Reinforcing carbon fiber bundle, method for manufacturing the same and method for manufacturing composite using the same

Patent metadata

Field	Value
Publication number	US-9732195-B2
Application number	US-201314401377-A
Country	US
Kind code	B2
Filing date	May 14, 2013
Priority date	May 15, 2012
Publication date	Aug 15, 2017
Grant date	Aug 15, 2017

Abstract

There is provided a reinforcing carbon fiber bundle of the present invention is a reinforcing carbon fiber bundle with a sizing agent adhered to surfaces of carbon fibers, and characterized in that the sizing agent is constituted by at least two components, a first component does not melt at 150° C., and a second component in flowable at 150° C., and the reinforcing carbon fiber bundle is improved in impregnation property and openability and is excellent in workability and optimum for a composite.

First claim

The invention claimed is:

1. A reinforcing carbon fiber bundle comprising a sizing agent adhered to a surface of carbon fibers,
wherein the sizing agent comprises at least two components,
a first component of the at least two components does not melt at 150° C., and
a second component of the at least two components is a polyamide ternary copolymer resin and has fluidity at 150° C.

2. The reinforcing carbon fiber bundle according to claim 1 ,
wherein the first component is in a granular form.

3. The reinforcing carbon fiber bundle according to claim 1 ,
wherein an amount of the sizing agent adhered to the carbon fibers is within a range of 0.1 to 20% by weight.

4. The reinforcing carbon fiber bundle according to claim 1 ,
wherein a content (weight ratio) of the first component is twice or more a content of the second component.

5. The reinforcing carbon fiber bundle according to claim 1 ,
wherein the first component is adhered to the surface of carbon fibers through the second component.

6. The reinforcing carbon fiber bundle according to claim 1 ,
wherein a melting point of the first component is 150° C. or more, and
a melting point of the second component is less than 150° C.

7. A composite comprising the reinforcing carbon fiber bundle according to claim 1 and a resin.

8. The composite according to claim 7 ,
wherein the resin is a thermoplastic resin.

9. The composite according to claim 7 ,
wherein the reinforcing carbon fiber bundle is composed of fibers having a length of 100 mm or less.

10. The composite according to claim 7 ,
wherein the reinforcing carbon fiber bundle is composed of continuous fibers.

11. A method for manufacturing a composite, comprising press molding a mixture of the reinforcing carbon fiber bundle according to claim 1 and a resin.

12. The method for manufacturing a composite according to claim 11 ,
wherein the reinforcing carbon fiber bundle in the mixture is arranged randomly in plane.

13. A method for manufacturing a reinforcing carbon fiber bundle, comprising drying a carbon fiber bundle to which a sizing liquid is imparted,
wherein the sizing liquid comprises at least two components, and
at a drying temperature, a first component of the at least two components does not melt and a second component of the at least two components is a polyamide ternary copolymer resin and has fluidity.

14. The method for manufacturing a reinforcing carbon fiber bundle according to claim 13 ,
wherein the first component is in a granular form.

15. The method for manufacturing a reinforcing carbon fiber bundle according to claim 13 ,
wherein the second component is in a granular form in the sizing liquid.

16. The method for manufacturing a reinforcing carbon fiber bundle according to claim 13 ,
wherein a particle size of the first component or a particle size of the second component is 5 μm or less.

17. The method for manufacturing a reinforcing carbon fiber bundle according to claim 13 ,
wherein a content (weight ratio) of the first component is twice or more a content of the second component.

18. The method for manufacturing a reinforcing carbon fiber bundle according to claim 13 ,
wherein a melting point of the first component is equivalent to or more than the drying temperature, and
a melting point of the second component is less than the drying temperature.

Assignees

• Teijin Ltd

Inventors

• Ono Tubasa
• Sakurai Hiroshi
• Naito Takeshi

Classifications

• B29K2077/00

  Use of {PA, i.e.} polyamides, e.g. polyesteramides {or derivatives thereof}, as moulding material · CPC title

• C08J2375/04

  Polyurethanes · CPC title

• C08J2377/02

  Polyamides derived from omega-amino carboxylic acids or from lactams thereof (C08J2377/10 takes precedence) · CPC title

• C08J5/24

  Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs · CPC title

• C08J5/042

  with carbon fibres · CPC title