Chopped carbon fiber bundles and method for producing chopped carbon fiber bundles

Patent metadata

Field	Value
Publication number	US-9803066-B2
Application number	US-201314647343-A
Country	US
Kind code	B2
Filing date	Nov 22, 2013
Priority date	Nov 26, 2012
Publication date	Oct 31, 2017
Grant date	Oct 31, 2017

Abstract

Provided are: chopped carbon fiber bundles which have high fluidity without decreasing the dispersibility of carbon fibers and the physical properties of a molded product; and a method for producing chopped carbon fiber bundles with high productivity. Chopped carbon fiber bundles, each of which contain a carbon fiber bundle having a total fineness of from 25,000 dtex to 45,000 dtex (inclusive) and a sizing agent in an amount of from 1% by mass to 5% by mass (inclusive) relative to the total mass of the chopped carbon fiber bundle. The length (L) of each chopped carbon fiber bundle along the fiber direction of the carbon fiber bundle is from 1 mm to 50 mm (inclusive); the ratio of the longest diameter (Dmax) to the shortest diameter (Dmin) of a cross section perpendicular to the fiber direction of each chopped carbon fiber bundle, namely Dmax/Dmin is from 6.0 to 18.0 (inclusive); and the orientation parameter of the single fibers present in the surface of each chopped carbon fiber bundle is 4.0 or less.

First claim

The invention claimed is:

1. A chopped carbon fiber bundle comprising:
a carbon fiber bundle having a total fineness of from 25,000 dtex to 45,000 dtex; and
a sizing agent in an amount of from 1% by mass to 5% by mass relative to the total mass of the chopped carbon fiber bundle,
wherein
a length (L) of the chopped carbon fiber bundle along the fiber direction of the carbon fiber bundle is from 1 mm to 50 mm,
a ratio (Dmax/Dmin) of the longest diameter (Dmax) and the shortest diameter (Dmin) of a cross-section perpendicular to the fiber direction of the chopped carbon fiber bundle is from 6.0 to 18.0, and
an orientation parameter of single fibers present at the surface of the chopped carbon fiber bundle is 4.0 or less.

2. The chopped carbon fiber bundle according to claim 1 , wherein the ratio (L/Dmin) of the length (L) along the fiber direction of the chopped carbon fiber bundle and the shortest diameter (Dmin) of a cross-section perpendicular to the fiber direction of the chopped carbon fiber bundle is from 5 to 30.

3. The chopped carbon fiber bundle according to claim 1 , wherein a bulk density of the chopped carbon fiber bundle is from 200 g/L to 650 g/L.

4. The chopped carbon fiber bundle according to claim 1 , wherein the sizing agent comprises at least one thermoplastic resin selected from the group consisting of a urethane-based resin, a nylon-based resin, a modified olefin-based resin, a modified epoxy-based resin, and a water-soluble nylon-based resin.

5. The chopped carbon fiber bundle according to claim 3 , wherein the sizing agent comprises at least one thermoplastic resin selected from the group consisting of a urethane-based resin, a nylon-based resin, a modified olefin-based resin, a modified epoxy-based resin, and a water-soluble nylon-based resin.

Assignees

• Mitsubishi Chem Corp

Inventors

• Ohtani Tadashi
• Kiriyama Takayuki
• Nishimoto Yukio

Classifications

• C08J5/24

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

• Y10T428/2918

  including free carbon or carbide or therewith [not as steel] · CPC title

• B05D1/18

  performed by dipping · CPC title

• C08K7/06 Primary

  Elements · CPC title

• D06M15/59

  Polyamides; Polyimides · CPC title