Method for producing graphite film

Patent metadata

Field	Value
Publication number	US-9845267-B2
Application number	US-201614995016-A
Country	US
Kind code	B2
Filing date	Jan 13, 2016
Priority date	Jun 22, 2009
Publication date	Dec 19, 2017
Grant date	Dec 19, 2017

Abstract

Provided is a long and large-area graphite film having improved thermal diffusivity and flex resistance, and accompanied by ameliorated ruffling. According to a method for producing a graphite film, in which graphitization of a heat-treated film consisting of a carbonized polymer film is carried out in a state being wrapped around an internal core, the method being characterized in that a heat treatment is executed by controlling distance(s) between the internal core and the film, and/or between the layers of the film, a graphite film accompanied by significantly ameliorated ruffling can be obtained.

First claim

The invention claimed is:

1. A method for producing a graphite film, the method comprising
providing a heat-treated film that is a polymer film that has been subjected to a heat treatment,
graphitizing the heat-treated film to give the graphite film, wherein the graphitizing comprises substeps (i) and (ii):
(i) subjecting the heat-treated film in a form of a roll without any internal core to a first graphitizing heat treatment at a temperature of not less than 2,000° C., wherein the heat-treated film is loosened by the first graphitizing heat treatment, and
(ii) winding up the heat-treated, loosened film around an internal core during the first graphitizing heat treatment, after the first graphitizing heat treatment and prior to a subsequent graphitizing heat treatment, or during a subsequent graphitizing heat treatment.

2. The method for producing a graphite film according to claim 1 , wherein the graphitizing heat treatment is carried out a plurality of times.

3. The method for producing a graphite film according to claim 2 , wherein the winding up is carried out during the plurality of times of the graphitizing heat treatment.

4. The method for producing a graphite film according to claim 3 , wherein the winding up is carried out after a first graphitizing heat treatment and prior to a subsequent graphitizing heat treatment.

5. The method for producing a graphite film according to claim 4 , wherein the film is cooled to room temperature when the winding up is carried out.

6. The method for producing a graphite film according to claim 1 , wherein the winding up is carried out during the graphitizing heat treatment before reaching a highest temperature of the graphitizing heat treatment.

7. The method for producing a graphite film according to claim 6 , wherein the winding up is carried out at a temperature of not less than 1,400° C.

8. The method for producing a graphite film according to claim 6 , wherein the winding up is carried out at a temperature of lower than 1,400° C.

9. The method for producing a graphite film according to claim 1 , wherein the heat-treated, loosened film consists of a carbonized polymer film.

10. The method for producing a graphite film according to claim 1 , wherein in the winding up, the heat-treated, loosened film is wound up such that (w 0 /r 0 ×100) is not greater than 7, wherein the length of the outer periphery of the internal core is defined as r 0 , and the spatial distance between the internal core and the first layer of the heat-treated film is defined as w 0 .

11. The method for producing a graphite film according to claim 1 , wherein in the winding up, the heat-treated, loosened film is wound up such that the distance w n is not greater than 5 mm in N h ×0.5 or more spaces between the layers of the heat-treated film from among spaces between the layers of the heat-treated film that are present in the number of N h , wherein the winding number of the heat-treated film is defined as N h , and the spatial distance between the n-th layer of the heat-treated film and the n+one-th layer (wherein n represents an integer of 0 to N h −1, and the null layer corresponds to the outer surface of the internal core) of the heat-treated film is defined as w n .

12. The method for producing a graphite film according to claim 1 , wherein in the winding up, the heat-treated, loosened film is wound up such that ((r n+1 −r n )/r n ×100) is not greater than 8, wherein the roll length of the n-th layer of the heat-treated film is defined as r n , and the roll length of the n+one-th layer of the heat-treated film is defined as r n+1 (wherein n is 0 or a nonnegative integer, and r 0 represents the length of the outer periphery of the internal core).

13. The method for producing a graphite film according to claim 1 , wherein in the winding up, the heat-treated, loosened film is wound up such that (D/(N h ×d)) is not less than 1 and not greater than 2.5, wherein the winding number of the heat-treated film is defined as N h , the thickness of the heat-treated film per layer is defined as d, and the apparent rolling thickness of the heat-treated film is defined as D.

14. The method for producing a graphite film according to claim 1 , wherein carrying out the graphitizing heat treatment to not less than 2,200° C. is followed by winding up of the heat-treated film.

15. The method for producing a graphite film according to claim 1 , wherein the winding up of the heat-treated, loosened film is carried out by rotating the internal core.

16. The method for producing a graphite film according to claim 1 , wherein the winding up of the heat-treated, loosened film is carried out by rotating the heat-treated, loosened film.

17. The method for producing a graphite film according to claim 1 , wherein the heat-treated, loosened film is rewound onto the internal core such that the innermost portion of the heat-treated, loosened film before unwinding is the outermost portion of the heat-treated, loosened film after re-winding.

18. The method for producing a graphite film according to claim 1 , wherein the winding up of the heat-treated, loosened film is carried out a plurality of times.

Assignees

• Kaneka Corp

Inventors

• Ohta Yusuke
• Mishiro Makoto
• Inada Takashi
• Nishikawa Yasushi

Classifications

• C01B32/19

  by exfoliation · CPC title

• Y10T428/30

  Self-sustaining carbon mass or layer with impregnant or other layer · CPC title

• C08J5/18

  Manufacture of films or sheets · CPC title

• C01B32/225

  Expansion; Exfoliation · CPC title

• C01B32/205 Primary

  Preparation · CPC title