Flame resistant polymer, polymer solution, flame resistant fiber, carbon fiber, and methods of producing same

Patent metadata

Field	Value
Publication number	US-2016153121-A1
Application number	US-201414904455-A
Country	US
Kind code	A1
Filing date	Jul 11, 2014
Priority date	Jul 12, 2013
Publication date	Jun 2, 2016
Grant date	—

Abstract

A flame resistant polymer is obtained by reacting polyacrylonitrile with amine and nitro compounds, the polyacrylonitrile being polymerized by aqueous suspension polymerization using a redox initiator and containing an S component at an amount of 3,000 μg/g or less. A PAN-based polymer in which both yarn producing properties and flame resistance are improved can be realized.

First claim

1 - 12 . (canceled)

13 . A flame resistant polymer obtained by reacting polyacrylonitrile with amine and nitro compounds, said polyacrylonitrile being polymerized by aqueous suspension polymerization using a redox initiator and containing an S component at an amount of 3,000 μg/g or less.

14 . The flame resistant polymer according to claim 13 , wherein said polyacrylonitrile is polymerized using a persulfate-based oxidant as an oxidant used for combination of said redox initiator in an amount of 0.5 to 6 wt % relative to acrylonitrile.

15 . The flame resistant polymer according to claim 13 , wherein said polyacrylonitrile is polymerized using a sulfite-based reductant as a reductant used for combination of said redox initiator in an amount of 0.25 to 3 wt % relative to acrylonitrile.

16 . The flame resistant polymer according to claim 13 , wherein said polyacrylonitrile has a number average molecular weight Mn of 30,000 or more and 300,000 or less, and a molecular weight distribution (Mw/Mn), which is a ratio of a weight average molecular weight Mw to said number average molecular weight Mn, of 1 or more and 5 or less.

17 . The flame resistant polymer according to claim 13 , wherein a content of an S component is 3,000 μg/g or less.

18 . A method of producing a flame resistant polymer comprising:
polymerizing polyacrylonitrile containing an S component at an amount of 3,000 μg/g or less by aqueous suspension polymerization using a redox initiator; and reacting said polyacrylonitrile with amine and nitro compounds.

19 . A polymer solution containing a flame resistant polymer according to claim 13 and an organic solvent.

20 . A method of producing a polymer solution comprising dissolving a flame resistant polymer prepared by the method according to claim 18 in an organic solvent.

21 . A flame resistant fiber prepared by solution spinning a polymer solution according to claim 19 .

22 . A method of producing a flame resistant fiber comprising a step of solution spinning a polymer solution prepared by the method according to claim 20 .

23 . A carbon fiber prepared by carbonizing a flame resistant fiber according to claim 21 .

24 . A method of producing a carbon fiber comprising a step of carbonizing a flame resistant fiber prepared by the method according to claim 22 .

25 . The flame resistant polymer according to claim 14 , wherein said polyacrylonitrile is polymerized using a sulfite-based reductant as a reductant used for combination of said redox initiator in an amount of 0.25 to 3 wt % relative to acrylonitrile.

26 . The flame resistant polymer according to claim 14 , wherein said polyacrylonitrile has a number average molecular weight Mn of 30,000 or more and 300,000 or less, and a molecular weight distribution (Mw/Mn), which is a ratio of a weight average molecular weight Mw to said number average molecular weight Mn, of 1 or more and 5 or less.

27 . The flame resistant polymer according to claim 15 , wherein said polyacrylonitrile has a number average molecular weight Mn of 30,000 or more and 300,000 or less, and a molecular weight distribution (Mw/Mn), which is a ratio of a weight average molecular weight Mw to said number average molecular weight Mn, of 1 or more and 5 or less.

28 . The flame resistant polymer according to claim 14 , wherein a content of an S component is 3,000 μg/g or less.

29 . The flame resistant polymer according to claim 15 , wherein a content of an S component is 3,000 μg/g or less.

30 . The flame resistant polymer according to claim 16 , wherein a content of an S component is 3,000 μg/g or less.

Assignees

• Univ Tokyo

Inventors

• Higuchi Tetsunori
• SAKAGUCHI Mami

Classifications

• C08L2203/12

  used for fibers · CPC title

• C08F120/44

  Acrylonitrile · CPC title

• D01F6/18 Primary

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

• D01F9/22

  from polyacrylonitriles · CPC title

• C08L2201/56

  Non-aqueous solutions or dispersions · CPC title