Stabilized fiber bundle and method of manufacturing carbon fiber bundle

Patent metadata

Field	Value
Publication number	US-11319648-B2
Application number	US-201916768923-A
Country	US
Kind code	B2
Filing date	Jan 17, 2019
Priority date	Jan 26, 2018
Publication date	May 3, 2022
Grant date	May 3, 2022

Abstract

A method manufactures a flame-retardant fiber bundle by flame retarding treatment of a polyacrylonitrile-based precursor fiber at 200-300° C. in an oxidizing atmosphere, wherein a fiber bundle is caused to travel so as to sequentially pass between an nth roller and an (n+1)th roller (n being an integer of at least 1 and no more than [m−1]) in a roller group formed from m (m being an integer of 3 or greater) contiguously set rollers, the roller axes of the m continuously set rollers being parallel to each other and perpendicular to the direction of travel of the fiber bundle, the roller diameter being 5-30 mm, and the specific gravity of the fiber bundle being 1.20-1.50.

First claim

The invention claimed is:

1. A method of manufacturing a stabilized fiber bundle, the method comprising the step of:
stabilizing a polyacrylonitrile precursor fiber bundle in an oxidizing atmosphere at 200 to 300° C. to manufacture a stabilized fiber bundle,
wherein in the stabilizing, a fiber bundle is caused to run, with respect to a roller group including m pieces where m is an integer of 3 or more of rollers arranged continuously, to sequentially pass between an n-th roller and an (n+1)-th roller where n is an integer of 1 or more and (m−1) or less,
the m pieces of rollers arranged continuously have roller axes parallel to each other and perpendicular to a running direction of the fiber bundle,
the rollers have a roller diameter of 5 to 30 mm,
the fiber bundle has a specific gravity of 1.20 to 1.50, and
satisfies all of conditions (a) to (d) below:
(a) L n satisfies 0.75×(R n +R n+1 )≤L n ≤2.0×(R n +R n+1 ), wherein R n [mm] is a roller diameter of an n-th roller, R n+1 [mm] is a roller diameter of an (n+1)-th roller, and L n [mm] is a distance between an n-th roller axis and an (n+1)-th roller axis;
(b) a width W 0 of the fiber bundle before contacting a first roller is 2.0×10 −4 to 6.0×10 −4 mm/dtex;
(c) a width W 2 of the fiber bundle after leaving an m-th roller satisfies 1.0≤W 2 /W 0 ≤1.1; and
(d) a width W 1 of the fiber bundle on second to (m−1)-th rollers satisfies W 1 /W 0 ≥1.4 in all the second to (m−1)-th rollers.

2. The method according to claim 1 , wherein an angle at which the fiber bundle contacts a roller is 15 to 70° for the first and m-th rollers, and is 30 to 140° for the second to (m−1)-th rollers.

3. The method according to claim 1 , wherein the fiber bundle has a tension of 30 to 180 mg/dtex.

4. A method of manufacturing a carbon fiber bundle comprising:
obtaining a stabilized fiber bundle by the method according to claim 1 ; and
carbonizing the stabilized fiber bundle in an inert atmosphere at 1000 to 2500° C.

5. The method according to claim 2 , wherein the fiber bundle has a tension of 30 to 180 mg/dtex.

6. A method of manufacturing a carbon fiber bundle comprising:
obtaining a stabilized fiber bundle by the method according to claim 2 ; and
carbonizing the stabilized fiber bundle in an inert atmosphere at 1000 to 2500° C.

7. A method of manufacturing a carbon fiber bundle comprising:
obtaining a stabilized fiber bundle by the method according to claim 3 ; and
carbonizing the stabilized fiber bundle in an inert atmosphere at 1000 to 2500° C.

Assignees

• Toray Industries

Inventors

• Nishikawa Yuki
• Ito Takahiro
• KAIKI Hiroyuki

Classifications

• D10B2321/10

  polymers of unsaturated nitriles, e.g. polyacrylonitrile, polyvinylidene cyanide · CPC title

• D01D10/02 Primary

  Heat treatment (heating for finishing D02J13/00) · CPC title

• D01F9/328

  for manufacturing filaments from polyaddition, polycondensation, or polymerisation products · CPC title

• D02J13/001

  in a tube or vessel · CPC title

• D02J13/005

  by contact with at least one rotating roll · CPC title