US2019194829A1PendingUtilityA1

Coagulated yarn and manufacturing method thereof, carbon fiber precursor fiber, and method of manufacturing carbon fiber

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Assignee: TORAY INDUSTRIESPriority: Sep 12, 2016Filed: Aug 30, 2017Published: Jun 27, 2019
Est. expirySep 12, 2036(~10.1 yrs left)· nominal 20-yr term from priority
Inventors:Kentaro KajiwaraAyanobu HorinouchiHaruki OkudaTomohisa NoguchiFumitaka Watanabe
D01F 6/18D01D 5/06D01F 9/225D01F 6/38D01F 9/22D01F 9/14
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Claims

Abstract

A coagulated yarn, which is used to manufacture carbon fiber, is a coagulated yarn the surface hole diameter of which is 30 nm or less and the degree of swelling is less than 100% or a coagulated yarn the surface hole diameter of which is 30 nm or less and the inner hole diameter is 30 nm or less. The carbon fiber precursor fiber and the carbon fiber are obtained using such a coagulated yarn.

Claims

exact text as granted — not AI-modified
1 - 11 . (canceled) 
     
     
         12 . A coagulated yarn used to produce a precursor fiber for carbon fiber, wherein pore size of the surface layer is 30 nm or less and degree of swelling is less than 100%. 
     
     
         13 . A coagulated yarn used to produce a precursor fiber for carbon fiber, wherein pore size of the surface layer is 30 nm or less and pore size of the inner layer is 30 nm or less. 
     
     
         14 . The coagulated yarn according to  claim 12 , wherein the pore size of the surface layer is 30 nm or less and pore size of the inner layer is 30 nm or less. 
     
     
         15 . A method of producing the coagulated yarn according to  claim 12  comprising coagulating the polymer using a coagulation bath prepared by mixing a non-solvent having a solubility parameter of −11 to +20 in relation to the solubility parameter of the polymer to form the coagulated yarn and a solvent of the polymer to form the coagulated yarn at a non-solvent to solvent ratio of 1:9 to 9:1. 
     
     
         16 . The method according to  claim 15  using a coagulation bath, wherein the non-solvent has a diffusion coefficient of up to 3.4×10 −10  m 2 ·S− 1 . 
     
     
         17 . The method according to  claim 15 , wherein the coagulation bath has a viscosity of 2 to 1000 mPa·s. 
     
     
         18 . The method according to  claim 15 , wherein the coagulation bath has a temperature 10 to 100° C. lower than the temperature of the polymer solution. 
     
     
         19 . The method according to  claim 15 , further comprising spinning at a spinning draft of 1 to 20. 
     
     
         20 . A method of producing a precursor fiber comprising stretching the coagulated yarn according to  claim 12 . 
     
     
         21 . A method of producing precursor fiber for carbon fiber comprising obtaining a coagulated yarn by the method according to  claim 15  and stretching the coagulated yarn. 
     
     
         22 . A method of producing a carbon fiber comprising producing a precursor fiber for carbon fiber by the method according to  claim 20  and subjecting the precursor fiber for carbon fiber to a heat treatment. 
     
     
         23 . A method of producing the coagulated yarn according to  claim 13  comprising coagulating the polymer using a coagulation bath prepared by mixing a non-solvent having a solubility parameter of −11 to +20 in relation to the solubility parameter of the polymer to form the coagulated yarn and a solvent of the polymer to form the coagulated yarn at a non-solvent to solvent ratio of 1:9 to 9:1. 
     
     
         24 . A method of producing the coagulated yarn according to  claim 14  comprising coagulating the polymer using a coagulation bath prepared by mixing a non-solvent having a solubility parameter of −11 to +20 in relation to the solubility parameter of the polymer to form the coagulated yarn and a solvent of the polymer to form the coagulated yarn at a non-solvent to solvent ratio of 1:9 to 9:1. 
     
     
         25 . The method according to  claim 16 , wherein the coagulation bath has a viscosity of 2 to 1000 mPa·s. 
     
     
         26 . The method according to  claim 16 , wherein the coagulation bath has a temperature 10 to 100° C. lower than the temperature of the polymer solution. 
     
     
         27 . The method according to  claim 17 , wherein the coagulation bath has a temperature 10 to 100° C. lower than the temperature of the polymer solution. 
     
     
         28 . The method according to  claim 16 , further comprising spinning at a spinning draft of 1 to 20. 
     
     
         29 . The method according to  claim 17 , further comprising spinning at a spinning draft of 1 to 20. 
     
     
         30 . The method according to  claim 18 , further comprising spinning at a spinning draft of 1 to 20.

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