Stock material or miscellaneous articles – Coated or structually defined flake – particle – cell – strand,... – Rod – strand – filament or fiber
Patent
1990-04-11
1994-01-11
Ryan, Patrick J.
Stock material or miscellaneous articles
Coated or structually defined flake, particle, cell, strand,...
Rod, strand, filament or fiber
428391, 428397, 428400, 428364, 4234471, 4234472, 525474, 501 75, B32B 900, D02G 300
Patent
active
052779734
DESCRIPTION:
BRIEF SUMMARY
TECHNOLOGICAL FIELD
This invention relates to carbon fibers having high strength and high modulus of elasticity, and polymer compositions for their production. More specifically, it relates to carbon fibers containing silicon, or both silicon and a specific transition metal atom, and polymer compositions for their production.
BACKGROUND TECHNOLOGY
Carbon fibers have light weight, high strength and high modulus of elasticity, and therefore, their utility is not only in sporting and leasure goods, but has been expanded to a wide range of fields including aircraft, automobiles and building materials.
PAN-type carbon fibers derived from polyacrylonitrile as a raw material and pitch-type carbon fibers obtained from petroleum and coal pitches as raw materials are known as the carbon fibers.
Japanese Laid-Open Patent Publication No. 223316/1984 discloses a process for producing fibers having high strength and high modulus of elasticity, which comprises
(a) hydrogenating a pitch, separating the solid from the hydrogenation product, and removing low-boiling components by distillation to obtain a hydrogenated pitch, mesophase pitch (containing not more than 90% by weight of mesophase carbon and at least 30% of optically anisotropic fibers), and thereafter
(c) melt-spinning the mesophase pitch, and rendering the fibers infusible and carbonize them.
International Patent Laid-Open WO87/05612 and Japanese Laid-Open Patent Publication No. 209139/1987, the corresponding Japanese priority application, discloses an organopolyarylsilane being soluble in organic solvents and comprising organosilane segments in which the skeletal portion is composed mainly of carbosilane and polysilane, said segments being connected at random via silicon-carbon linking groups.
Laid-Open International Patent WO 87/05612 and Japanese Laid-Open Patent Publication No. 215016/1987, the corresponding Japanese priority application, disclose continuous SiC-C type inorganic fibers composed of molecules having carbon and SiC as main constituents and containing 5 to 55% by weight of Si, 40 to 95% by weight of C and 0.01 to 15% by weight of 0, said inorganic fibers showing excellent thermally resistant strength and oxidation resistance with a volume resistivity of 10 to 10.sup.-3 ohms-cm.
The above laid-open specifications describe a process for producing inorganic fibers having properties intermediate between the silicon carbide fibers and carbon fibers, which comprise mixing an organic solvent-soluble component of a coal or petroleum pitch with a polysilane, and reacting the mixture under heat to synthesize an organopolyarylsilane, and spinning it and rendering the fibers infusible and curing the fibers.
However, in the above process, a pitch quite free from an organic solvent-insoluble portion is selected as one of the starting materials, and in the production of the organopolyarylsilane, the reaction is carried out under such conditions that no organic solvent-insoluble portion is formed.
Accordingly, the resulting product as a spinning material does not at all contain the above insoluble portion in the mesophase, which is said to be the most important component for development of strength by carbon fibers.
Inorganic fibers obtained by spinning, rendering the fibers infusible and curing them gives a diffraction line (002) corresponding to the graphite crystals of carbon under certain conditions, but no orientation inherent to pitch fibers is noted. Furthermore, in the process described in the above patent documents, the heat resistance of the fibers in an inert gas is enhanced as the proportion of the pitch content increases. But, on the contrary, the oxidation resistance of the fibers is decreased, and moreover, their mechanical characteristics tend to be reduced markedly.
Japanese Laid-Open Patent Publication No. 7737/1987 discloses a composite material comprising a matrix of a plastic and as a reinforcing material hybrid fibers consisting of inorganic fibers containing silicon, titanium (or zirconium), carbon and oxygen and at least one kind of
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patent: 4376747 (1983-03-01), Nazem
patent: 4504454 (1985-03-01), Riggs
patent: 4628001 (1986-12-01), Sasaki et al.
patent: 4818612 (1989-04-01), Hara et al.
patent: 4879334 (1989-11-01), Hasegawa et al.
Ishikawa Toshihiro
Kugimoto Junichi
Shibuya Masaki
Sioji Yasuhiro
Yamamura Takemi
Gray J. N.
Ryan Patrick J.
Ube Industries Ltd.
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