Toray Industries, Inc.

Makoto Endo

Tomoko Ichikawa

Nobuyuki Arai

Hiroshi Taiko

Jun Misumi

Masanobu Kobayashi

Daigo Kobayashi

Haruki Morikawa

Toshiya Kamae

Yoshifumi Nakayama

Eiichi Yamamoto

Fumihiko Tanaka

Keizo Ono

Toshiyuki Miyoshi

Toshinori Kawamura

Mikiya Takechi

Masakatsu Shinto

Shuichi Yamanaka

Jun Yamazaki

Atsuki Tsuchiya

Toshihide Sekido

Takao Sano

Yuuki Okishima

Kazuki Yoshihiro

Seiji Mizukami

Masafumi Ise

Takumi Hiasa

Kousuke Yoshimura

Isao Nakayama

Hisafumi Mizuta

A prepreg includes; sizing agent-coated carbon fibers coated with a sizing agent; and a thermosetting resin composition impregnated into the sizing agent-coated carbon fibers. The sizing agent includes an aliphatic epoxy compound (A) and an aromatic compound (B) at least containing an aromatic epoxy compound (B1). The thermosetting resin composition includes a thermosetting resin (D) and a latent hardener (E), and optionally includes an additive (F) other than the thermosetting resin (D) and the latent hardener (E). The (a)/(b) ratio is within a predetermined range where (a) is the height of a component at a binding energy assigned to CHx, C&#x2014;C, and C&#x2550;C and (b) is the height of a component at a binding energy assigned to C&#x2014;O in a Ccore spectrum of the surfaces of the sizing agent-coated carbon fibers analyzed by X-ray photoelectron spectroscopy.

Prepreg and carbon fiber-reinforced composite material

Sizing agent coated carbon fibers obtained by coating carbon fibers with a sizing agent comprising at least one of (A) to (C) in a total amount of 80 mass % or more with respect to the whole sizing agent, the carbon fibers each having a surface layer which has a thickness of 10 nm or larger and has an oxygen content of 4% or higher with respect to all the elements, wherein when the sizing agent coated carbon fibers are subjected three times to a 10-minute ultrasonic treatment in an acetone solvent, then the amount of the remaining sizing agent is 0.1-0.25 parts by mass per 100 parts by mass of the sizing agent coated carbon fibers. (A) At least one polymer selected from the group consisting of polyimides, polyetherimides, and polysulfones (B) A compound having a terminal unsaturated group and a polar group in the molecule (C) A polyether-type aliphatic epoxy compound and/or a polyol-type aliphatic epoxy compound which each have an epoxy equivalent of 250 g/eq or less and have two or more epoxy groups in the molecule.

Sizing agent coated carbon fiber, method for producing sizing agent coated carbon fiber, carbon fiber reinforced composite material, and method for producing carbon fiber reinforced composite material

A carbon fiber-reinforced resin composition of the present invention includes: sizing agent-coated carbon fibers in which carbon fibers are coated with a sizing agent; and a matrix resin. The sizing agent includes at least an aliphatic epoxy compound (A) and an aromatic epoxy compound (B1) as an aromatic compound (B). The sizing agent-coated carbon fibers have a ratio (a)/(b) of 0.50 to 0.90 where (a) is the height (cps) of a component having a binding energy (284.6 eV) attributed to CHx, C&#x2014;C, and C&#x2550;C and (b) is the height (cps) of a component having binding energy (286.1 eV) attributed to C&#x2014;O in a Ccore spectrum of the surface of the sizing agent measured by X-ray photoelectron spectroscopy at a photoelectron takeoff angle of 15&#xb0;.

Carbon fiber-reinforced resin composition, method for manufacturing carbon fiber-reinforced resin composition, molding material, method for manufacturing molding material, and carbon fiber-reinforced resin molded article

Sizing agent-coated reinforcing fibers include reinforcing fibers and a sizing agent containing a polyrotaxane, the reinforcing fibers being coated with the sizing agent. Provided are sizing agent-coated reinforcing fibers that provide a fiber-reinforced composite material with excellent mechanical properties, a method for producing the sizing agent-coated reinforcing fibers, a prepreg including the sizing agent-coated reinforcing fibers, and a fiber-reinforced composite material with excellent mechanical properties including the sizing agent-coated reinforcing fibers.

Sizing agent-coated reinforcing fibers, method for producing sizing agent-coated reinforcing fibers, prepreg, and fiber-reinforced composite material

The carbon fiber forming raw material is a carbon fiber forming raw material (Z) as a prepreg including sizing agent-coated carbon fibers and a thermosetting resin or a carbon fiber forming raw material (Y) as a forming material that includes sizing agent-coated carbon fibers and has a woven fabric form or a braid form. The sizing agent includes components (A) and (B). The component (A) is an epoxy compound having two or more epoxy groups or two or more types of functional groups. The component (B) is one or more compounds selected from the group consisting of a tertiary amine compound, a tertiary amine salt, a quaternary ammonium salt, a quaternary phosphonium salt, and a phosphine compound. The component (B) is contained in an amount of 0.1 to 25 parts by mass relative to 100 parts by mass of the component (A).

Carbon fiber forming raw material, formed material, and carbon fiber-reinforced composite material

Sizing agent-coated carbon fibers includes: a sizing agent including an aliphatic epoxy compound (A) and at least containing an aromatic epoxy compound (B1) as an aromatic compound (B); and carbon fibers coated with the sizing agent, wherein the sizing agent-coated carbon fibers have an (a)/(b) ratio of 0.50 to 0.90 where (a) is a height (cps) of a component at a binding energy (284.6 eV) assigned to CHx, C&#x2014;C, and C&#x2550;C and (b) is a height (cps) of a component at a binding energy (286.1 eV) assigned to C&#x2014;O in a Ccore spectrum of a surface of the sizing agent applied onto the carbon fibers analyzed by X-ray photoelectron spectroscopy using AlK&#x3b1;as an X-ray source at a photoelectron takeoff angle of 15&#xb0;.

Sizing agent-coated carbon fibers, process for producing sizing agent-coated carbon fibers, prepreg, and carbon fiber reinforced composite material

Disclosed is a method for producing a sizing agent-coated carbon fibers, wherein at least one kind of sizing agent that is selected from the group consisting of sizing agents (a), (b) and (c) is used for coating, in each of the sizing agents a bi- or higher functional epoxy compound (A1) and/or an epoxy compound (A2) being used as a component (A), and the epoxy compound (A2) having a mono- or higher functional epoxy group and at least one functional group that is selected from among a hydroxyl group, an amide group, an imide group, a urethane group, a urea group, a sulfonyl group and a sulfo group. The sizing agent is applied to carbon fibers and the resulting is subjected to a heat treatment within the temperature range of 160-260&#xb0; C. for 30-600 seconds.

Method for producing sizing agent-coated carbon fibers, and sizing agent-coated carbon fibers

A prepreg is formed by impregnating sizing agent-coated carbon fibers coated with a sizing agent with a thermosetting resin composition. The sizing agent contains an aliphatic epoxy compound (A) and an aromatic compound (B) at least containing an aromatic epoxy compound (B1). The sizing agent-coated carbon fibers has an (a)/(b) ratio of 0.50 to 0.90 where (a) is a height (cps) of a component at a binding energy (284.6 eV) assigned to CHx, C&#x2014;C, and C&#x2550;C and (b) is a height (cps) of a component at a binding energy (286.1 eV) assigned to C&#x2014;O in a Ccore spectrum of a surface of the sizing agent applied onto the carbon fibers analyzed by X-ray photoelectron spectroscopy using AlK&#x3b1;as an X-ray source at a photoelectron takeoff angle of 15&#xb0;.

Prepreg and carbon fiber reinforced composite material

A prepreg includes; agent-coated carbon fibers coated with a sizing agent; and a thermosetting resin composition impregnated into the sizing agent-coated carbon fibers. The sizing agent includes an aliphatic epoxy compound (A) and an aromatic epoxy compound (B1). The sizing agent-coated carbon fibers are in a shape of woven fabric or braid. The thermosetting resin composition includes a thermosetting resin (D), a thermoplastic resin (F), and a latent hardener (G). The sizing agent-coated carbon fibers have an (a)/(b) ratio in a certain range where (a) is the height of a component at a binding energy assigned to CHx, C&#x2014;C, and C&#x2550;C and (b) is the height of a component at a binding energy assigned to C&#x2014;O in a Ccore spectrum of the surfaces of the sizing agent-coated carbon fibers analyzed by X-ray photoelectron spectroscopy.

Provided are a carbon fiber-reinforced thermoplastic resin composition excellent in interfacial adhesion between carbon fiber and a thermoplastic resin and excellent in dynamic characteristics, and a molding material, a prepreg, and a method for producing the same. The carbon fiber-reinforced thermoplastic resin composition includes the following components (A) and (B), carbon fiber and a thermoplastic resin; component (A): (A1) a bifunctional or higher functional epoxy compound and/or (A2) an epoxy compound which has a monofunctional or higher epoxy group and has one or more taypes of functional groups selected from a hydroxyl group, an amide group, an imide group, a urethane group, a urea group, a sulfonyl group and a sulfo group; and component (B): 0.1 to 25 parts by mass, based on 100 parts by mass of the component (A), of at least one reaction accelerator selected from the group consisting of [a] a specific tertiary amine compound (salt) (B1), [b] a specific quaternary ammonium salt (B2) and [c] a quaternary phosphonium salt and/or phosphine compound (B3).

Carbon fiber-reinforced thermoplastic resin composition, molding material, prepreg, and methods for producing same

A polyacrylonitrile-based polymer which satisfies at least one of [a] to [d]: [a] Z-average molecular weight (Mz) determined by gel-permeation chromatograph is 800,000 to 6,000,000 and degree of polydispersity (Mz/Mw) (Mw denotes weight average molecular weight) is 3.0 to 10.0; [b] Z+1-average molecular weight (Mz+1) determined by GPC method is 3,000,000 to 10,000,000 and degree of polydispersity (Mz+1/Mw) is 6.0 to 25.0; [c] Mzm determined by gel-permeation chromatograph multi-angle laserlight scattering photometry is 400,000 to 1,000,000 and degree of polydispersity (Mzm/Mwm) is 3.0 to 10.0; and [d] Z-average radius of gyration (Rz) determined by gel-permeation chromatograph multi-angle laserlight scattering photometry is 25 to 45 nm and its ratio to weight average radius of gyration (Rz/Rw) is 1.3 to 2.5.

Polyacrylonitrile polymer, method of producing the same, method of producing precursor fiber used for producing carbon fiber, carbon fiber and method of producing the same

A carbon fiber precursor fiber having a weight average molecular weight M(F) of 200,000 to 700,000 and a degree of polydispersity M(F)/M(F), wherein M(F) indicates Z-average molecular weight of the fiber, of 2 to 5.

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Ehime, Japan

Makoto Endo