Carbon fiber complex material and manufacturing method thereof, manufacturing apparatus for carbon fiber complex material, prepreg, and carbon fiber reinforced plastic composite material

Patent metadata

Field	Value
Publication number	US-2020208341-A1
Application number	US-202016813832-A
Country	US
Kind code	A1
Filing date	Mar 10, 2020
Priority date	Sep 11, 2017
Publication date	Jul 2, 2020
Grant date	—

Abstract

A carbon fiber complex material for a carbon fiber reinforced plastic composite material includes a carbon fiber material formed from a continuous carbon fiber, and carbon nanowalls formed on a surface of the continuous carbon fiber.

First claim

What is claimed is:

1 . A carbon fiber complex material for a carbon fiber reinforced plastic composite material, comprising:
a carbon fiber material formed from a continuous carbon fiber; and carbon nanowalls formed on a surface of the continuous carbon fiber.

2 . The carbon fiber complex material according to claim 1 , wherein the carbon fiber material is a carbon fiber fabric woven from the continuous carbon fibers.

3 . The carbon fiber complex material according to claim 1 , wherein the carbon nanowalls are formed upright on the surface of the continuous carbon fiber.

4 . The carbon fiber complex material according to claim 3 , wherein the carbon nanowalls are formed to extend outward in a radial direction of the continuous carbon fiber.

5 . The carbon fiber complex material according to claim 1 , wherein the carbon nanowalls are formed away from one another.

6 . The carbon fiber complex material according to claim 1 , wherein
a height of each carbon nanowall is equal to or below 100 nm.

7 . The carbon fiber complex material according to claim 1 , wherein a length of the continuous carbon fiber is equal to or above 3 m.

8 . A method of manufacturing a carbon fiber complex material for a carbon fiber reinforced plastic composite material, comprising:
a feeding step of feeding a carbon fiber material formed from a continuous carbon fiber out of a feeding bobbin around which the carbon fiber material is wound; a carbon nanowall forming step of forming carbon nanowalls on a surface of the continuous carbon fiber of the carbon fiber material by heating the carbon fiber material fed out of the feeding bobbin to 500° C. or above and supplying a raw material gas containing a carbon source gas to cause a reaction in plasma; and a winding step of winding the carbon fiber material, which is provided with the carbon nanowalls on the surface of the continuous carbon fiber, around a winding bobbin.

9 . The method of manufacturing a carbon fiber complex material according to claim 8 , further comprising:
a surface activation treatment step of supplying plasma containing an inert gas but no carbon source gas to the continuous carbon fiber of the carbon fiber material fed out of the feeding bobbin before formation of the carbon nanowalls on the surface of the continuous carbon fiber.

10 . The method of manufacturing a carbon fiber complex material according to claim 8 , wherein the carbon nanowall forming step includes mixing the raw material gas with hydrogen gas.

11 . A manufacturing apparatus for a carbon fiber complex material for a carbon fiber reinforced plastic composite material, comprising:
an apparatus body provided with a chamber; a raw material gas supply unit provided to the apparatus body and configured to supply a raw material gas containing a carbon source gas to the chamber; a plasma generation unit provided to the apparatus body and configured to generate plasma in the chamber; a feeding bobbin around which a carbon fiber material formed from a continuous carbon fiber is wound, the feeding bobbin configured to feed the carbon fiber material out; a winding bobbin configured to wind the carbon fiber material provided with carbon nanowalls on a surface of the continuous carbon fiber; and a heating unit located opposite to the plasma generated in the chamber while interposing the carbon fiber material in between, and configured to heat the carbon fiber material.

12 . The manufacturing apparatus for the carbon fiber complex material according to claim 11 , wherein the heating unit comprises a preheating unit provided to extend toward the feeding bobbin and configured to preheat the continuous carbon fiber of the carbon fiber material before formation of the carbon nanowalls.

13 . A manufacturing apparatus for a carbon fiber complex material for a carbon fiber reinforced plastic composite material, comprising:
an apparatus body provided with a chamber, the chamber including
a first sub-chamber in which a carbon fiber material formed from a continuous carbon fiber is subjected to a surface activation treatment,
a second sub-chamber in which carbon nanowalls are formed on a surface of the continuous carbon fiber of the carbon fiber material subjected to the surface activation treatment, and
a partition wall partitioning the first sub-chamber and the second sub-chamber, the partition wall including a slit to allow insertion of the carbon fiber material subjected to the surface activation treatment;
a surface activation treatment gas supply unit provided to the apparatus body and configured to supply a surface activation treatment gas containing an inert gas but no carbon source gas to the first sub-chamber; a raw material gas supply unit provided to the apparatus body and configured to supply a raw material gas containing the carbon source gas to the second sub-chamber; a first plasma generation unit provided to the apparatus body and configured to generate plasma in the first sub-chamber; a second plasma generation unit provided to the apparatus body and configured to generate plasma in the second sub-chamber; a feeding bobbin around which the carbon fiber material is wound, the feeding bobbin provided to the first sub-chamber and configured to feed the carbon fiber material out; a winding bobbin provided to the second sub-chamber and configured to wind the carbon fiber material provided with the carbon nanowalls on the surface of the continuous carbon fiber; a first heating unit provided to the first sub-chamber, located opposite to the first plasma generation unit while interposing the carbon fiber material in between, and configured to heat the carbon fiber material; and a second heating unit provided to the second sub-chamber, located opposite to the second plasma generation unit while interposing the carbon fiber material subjected to the surface activation treatment in between, and configured to heat the carbon fiber material subjected to the surface activation treatment.

14 . A prepreg comprising:
the carbon fiber complex material according to claim 1 ; and a semicured resin layer made of a semicured resin and provided to the carbon fiber complex material.

15 . A carbon fiber reinforced plastic composite material comprising:
the carbon fiber complex material according to claim 1 ; and a matrix resin layer made of a cured resin material and provided to the carbon fiber complex material.

Assignees

• Ihi Corp

Inventors

• Yoshimura Akihiko
• Chishina Hirotsugu
• Hirata Kensuke

Classifications

• C08J5/248

  using pre-treated fibres · CPC title

• D06M2200/50

  Modified hand or grip properties; Softening compositions · CPC title

• D06M2101/40

  Fibres of carbon · CPC title

• D06M13/03

  with unsaturated hydrocarbons, e.g. alkenes, or alkynes · CPC title

• D06M13/02

  with hydrocarbons · CPC title