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The Japanese New Energy Industry and Technology Development Agency (NEDO), on January 14, 2016, developed a new process to increase the production efficiency of polyacrylonitrile (PAN)-based carbon fibers by 10 times compared with the old process. But also reduce the production of energy and CO2 emissions.
Carbon fiber is mainly used as a reinforcing agent for carbon fiber reinforced resin matrix composites (CFRP) and its representative application is aircraft. Recently, with the high-priced models as the center, the adoption of automobile bodies and the like has also advanced. CFRP is expensive, so there is a strong demand for lowering prices centered on the automotive industry. One of the problems that hamper the price reduction of CFRP is that carbon fiber raw materials are expensive and production efficiency is low.
The original PAN-based carbon fiber manufacturing process consists of roughly four processes: (1) PAN made of melted solvent is made into "thread making" of filamentous PAN fibers; (2) Heat treatment is performed before PAN fibers are carbonized in advance. It is oxidized to improve the "resistance" of heat resistance; (3) "carbonization" of PAN fiber after high-temperature heating and carbonization and flame resistance; (4) "surface treatment". The bottleneck of this manufacturing process is (2) the refractory process. This process is difficult to manage and it is difficult to process a large amount of PAN fibers at a time.
In the conventional manufacturing process, the PAN fiber after spinning was heated in the air at 200 to 300° C. for 30 to 60 minutes for flameproofing. After that, the treated PAN fiber is heated at 1000 to 2000° C. to carbonize it, and finally subjected to surface treatment to produce carbon fiber.
A new manufacturing process that increases production efficiency, using a newly developed “solvent-soluble refractory polymer†eliminates the refractory process. Solvent-soluble fire-resistant polymers are easily spun and have fire resistance. Because of the fire-resistance at the spinning stage, it is no longer necessary to make a refractory treatment after spinning. The solvent-soluble flame-resistant polymer can be manufactured by adding a dissolution accelerator and an oxidizing agent to a low-priced PAN for clothing.
While eliminating the refractory process, new technologies that can use microwave direct heating have also been developed in the carbonization process. This eliminates the need to keep the carbonization furnace at a high temperature. It also reduces the time required for carbonization.
In surface treatment, new techniques using plasma have also been developed. The surface treatment process can be simplified, and the energy required for the surface treatment process can be reduced by about 50% compared with the conventional method.
The manufacturing process is based on the research and development of NEDO's material and joint and technology integrated development project that aims to halve the weight of automobiles, and “research and development on innovative new construction materialsâ€, with the University of Tokyo as the center, and the Japan Industrial Technology Research Institute. , Toray, Teijin, Dong Bangte Nike Si (Teijin Group), Mitsubishi Rayon jointly developed. The four companies mentioned above hold a global share of 65% in the PAN-type carbon fiber industry in 2014.
In the future, the industrialization of the manufacturing process will be realized, and empirical experiments are being conducted in the factory. We will also develop technologies that enable carbon fibers to achieve high strength and coarse diameter.
The technology announced this time will be exhibited at the 15th International Nanotechnology Comprehensive Exhibition and Technical Conference held at Tokyo International Convention and Exhibition Center from January 27 to 29, 2016. (Reporter: Masahiro Matsuo)
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