Background of the Invention
Field of the Invention
[0001] This invention relates to pitch-based high performance carbon fibers having superior
workability and their production method. More particularly, it relates to pitch-based
carbon fibers obtained by mitigating carbonization treatment to such an extent that
silicone types spin finish oils coated at the time of spinning of pitch are remained,
having a high cohesiveness of bundles and lubricity by the remaining silicone type
spin finish oils and having a superior workability and to their producing method.
[0002] The carbon fibers obtained from a pitch according to a method of the present invention
is incomplete in crystallization and orientation structure of carbon hexagonal network
and yet have capability of increasing their tensile strength and modulus of elasticity
greatly by an additive heat treatment carried out under a relaxed state whereby the
growth of graphitic crystalline and orientation structure proceed.
[0003] The carbon fibers of the present invention are superior in adaptation to various
kinds of processes such as taking up on bobbins, transportation to a higher grade
of carbonization or graphitization step, weaving,knitting and working for the reinforcement
of resin.
[0004] The pitch-based carbon fibers of the present invention are easy in working because
of their lower carbonization grade, and their cost is lower than those of a higher
carbonization grade. Thus even when working loss is produced, they have an advantage
because the influence upon the cost of product is small.
[0005] The carbon fibers derived from a pitch according to the present invention are patient
against bending of small radius of curvature compared with carbon fibers subjected
to higher grade of carbonization and have superior characteristic properties because
their bent portions receive stress relaxation by the carbonization treatment applied
thereafter and show superior resistance to abrasion, flexion and scratching.
[0006] A method for obtaining carbon fibers by subjecting a pitch having a high softening
point to melt-spinning, oxidizing the resulting fibers to make them infusible, followed
by carbonization carried out in an inert gas atmosphere, is disclosed in Japanese
official gazette of examined application (Tokuko) 15728 of 1966. This is certainly
a superior production method of pitch-based carbon fibers but according to the disclosed
method, it is necessary to keep fibers in a stretched state during the carbonization
to obtain fibers having high modulus of elasticity. Since thermoset pitch fibers are
extremely brittle, it is difficult to hold them in a stretched state. It is considered
actually to be impossible to obtain high modulus carbon fibers by this method.
[0007] In order to work out a solution to this problem, a method in which optically anisotropic
pitch is used has been proposed as disclosed in Japanese official gazette of examined
application (Tokuko) 8634 of 1974 and Japanese official gazette of unexamined application
(Tokukai) 19127 of 1974. An optically anisotropic pitch is easily graphitizable material
and has superior properties as raw material for high strength, high modulus carbon
fibers. Particularly, there is no need of being kept in a stretched state during the
carbonization; it is considered to be an advantageous method in view of cost and
quality.
[0008] Carbon fibers from an optically anisotropic pitch can be easily made into a high
strength and high modulus fibers but on the other hand, they have such weak points,
that they are liable to be flawed, e.g. liable to be broken at the time of working.
Such weak points exist more or less in case of brittle fibers. Glass fibers, PAN-based
carbon fibers, etc. are coated by sizing agents to give lubricity and cohesiveness
of bundles. In case of carbon fibers from optically anisotropic pitch, there is a
tendency of repelling a sizing agent due to harmful effect of easily graphitizable
property. Since uniform coating is difficult, shortages of lubricity and cohesiveness
of bundles are also weak points.
[0009] In order to solve these problems, Japanese unexamined patent application (Tokukai)
21911 of 1985 discloses a method in which light grade of carbonization is carried
out at a temperature of 400 - 650°C after thermosetting. This method is effective
to some-extent for keeping the modulus of elasticity of carbon fibers small and for
preventing them from being flawed but since bundles of the fibers have no cohesiveness
and no lubricity, there are problems in insufficiency of workability. In order to
solve such problems, it is a general method to coat an oiling agent after carbonization
but in case of lightly carbonized pitch fibers, a tendency of repelling an oiling
agent is created, and there is a problem of the fibers being liable to be flawed at
the time of coating of the oiling agent on one hand because strength of the fibers
is not increased.
[0010] In the treatment of pitch-based carbon fibers, the most severe condition for spin
finish oils is a thermosetting which is a heat treatment carried out in the oxidative
atmosphere. In order to cover the oxidative decomposition of spin finish oils, it
is considered advantageous to impart second oils after thermosetting process. The
problem of this method is the liability of being flawed at the time of imparting the
second oils because the pitch fibers after thermosetting are equally or more brittle
than the pitch fibers after spinning.
[0011] For imparting the second oils at this step, a spray method can be adopted, but the
loss of the second oils by scattering is so great that there is an economical problem
specially in the case of expensive silicone type oils.
[0012] It is an object of the present invention to overcome the brittleness, shortage of
lubricity and cohesiveness of bundles of carbon fibers produced from an optically
anisotropic pitch or from a high softening point pitch having characteristic carbonization
properties similar to the optically anisotropic pitch.
[0013] The carbonization of pitch-based fibers is carried out generally by the heat treatment
in the atmosphere of an inert gas and its effect is considered, in general, to be
depend on temperature and time. However, when a detailed investigation is carried
out for workability, it has become clear that there is the effect of spin finish oils
remained. Particularly, it has become clear that the effect for lubricity and cohesiveness
of bundles are notable. Further there seems to be a difference of effectiveness between
apparatus for carbonization.
[0014] Though the reason is not clear, it is inferred that a shape of bundles, which is
formed at the stage of bundles of pitch fibers possessing a good lubricity and cohesiveness,
is maintained by spin finish oils remaining in a slight amount and that this gives
a large influence upon workability.
Summary of the Invention
[0015] In a method for producing pitch-based carbon fibers by subjecting a pitch having
a high softening point to melt-spinning, thermosetting and carbonization or carbonization
and then graphitization, the present invention comprises coating spun pitch fibers
with silicone type spin finish oils, introducing said pitch fibers in the oxidative
atmosphere at a maximum temperature of 200 - 400°C to effect the thermosetting and
subsequently subjecting said pitch fibers to the carbonization treatment in the atmosphere
of an inert gas at a temperature of 400 - 1000°C under the condition that the silicone
type finish oils remained on said pitch fibers are in the range of 0.1% - 2.0% by
weight of said fibers and transferring them to a next working step.
Detailed Description of the Preferred Embodiment of the Invention
[0016] A high softening point pitch referred to in the present invention is an easily graphitizing
pitch such as an optically anisotropic pitch. The easily graphitizing pitch forms
needle cokes by dry distillation. Further, at the time of carbonization of pitch fibers,
it produces high modulus carbon fibers even under a tensionless condition.
[0017] The easily graphitizing pitches include, besides optically anisotropic pitches, dormant
mesophase pitches, and premesophase carbonaceous materials which show similar graphitizing
property.
[0018] The silicone type oil used in the present invention is preferably a matter having
a heat resistance of 500°C or more. The heat resistance of oils, referred to herein,
is defined as a temperature at which a reduction of the weight of oils measured by
using a thermobalance (TG high temperature type CN 8068 AZ manufactured by Rigaku
Denki was used; Sample size 10 mg, flow amount of nitrogen; 40 mℓ/min. cell diameter;
5mm, cell depth 2.5 mm) at a heating rate of 10°C/min. in the stream of nitrogen becomes
practically zero. (It means that the change of the weight in a temperature range of
100°C becomes less than the sensitivity. The sensitivity is adjusted as 0.1% of the
initial weight.)
[0019] As the silicone type spin finish oils, those which show smaller amount of decomposition
sludge by heating is preferable. Polysiloxane type and polyaminosiloxane type are
preferable. At the time of coating spin finish oils on pitch fibers it is possible
to mix therewith, besides a solvent as a diluent, those such as a surfactant which
is not a silicone type, a lubricant or an antioxidant.
[0020] With regard to the measurement of the remaining amount of oils, fibers are burnt
out to ash and silicon content was measured by IPC emission spectrochemical analysis,
and by regarding its numerical value as silicon content of principal constituent molecule
of the silicone type oils, the remaining amount of the oils was calculated.
[0021] Further by an elemental analysis, carbon fibers of the present invention were determined
to contain 2.0 - 15.0% by weight of oxygen, 0.07 - 0.7% by weight of sulfur. If these
contents are too little, those inferior in workability are resulted. On the contrary,
if they are too much, there is a tendency that the properties of ultimate products
which are carbonized at a temperature of 2000°C or more, are lowered.
[0022] The remaining amount of the oils is preferably in the range of 0.2 - 1.0% by weight
of fibers. In case of the remaining amount of the oils being too small, the cohesiveness
and lubricity of bundle of filament yarns become poor and are liable to produce trouble
by static electricity. In case of the remaining amount of the oils being too much,
it is not preferable not only because of the increase of the amount of oils imparted
at the time of spinning which is disadvantageous in view of the cost but also because
of reduction of thermosetting velocity. The reason for reduction of thermosetting
velocity is not clear completely but it seems to be caused by the prevention of diffusion
of oxygen by the film of the oils and reduction of the effective oxygen concentration
caused by the large amount of vapour due to the oils generated in the inside of a
furnace which drives oxygen out of the furnace.
[0023] Carbon fibers produced by the present invention have a tensile strength of 5 - 50
Kgf/mm², an elongation of 0.3 - 8.0% and a capability of increasing its tensile strength
to 150 Kgf/mm² or more and its modulus of elasticity to 30,000 Kgf/mm² or more by
the additive heat treatment carried out in the relaxed state. If the tensile strength
becomes smaller than this range, it is not preferable because fibers become liable
to be flawed at the step of next working. If the tensile strength becomes greater
than this range, it is not preferable because fibers become liable to be broken at
the time of working and abrasion resistance is reduced. The tensile strength is preferably
in the range of 10 - 45 Kgf/mm². If the elongation of fibers is smaller than above-mentioned
range, it is not preferable because fibers become liable to be flawed. If the elongation
is greater than above-mentioned range, it is not preferable because the shape and
dimensional stability of final products become worse. The elongation is preferably
in the range of 0.6 - 5.0%.
[0024] Increase of tensile strength and increase of modulus of elasticity by the additive
heat treatment carried out in the relaxed state are phenomena usually observable in
case of easily graphitizing pitch but those having a tensile strength smaller than
above-mentioned range after an additive heat treatment is not preferable because
resistance to fatique and resistance to oxidation are inferior.
[0025] Those having a tensile strength smaller than above-mentioned range after the additive
heat treatment have a smaller tendency of repelling a sizing agent after the heat
treatment. Therefore, necessity of using the method of the present invention is smaller.
The tensile strength after the additive heat treatment is preferably in the range
of 200 - 450 Kgf/mm². Those having a modulus of elasticity smaller than above-mentioned
range are not preferable because resistance to fatique and resistance to oxidation
is inferior and change of dimension at the time of working is greater. The modulus
of elasticity after the additive heat treatment is preferably in the range of 40,000
- 100,000 Kgf/mm².
[0026] The carbon fibers produced according to the present invention have, preferably a
specific gravity of 1.30 - 1.70, a specific electric resistance of 5 × 10⁸ - 5 Ω·cm,
a stack height of graphitic layers L
c (002) of 8 - 32Å, a graphitic interlayer spacing distance d 002 of 3.46 - 3.49Å and
after strength and modulus have been increased by the additive heat treatment, a stack
height of graphitic layers L
c (002) of 36Å or more, increase of a stack height L
c (002) of 5Å or more, a graphitic interlayer spacing distance d 002 is 3.46Å or less
and decrease of interlayer spacing distance d 002 is 0.03Å or more. Most preferably,
a specific gravity is 1.35 - 1.60, a specific electric resistance is 1 × 10⁸ ∼ 1 ×
10² Ω·cm and after strength and modulus have been increased by the additive heat treatment,
a stack height of graphitic layers Lc (002) of 70 -240Å and a graphitic interlayer
spacing distance d 002 is 3.36 - 3.44Å.
[0027] After a high softening point pitch is subjected to melt-spinning in the present invention,
preferably resulting pitch fibers are wound up on bobbins or without being wound up
on bobbins and introduced continuously into an oxidative atmosphere at a maximum
temperature of 200 - 400°C while being placed on a transportation belt for thermosetting,
subsequently the fibers are subjected to carbonizing treatment in the atmosphere of
an inert gas at a temperature of 400 - 1000°C while being placed on a transportation
belt, under the condition to make the silicone type oils remaining on the pitch fibers
in the adhered state in the amount of 0.1% - 2.0% by weight of said fibers and said
fibers are transferred to a next step. The spin finish oils and a sizing agent are
imparted during the spinning step before the pitch fibers are placed on a transportation
belt. The remaining of these chemical agents is effective in improving handling property
at the time of winding up of fibers after carbonization or various kind of working.
[0028] Though the reason for the fact hereinafter described is not clear, handling property
is different between apparatus for carbonization, and those which have been carbonized
on a transportation belt is most superior in handling property. Those which have been
carbonized while the pitch fibers were wound up on heat-proof bobbins, those carbonized
in cans and those carbonized on a belt have been examined. All showed values which
are not greatly different each other in a tensile strength, an elongation, and a modulus
of elasticity but at the time of working such as winding, weaving and knitting, those
which have been carbonized while the pitch fibers were placed on a blet, were superior
in cohesiveness of bundles.
[0029] With regard to the way of placement of spun pitch fibers on a transportation belt,
any way is allowable so long as reversal of order of fiber-bundles does not occur
e.g. such a way where it does not occur that fibers placed afterwards get into the
previously formed fiber layers and order of fibers is disturbed. It is preferable
to use a porous transportation belt and to press and adhere the fibers by suction
from the back side so as to prevent the fibers placed on the transportation belt from
moving due to vibration or gas flow. In this case, it is preferable that a transportation
belt is a net conveyer When the fiber-bundles are delivered from a direction close
to the vertical to the transportation belt surface, it often happens that they get
into the holes of belt or previously formed fiber layers. It is preferable to make
the angle between the direction of delivery of the fibers and a surface of belt, smaller
by swinging the running fibers so as to perform a circular movement or a movement
which draws a figure "8". At the time of collision of the fibers with the belt, it
often happens that the fiber-bundles are opened by shock and becomes a cause of reversal
of order of the fibers or a cause of drawback during a working after carbonization.
[0030] The fibers are subjected to thermosetting in the oxidative atmosphere at a maximum
temperature of 200° - 400°C preferably while being placed on a transportation belt
after spinning. As for heating temperature, it is preferable to select a temperature
lower than 200°C at the inlet and to elevate the temperature slowly to give the highest
temperature at the outlet, rather than to keep a fixed temperature throughout the
whole process. Most preferably the maximum temperature is 250 - 350°C.
[0031] Since the pitch fibers after thermosetting are extremely weak, they cannot be subjected
to a treatment in which a force is applied to the fibers. It is preferable to send
them into a carbonization apparatus as they are in the state placed on the transportation
belt. During the treatment carried out in the state placed on the transportation belt,
there is no need of imparting oils or sizing agents.
[0032] The carbonization treatment is carried out at a temperature of 400 - 1000°C in an
inert gas atmosphere under the condition in which silicone type oils are remaining
in the state adhered on the pitch-based fibers in an amount of 0.1% - 2.0% by weight
based upon said fibers. In the beginning of carbonization treatment, it is preferable
to start from the substitution of the oxidative atmosphere by an inert gas at a temperature
close to about 400°C. If the substitution by the inert gas is insufficient, a problem
such as a decrease of fiber diameter, insufficiency of an increase of strength or
the like may occur. Treatment time varies according to the diameter of fibers but
it is preferable to elevate the temperature slowly at a rate of 10 - 100°C/min at
the beginning and carry out the substitution of the atmosphere sufficiently by an
inert gas and to maintain at a constant temperature for several seconds or several
hundred seconds in the final stage.
[0033] Resulting fibers are subsequently taken up on bobbin or the like and subjected to
a next processing. If necessary after subjecting to a further processing, such as
weaving, knitting or the like, an additional carbonization can be applied to produce
high strength, high modulus carbon fibers. Further it is possible to treat the fibers
at higher temperature to graphitize the fibers. At the time of the additional carbonization,
it is possible to stretch the fibers to increase a tensile strength and a modulus
of elasticity.
[0034] In case of winding up of resulting fivers from the transportation belt onto bobbins
or the like or sending to the next higher temperature treatment, it is necessary to
pull out the bundles of fibers through rollers or the like. At this time, it is preferable
to reverse the fiber layers on the transportation belt and then pull out the fibers
to correct the shape of bundles to a straight line form. In order to reverse the fiber
layers on the transportation belt in the direction of thickness, various kinds of
processes may be adopted, but it is most preferable to use a second belt. The second
belt is caused to contact the fiber layers from upper side, and while putting the
fiber layers between both the belts, the top and the bottom are reversed. Therefore,
the fiber layers are placed on the second belt and resulting fibers are pulled out
from the top thereof.
[0035] The carbon fibers obtained according to the present invention, differently from the
fibers highly carbonized, have a smaller modulus of elasticity, a superiority in cohesiveness
of bundles and a superiority in workability to such works as those containing a step
of bending at a small radius of curvature e.g. weaving and knitting. Further since
the fibers of the present invention are of lower cost than fibers of advanced carbonization
state, they are extremely advantageous in case of products which cause a large amount
of working loss. Since relaxation of strain occurs at the time of carbonization, they
are superior in abrasion resistance and fatique resistance of bent parts of small
radium of curvature. Further they show a resistance against a fluff forming by abrasion
and against a flexion and a scratching.
[0036] The carbon fibers obtained according to the present invention are liable to be wetted
by a resin prepolymer, an adhesive, an oiling agent and a sizing agent and have superior
workability.
[0037] The graphitic interlayer spacing distance of the pitch-based carbon fibers of the
present invention was measured by using a X-ray diffraction apparatus. Fibers were
ground to powder. About 10% by weight of high purity silicon powder for X-ray standard
was admixed as a internal standard substance, and mixture was filled in a sample cell.
By a X-ray diffractometer method, in which Cu Kα ray was used as a source of ray,
carbon 002 diffraction line and the standard. silicon 111 diffraction line were measured,then
the diffraction angle of(ϑ)of carbon 002 plane was calculated from 002 diffraction
peak position to which correction relating to Lorentz polarization factor, atomic
scattering factor and absorption factor have been made. And d002 was calculated from
a formula of d002=1.5418 Å/ 2Sin ϑ. L
c (002) was obtained by calculating the half value width (β) of carbon 002 diffraction
peak in the above-mentioned X ray diffraction curve, to which correction for Kα₁
Kα₂ doublet lines have been applied and by using a formula of L
c = 91/β.
[0038] Hereinafter the present invention will be more fully explained. All "%" are percentages
by weight unless otherwise described.
Example 1
[0039] A distillate fraction of a residual oil of a thermal catalytic cracking (FCC) having
an initial fraction of 450°C and a final fraction of 560°C (converted to an atmospheric
pressure) was subjected to heat treatment at a temperature of 400°C for 6 hours while
sending methane gas therein and further heated at a temperature of 330°C for 8 hours
to grow mesophase and the mesophase pitch was separated by sedimentation taking advantage
of difference of specific gravities. This pitch had an optically anisotropic portion
of 100%, a quinoline insoluble portion of 43% and a toluene insoluble portion of 82%.
[0040] This pitch was spun through a spinning hole having an enlarged part at an outlet.
After spin finish oils were coated upon the spun fibers according to a common procedure,
the pitch fibers were taken up at a rate of 270 m/min. and piled up on a transportation
belt while giving waving motion so as to form spiral shape locus. As the spin finish
oils, silicone type oils having a heat resistance of 630°C and a viscosity of 230
centi-Stokes was used. The amount of adhered spin finish oils was 3.0% based upon
the weight of the pitch fibers.
[0041] Subsequently, resulting fibers were subjected to thermosetting by an oxidation treatment
with air while elevating a temperature at a rate of 3°C/min. in a furnace having a
temperature of 160°C at an inlet and 320°C at an outlet. The fibers which came out
of a furnace were sent into a carbonization furnace while being kept on the transportation
belt. The temperature at the inlet was 420°C. While elevating temperature at a rate
of 5°C/min. till 500°C and at a rate of 20°C/min. till 580°C, substitution of the
atmosphere with an inert gas was carried out. After the treatment at 580°C was continued
for 45 seconds, the fibers were taken out of the furnace and after reversing the upper
and lower layer while putting the fibers between the transportation belt and a second
belt, the fibers were wound up on bobbins.
[0042] The amount of the oils remaining on the resulting fibers was 0.25%. A tensile strength,
a modulus of elasticity, an elongation, a specific gravity and a specific electric
resistance were, 27 Kgf/mm², 820 Kgf/mm², 3.3%, 1.52 and 2 × 10⁷ Ω·cm, respectively.
[0043] When said fibers were treated in the atmosphere of argon at a temperature of 2800°C
for 2 minutes, high strength, high modulus carbon fibers having a tensile strength
of 290 Kgf/mm² a modulus of elasticity of 75,000 Kgf/mm² and an elongation of 0.4
were obtained.
[0044] By using the fibers before and after the heat treatment in the atmosphere of argon,
their weaving properties were investigated. In case of a plain weave, there were no
notable difference between the two. In case of a double weave, the fibers before the
heat treatment were easier in weaving. In case of a multiple axis weaving and a three
dimensional weaving, weaving of the fibers after the heat treatment were difficult.
[0045] The properties of plain woven fabrics before and after the heat treatment in the
atmosphere of argon were investigated. The woven fabrics of the fibers before the
heat treatment were compared after an additive heat treatment carried out in the atmosphere
of argon. Both did not show big difference in a tensile strength, an elongation and
a modulus of elasticity but the woven fabrics made from the fibers after the heat
treatment were slightly bulky, had a tendency of being fluffy by abrasion, and were
slightly inferior in resistance to flexion and scratching and the resistance to abrasion
of their selvage parts was inferior greatly.
Comparative example 1
[0046] The pitch fibers spun as in Example 1 were wound up on bobbins made of alumina porcelain
and subjected to a thermosetting and a carbonization treatment under a condition for
heating similar to Example 1. The amount of the oils remaining was 0.09%. It seems
that a cooling rate after the carbonization treatment was slow and on this account
decomposition loss was large.
[0047] The tensile strength, the elongation, the modulus of elasticity and the crystalline
state did not show much difference from Example 1 but the weaving property was greatly
inferior, and weaving of the multiple axial fabrics and the three-dimensional fabrics
were difficult.
[0048] Further when the amount of the spin finish oils after spinning was increased than
in Example 1 and the remaining amount was 0.25%, the weaving property became close
to Example 1, but the wound-up shape of filaments was worse, breakage of filaments
occurred frequently and it was difficult to pass through the preparation step for
weaving.
Comparative example 2
[0049] Pitch fibers spun as Example 1 were taken in a cans made of a heat-proof alloy and
subjected to a thermosetting and a carbonization treatment under a temperature-elevating
condition similar to Example 1. The remaining amount of the oils was 0.08%. Since
a cooling rate after the carbonization treatment was slow as in Comparative example
1, it seems that decomposition loss increased. The tensile strength, the elongation,
the modulus of elasticity and the crystalline state of the fibers were not different
greatly from these values of Example 1. But because taking out of the cans was difficult,
the estimation of the weaving property was difficult.
[0050] Further when the amount of adhesion of the spin finish oils after spinning was increased
to about 0.25% which was more than that of Example 1 and the pitch fibers were taken
in a cans, because the amounts of the remaining oils of the surface part and the bottom
were greatly different, there was formed an unequality in working characteristics
and woven fabrics having a good quality could not be produced.
Example 2
[0051] By using the pitch same with Example 1, spinning was carried out under the same spinning
condition with Example 1. The fibers after a thermosetting in the state piled up on
a transportation belt were subjected to a carbonization treatment by changing the
maximum temperature of a carbonization furnace. Then the fibers were wound up on bobbins
and the remaining amount of the oils was measured and the working property was evaluated
by weaving. The result thereof is shown in Table 1.

Effectiveness of the Invention
[0052] The pitch-based carbon fibers produced according to the present invention are superior
in cohesiveness and lubricity of bundles and in processability or workability even
when second oils or the like are not imparted after the thermosetting or the carbonization.
[0053] The pitch-based carbon fibers produced according to the present invention can be
easily processed than conventional products with no remaining spin finish oils and
having higher carbonization grade and are inexpensive in cost because there is no
need of an additional imparting of second oils or the like. Compared with carbon fibers
with no remaining spin finish oils and having higher carbonization grade, the carbon
fibers produced according to the present invention, are patient against a bending
of small radius of curvature and are superior in resistance to abrasion, to flexion
and to scratching of bent parts because the bent parts receive a stress relaxation
by the carbonization treatment carried out in the later stage.
[0054] The carbon fibers produced according to the present invention can be used in various
kind of fiber reinforced composite materials as they are or after the carbonization
treatment or the graphitization treatment. Further they can be used as raw materials
for activated carbon fibers.