JP5899669B2 - Method for producing flame-resistant fiber bundle - Google Patents
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本発明は、高性能、高品位な耐炎化繊維束を高い生産性で製造可能な耐炎化繊維束の製造方法に関する。 The present invention relates to a method for producing a flame resistant fiber bundle capable of producing a high performance, high quality flame resistant fiber bundle with high productivity.
アクリル系前駆体繊維束を用いて炭素繊維束を製造する一般的な方法として、アクリル系前駆体繊維束を２００〜３００℃の酸化性雰囲気下で耐炎化処理（耐炎化工程）を行った後、３００〜１０００℃での前炭素化処理（前炭素化工程）を行い、さらに１０００℃以上の不活性ガス雰囲気中で炭素化（炭素化工程）を行う方法が知られている。 After performing a flameproofing treatment (flameproofing process) on an acrylic precursor fiber bundle in an oxidizing atmosphere at 200 to 300 ° C. as a general method for producing a carbon fiber bundle using an acrylic precursor fiber bundle There is known a method of performing a pre-carbonization treatment (pre-carbonization step) at 300 to 1000 ° C. and further performing a carbonization (carbonization step) in an inert gas atmosphere at 1000 ° C. or higher.
上記製造方法のうち、耐炎化工程では、酸化性雰囲気下で前駆体繊維束を熱処理するが、アクリロニトリルを主成分とする前駆体繊維束には、発熱を伴う酸化反応により、耐炎性が付与される。従って、反応に必要な熱を与えつつ、除熱も同時に行うため低温且つ長時間、酸化性雰囲気に晒し反応を進める方式（以下「熱風循環方式」という）が現在主流となっている。しかしながら、この方式では発熱が除熱を上回り、繊維束内部に蓄熱して暴走反応を起こさないように、熱処理温度は２００〜３００℃と低く設定される。このため、所定の耐炎化繊維束を得るには長時間の熱処理が必要である。 Among the above production methods, in the flameproofing step, the precursor fiber bundle is heat-treated in an oxidizing atmosphere, but the precursor fiber bundle mainly composed of acrylonitrile is given flame resistance by an oxidation reaction accompanied by heat generation. The Therefore, a method of proceeding the reaction by exposing it to an oxidizing atmosphere at a low temperature for a long time (hereinafter referred to as a “hot air circulation method”) is currently mainstream because heat removal is simultaneously performed while giving heat necessary for the reaction. However, in this method, the heat treatment temperature is set as low as 200 to 300 ° C. so that heat generation exceeds heat removal and heat is accumulated inside the fiber bundle to cause a runaway reaction. For this reason, long-time heat treatment is required to obtain a predetermined flameproof fiber bundle.
特許文献１には、アクリル系前駆体繊維束を直接加熱体に接触させる方式（以下「接触加熱方式」という）で、熱伝導性の良い加熱体に接触した状態で反応に必要な熱を付与し、反応で生じた熱を接触したロールに逃がして制御する技術が記載されている。 Patent Document 1 gives heat necessary for the reaction in a state where the acrylic precursor fiber bundle is brought into direct contact with the heating body (hereinafter referred to as “contact heating system”) while being in contact with the heating body having good thermal conductivity. However, a technique is described in which heat generated by the reaction is released to the contact roll and controlled.
しかしながら、特許文献１に記載された接触加熱方式は、アクリル系前駆体繊維束を直接加熱体に接触させて耐炎化を進行させるため繊維間の融着が生じ易く、そのため加熱体の温度を徐々に上げていく必要があり、所定の密度に上げるまでに加熱体への接触を一回当たりの接触時間を１秒以下に抑え、１００回以上繰り返す必要がある。この方式で複数錘の処理を実施するには多数のロールを必要とするため、事実上不可能であり、単錘処理装置を並列して実施することになり、生産性に問題があった。 However, in the contact heating method described in Patent Document 1, since the acrylic precursor fiber bundle is directly brought into contact with the heating body to promote flame resistance, fusion between fibers is likely to occur, and therefore the temperature of the heating body is gradually increased. In order to increase the density to a predetermined density, it is necessary to reduce the contact time per heating to 1 second or less and repeat 100 times or more until the density is increased to a predetermined density. Since a large number of rolls are required to carry out the processing of a plurality of spindles by this method, it is practically impossible, and the single spindle processing apparatus is executed in parallel, which causes a problem in productivity.
また接触回数の増加は製造にかかる電気消費量が増大するので好ましくない。しかもこの方式では加熱体への接触と剥離をくり返し行うので、得られる炭素繊維には繊維束からの毛羽発生が多く見受けられる。また二本のロールを対とし、二本のロールの回転軸を完全な平行から微小角ずらすことで、二本のロールの異なる位置に、搬送物の複数回の巻き付けを可能とする方式（ネルソン方式）では同一温度設定の加熱体への接触となるため、反応の制御が難しく融着が起こりやすいという問題があり、強度発現性にも問題があり、さらなる改善が望まれていた。 Also, an increase in the number of contacts is not preferable because the amount of electricity consumed for manufacturing increases. In addition, in this system, contact with the heating body and peeling are repeated, and thus the resulting carbon fiber is often generated with fluff from the fiber bundle. In addition, the two rolls are paired, and the rotation axis of the two rolls is shifted by a small angle from perfect parallel, so that the transported object can be wound multiple times at different positions on the two rolls (Nelson In the system), since the contact is made with the heating body at the same temperature setting, there is a problem that the reaction is difficult to control and fusion is likely to occur, and there is a problem in strength development, and further improvement has been desired.
前記課題は、以下の本発明によって解決される。 The said subject is solved by the following this invention.
本発明は、アクリル系前駆体繊維束に対して酸化性雰囲気中において非接触加熱方式による酸化処理を施し、引き続き、酸化性雰囲気中において接触加熱方式により２つ以上の異なる温度条件で酸化処理を施す、アクリル系前駆体繊維束からの耐炎化繊維束の製造方法である。 In the present invention, the acrylic precursor fiber bundle is subjected to an oxidation treatment by a non-contact heating method in an oxidizing atmosphere, and subsequently subjected to an oxidation treatment by two or more different temperature conditions in the oxidizing atmosphere by a contact heating method. A method for producing a flame-resistant fiber bundle from an acrylic precursor fiber bundle.
本発明によれば、耐炎化の進行状況が均一で単繊維間の融着が防止された耐炎化繊維束を生産性良く提供できる。また、繊維束からの毛羽発生が少ない炭素繊維束を得ることができる。 According to the present invention, it is possible to provide a flame-resistant fiber bundle having a uniform progress of flame resistance and preventing fusion between single fibers with high productivity. In addition, a carbon fiber bundle with less fluff generation from the fiber bundle can be obtained.
以下に本発明を詳細に説明する。 The present invention is described in detail below.
（アクリル系前駆体繊維束）
本発明に用いるアクリル系前駆体繊維束を構成する重合体としては、アクリロニトリル単位９０モル％以上と、アクリロニトリルと共重合可能なビニル系モノマー単位１０モル％以下からなるアクリル系共重合体が好ましい。アクリロニトリルと共重合可能なビニル系モノマーとしては、例えばアクリル酸、メタクリル酸、イタコン酸およびそれらのアルカリ金属塩、アンモニウム塩および低級アルキルエステル類、アクリルアミドおよびその誘導体、アリルスルホン酸、メタリルスルホン酸およびそれらの塩類またはアルキルエステル類などを挙げることができる。アクリル系共重合体中の共重合成分が１０モル％以下であると後述する耐炎化工程で単繊維間接着の発生を抑制する事ができるため好ましい。また、アクリル系共重合体の重合方法は、特に限定されないが、溶液重合法、懸濁重合法、乳化重合法などを適用することができる。
(Acrylic precursor fiber bundle)
The polymer constituting the acrylic precursor fiber bundle used in the present invention is preferably an acrylic copolymer comprising 90 mol% or more of acrylonitrile units and 10 mol% or less of vinyl monomer units copolymerizable with acrylonitrile. Examples of vinyl monomers copolymerizable with acrylonitrile include acrylic acid, methacrylic acid, itaconic acid and their alkali metal salts, ammonium salts and lower alkyl esters, acrylamide and its derivatives, allyl sulfonic acid, methallyl sulfonic acid and Examples thereof include salts or alkyl esters thereof. It is preferable that the copolymerization component in the acrylic copolymer is 10 mol% or less because the occurrence of adhesion between single fibers can be suppressed in the flameproofing step described later. In addition, the polymerization method of the acrylic copolymer is not particularly limited, but a solution polymerization method, a suspension polymerization method, an emulsion polymerization method, and the like can be applied.
アクリル系重合体を紡糸する際に使用する溶媒としては、特に限定されないが、ジメチルスルホキシド、ジメチルアセトアミド、ジメチルホルムアミド、塩化亜鉛水溶液、硝酸などの有機・無機の溶媒を使用することができる。 The solvent used for spinning the acrylic polymer is not particularly limited, and organic and inorganic solvents such as dimethyl sulfoxide, dimethylacetamide, dimethylformamide, an aqueous zinc chloride solution, and nitric acid can be used.
紡糸方法としては、特に限定されないが、湿式紡糸法、乾湿式紡糸法、乾式紡糸法などを適用することができる。湿式紡糸法、乾湿式紡糸法、乾式紡糸法などで得られた凝固糸は、従来公知の水洗、浴延伸、工程油剤付与、乾燥緻密化、スチーム延伸などを行うことにより所定の繊度を有するアクリル系前駆体繊維束とされる。 The spinning method is not particularly limited, and a wet spinning method, a dry wet spinning method, a dry spinning method, and the like can be applied. A coagulated yarn obtained by a wet spinning method, a dry-wet spinning method, a dry spinning method, etc. is an acrylic having a predetermined fineness by performing conventionally known water washing, bath drawing, process oil application, dry densification, steam drawing, etc. A system precursor fiber bundle is used.
工程油剤には、従来公知のシリコーン系油剤やケイ素を含まない有機化合物からなる油剤などを用いることができる。後述する耐炎化工程や前炭素化工程での単繊維間の接着を防止できれば、工程油剤として好適に使用できる。シリコーン系油剤としては、耐熱性の高いアミノ変性シリコーンを含有するものが好ましい。 As the process oil, a conventionally known silicone oil or an oil composed of an organic compound not containing silicon can be used. If adhesion between single fibers in a flameproofing process and a pre-carbonization process described later can be prevented, it can be suitably used as a process oil. As the silicone oil, those containing amino-modified silicone with high heat resistance are preferable.
工程油剤を付与された繊維束は、加熱により乾燥するのが良い。乾燥処理は５０℃以上２００℃以下の温度に設定した加熱ロールに接触させて行うのが効率的である。繊維束の含有水分率が１質量％以下となるまで乾燥し、繊維構造を緻密化させることが好ましい。 The fiber bundle to which the process oil is applied is preferably dried by heating. It is efficient to carry out the drying treatment by contacting with a heating roll set to a temperature of 50 ° C. or higher and 200 ° C. or lower. It is preferable to dry the fiber bundle until the moisture content of the fiber bundle is 1% by mass or less, thereby densifying the fiber structure.
また、乾燥された繊維束は、引き続き延伸を施すことができる。延伸方法としては、特に限定されないが、乾熱延伸法、熱板延伸法、スチーム延伸法などを適用することができる。 Further, the dried fiber bundle can be continuously stretched. The stretching method is not particularly limited, and a dry heat stretching method, a hot plate stretching method, a steam stretching method, and the like can be applied.
アクリル系前駆体繊維束の構成本数としては、好ましくは１０００本以上７００００本以下、より好ましくは１２０００本以上７００００本以下の範囲である。 The number of the acrylic precursor fiber bundles is preferably in the range of 1000 to 70000, more preferably 12000 to 70000.
アクリル系前駆体繊維束の単繊維繊度としては、好ましくは０．６ｄｔｅｘ以上３ｄｔｅｘ以下、より好ましくは０．７ｄｔｅｘ以上２．５ｄｔｅｘ以下、さらに好ましくは０．８ｄｔｅｘ以上２．０ｄｔｅｘ以下である。アクリル系前駆体繊維束の単繊維繊度が０．６ｄｔｅｘ以上３ｄｔｅｘ以下の範囲であれば、得られる炭素繊維の繊維径が適度な大きさとなり、複合材料の強化繊維として用いた場合の圧縮応力下での座屈変形を抑制でき、圧縮強度向上の観点から好ましい。また単繊維繊度がこの範囲であれば、耐炎化工程において焼成斑を起こすことがないため、好ましい。 The single fiber fineness of the acrylic precursor fiber bundle is preferably 0.6 dtex or more and 3 dtex or less, more preferably 0.7 dtex or more and 2.5 dtex or less, and further preferably 0.8 dtex or more and 2.0 dtex or less. When the single fiber fineness of the acrylic precursor fiber bundle is in the range of 0.6 dtex or more and 3 dtex or less, the fiber diameter of the obtained carbon fiber becomes an appropriate size, and under the compressive stress when used as the reinforcing fiber of the composite material. This is preferable from the viewpoint of improving the compressive strength. Moreover, if the single fiber fineness is within this range, firing spots are not caused in the flameproofing step, which is preferable.
（非接触加熱方式による酸化処理）
本発明においてアクリル系前駆体繊維束の耐炎化は、２方式の酸化処理を順次施すことによって行われる。
(Oxidation treatment by non-contact heating method)
In the present invention, the acrylic precursor fiber bundle is made flame resistant by sequentially performing two types of oxidation treatments.
アクリル系前駆体繊維束は、先ず、酸化性雰囲気中において非接触加熱方式による酸化処理を受ける。非接触加熱方式による酸化処理としては、熱風循環方式、赤外線照射方式、蒸気加熱酸化方式等による酸化処理が挙げられる。コスト的な有利さ、均一処理のしやすさの点から熱風循環方式が好ましい。 First, the acrylic precursor fiber bundle is subjected to an oxidation treatment by a non-contact heating method in an oxidizing atmosphere. Examples of the oxidation treatment by the non-contact heating method include oxidation treatment by a hot air circulation method, an infrared irradiation method, a steam heating oxidation method, and the like. The hot air circulation system is preferable from the viewpoint of cost and ease of uniform processing.
熱風循環方式で酸化処理を施す条件としては、例えば、酸化性雰囲気中、２００℃以上３００℃以下の温度、緊張下で、２０分〜９０分程度、加熱処理する条件が採用される。繊維の密度が、好ましくは１．２２ｇ／ｃｍ3以上１．３８ｇ／ｃｍ3以下、より好ましくは１．２４ｇ／ｃｍ3以上１．３６ｇ／ｃｍ3以下となるまで加熱するのがよい。 As a condition for performing the oxidation treatment by the hot air circulation method, for example, a condition of heat treatment in an oxidizing atmosphere at a temperature of 200 ° C. or more and 300 ° C. or less and under tension for about 20 minutes to 90 minutes is employed. Density of the fibers is preferably 1.22 g / cm 3 or more 1.38 g / cm 3 or less, more preferably to heat until the 1.24 g / cm 3 or more 1.36 g / cm 3 or less.
繊維の密度が１．２２ｇ／ｃｍ3以上１．３８ｇ／ｃｍ3以下の範囲であると、後述する接触加熱方式によって耐炎化処理を施す際、高温接触体上での延伸による糸切れを抑制できる。 If the density of the fibers is 1.22 g / cm 3 or more 1.38 g / cm 3 or less of the range, when subjected to flame treatment by contact heating method which will be described later, can be suppressed yarn breakage by stretching on a high temperature contact body .
本発明において酸化性雰囲気としては、空気、酸素、二酸化窒素など公知の酸化性雰囲気を採用できるが、経済性の面から空気が好ましい。 In the present invention, as the oxidizing atmosphere, a known oxidizing atmosphere such as air, oxygen, nitrogen dioxide and the like can be adopted, but air is preferable from the viewpoint of economy.
（接触加熱方式による酸化処理）
引き続き行われる接触加熱方式による酸化処理は、酸化性雰囲気中、緊張下、加熱体の温度を２４０℃以上３７０℃以下の範囲で行うことが好ましい。より好ましくは２６０℃以上３６０℃以下の温度、また、２７０℃以上３５０℃以下の温度に設定することがさらに好ましい。加熱体の温度を２４０℃以上３７０℃以下の範囲とすると、耐炎化反応の進行が適度になり、さらに分解反応の進行を抑制でき、極端な質量減少による歩留まりの低下ならびに糸切れを抑制できるので好ましい。
(Oxidation treatment by contact heating method)
The subsequent oxidation treatment by the contact heating method is preferably carried out in an oxidizing atmosphere under tension in a range of 240 ° C. or more and 370 ° C. or less of the temperature of the heating element. More preferably, the temperature is set to 260 ° C. or higher and 360 ° C. or lower, and more preferably 270 ° C. or higher and 350 ° C. or lower. When the temperature of the heating body is in the range of 240 ° C. or more and 370 ° C. or less, the progress of the flameproofing reaction becomes moderate, the progress of the decomposition reaction can be suppressed, and the yield reduction and yarn breakage due to the extreme mass reduction can be suppressed. preferable.
加熱体を用いた接触加熱によって、繊維束の密度が１．３３ｇ／ｃｍ3以上１．４２ｇ／ｃｍ3以下となるまで加熱するのが好ましい。接触加熱時間は、例えば１分程度である。加熱体としては、加熱ロール、熱板等が挙げられる。 It is preferable that heating is performed until the density of the fiber bundle becomes 1.33 g / cm 3 or more and 1.42 g / cm 3 or less by contact heating using a heating body. The contact heating time is, for example, about 1 minute. Examples of the heating body include a heating roll and a hot plate.
加熱ロールを用いる酸化処理としては、温度範囲が異なる加熱ロール群を使用する、以下の三工程を順次行う方法が好ましい。
（１）温度２４０℃〜２９０℃の加熱ロール群１を用いる酸化処理によって繊維の密度を１．２７〜１．３８ｇ／ｃｍ3（ρ１）とする工程、
（２）工程（１）に引き続いて、温度２６０℃〜３３０℃の加熱ロール群２を用いる酸化処理によって繊維の密度を１．３０〜１．４０ｇ／ｃｍ3（ρ２）とする工程、
（３）工程（２）に引き続いて、温度２８０℃〜３７０℃の加熱ロール群３を用いる酸化処理によって繊維の密度を１．３３〜１．４２ｇ／ｃｍ3（ρ３）とする工程。
As the oxidation treatment using a heating roll, a method of sequentially performing the following three steps using heating roll groups having different temperature ranges is preferable.
(1) The process which makes the density of a fiber 1.27-1.38g / cm < 3 > ((rho) 1) by the oxidation process using the heating roll group 1 of temperature 240 degreeC-290 degreeC,
(2) Subsequent to step (1), the step of setting the density of the fibers to 1.30 to 1.40 g / cm 3 (ρ2) by oxidation using the heated roll group 2 at a temperature of 260 ° C. to 330 ° C.,
(3) Following the step (2), a step of setting the density of the fibers to 1.33 to 1.42 g / cm 3 (ρ3) by oxidation using the heating roll group 3 having a temperature of 280 ° C. to 370 ° C.
加熱ロールをこのような三つのロール群に分けることで、繊維束の均一性を上げ、単繊維間の融着を防ぐことができる。三工程の接触加熱によって繊維はρ１＜ρ２＜ρ３となる段階的な密度上昇を経る。繊維束の均一性を上げ、単繊維間の融着を防ぐことで、後工程の炭素化で得られる炭素繊維のストランド強度の低下を防ぐことができる。 By dividing the heating roll into such three roll groups, it is possible to increase the uniformity of the fiber bundle and prevent fusion between single fibers. The three-step contact heating causes the fiber to undergo a stepwise density increase such that ρ1 <ρ2 <ρ3. By increasing the uniformity of the fiber bundle and preventing the fusion between the single fibers, it is possible to prevent a decrease in the strand strength of the carbon fiber obtained by carbonization in the subsequent process.
以上のようにして製造された耐炎化繊維束は、公知の前炭素化処理、炭素化処理を経て炭素繊維束とされ、必要に応じてサイジング処理等される。以下、代表的な前炭素化処理条件、炭素化処理条件、黒鉛化処理条件、電解酸化処理条件、サイジング処理条件を例示する。 The flame-resistant fiber bundle produced as described above is made into a carbon fiber bundle through known pre-carbonization treatment and carbonization treatment, and is subjected to sizing treatment as necessary. Hereinafter, typical pre-carbonization treatment conditions, carbonization treatment conditions, graphitization treatment conditions, electrolytic oxidation treatment conditions, and sizing treatment conditions will be exemplified.
（耐炎化繊維束の前炭素化）
本発明の製造方法によって得られた耐炎化繊維束は、窒素等の不活性雰囲気中、最高温度が７００℃で、張力が０．５〜１ｍＮ／ｄＴｅｘでの緊張下に加熱して、前炭素化処理が行われる。この前炭素化処理での３００〜５００℃での昇温速度は２００℃／分以下に、３００℃以上での処理時間は１．５分以上であることが炭素繊維の機械的特性を向上させるために有効である。
(Pre-carbonization of flame resistant fiber bundle)
The flame-resistant fiber bundle obtained by the production method of the present invention is heated under tension at a maximum temperature of 700 ° C. and a tension of 0.5 to 1 mN / dTex in an inert atmosphere such as nitrogen, Processing is performed. The temperature increase rate at 300 to 500 ° C. in this pre-carbonization treatment is 200 ° C./min or less, and the treatment time at 300 ° C. or more is 1.5 minutes or more to improve the mechanical properties of the carbon fiber. It is effective for.
（前炭素化繊維束の炭素化）
前炭素化繊維束の炭素化条件としては、不活性雰囲気中、最高温度が１２００〜２０００℃で緊張下に、１０００〜１２００℃の温度領域において５００℃／分以下、好ましくは３００℃／分以下の昇温速度で加熱することが炭素繊維の機械的特性を向上させるために有効である。雰囲気については、窒素、アルゴン、ヘリウムなど公知の不活性雰囲気を採用できるが、経済性の面から窒素が望ましい。
(Carbonization of pre-carbonized fiber bundle)
As the carbonization condition of the pre-carbonized fiber bundle, 500 ° C./min or less, preferably 300 ° C./min or less in the temperature range of 1000 to 1200 ° C. under tension in an inert atmosphere at a maximum temperature of 1200 to 2000 ° C. In order to improve the mechanical properties of the carbon fiber, it is effective to heat at a rate of temperature increase of. As the atmosphere, a known inert atmosphere such as nitrogen, argon or helium can be adopted, but nitrogen is desirable from the viewpoint of economy.
（炭素化繊維束の黒鉛化）
さらに、必要に応じて公知の方法により黒鉛化することができる。例えば、かかる炭素化繊維束を、不活性雰囲気中、最高温度が２０００〜３０００℃で緊張下に加熱することにより黒鉛化することができる。
(Graphitization of carbonized fiber bundles)
Furthermore, if necessary, it can be graphitized by a known method. For example, such a carbonized fiber bundle can be graphitized by heating under tension at a maximum temperature of 2000 to 3000 ° C. in an inert atmosphere.
（電解酸化処理）
こうして得られた炭素化（黒鉛化）繊維束の表面改質のため、電解酸化処理をすることができる。電解酸化処理に用いる電解液には、硫酸、硝酸、塩酸等の酸性溶液や、水酸化ナトリウム、水酸化カリウム、アンモニア、テトラエチルアンモニウムヒドロキシドといったアルカリまたはそれらの塩を水溶液として使用することができる。ここで、電解酸化処理に要する電気量は、適用する炭素繊維により適宜選択することができる。かかる電解酸化処理により、複合材料において炭素繊維とマトリックス樹脂との接着性を適正化でき、バランスのとれた強度特性が発現されるようになる。
(Electrolytic oxidation treatment)
In order to modify the surface of the carbonized (graphitized) fiber bundle thus obtained, electrolytic oxidation treatment can be performed. As an electrolytic solution used for the electrolytic oxidation treatment, an acidic solution such as sulfuric acid, nitric acid, hydrochloric acid, an alkali such as sodium hydroxide, potassium hydroxide, ammonia, tetraethylammonium hydroxide, or a salt thereof can be used as an aqueous solution. Here, the amount of electricity required for the electrolytic oxidation treatment can be appropriately selected depending on the carbon fiber to be applied. By such electrolytic oxidation treatment, the adhesiveness between the carbon fiber and the matrix resin can be optimized in the composite material, and balanced strength characteristics can be expressed.
（サイジング処理）
引き続き、炭素繊維束に集束性を付与するため、サイジング処理をすることもできる。サイジング剤には、樹脂との相溶性の良いサイジング剤を、使用する樹脂の種類に応じて適宜選択することができる。
(Sizing process)
Subsequently, a sizing treatment can be performed in order to impart bundling properties to the carbon fiber bundle. As the sizing agent, a sizing agent having good compatibility with the resin can be appropriately selected according to the type of resin used.
以下、実施例により、本発明をより具体的に説明する。尚、炭素繊維束について、以下の方法によって、樹脂含浸ストランド特性、毛羽量、融着量を評価した。 Hereinafter, the present invention will be described more specifically by way of examples. The carbon fiber bundles were evaluated for resin-impregnated strand characteristics, fluff amount, and fusion amount by the following methods.
〔１．樹脂含浸ストランド特性〕
ＪＩＳ−Ｒ ７６０８準拠して、弾性率と強度を測定した。
[1. (Resin impregnated strand characteristics)
The elastic modulus and strength were measured according to JIS-R 7608.
〔２．毛羽量の測定〕
繊維束に１０００ｄｔｅｘあたり１００ｇの張力を付与した状態で、１０ｍ／分の速度で１００ｍ走行させ、繊維束上部面より５ｍｍ離れた固定点にレーザー光を通し、そこを通過した毛羽の本数を測定し、１ｍあたりの平均値をもって毛羽量とした。
[2. (Measurement of fluff amount)
With a tension of 100 g per 1000 dtex applied to the fiber bundle, run 100 m at a speed of 10 m / min, pass a laser beam through a fixed point 5 mm away from the upper surface of the fiber bundle, and measure the number of fluff that passed there. The average value per 1 m was used as the amount of fluff.
〔３．融着量の測定〕
１本の繊維束を１２０００本単位の束に分けた後、長さ３ｍｍに切断し、３００ｍｌビーカーに投入し、更に２００ｍｌのイオン交換水を加え、長さ１５ｍｍのマグネティックスターラを５０回転／分の速度で１０分間回転させ、直ちに直径２００ｍｍのシャーレに移し、シャーレ内で全ての繊維が沈んだことを確認した後、虫眼鏡を用いて単繊維が接着している箇所を計数した。
[3. (Measurement of fusion amount)
After dividing one fiber bundle into bundles of 12000 units, cut into 3 mm lengths, put into a 300 ml beaker, add 200 ml ion-exchanged water, and turn a 15 mm long magnetic stirrer at 50 rpm. It was rotated at a speed for 10 minutes, immediately transferred to a petri dish having a diameter of 200 mm, and after confirming that all the fibers had sunk in the petri dish, the locations where single fibers were adhered were counted using a magnifying glass.
（実施例１）
アクリロニトリル単位９６モル％と、アクリルアミド単位３モル％と、メタクリル酸単位１モル％とからなるアクリル系重合体の２０質量％ジメチルアセトアミド（ＤＭＡｃ）溶液を作製した。この溶液を孔径６０μｍ、孔数６万個の紡糸口金を通して、ＤＭＡｃ水溶液中（温度３５℃、溶剤濃度６７質量％）で凝固させて凝固繊維束を得た。この凝固繊維束を水洗後、９５℃の熱水浴中で３倍に延伸し、アミノ変性シリコーン油剤を付与した後、温度１３５℃で３分間乾燥した。さらに加圧スチーム処理装置を用いて３倍に延伸処理を行い、単繊維繊度１．０ｄＴｅｘ、総繊度６００００ｄＴｅｘのアクリル系前駆体繊維束を得た。
(Example 1)
A 20% by mass dimethylacetamide (DMAc) solution of an acrylic polymer composed of 96 mol% of acrylonitrile units, 3 mol% of acrylamide units, and 1 mol% of methacrylic acid units was prepared. This solution was solidified in a DMAc aqueous solution (temperature: 35 ° C., solvent concentration: 67% by mass) through a spinneret having a pore diameter of 60 μm and a pore number of 60,000 to obtain a coagulated fiber bundle. This coagulated fiber bundle was washed with water, then stretched 3 times in a hot water bath at 95 ° C., provided with an amino-modified silicone oil, and then dried at a temperature of 135 ° C. for 3 minutes. Furthermore, it extended | stretched 3 times using the pressurization steam processing apparatus, and obtained the acrylic type precursor fiber bundle of single fiber fineness 1.0dTex and total fineness 60000dTex.
得られたアクリル系前駆体繊維束を、空気中、温度２２０〜２５０℃、張力２ｍＮ／ｄＴｅｘの緊張下で加熱して（熱風循環方式）、密度１．３０ｇ／ｃｍ3の繊維束とした。さらに四本の加熱ロールで構成される加熱ロール群１（進行方向手前から順に、温度は、２４０℃、２４０℃、２６０℃および２６０℃）を通し、続いて四本の加熱ロールで構成される加熱ロール群２（進行方向手前から順に、温度は、２８０℃、２８０℃、３００℃および３００℃）を通し、更に、八本の加熱ロールで構成される加熱ロール群３（進行方向手前から順に、温度は、３１０℃、３１０℃、３２０℃、３２０℃、３３０℃、３３０℃、３４０℃および３４０℃）を通した。各ロールでの接触時間を１０秒（総接触時間１６０秒）とすることで、密度１．４０ｇ／ｃｍ3の耐炎化繊維束を得た。尚、加熱ロール群１通過後および加熱ロール群２通過後の耐炎化繊維束の密度は、それぞれ１．３３ｇ／ｃｍ3および１．３６ｇ／ｃｍ3であった。 The obtained acrylic precursor fiber bundle was heated in air at a temperature of 220 to 250 ° C. under a tension of 2 mN / dTex (hot air circulation method) to obtain a fiber bundle having a density of 1.30 g / cm 3 . Furthermore, the heating roll group 1 composed of four heating rolls (in order from the front in the traveling direction, the temperatures are 240 ° C., 240 ° C., 260 ° C. and 260 ° C.), followed by four heating rolls. Heat roll group 2 (in order from the front in the traveling direction, the temperatures are 280 ° C., 280 ° C., 300 ° C. and 300 ° C.), and further, heating roll group 3 composed of eight heating rolls (in the order from the front in the traveling direction) The temperature was passed through 310 ° C., 310 ° C., 320 ° C., 320 ° C., 330 ° C., 330 ° C., 340 ° C. and 340 ° C.). By setting the contact time at each roll to 10 seconds (total contact time 160 seconds), a flame-resistant fiber bundle having a density of 1.40 g / cm 3 was obtained. The density of the oxidized fiber bundle after heating rolls 1 pass and heating rolls 2 after passing through, were respectively 1.33 g / cm 3 and 1.36 g / cm 3.
得られた耐炎化繊維束を窒素雰囲気中、最高温度が７００℃で、張力が０．８ｍＮ／ｄＴｅｘでの緊張下に加熱して、前炭素化繊維束とした。この前炭素化処理での３００〜５００℃での昇温速度は２００℃／分であり、３００℃以上での処理時間は１．５分であった。 The obtained flame-resistant fiber bundle was heated in a nitrogen atmosphere under tension of a maximum temperature of 700 ° C. and a tension of 0.8 mN / dTex to obtain a pre-carbonized fiber bundle. The heating rate at 300 to 500 ° C. in the pre-carbonization treatment was 200 ° C./min, and the treatment time at 300 ° C. or higher was 1.5 minutes.
得られた前炭素化繊維束を、不活性ガス雰囲気中、最高温度が１３５０℃、張力が２．５ｍＮ／ｄＴｅｘでの緊張下に加熱して、炭素化繊維束とした。この炭素化処理での１０００〜１３００℃での昇温速度は２００℃／分であり、１０００℃以上での処理時間は１．５分であった。 The obtained pre-carbonized fiber bundle was heated in an inert gas atmosphere under tension at a maximum temperature of 1350 ° C. and a tension of 2.5 mN / dTex to obtain a carbonized fiber bundle. The heating rate at 1000 to 1300 ° C. in this carbonization treatment was 200 ° C./min, and the treatment time at 1000 ° C. or higher was 1.5 minutes.
得られた炭素化繊維束を表面処理後、サイジング剤を付与し、総繊度６００００ｄＴｅｘの炭素繊維束を得た。この炭素繊維束の樹脂含浸ストランド特性を測定すると、弾性率２６０ＧＰａ、強度４５００ＭＰａであった。毛羽量は２本/ｍであり、融着量は０個/１００００本であった。 The obtained carbonized fiber bundle was subjected to a surface treatment, and then a sizing agent was applied to obtain a carbon fiber bundle having a total fineness of 60000 dTex. When the resin-impregnated strand characteristics of this carbon fiber bundle were measured, the elastic modulus was 260 GPa and the strength was 4500 MPa. The amount of fluff was 2 / m, and the amount of fusion was 0/10000.
（実施例２）
加熱ロール群による加熱方法を、二本の加熱ロールで構成される加熱ロール群１（進行方向手前から順に、温度は、２４０℃および２６０℃）、二本の加熱ロールで構成される加熱ロール群２（進行方向手前から順に、温度は、２８０℃および３００℃）、四本の加熱ロールで構成される加熱ロール群３（進行方向手前から順に、温度は、３１０℃、３２０℃、３３０℃および３４０℃）とし、各ロールでの接触時間を１０秒（総接触時間８０秒）とした。これ以外は、実施例１と同じ方法で、密度１．３８ｇ／ｃｍ3の耐炎化繊維束を得た。尚、加熱ロール群１通過後および加熱ロール群２通過後の耐炎化繊維束の密度は、それぞれ１．３２ｇ／ｃｍ3および１．３５ｇ／ｃｍ3であった。
(Example 2)
The heating method by a heating roll group is the heating roll group 1 comprised by two heating rolls (the temperature is 240 degreeC and 260 degreeC in order from the advancing direction front), the heating roll group comprised by two heating rolls. 2 (in order from the front in the traveling direction, the temperatures are 280 ° C. and 300 ° C.), a heating roll group 3 composed of four heating rolls (in order from the front in the traveling direction, the temperatures are 310 ° C., 320 ° C., 330 ° C. and 340 ° C.), and the contact time with each roll was 10 seconds (total contact time 80 seconds). Except for this, a flame-resistant fiber bundle having a density of 1.38 g / cm 3 was obtained in the same manner as in Example 1. The density of the oxidized fiber bundle after heating rolls 1 pass and heating rolls 2 after passing through, were respectively 1.32 g / cm 3 and 1.35 g / cm 3.
引き続き、実施例１と同様に前炭素化、炭素化、表面処理を行い、弾性率２６０ＧＰａ、強度４３００ＭＰａの樹脂含浸ストランド特性を有する炭素繊維束を得た。また、毛羽量は０本／ｍ、融着量は１個／１００００本であった。 Subsequently, pre-carbonization, carbonization, and surface treatment were performed in the same manner as in Example 1 to obtain a carbon fiber bundle having a resin-impregnated strand characteristic having an elastic modulus of 260 GPa and a strength of 4300 MPa. Further, the amount of fluff was 0 / m, and the amount of fusion was 1/10000.
（比較例１）
加熱ロール群による加熱処理を行わずに、実施例１と同様の熱風循環方式のみで酸化処理を行ない耐炎化繊維束を得た。この繊維束を実施例１と同じ方法で前炭素化処理し、密度１．３３ｇ／ｃｍ3の繊維束を得た。引き続き、実施例１と同様に炭素化、表面処理を行い、弾性率２４０ＧＰａ、強度３４００ＭＰａの樹脂含浸ストランド特性を有する炭素繊維束を得た。また、毛羽量は０本／ｍ、融着量は４個／１００００本であった。
(Comparative Example 1)
Without performing the heat treatment by the heating roll group, the oxidation treatment was performed only by the same hot air circulation method as in Example 1 to obtain a flame-resistant fiber bundle. This fiber bundle was pre-carbonized in the same manner as in Example 1 to obtain a fiber bundle having a density of 1.33 g / cm 3 . Subsequently, carbonization and surface treatment were performed in the same manner as in Example 1 to obtain a carbon fiber bundle having a resin-impregnated strand characteristic having an elastic modulus of 240 GPa and a strength of 3400 MPa. Further, the amount of fluff was 0 / m, and the amount of fusion was 4/10000.
（比較例２）
実施例１で得られたアクリル系前駆体繊維束を、空気中、温度２２０〜２５０℃、張力２ｍＮ／ｄＴｅｘの緊張下で加熱して（熱風循環方式）、密度１．３０ｇ／ｃｍ3 の繊維束とした後、ネルソン方式の接触方式処理により、温度２５０℃の加熱ロールに一回当たりの接触時間が５秒で、１２０回接触させ（総接触時間１０分）、密度１．３８ｇ／ｃｍ3 の耐炎化繊維束を得た。引き続き、実施例１と同様に前炭素化、炭素化、表面処理を行い、弾性率２６０ＧＰａ、強度３０００ＭＰａの樹脂含浸ストランド特性を有する炭素繊維束を得た。また毛羽量は５０本/ｍ、融着量は１５０個/１００００本であった。
(Comparative Example 2)
The acrylic precursor fiber bundle obtained in Example 1 is heated in air at a temperature of 220 to 250 ° C. under a tension of 2 mN / dTex (hot air circulation method) to obtain a fiber having a density of 1.30 g / cm 3 . After forming a bundle, the contact time is 5 seconds for 120 seconds (total contact time 10 minutes) with a heating roll having a temperature of 250 ° C. by a Nelson-type contact method treatment, and the density is 1.38 g / cm 3. A flame-resistant fiber bundle was obtained. Subsequently, pre-carbonization, carbonization, and surface treatment were performed in the same manner as in Example 1 to obtain a carbon fiber bundle having a resin-impregnated strand characteristic with an elastic modulus of 260 GPa and a strength of 3000 MPa. Further, the amount of fluff was 50 pieces / m, and the amount of fusion was 150 pieces / 10000 pieces.
（比較例３）
ネルソン方式の接触方式処理による、温度２５０℃の加熱ロールに一回当たりの接触時間を０．５秒とし、１２００回接触させた（総接触時間１０分）以外は、比較例２と同様に処理をして炭素繊維束を得た。得られた炭素繊維束の樹脂含浸ストランド特性を測定すると、弾性率２６０ＧＰａ、強度３６００ＭＰａであった。また毛羽量は８０本／ｍであり、融着量は８個／１００００本であった。
(Comparative Example 3)
The same treatment as in Comparative Example 2 except that the contact time per time was set to 0.5 seconds with the heating roll at a temperature of 250 ° C. by the Nelson-type contact method treatment and the contact time was 1200 times (total contact time 10 minutes). To obtain a carbon fiber bundle. When the resin-impregnated strand characteristics of the obtained carbon fiber bundle were measured, the elastic modulus was 260 GPa and the strength was 3600 MPa. Further, the amount of fluff was 80 / m, and the amount of fusion was 8/10000.
Claims (3)
引き続き、酸化性雰囲気中において接触加熱方式により２つ以上の異なる温度条件で酸化処理を施す、アクリル系前駆体繊維束からの耐炎化繊維束の製造方法であって、
前記接触加熱方式による酸化処理が、加熱ロールを用いる酸化処理であり、
前記加熱ロールを用いる酸化処理が以下の三工程である、
耐炎化繊維束の製造方法。
（１）温度２４０℃〜２９０℃の加熱ロール群１を用いる酸化処理によって繊維の密度を１．２７〜１．３８ｇ／ｃｍ３とする工程。
（２）工程（１）に引き続いて、温度２６０℃〜３３０℃の加熱ロール群２を用いる酸化処理によって繊維の密度を１．３０〜１．４０ｇ／ｃｍ３とする工程。
（３）工程（２）に引き続いて、温度２８０℃〜３７０℃の加熱ロール群３を用いる酸化処理によって繊維の密度を１．３３〜１．４２ｇ／ｃｍ３とする工程。 Subjected to oxidation treatment with a non-contact heating method in an oxidizing atmosphere relative to the acrylic precursor fiber bundle, the density of the fiber and 1.22 g / cm 3 or more 1.38 g / cm 3 or less,
Subsequently, a method for producing a flame-resistant fiber bundle from an acrylic precursor fiber bundle, which is subjected to oxidation treatment at two or more different temperature conditions by a contact heating method in an oxidizing atmosphere,
The oxidation treatment by the contact heating method is an oxidation treatment using a heating roll,
The oxidation treatment using the heating roll is the following three steps ,
A method for producing a flameproof fiber bundle.
(1) The process which makes the density of a fiber 1.27-1.38g / cm < 3 > by the oxidation process using the heating roll group 1 with a temperature of 240 to 290 degreeC.
(2) A step of setting the density of the fibers to 1.30 to 1.40 g / cm 3 by oxidation treatment using the heating roll group 2 having a temperature of 260 ° C. to 330 ° C. following the step (1).
(3) The process of setting the density of a fiber to 1.33-1.42 g / cm < 3 > by the oxidation process using the heating roll group 3 of temperature 280 degreeC-370 degreeC following process (2).
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| JPS5146593A (en) * | 1974-10-21 | 1976-04-21 | Toray Industries | Tansoseihinno seizohoho |
| JPS5930914A (en) * | 1982-08-09 | 1984-02-18 | Toray Ind Inc | Preparation of carbon fiber |
| JPS61167023A (en) * | 1985-01-18 | 1986-07-28 | Asahi Chem Ind Co Ltd | Production of flameproofing yarn |
| JPS61174423A (en) * | 1985-01-26 | 1986-08-06 | Asahi Chem Ind Co Ltd | Production of flameproofed fiber |
| JPH026625A (en) * | 1988-06-23 | 1990-01-10 | Mitsubishi Rayon Co Ltd | Production of flame-resistant fiber |
-
2011
- 2011-06-09 JP JP2011129328A patent/JP5899669B2/en not_active Expired - Fee Related
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