases. Thus superior effects as achieved in the present invention cannot be obtained.
The carbon fiber obtained by the etching treatment with a conc. inorganic acid, followed by a heat treatment in an inert atmosphere tends to lose the crystalline completeness not only in the surface region of the fiber but also up to the deep inner region thereof upon etching on the surface of the fiber (in other words, to have a larger (thicker) area of the surface layer region poorer in the crystalline completeness than the central region of the fiber), and to have incomplete inactivation because to a difficulty encountered in inactivating the whole region of the fiber surface layer (in other words, to be insufficiently stripped of functional groups in the whole region having an incomplete crystallinity). Thus, the content of heatdecomposable organic components in the carbon fiber obtained is high as compared with that of the carbon fiber of the present invention.
In the combination of the etching treatment with a conc. inorganic acid and the subsequent inactivation treatment, it may be possible to adopt an etching treatment condition under which the carbon fiber does not lose the crystalline completeness up to the deep inner layer region of the fiber. In this case, however, surface flaws of the carbon fiber cannot be effectively eliminated through the purpose of the etching treatment is removal of scratches. On the other hand, in order to inactivate the whole region having a damaged crystalline completeness and extending to the deep inner layer by removing functional groups therefrom, a severe inactivation treatment condition is required, which, however, may lower the mechanical strength of the carbon fiber itself. Thus, such a condition cannot provide an ultrahigh strength carbon fiber having an average filament strength of 480 kg/mm2 or more, and rather leads to loss of the function of the carbon fiber as reinforcing fiber for a composite material prepared therefrom. As described above, the structural feature of the carbon fiber of this invention comprising a surface layer region having substantially the same level of the crystalline completeness as that in the central region of the carbon fiber and an ultrathin outermost layer easily stripped of functional groups cannot be obtained by the foregoing combination of the etching treatment with a conc. inorganic acid and the subsequent inactivation treatment, which, therefore, cannot provide the effects of the carbon fiber of this invention on an improvement of the utility of carbon fiber strength in a composite material and the decrease of resin dependency.
The crystalline completeness in any of the central region of the fiber, the surface layer region of the fiber, and the ultrathin outermost layer of the surface layer region is measured by transmission electron diffractometry (TEM). Specifically, as will be described later, the crystalline completeness in the surface layer region of the fiber or the ultrathin outermost layer of the surface layer region is compared with that in the central portion of the fiber, which is used as a standard. In this invention, by comparison, the surface layer region shows substantially the same level of the crystalline completeness as that in the central region of the fiber, and the ultrathin outermost layer of the surface layer region shows a poorer crystalline completeness than that in the central region of the fiber. According to the measurement method described later, the surface layer region is a layer of about 1.5 microns or less on the average in thickness measured from the surface of the carbon fiber, and the ultrathin outermost layer is a layer of about 0.2 micron or less, preferably 0.1 micron or less on the average in thickness measured from the surface of the carbon fiber.
The term "substantially the same level of the crystalline completeness as that in the central region of the fiber" is intended to mean that the ratio of the crystalline completeness in the surface layer region of the fiber to that in the central region of the fiber is substantially one or more and, in terms of a more precise numerical value, aboput 0.98 or more, preferably 1.0 or more.
The carbon fiber of this invention having an ultrathin outermost layer as described above is desired to have a functional group ratio (Ols /Cls) (O1s /C1s) of 0.1 to 0.4, preferably 0.15 to 0.4, more preferably 0.20 to 0.25 as detected by X-ray photoelectron spectroscopy. As for the heatdecomposable organic components in the carbon fiber which is a parameter indicative of the amount of chemical functional groups present in the surface and inside the carbon fiber, particularly mainly the amount of chemical functional groups present in the above-mentioned ultrathin outermost layer, the carbon fiber of the present invention is desired to have a content of heatdecomposable organic components, of 0.05 to 0.5 wt. %, preferably 0.1 to 0.4 wt. %, more preferably 0.15 to 0.30 wt. % as hereinbefore described. If the content is lower than 0.05 wt. %, the adhesion of a resin to the carbon fiber is unfavorably low. On the other hand, if the content is higher than 0.5%, inactivation of the carbon fiber is insufficient, unfavorably leading to a decrease in the resin-impregnated strand strength and an increase in the resin dependency. Namely, when the amount of functional groups in the surface layer region of the carbon fiber subjected to the treatment for removal of functional groups is outside the range specified above in the above-mentioned terms, a carbon fiber having a high resin-impregnated strand strength cannot be obtained.
Here, the carbon fiber of this invention has an excellent mechanical property, namely an average filament strength of at least 480 kg/mm2 preferably 500 kg/mm2, or more, especially preferably 530 kg/mm2 or more. As will be described later, a fiber property of at least 480 kg/mm2 in average filament strength can be obtained for the first time by formation of a fiber surface layer region having a structural feature of an ultrathin outermost layer as in the carbon fiber of this invention. With an extremely high mechanical property of 480 kg/mm2 in average filament strength, the carbon fiber of this invention has a largely improved usefulness as the reinforcing fiber for a composite material and as the carbon fiber for a reinforced materials.
The process for producing a carbon fiber according to the present invention will now be specifically described in detail.
In the present invention, "carbon fibers formed from acrylic precursors" means a carbon fiber obtained from a precursor fiber prepared from a homopolymer or copolymer comprising acrylonitrile monomer units as the main component.
According to the invention, carbon fiber is produced by a process which differs from each of the two conventional methods, one operating an electrolysis treatment for forming functional groups on surfaces of carbon fibers so as to improve the ILSS, the other operating etching with a concentrated inorganic acid to eliminate surface flaws produced in the process of the carbon fiber manufacture and then heat-treating the etched carbon fiber to remove the functional groups formed on the fiber surface through the etching so as to adjust the adhesion affinity of the carbon fiber toward a matrix resin to be used, and the production of carbon fibers is made according to the invention by operating such an electrolysis treatment which is carried out in an electrolyte aqueous solution containing nitrate ions as essential component, at an elevated temperature and using the carbon fiber as anode, that is to say, it is operated to electrochemically oxidizing the raw material of a carbon fiber so that, with the crystalline completeness of the carbon fiber maintained as much intact as possible, only an extremely limited surface region of the fiber, namely an ultrathin outermost layer thereof alone, is selectively made amorphous, that is to say, formed is a layer in which the crystalline completeness is lower and of which the removal of functional groups can more readily take place, in comparison to the central region in the carbon fiber, and thereafter a heat-treatment is operated to substantially inactivate functional groups formed in such ultrathin outermost layer through the preceding electrochemical oxidation, namely, effect removal of functional groups; in greater detail, according to the invention, an inactivation treatment is operated so as to obtain a value of 0.05 to 0.5% by weight for the content of thermally decomposable organic components and a value within a range of about 0.1 to 0.4 for the ratio (Ols /Cls) (O1s /C1s) to be detected by the X-ray photoelectron spectroscopy, and thereby substantially remove functional groups formed in the ultrathin outermost layer of the fiber.
As a raw material carbon fiber to be subjected to the treating process of the present invention has a higher mechanical strength, the mechanical strength of a carbon fiber obtained is advantageously higher. To obtain a carbon fiber having an average filament strength of at least 480 kg/mm2, preferably 500 kg/mm2 or more, more preferably 530 kg/mm2 or more by the treatment of this invention, the raw material carbon fiber is desired to have, for example, an average filament strength of at least 400 kg/mm2, preferably 450 kg/mm2 or more. If the mechanical strength of the raw material carbon fiber is low, a fiber having an average filament strength of 480 kg/mm2 or more becomes difficult to obtain even though an ultrathin outermost layer as described above is formed by that process. Thus the strength of the raw material carbon fiber to be subjected to the process is desired to be as high as possible.
As the process for producing a raw material carbon fiber of 400 kg/mm2 or more in average filament strength, there is no particular limitation, and there may be used, as a precursor, an acrylonitrile fiber having a high denseness of specifically 5 to 45, preferably 10 to 30, in terms of the iodine adsorption level (ΔL) as later to be described. To obtain the above-mentioned precursor, there may be used a dry-jet wet spinning method which comprises extruding an acrylonitrile (hereinafter abbreviated as "AN")- based polymer into air an inert atmosphere, and subsequently introducing the extruded filament; into a coagulation bath to coagulate it. The coagulated fiber obtained by the method may be washed with water, stretched and treated with a silicone lubricant, followed by drying. The resulting fiber, which has a smooth surface and a high denseness, is advantageously employed for the process of this invention.
The condition of oxidation and the carbonization condition are preferably so set as to provide a carbon fiber having a few structural defects such as surface flaws, internal voids, impurities and residual stress etc.
Since the acrylic precursors are converted to carbon fibers under extremely severe conditions, the structural defects are likely, especially when the fibers are exposed to a rapid temperature rise in the process of a higher temperature treatment. Thus, the carbonization conditions are advantageously set so as to avoid the structural defects. For example, the temperature rising rate is advantageously set to be about 1,000° C./min or less, preferably 500°C/min or less in the temperature ranges of from 300° to 700°C and from 1,000° to 1,200°C for carbonization, though it is not limited to the above-mentioned range.
The raw material carbon fiber thus obtained is subjected to an electrochemical oxidation treatment in an electrolyte aqueous solution containing nitrate ions as the indispensable component. To restrict oxidation of the carbon fiber only to a very thin surface layer region as much as possible and avoid its expansion to the inner layer region, the following treatment conditions are preferred. The nitrate ion concentration is preferably 0.1 to 16 Normal (N), more preferably 1 to 11 N. The electrolyte temperature is preferably 40° to 120°C, more preferably 50° to 100°C The quantity of electricity in the electrolysis treatment is 50 to 600 coulomb, preferably 100 to 500 coulomb per gram of the fiber. The treatment time is preferably 0.05 to 10 min, more preferably 0.1 to 3 min.
As the electrolyte solution containing nitrate ions as the indispensable component, there can be mentioned an aqueous nitric acid solution, and solutions of a nitrate(s) capable of generating nitrate ions in a solution, such as ammonium nitrate, sodium nitrate, aluminum nitrate, potassium nitrate, or calcium nitrate.
Where any one of the electrolyte concentration, the electrolyte temperature, the treatment time, and the quantity of electricity is below the above-mentioned lower limit, the defects and residual stress in the surface layer region of the carbon fiber may not be effectively decreased nor removed by the electrochemical oxidation treatment. Where it is above the abovementioned upper limit, the oxidation may advance to the inner layer region of the carbon fiber, and hence the layer having functional groups formed by the oxidation and having a poorer crystalline completeness than that in the central region of the fiber (namely, a layer corresponding to the "ultrathin outermost layer" in the carbon fiber of this invention) becomes thick, leading to a difficulty in inactivation or removel of the functional groups in this layer.
The carbon fiber subjected to the oxidation treatment is, after washing with water and drying, subjected to a heating treatment in an inert atmosphere of nitrogen, helium, argon, or the like, or in a reducing atmosphere of hydrogen, a hydrogen compound and a metal vapor or the like at a high temperature of, for example, 600° to 1000°C, preferably 650° to 850°C for 0.1 to 10 min, preferably 0.2 to 2 min. to inactivate the functional groups formed in the ultrathin outermost layer of the fiber by the above-mentioned electrochemical oxidation treatment, whereby the content of heatdecomposable organic components in the carbon fiber obtained may be 0.05 to 0.5 wt. %, preferably 0.1 to 0.4 wt. %, more preferably 0.15 to 0.30 wt. % and the Ols /Cls O1s /C1s ratio of the carbon fiber as detected by X-ray photoelectron spectroscopy is about 0.1 to 0.4, preferably 0.15 to 0.3, more preferably 0.20 to 0.25.
Where the heating temperature and heating time in the inactivation treatment is outside the above-mentioned ranges, inactivation of the ultrathin outermost layer for substantially removing functional groups in that layer may be so insufficient that the content of heat-decomposable organic materials and the Ols /Cls O1s /C1s ratio as detected by X-ray photoelectron spectroscopy may tend to be outside the above-mentioned ranges. Thus a carbon fiber obtained shows a small large resin dependency, or the mechanical strength of the carbon fiber may disadvantageously be lowered by the inactivation.
In the present invention, the above-mentioned electrochemical oxidation treatment and the functional group removing treatment may be repeated at least twice.
Thus the surface layer region formed on the surface of the carbon fiber of this invention shows substantially the same level of crystalline completeness as measured by transmission electron diffractometry (TEM) as compared with the central region in the fiber, specifically a ratio of the crystalline completeness in the fiber surface layer region to that in the fiber central region of about 0.98 or more, preferably 1.0 or more. The ultrathin outermost layer on the surface layer region of the carbon fiber of this invention thus obtained shows a poorer crystalline completeness than that in the fiber central region, specifically a ratio of the crystalline completeness in the ultrathin outermost layer to that in the central region of 1.0 or less, preferably 0.98 or less, more preferably 0.96 or less.
In addition, the amount of heat-decomposable organic components in the carbon fiber thus obtained is in the range of 0.05 to 0.5 wt. %, preferably 0.1 to 0.4 wt. %, more preferably 0.15 to 0.30 wt. %, and the functional group amount ratio (Ols /Cls) (O1s /C1s) as detected in the outermost layer of the carbon fiber by X-ray photoelectron spectroscopy (XPS) is in the range of 0.10 to 0.40, preferably 0.15 to 0.30, more preferably 0.20 to 0.25.
The transmission electron diffractometry (TEM), the determination of the amount of heat-decomposable organic components in the carbon fiber and the X-ray photoelectron spectroscopy (XPS) are made in accordance with the following respective procedures.
Sample filaments of a carbon fiber are put in order in the direction of fiber axis, and embedded in a cold-setting epoxy resin, which is then cured.
The cured carbon fiber-embedded block is subjected to trimming to expose at least 2 to 3 filaments of the carbon fiber. Subsequently, a longitudinal ultrathin slice of 150 to 200 angstroms (Å) in thickness is prepared using a microtome equipped with a diamond knife. This ultrathin slice is mounted on a gold-coated microgrid, and subjected to electron diffractometry with a high resolution electron microscope. In this case, an electron diffraction pattern from a given portion is examined by selected area electron diffractometry for detecting a structural difference between the inner and outer portions of the carbon fiber.
The electron diffraction photograph ranging from the edge of the above-mentioned ultrathin slice to the core thereof is taken using an electron microscope model H-800 (transmission type) manufactured by Hitachi Limited with an accelerating voltage of 200 KV and with a selected area aperture which selects an area of 0.2 μm in diameter at the specimen. FIGS. 1A and 1B show a photograph and a type diagram taken thereof, respectively, of the electron diffraction pattern thus taken.
Subsequently, a scanning profile of diffraction intensity in the equatorial direction as to (002) in the electon diffraction pattern as shown in FIG. 1A is prepared using a densitometer manufactured by Rigaku Denki K.K. FIG. 2 is a diagram showing an example of the diffraction intensity scanning profile shown in FIG. 1A.
The photograph is taken of an about 0.1 micron-deep portion of the ultrathin outermost layer extending from the surface of the fiber, precisely with half the selected area of 0.2 μm in diameter covered by the ultrathin outermost layer and the remaining half not covered by the fiber. As for the surface layer portion, the electron diffraction photograph is taken of the portion up to about 1.5 micron, preferably in the range of 0.3 to 1.0 micron, from the surface of the fiber. As for the central portion or region of the fiber, the electron diffraction photograph is taken of the portion around the approximate center of the fiber. As to (002) in these electron diffraction patterns, the respective scanning profiles of diffraction intensity in the equatorial direction are prepared. Half value widths in these scanning profiles are determined. The reciprocal of a half value width is a parameter of the crystalline completeness. Thus the ratios of the reciprocals of the half value widths of the ultrathin outermost layer and the surface layer region, respectively, to the reciprocal of the half value width of the fiber central region are determined.
FIGS. 2 and 3 show examples of measured charts of scanning profiles of diffraction intensity in the equatorial direction as to (002) in electron diffraction patterns, which charts were obtained using the abovementioned electron diffraction photographs, and are used in determining half value widths from the scanning profiles.
In a measured chart, the middle points of noise widths in a scanning profile are taken to prepare a smooth scanning profile. As shown in FIGS. 2 and 3, a baseline is drawn, and a half value width is determined from a smoothened diffraction peak and the baseline according to the customary method. Particularly where the point corresponding to half the peak height is lower than a peak trough as in FIG. 3, a diffraction peak line is extended to find a half value width.
The surface layer portion of the carbon fiber of this invention is up to about 1.5 micron in thickness from the fiber surface, preferably in the range of from 0.3 to 1 micron from the fiber surface, more strictly 1/3 or less the radius of the carbon fiber and 1.5 micron or less in thickness from fiber surface. As the diameter of the fiber is decreased, the thickness of the surface layer portion is, of course, decreased.
About 20 mg of a carbon fiber (sample) is cleaned with a solvent to remove a sizing, etc. adhering to the fiber surface, and subjected to a measurement using a CHN-Corder Model MT-3 manufactured by Yanagimoto Seisakusho under the following conditions:
In the CHN-Corder, the temperature is elevated to 950°C in a sample combustion furnace, to 850°C in an oxidation furnace, and to 550°C in a reduction furnace. Helium is allowed to flow into the Corder at a rate of 180 m/l min ml/min. The above-mentioned cleaned carbon fiber is accurately weighed and introduced into the sample combustion furnace.
Part of a decomposition gas in the sample combustion furnace is drawn out via the oxidation furnace and the reduction furnace by a suction pump for 5 min, and determined in terms of CO2 amount by the thermal conductivity type detector of the CHN-Corder. The heatdecomposable organic components content are found in terms of content (wt. %) of C derived from the heat-decomposable organic components in the sample by calibration. The feature of this measuring technique resides in that the determination of heat-decomposable organic substances such as CO, CO2, CH4, etc. in a carbon fiber can be made by heating the carbon fiber in an atmosphere of only a helium gas without flowing an oxygen gas in a common C, H, and N element analysis apparatus.
A model ES-200 manufactured by Kokusai Denki K.K. is used.
A carbon fiber (sample) is cleaned with a solvent to remove surface-stuck materials such as a sizing. Subsequently the carbon fiber is cut and spread over a copper sample bed. AlKα1 and 2 are used as the X-ray source. The inside of the sample chamber is maintained at 1*10E(-b 8)1*10E(-8) Torr. The surface oxygen atom to surface carbon atom ratio (Ols /Cls) (O1s /C1s) is found from a ratio of an Ols O1s peak area of 955 eV in kinetic energy to a Cls C1s peak area of 1202 eV in kinetic energy.
The measurement is made in accordance with the filament testing method as stipulated in JIS R-7601. The average of values obtained by repeating the measurement 100 times is taken.
The resin-impregnated strand strength is found in accordance with the resin-impregnated strand testing method as stipulated in JIS R-7601. In the test, the following two kinds of resin formulations A and B and curing conditions therefor are employed and, at the same time, the resin dependency is evaluated.
| ______________________________________ |
| Resin Formulation A: |
| "Bakelite" ERL-4221 100 parts |
| boron trifluoride/monoethylamine |
| 3 parts |
| (BF3 MEA) |
| acetone 4 parts |
| curing conditions: 130°C, 30 min |
| Resin Formulation B: |
| "Epikote" 828 35 parts |
| N,N,N',N'-tetraglycidylaminodiphenylmethane |
| ("ELM" 434) 35 parts |
| "Epiclon" 152 30 parts |
| 4,4'-diaminodiphenyl sulfone |
| 32 parts |
| (DDS) |
| BF3 MEA 0.5 part |
| ______________________________________ |
curing conditions: The carbon fiber is impregnated with a methyl ethyl ketone solution having a resin content of 55%. The resulting impregnated fiber is stripped of the solvent in a vacuum drier at 60°C for about 12 hours, and heated at 180°C for about 2 hours.
The average of values obtained by repeating the strand testing 10 times is taken.
A dried precursor (sample) is cut to about 6 cm in length, opened by a hand card, and accurately weighed to prepared two samples of 0.5 g. One sample is put into a 200 ml Erlenmeyer flask with a ground stopper. 100 ml of an iodine solution (prepared by weighing 50.76 g of I2, 10 g of 2,4-dichlorophenol, 90 g of acetic acid, and 100 g of potassium iodide, putting them into a 1 liter measuring flask, and dissolving them with water to a predetermined volume) is added to the Erlenmeyer flask, and subjected to an adsorption treatment while shaking at 60°±0.5°C for 50 min.
The sample having iodine adsorbed thereon is washed in flowing water for 30 min, and centrifugally dehydrated. The dehydrated sample is further air-dried for about 2 hours, and opened by the hand card again. The sample subjected to iodine adsorption and the one not subjected to this procedure are put in order as to the direction of filaments, and the simultaneously subjected to an L value measurement using a color difference meter. Given L1 and L2 for the L values of the sample not subjected to iodine adsorption and the one subjected to this procedure, respectively, ΔL is defined by (L1 --L2), which indicate a difference between L values before and after iodine adsorption.
The effects of the present invention will be specifically described hereinbelow.
Ammonia was blown into a dimethyl sulfoxide (DMSO) solution of an acrylonitryle copolymer consisting of 99.5 mole % of acrylontrile (AN) and 0.5 mole % of itaconic acid and having an intrinsic viscosity [η] of 1.80 to substitute the terminal hydrogen atoms of carboxyl groups of the copolymer with ammonium groups for effecting modification of the copolymer. Thus a 20 wt. % DMSO solution of the modified copolymer was prepared.
The solution was filtered through a sintered metallic filter having a pore opening of 5μ, extruded into the air through a spinneret having 1,500 holes of 0.15 mm in diameter, run through an about 3 mm-long space of air, and introduced into a 30% aqueous DMSO solution maintained at about 30°C to coagulate extruded fiber filaments. The coagulated fiber filaments were washed with water, and stretched by 4 times in a warm water to obtain water-swollen fiber filaments. The water-swollen fiber filaments were immersed in a mixed lubricant bath of a 0.8% aqueous solution of polyethylene glycol (PEG)-modified polydimethylsiloxane (amount of modifying PEG: 50 wt. %) and a 0.8% aqueous dispersion consisting of 85 parts of amino-modified polydimethylsiloxane (amount of modifying amino: 1 wt. %) and 15 parts of a nonionic surface active agent, and dried on a heating roll having a surface temperature of 130°C to effect densification. The dried and densified fiber filaments were oriented by 3 times in a heated steam to obtain acrylic fiber filaments of 0.8 denier (d) in filament fineness and 1200 D in total denier.
The ΔL of the fiber filaments thus obtained was 25.
Three acrylic fiber filament yarns, each yarn having 1200 D in total denier, were bundled and bundled yarns were subjected to an air opening treatment using a ring nozzle under a pressure of 0.7 kg/cm2, and heated in hot air of 240° to 260°C with a stretching ratio of 1.05 to prepare oxidized fiber filaments having a moisture content of 4.5%.
Subsequently, the oxidized fiber filaments were carbonized in a nitrogen atmosphere having a maximum temperature of 1400°C at a temperature elevating rate of about 250°C/min in a temperature zone ranging from 300°C to 700°C and at a temperature elevation rate of about 400°C/min in a temperature zone ranging 1,000°C to 1,200°C to prepare carbon fiber filaments. The carbon fiber filaments thus obtained were 450 kg/mm2 in average filament strength and 560 kg/mm2 in resinimpregnated strand strength (resin formula A). A longitudinal ultrathin slice of the carbon fiber filament was prepared, and was subjected to a measurement of crystalline completeness by selected area electron diffractometry with respect to the central portion of the fiber, the zone of about 0.1 micron in depth from the fiber surface (zone of the ultrathin outermost layer), and the zone of about 0.4 micron in depth from the fiber surface (zone of the surface layer portion). The ratios of the crystalline completeness in the about 0.1 micron-deep zone and the one in the about 0.4 micron-deep zone to the one in the fiber central portion were found to be 1.05 and 1.03, respectively. Thus the crystalline completeness in the about 0.1 micron-deep zone (the ultrathin outermost layer) was higher than that in the fiber central portion, and the crystalline completeness in the about 0.4 micron-deep zone (the surface layer) was substantially the same as that in the fiber central portion.
The raw material carbon fiber filaments thus obtained were introduced through a ceramic guide into a treatment bath filled with a 5N aqueous nitric acid solution of 80°C in temperature, and continuously run at a rate of 0.3 m/min. Just in front of the treatment bath, there was a metal guide roller, by which a positive voltage was applied to the carbon fiber filaments, and between which and a cathode disposed in the treatment bath an electric current of 0.12A was allowed to flow. Here, the immersion length in the treatment bath for the carbon fiber filaments was about 0.2 m, the treatment time was about 40 sec, and the quantity of electricity per gram of the carbon fiber was 150 coulomb (c).
The carbon fiber filaments thus subjected to the electrochemical oxidation treatment were washed with water, dried in a heated air of about 200°C, and heated in a nitrogen atmosphere of 700°C for about one minute to remove the functional groups in the fiber. The carbon fiber filaments thus obtained were tested and found to be 550 kg/mm2 in average filament strength, and 680 kg/mm2 and 670 kg/mm2 in resin-impregnated strand strength for the resin formulations A and B, respectively.
An ultrathin slice of the carbon fiber filament thus obtained was prepared, and subjected to the same measurement of crystalline completeness as described above with respect to the fiber central portion, and the about 0.1 micron-deep zone and the about 0.4 micron-deep zone from the fiber surface. The ratios of the crystalline completeness in the about 0.1 micron-deep zone and the one in the about 0.4 micron-deep zone to the one in the fiber central portion were found to be 0.92 and 1.03, respectively. Thus the crystalline completeness in the about 0.1 micron-deep zone (the ultrathin outermost layer) was lower than that in the fiber central portion, and the crystalline completeness in the about 0.4 micron-deep zone (the surface layer) was substantially the same as that in the fiber central portion.
About a dozen of carbon fiber filaments shown in Table 1 were prepared by using the same raw material carbon fiber filaments and the same kinds of treatment procedures as in Example 1 under varied electrochemical oxidation conditions in an aqueous nitric acid solution and functional group removing treatment conditions as listed in Table 1.
The results of measurement of mechanical properties and fiber structures of the carbon fiber filaments thus prepared are shown in Table 1.
| TABLE 1 |
| __________________________________________________________________________ |
| Electrochemical oxidation conditions |
| Inactivation conditions |
| Kind of Temperature |
| Concen- |
| Quantity of |
| Time |
| Atmos- |
| Temperature |
| Time |
| No. electrolyte |
| (°C.) |
| tration (N) |
| electricity (C/g) |
| (min) |
| phere |
| (°C.) |
| (min) |
| __________________________________________________________________________ |
| Example 1 |
| nitric acid |
| 80 5 150 0.7 N2 |
| 700 1.0 |
| Comparative |
| nitric acid |
| 30 5 150 0.7 N2 |
| 700 1.0 |
| Example 1 |
| Example 2 |
| nitric acid |
| 50 5 150 0.7 N2 |
| 700 1.0 |
| Example 3 |
| nitric acid |
| 95 5 150 0.7 N2 |
| 700 1.0 |
| Comparative |
| nitric acid |
| 80 0.01 150 0.7 N2 |
| 700 1.0 |
| Example 2 |
| Example 4 |
| nitric acid |
| 80 0.1 150 0.7 N2 |
| 700 1.0 |
| Example 5 |
| nitric acid |
| 80 1 150 0.7 N2 |
| 700 1.0 |
| Example 6 |
| nitric acid |
| 120 15 150 0.7 N2 |
| 700 1.0 |
| Comparative |
| nitric acid |
| 80 5 30 0.7 N2 |
| 700 1.0 |
| Example 3 |
| Example 7 |
| nitric acid |
| 80 5 70 0.7 N2 |
| 700 1.0 |
| Comparative |
| nitric acid |
| 80 5 700 0.7 N2 |
| 700 1.0 |
| Example 4 |
| Comparative |
| nitric acid |
| 80 5 150 0.7 -- -- -- |
| Example 5 |
| Comparative |
| nitric acid |
| 80 5 150 0.7 N2 |
| 500 1.0 |
| Example 6 |
| Example 8 |
| nitric acid |
| 80 5 150 0.7 N2 |
| 600 1.0 |
| Example 9 |
| nitric acid |
| 80 5 150 0.7 N2 |
| 800 1.0 |
| Comparative |
| nitric acid |
| 80 5 150 0.7 N2 |
| 1050 1.0 |
| Example 7 |
| Example 10 |
| ammonium nitrate |
| 80 1 150 0.7 N2 |
| 700 1.0 |
| Example 11 |
| aluminum nitrate |
| 80 2 200 0.7 N2 |
| 700 1.0 |
| Comparative |
| caustic soda |
| 80 5 150 0.7 N2 |
| 700 1.0 |
| Example 8 |
| Example 12 |
| nitric acid |
| 80 5 150 0.7 H2 /N2 |
| 800 1.0 |
| 3/97 |
| __________________________________________________________________________ |
| Average |
| Structural properties |
| Resin-impregnated strand |
| filament |
| Outermost layer/inner |
| Heat decomposable |
| strength (kg/mm2) |
| strength |
| layer crystalline |
| organic components |
| XPS |
| No. Resin formula A |
| Resin formula B |
| (kg/mm2) |
| completeness ratio |
| content (wt. %) |
| [(O1s /C1s)] |
| __________________________________________________________________________ |
| Example 1 |
| 680 670 550 0.92 0.23 0.22 |
| Comparative |
| 580 570 460 1.03 0.11 0.09 |
| Example 1 |
| Example 2 |
| 670 660 520 0.97 0.19 0.20 |
| Example 3 |
| 680 670 540 0.89 0.28 0.24 |
| Comparative |
| 570 580 470 1.01 0.12 0.11 |
| Example 2 |
| Example 4 |
| 620 610 490 0.99 0.14 0.14 |
| Example 5 |
| 660 650 530 0.94 0.19 0.23 |
| Example 6 |
| 640 610 540 0.88 0.33 0.26 |
| Comparative |
| 575 580 460 1.02 0.09 0.09 |
| Example 3 |
| Example 7 |
| 620 620 500 0.96 0.13 0.23 |
| Comparative |
| 450 400 570 0.84 0.52 0.25 |
| Example 4 |
| Comparative |
| 560 530 540 0.90 0.42 0.55 |
| Example 5 |
| Comparative |
| 590 570 550 0.91 0.38 0.42 |
| Example 6 |
| Example 8 |
| 640 620 540 0.93 0.29 0.36 |
| Example 9 |
| 660 660 510 0.92 0.22 0.16 |
| Comparative |
| 510 500 430 0.94 0.13 0.10 |
| Example 7 |
| Example 10 |
| 670 660 530 0.94 0.24 0.23 |
| Example 11 |
| 670 630 540 0.95 0.28 0.25 |
| Comparative |
| 470 480 400 1.01 0.21 0.28 |
| Example 8 |
| Example 12 |
| 690 680 540 0.93 0.20 0.21 |
| __________________________________________________________________________ |
An AN copolymer (intrinsic [η]: 1.80) prepared from 99.5 mol % of AN and 0.5 mol % of itaconic acid was modified with ammonia. A 20 wt. % DMSO solution of the resulting modified copolymer was prepared, and sufficiently filtered. The spinning dope thus obtained was adjusted to 60°C, and extruded through a spinneret having 4,500 holes of 0.05 mm in diameter into a 25% aqueous DMSO solution of 60°C at a take-up rate of 5 m/min at the time of coagulation. The coagulated fiber filaments were washed with water, stretched by 4 times in a heated water. A silicone lubricant was applied to the stretched fiber filaments, which were then dried and densified by contacting with a roller surface heated at 130° to 160°C, and oriented by 3 times in a pressurized steam. Acrylic fiber filament yarn of 0.8 denier (d) in filament fineness, 3600 D in total denier and 42 in ΔL were obtained.
The acrylic fiber filaments were oxidized and carbonized in the same manner as in Example 1 to give carbon fiber filaments, which was 470 kg/mm2 in average filament strength. The ratios of the crystalline completeness in the 0.1 micron-deep zone from the surface (the ultrathin outermost layer) and the one in the 0.4 micron-deep zone from the surface (the surface layer) to the one in the fiber central portion were 1.07 and 1.05, respectively.
The carbon fiber filaments thus obtained was subjected to substantially the same electrochemical oxidation treatment as in Example 1 except that the quantity of electricity was 400 coulomb per gram of the carbon fiber. After water washing and drying, the carbon fiber filaments thus electrochemically oxidized were subjected to the same functional group-removing treatment as in Example 1.
The results of measurement of mechanical properties and fiber structures of the carbon fiber filaments thus treated were as shown in Table 2.
Acrylic fiber filaments of 52 in ΔL were prepared in substantially the same manner as in Example 13 except that the concentration of the coagulation bath and the take-up rate at the time of coagulation were 50% and 18 m/min, respectively.
The acryl fiber filaments obtained were oxidized and carbonized under the same conditions as in Example 1 to prepare carbon fiber filaments, which were 380 kg/mm2 in average filament strength. The ratios of the crystalline completeness in a zone about 0.1 micron-deep from the fiber surface (the ultrathin outermost layer) and the one in a zone about 0.4 micron-deep from the fiber surface (the surface layer) to the one in the fiber central region were 1.05 and 1.03, respectively.
The carbon fiber filaments thus obtained was subjected to the same electrochemical oxidation treatment and functional group-removing treatment as in Example 13. The mechanical properties and structures of the carbon fiber filaments thus treated were examined. The results are shown in Table 2.
| TABLE 2 |
| __________________________________________________________________________ |
| Average |
| Structural properties |
| Resin-impregnated strand |
| filament |
| Outermost layer/inner |
| Heat-decomposable |
| strength (kg/mm2) |
| strength |
| layer crystalline |
| organic components |
| XPS |
| Resin formula A |
| Resin formula B |
| (kg/mm2) |
| completeness ratio |
| content (wt. %) |
| [(O1s /C1s)] |
| __________________________________________________________________________ |
| Example 13 |
| 650 620 540 0.93 0.33 0.22 |
| Comparative |
| 590 570 460 0.89 0.36 0.25 |
| Example 9 |
| __________________________________________________________________________ |
About 20 m each of two kinds of carbon fiber filaments obtained in Example 1 and Comparative Example 9 was wound on a Pyrex glass frame, immersed in 68% conc. nitric acid at 120°C for 45 min, washed with water for about 60 min, and dried in an oven of 120°C for about 30 min. The carbon fiber filaments thus treated was heated in a nitrogen atmosphere in an electric furnace of 700°C for about one minute to remove functional groups.
The results of measurement of mechanical properties and structures of the carbon fiber filaments thus obtained and those obtained in Example 1 are shown in Table 3.
As is apparent from Table 3, both of the two kinds of carbon fibers subjected to the conc. nitric acid treatment and functional group-removing treatment were poor in average filament strength, high in the content heat-decomposable organic components, and large in the resin dependency as demonstrated by the resinimpregnated strand strengths as to the resin formulae A and B as compared with the carbon fiber of this invention obtained in Example 1.
| TABLE 3 |
| __________________________________________________________________________ |
| Average |
| Structural properties |
| Resin-impregnated strand |
| filament |
| Outermost layer/inner |
| Heat-decomposable |
| Raw material |
| strength (kg/mm2) |
| strength |
| layer crystalline |
| organic components |
| XPS |
| carbon fiber |
| Resin formula A |
| Resin formula B |
| (kg/mm2) |
| completeness ratio |
| content (wt. %) |
| [(O1s /C1s)] |
| __________________________________________________________________________ |
| the same as |
| 640 480 520 0.87 0.51 0.28 |
| in Example 1 (0.96) |
| the same as in |
| 570 450 480 0.85 0.55 0.27 |
| Comparative (0.93) |
| Example 9 |
| __________________________________________________________________________ |
| In the column of "Outermost layer/inner layer crystalline completeness |
| ratio", the figures not enclosed by parentheses show the crystalline |
| completeness in the 0.1 μmdeep zone from the fiber surface, while thos |
| enclosed by the parentheses show the crystalline completeness in the 0.4 |
| μmdeep zone from the fiber surface. |
Hiramatsu, Tohru, Higuchi, Tomitake, Matsuhisa, Yohji
| Patent | Priority | Assignee | Title |
| 5348802, | Dec 26 1988 | Toray Industries, Inc.; Toray Research Center, Inc. | Carbon fiber made from acrylic fiber and process for production thereof |
| 6019157, | Jan 19 1996 | Kimura Chuzosho Co., Ltd. | Method of regenerating foundry sand |
| Patent | Priority | Assignee | Title |
| 3657082, | |||
| 3746560, | |||
| 4070446, | Feb 01 1973 | Sumitomo Chemical Company, Limited | Process for production of carbon fiber |
| 4073869, | Jun 05 1975 | Inmont Corporation | Internal chemical modification of carbon fibers to yield a product of reduced electrical conductivity |
| 4113847, | Sep 01 1975 | SUMIKA-HERCULES CO , LTD , A CORP OF JAPAN | Process for producing carbon fibers |
| 4131644, | Mar 29 1974 | Ube Industries, Inc. | Process for producing carbon fiber |
| 4349523, | Apr 05 1977 | Toray Industries, Inc. | Process for producing carbon fiber of improved oxidation resistance |
| 4555393, | Oct 01 1982 | Bendix Corporation | Method for making carbon microfibers |
| JP5571613, | |||
| JP59187624, |
| Executed on | Assignor | Assignee | Conveyance | Frame | Reel | Doc |
| Jan 18 1989 | Toray Industries, Inc. | (assignment on the face of the patent) | / |
| Date | Maintenance Fee Events |
| Jan 22 1995 | EXP: Patent Expired for Failure to Pay Maintenance Fees. |
| Jul 06 1998 | M185: Payment of Maintenance Fee, 12th Year, Large Entity. |
| Date | Maintenance Schedule |
| Feb 12 1994 | 4 years fee payment window open |
| Aug 12 1994 | 6 months grace period start (w surcharge) |
| Feb 12 1995 | patent expiry (for year 4) |
| Feb 12 1997 | 2 years to revive unintentionally abandoned end. (for year 4) |
| Feb 12 1998 | 8 years fee payment window open |
| Aug 12 1998 | 6 months grace period start (w surcharge) |
| Feb 12 1999 | patent expiry (for year 8) |
| Feb 12 2001 | 2 years to revive unintentionally abandoned end. (for year 8) |
| Feb 12 2002 | 12 years fee payment window open |
| Aug 12 2002 | 6 months grace period start (w surcharge) |
| Feb 12 2003 | patent expiry (for year 12) |
| Feb 12 2005 | 2 years to revive unintentionally abandoned end. (for year 12) |