Sizing agent composition, carbon fiber material and composite material

Patent metadata

Field	Value
Publication number	US-11898306-B2
Application number	US-202217851681-A
Country	US
Kind code	B2
Filing date	Jun 28, 2022
Priority date	Jun 28, 2021
Publication date	Feb 13, 2024
Grant date	Feb 13, 2024

Abstract

The present application relates to a sizing agent composition, a carbon fiber material and a composite material. The sizing agent composition comprises specific compositions, thereby producing a sizing agent having emulsion droplets with specific diameter. The sizing agent has excellent emulsion stability, and it can efficiently improve hygroscopicity and dimensional stability of the carbon fiber material. Besides, the sizing agent can improve bonding properties between the carbon fiber material and resin matrix, therefore enhancing properties of the composite material.

First claim

What is claimed is:

1. A sizing agent composition, comprising:
an epoxy compound;
a dicyclopentadiene compound, wherein the dicyclopentadiene compound has a structure shown as the following formula (I):

wherein A independently represents a non-polar cyclic group; R independently represents a hydrogen atom or a functional group shown as the following formula (I-1) to formula (I-3); and n represents 0 or 1;

in the formula (I-3), m represents 1 to 5;
a surfactant; and
water,
wherein based on an amount of the sizing agent composition as 100 parts by weight, an amount of the epoxy compound is 2 parts by weight to 30 parts by weight, an amount of the dicyclopentadiene compound is 2 parts by weight to 30 parts by weight, an amount of the surfactant is 0.5 parts by weight to 15 parts by weight, and an amount of the water is 25 parts by weight to 95.5 parts by weight.

2. The sizing agent composition of claim 1 , wherein an epoxy equivalent of the epoxy compound is 100 g/eq to 1500 g/eq.

3. The sizing agent composition of claim 1 , wherein at least one of the R represents the structure shown as the formula (I-3).

4. The sizing agent composition of claim 1 , wherein the dicyclopentadiene compound has a structure shown as the following formula (III):

in the formula (III), R 1 and R 2 represent a hydrogen atom, and R 3 represents the structure shown as the formula (I-3).

5. The sizing agent composition of claim 1 , wherein the surfactant includes a nonionic surfactant.

6. The sizing agent composition of claim 1 , wherein the surfactant includes an anionic surfactant or a combination of an anionic surfactant and a nonionic surfactant.

7. The sizing agent composition of claim 1 , wherein the surfactant includes an anionic surfactant with ammonium ion.

8. The sizing agent composition of claim 1 , wherein the sizing agent composition excludes an organic solvent.

9. The sizing agent composition of claim 1 , wherein the sizing composition is an emulsion and in a form of emulsified droplets, and a droplet diameter of the emulsified droplets is not larger than 1 μm.

10. A carbon fiber material, comprising:
a carbon fiber substrate; and
a sizing agent comprising the sizing agent composition of claim 1 , wherein the sizing agent is coated on a surface of the carbon fiber substrate, and a droplet diameter of the sizing agent is not larger than 1 μm.

11. The carbon fiber material of claim 10 , wherein the sizing agent is not subjected to a thermal reaction at a temperature less than and equal to 250° C., and the thermal reaction is induced by heat energy.

12. The carbon fiber material of claim 10 , wherein a sizing ratio of the carbon fiber material is 0.1 wt % to 5 wt %.

13. The carbon fiber material of claim 12 , wherein a hygroscopicity of the carbon fiber material is lower than 0.05%, and a dimensional change ratio of the carbon fiber material is lower than 0.05%.

14. A composite material, comprising:
a resin matrix; and
the carbon fiber material of claim 10 , wherein the carbon fiber material is dispersed in the resin matrix, and interlaminar shear strength (ILSS) between the resin matrix and the carbon fiber material is not less than 8 kgf/mm 2 .

Assignees

• Formosa Plastics Corp

Inventors

• Chen Hsuan-Yin
• Hwang Long-Tyan

Classifications

• D06M15/55 Primary

  Epoxy resins · CPC title

• C08K9/04

  Ingredients treated with organic substances {(treated with macromolecular compounds C08K9/08)} · CPC title

• D01F9/12

  Carbon filaments; Apparatus specially adapted for the manufacture thereof · CPC title

• D01F11/14

  with organic compounds, e.g. macromolecular compounds · CPC title

• D06M13/07

  Aromatic hydrocarbons · CPC title