Method for manufacturing carbon fiber bundle

Patent metadata

Field	Value
Publication number	US-12359349-B2
Application number	US-202117911776-A
Country	US
Kind code	B2
Filing date	Mar 15, 2021
Priority date	Mar 30, 2020
Publication date	Jul 15, 2025
Grant date	Jul 15, 2025

Abstract

A method for manufacturing a carbon fiber bundle includes a stabilization process of subjecting an acrylic fiber bundle to a heat treatment within a range of 200° C. to 300° C. in an oxidizing atmosphere; a pre-carbonization process of performing a heat treatment within a range of 300° C. to 1,000° C. using a heat treatment furnace having at least one inert gas supply port on each of an incoming side and an outgoing side of the fiber bundle and at least one exhaust port between the incoming-side and outgoing-side inert gas supply ports, the heat treatment being performed with a temperature of an inert gas supplied being higher on the outgoing side than on the incoming side; and a carbonization process of performing a heat treatment at a temperature of 1,000° C. to 2,000° C. in an inert gas atmosphere, in which from a position at which an atmospheric temperature in the heat treatment furnace is 300° C., the position being closest to the outgoing side in a machine length direction, up to the inert gas supply port on the incoming side, a flow of an inert atmosphere within the heat treatment furnace in the pre-carbonization process consists only of a flow in a parallel flow direction with respect to a travel direction of the fiber bundle in the machine length direction. Provided is a method for manufacturing a carbon fiber bundle by which manufacturing can be performed continuously for a long time by preventing entry into a temperature zone causing deposition of a gasified decomposition product, such as tar, that is generated at the time of the pre-carbonization treatment in manufacturing of carbon fibers and that stays within the heat treatment furnace.

First claim

The invention claimed is:

1. A method for manufacturing a carbon fiber bundle, the method comprising:
a stabilization process of subjecting an acrylic fiber bundle to a heat treatment within a range of 200° C. to 300° C. in an oxidizing atmosphere;
a pre-carbonization process of performing a heat treatment within a range of 300° C. to 1,000° C. using a heat treatment furnace having at least one inert gas supply port on each of an incoming side and an outgoing side of the fiber bundle and at least one exhaust port between the incoming-side and outgoing-side inert gas supply ports, the heat treatment being performed with a temperature of an inert gas supplied being higher on the outgoing side than on the incoming side; and
a carbonization process of performing a heat treatment at a temperature of 1,000° C. to 2,000° C. in an inert gas atmosphere,
wherein, from a position at which an atmospheric temperature in the heat treatment furnace is 300° C., the position being on the most outgoing side in a machine length direction, up to the inert gas supply port on the incoming side, a flow of an inert atmosphere within the heat treatment furnace in the pre-carbonization process consists only of a flow in a parallel flow direction with respect to a travel direction of the fiber bundle in the machine length direction.

2. The method for manufacturing a carbon fiber bundle according to claim 1 ,
wherein the pre-carbonization process is performed in the heat treatment furnace having 3 or more sections in which temperature control is possible in the machine length direction, and
the temperature of the inert gas supplied to the heat treatment furnace satisfies 2 conditions below, where T 1 [° C.] represents an atmospheric temperature at a fiber bundle height at a central position in the machine length direction in a section that is on the most incoming side with respect to the machine length direction of a heat treatment chamber, and T 2 [° C.] represents an atmospheric temperature at a fiber bundle height at a central position in the machine length direction in a section that is on the most outgoing side with respect to the machine length direction of the heat treatment chamber:
temperature range of inert gas supplied on incoming side [° C.]: |T 1 −(temperature of inert gas supplied on incoming side)|=ΔT 1 ≤50, and
temperature range of inert gas supplied on outgoing side [° C.]: |T 2 −(temperature of inert gas supplied on outgoing side)|=ΔT 2 ≤100.

3. The method for manufacturing a carbon fiber bundle according to claim 1 ,
wherein a cross-sectional area is substantially uniform in the machine length direction of the heat treatment furnace in the pre-carbonization process, and
an absolute value ratio (|V 1 |/|V 2 |) of a flow speed V 1 described below to a flow speed V 2 described below satisfies 0.5≤|V 1 |/|V 2 |≤2.0,
where V 1 [m/s] is a flow speed of the inert atmosphere in a horizontal direction at a central position in the machine length direction of a section on the most incoming side with respect to the machine length direction of the heat treatment chamber, and
V 2 [m/s] is a flow speed of the inert atmosphere in the horizontal direction at a central position in the machine length direction in a section on the most outgoing side with respect to the machine length direction of the heat treatment chamber.

Assignees

• Toray Industries

Inventors

• Kataoka Takuya
• Hosotani Naoto
• Hirose Takamitsu
• Kuji Yusuke

Classifications

• F27D2007/023

  Conduits · CPC title

• F27D7/02

  Supplying steam, vapour, gases or liquids · CPC title

• F27B9/40

  Arrangements of controlling or monitoring devices · CPC title

• F27B9/047

  the atmosphere consisting of protective gases · CPC title

• D01F9/32 Primary

  Apparatus therefor · CPC title