Carbon fiber made from acrylic fiber and process for production thereof

Abstract: Disclosed is a carbon fiber made from an acrylic fiber, the carbon crystal of which has a crystal size Lc of 15 to 65 Å as determined by the wide angle X-ray diffractometry. This carbon fiber has regions with a lower crystallinity in the surface layer portion thereof than that of the central portion thereof, and the compressive strength σ cf (GPa) of the single filament thereof determined by the loop method satisfies formula (I): σ cf ≧ 10.78 - 0.1176 x Lc (I). The carbon fiber is produced by ionizing in vacuo an atom or molecule which is solid or gaseous at normal temperature, accelerating the ionized atom or molecule by an electric field, and implanting the accelerated ionized atom or molecule in a bundle of carbon fibers.

Description: The present invention relates to carbon fibers and to a process for producing them. More particularly, it relates to a carbon fiber made from an acrylic fiber having an excellent compressive strength, and a process for the production of this carbon fiber. With the recent increase in the use of carbon fibers, the requirements for carbon fibers have become very strict. To date the main emphasis has been placed upon their tensile characteristics, and therefore, the tensile strength has been greatly increased. Nevertheless, their compressive strength is little improved, and therefore, the problem arising from a suppression of improvement in other practically useful characteristics, such as their flexural strength, due to the low compressive strength has become serious. In a graphite fiber having an elastic modulus of at least 390 GPa, formed by a heat treatment at a high temperature, i.e., having a large crystal size Lc, the compressive strength of single filament is about 3.5 GPa. This value is as low as about 1/2 of the compressive strength (7 GPa) of a single filament of a carbon fiber having an elastic modulus of 245 GPa. This is a serious problem. Many proposals have been made for techniques of improving the tensile characteristics, but very few proposals have been made for techniques of improving the compressive strength. A graphite fiber having a high compressive strength and a high elastic modulus of at least 340 GPa has been proposed, which is formed by adopting particular specific spinning and heat-treating conditions (JP-A-63-211326). A chemical oxidization treatment of a carbon fiber with a hot concentrated inorganic acid such as sulfuric acid, nitric acid or phosphoric acid, or an electrochemical oxidation treatment of a carbon fiber in an aqueous solution of an electrolyte containing a nitric acid ion and a subsequent inactivating treatment has been proposed (JP-A-58-214527 and JP-A-61-225330) as a technique for reducing the crystallinity of the surface layer. Each of these proposals effectively improves the tensile strength, but does not greatly improve the compressive strength. Furthermore, in the above-mentioned treatments, an excessive amount of oxygen-containing functional groups is formed in the surface layer of the carbon fiber, and since the functional groups are removed by the treatment, an inactivating treatment, which is not desirable in view of costs, must be carried out. The technique of accelerating an ionized atom or molecule and implanting it into the surface of a material, i.e., the ion-implanting method, has been examined as a technique for modifying the structure of the surface layer portion, mainly in the field of semiconductors (JP-A-58-87818 and JP-A-58-87894). It has also been proposed to implant an ionized atom or molecule into a carbon material (JP-A-62-235280). In connection with the ion implantation into a carbon fiber, ion implantation into a vapor-phase grown carbon fiber has been reported; see Yugo et al, Tanso (1981), No. 104, 2-8. However, such vapor-phase grown carbon fibers have a high anisotropy, and when such highly anisotropic fibers are subjected to the ion implantation treatment, a noticeable improvement of the compressive characteristics, as obtained in an acrylic carbon fiber, cannot be obtained. Therefore, the primary object of the present invention is to provide a carbon fiber having a high compressive strength not obtainable by conventional techniques, and a process for the production of this carbon fiber. According to one aspect of the present invention, there is provided a carbon fiber made from an acrylic fiber, having a crystal size Lc of 15 to 65 angstroms (1.5 to 6.5 nm) as determined by wide angle X-ray diffractometry, and having regions with a lower crystallinity in the surface layer portion thereof than that in the central portion thereof and whose compressive strength (σ cf ) of the single filament determined by the loop method satisfies the requirement represented by the following formula (I): σ cf ≤ 10.78 - 0.1176 x Lc where σ cf is expressed in GPa and Lc is the crystal size in Å (10 -1 nm). The variation in crystallinity as between surface and central portions of the fiber is identified by a required νa/νb ratio of at least 1.5 where νa is a half width of the scattering peak at 1320 to 1380 cm -1 of the laser Raman spectrum of at least part of the regions in the surface layer portion of a single filament and νb is a half width of the scattering peak at 1320 to 1380 cm -1 of the laser Raman spectrum of the cental portion of the single filament. According to another aspect, the invention provides a method of producing a carbon fiber containing ion-implanted material in which a carbon fiber is made from acrylic fiber, which is then subjected to an ion-implantation process comprising ionizing in vacuo an atom or molecule which is solid or gaseous at room temperature, accelerating the ionized atom or molecule by an electric field, and implanting the accelerated ionized atom or molecule in a bundle of the carbon fibers through the surface thereof. Preferred embodiments will now be described wich reference to the accompanying drawings in which Figs. 1, 2 and 3, illustrate distribution of crystallinity in the depth direction from the surface of a graphite fiber implanted with 10 16 /cm 2 of boron ions as determined by laser Raman spectroscopy, in which Fig. 1 shows the results of the peak division of the Raman spectrum of a surface layer portion of the ion-implanted fiber by three Gaussian functions, Fig. 2 shows the results of the peak division of the Raman spectrum of the central portion of the ion-implanted fiber by four Lorenz functions, and Fig. 3 is a diagram in which the half width of the peak in the region of 1320 to 1380 cm -1 is plotted relative to the depth from the surface of the fiber; Figs. 4, 5 and 6 illustrate distribution of crystallinity on a graphite fiber surface determined by laser Raman spectroscopy, in which Fig. 4 shows the results of the peak division of the Raman spectrum of the modified graphitized fiber implanted with 10 16 /cm 2 of boron ions by three Gaussian functions, Fig. 5 shows the results of the peak division of the Raman spectrum of the modified graphite fiber implanted with 10 15 /cm 2 of boron ions by three Gaussian functions, and Fig. 6 shows the results of the peak division of the Raman spectrum of the graphite fiber before the implantation with boron ions by four Gaussian functions; Fig. 7 and 8 are diagrams illustrating a method of measuring the compressive strength of a single filament by the loop method, in which Fig. 7 shows a method of measuring the minor axis (D) and major axis () of the loop, and Fig. 8 is a diagram in which the strain ε is plotted on the abscissa and the major axis/minor axis ratio (/D) is plotted on the ordinate; Fig. 9 is a diagram illustrating a method of measuring the torsional modulus of elasticity; Fig. 10 is a diagram illustrating the relationship between the crystal size Lc and the compressive strength of the single filament, observed in the examples and comparative examples, and illustrating the results of the measurement of conventional commercially available carbon fibers as reference data; and, Fig. 11 illustrates distribution of implanted elements in the depth direction from the surface of the fiber as determined by the secondary ion mass spectrometry (SIMS), wherein the abscissa indicates the depth from the surface and the ordinate the secondary ion intensity of boron ions. Hereinafter, "surface layer portion" of a fiber means a region which is within the region spanning from the surface of a single filament to a depth corresponding to a half of the radius thereof and which spans from the surface to a depth of 2.0 µm, provided that the surface of the single filament is excluded from the surface layer portion. The "central portion"of the fiber means the region within 0.3 µm from the center of the single filament. The crystallinity is determined by laser Raman spectroscopy described hereinafter. The crystallinity is a characteristic determined by the size of the crystal constituting the carbon fiber and the orientation of the carbon crystal arrangement. When the size of the crystal is large and the orientation of the carbon crystal arrangement is high, the crystallinity is considered high. The fact that in the present invention, the crystallinity of the surface layer portion is lower than the crystallinity of the central portion means that in the analysis of the crystallinity of the section of the single filament by laser Raman spectroscopy as described hereinafter, the ratio (νa/νb) of the half width (νa) of the scattering peak in the region of 1320 to 1380 cm -1 (which region is hereinafter referred to "the vicinity of 1350 cm -1 ") of the Raman spectrum of the surface layer portion to the half height width (νb) of the scattering peak in the vicinity of 1350 cm -1 of the Raman spectrum of the central portion of the fiber exceeds 1.5. The carbon fiber of the present invention has regions with a lower crystallinity in the surface layer portion thereof than that of the central portion defined as above. A process for the production of the high-performance carbon fiber embodying the present invention will now be described. The acrylic polymer constituting an acrylic fiber (precursor) as the starting material for producing the carbon fiber can be a copolymer comprising at least 90 mole% of acrylonitrile and less than 10 mole% of a copolymerizable vinyl monomer, for example, acrylic acid, methacrylic acid or itaconic acid, an alkali metal salt, an ammonium salt or a lower alkyl ester thereof, acrylamide or a derivative thereof, or allylsulfonic acid or methallylsulfonic acid or a salt or alkyl ester thereof. Any known solution polymerization, suspension polymerization, and emulsion polymerization process can be adopted as the polymerization process. The degree of polymerization is such that the intrinsic viscosity ([η]) is preferably at least 1.2, more preferably at least 1.7. In general, the intrinsic viscosity [η] should be not more than 5.0 in view of the spinning stability. The wet spinning method, dry jet wet spinning method, and dry spinning method can be adopted as the spinning method, although the dry jet wet spinning method is most preferably adopted because a dense precursor is obtained thereby. The use of a precursor having a high density is effective for obtaining a carbon fiber having high compression characteristics. More specifically, a dense precursor having a ΔL value not larger than 45, preferably not larger than 30, most preferably not larger than 10, as determined by the iodine adsorption method, is generally used. In general, it is difficult to obtain a ΔL value of smaller than 5. Effective means for obtaining a dense precursor having a ΔL value not larger than 45 is a method in which the degree of swelling of a coagulated fiber is kept at a low level by increasing the polymer concentration in the spinning solution, lowering the temperatures of the spinning solution and coagulating solution, and reducing the tension at the coagulation, and maintaining the degree of swelling of a drawn yarn at a low level by selecting the optimum conditions for the number of drawing stages in the bath drawing, the draw ratio, and the drawing temperature. The thickness of a single precursor filament is preferably not larger than 2.0 denier, more preferably not larger than 1.5 denier, and most preferably not larger than 1.0 denier. In general, it is difficult to prepare a filament having a fine denier lower than about 0.1 denier. A preferred method of oxidizing the precursor is to heat the precursor at 240 to 300°C in an oxidizing atmosphere under tension or drawing, so that the density is increased to at least 1.25 g/cm 3 , more preferably at least 1.30 g/cm 3 . In general, a density of not larger than 1.6 g/cm 3 is adopted in view of the physical properties. Any known oxidizing atmospheres such as air, oxygen, nitrogen dioxide, and hydrogen chloride can be used, but air is preferable from the viewpoint of economy. The obtained oxidized fiber is carbonized at a temperature of at least 1,000°C, but lower than 2,000°C in an inert atmosphere, and is then graphitized at a temperature of at least 2,000°C according to need. To obtain a dense carbon fiber having few internal defects such as voids, preferably, in the temperature regions of from 350 to 500°C and from 1,000 to 1,200°C, the temperature-elevating rate is preferably not higher than 500°C/min, more preferably not higher than 300°C/min, most preferably not higher than 150°C/min. The minimum permissible temperature-elevating rate is about 10°C/min in view of productivity. To improve the density, preferably a method is adopted in which, in the temperature region of from 350 to 500°C or at a temperature of at least 2,300°C, the calcination is preferably carried out under a drawing of at least 1%, more preferably at least 5%, most preferably at least 10%. A drawing exceeding 40% is not preferable because fuzz is undesirably formed. At the calcination treatment, a mixed atmosphere with an active atmosphere such as hydrogen chloride can be adopted in the temperature region of from 300°C to 1,500°C. The acrylic carbon fiber of the present invention can be obtained by implanting the surface of the obtained carbon fiber with an accelerated atom or molecule. The most preferable method of forming an accelerated atom or molecule and implanting. the atom or molecule into the carbon fiber from the surface thereof is the ion-implanting method, comprising ionizing an atom or molecule in vacuo and accelerating the ionized atom or molecule by an electric field. According to this method, by increasing the intensity of the electric field, an atom or molecule having an energy proportional to the intensity of the electric field can be obtained, and therefore, the atom or molecule can be implanted to a desired depth. The accelerated atom or molecule collides with a carbon atom constituting the carbon fiber to impart the kinetic energy of the atom or molecule to the carbon atom, whereby implantation damage occurs in the carbon fiber. Since such implantation damage is accumulative, a layer having a low crystallinity, i.e., a substantially isotropic layer, is formed in the surface layer portion of the carbon fiber. When the graphitized carbon fiber is subjected to the ion-implanting treatment, the graphite in the surface layer of the single filament is modified to form a substantially isotropic structure resembling a diamond-like carbon film structure. Namely, the carbon fiber structure of the present invention is characterized in that the surface layer portion is substantially isotropic. As the means for rendering the surface layer portion substantially isotropic, a method can be adopted in which the surface layer portion having a high crystallinity is damaged, to render it substantially isotropic, and/or a method in which the surface layer is modified so that a crystal structure resembling that of diamond is produced. When the graphitized fiber is examined by laser Raman spectroscopy, two peaks are observed in the region of 1550 to 1610 cm -1 (which region is hereinafter referred to "the vicinity of 1580 cm -1 ") and in the vicinity of 1350 cm -1 . It is considered that the peak in the vicinity of 1580 cm -1 corresponds to the complete graphite crystal, and as the amount of graphite crystal having a disturbed structure increases, the peak intensity ratio and the half width of the peak in the vicinity of 1360 cm -1 are enhanced. By the peak intensity ratio is meant a ratio of the peak intensity at 1350 cm -1 to the peak intensity at 1580 cm -1 . A graphite fiber having an elastic modulus of at least 340 GPa is obtained by graphitizing the carbon fiber to a structure having a carbon content, as determined by elemental analysis, of at least 98%, a carbon crystal size Lc, as determined by wide angle X-ray diffractometry, of at least 22 angstroms (2.2 nm), and an orientation degree π 002 in the fiber axis direction of at least 85%. When this graphite fiber is analyzed by laser Raman spectroscopy, two relatively sharp peaks are observed in the vicinity of 1580 cm -1 and in the vicinity of 1350 cm -1 . The inventors found that, if ions of boron or the like are implanted under a high vacuum and high acceleration voltage into the above-mentioned graphite fiber, the single filament tensile strength and single filament compressive strength of the graphite fiber can be greatly improved. It also was found that, when the ion-implanted graphite fiber is analyzed by the laser Raman spectroscopy, a spectrum resembling that of the above-mentioned diamond-type carbon film is obtained. The inventors carried out research into the relationships between changes of the laser Raman spectrum and the degrees of improvement of the single filament tensile strength and single filament compressive strength. More specifically, if the peak division of the obtained Raman spectrum is performed by curve fitting by using a Gaussian functional profile, a peak is observed in the range of from 1400 to 1500 cm -1 in addition to the peak in the vicinity of 1580 cm -1 and the peak in the vicinity of 1350 cm -1 . As the peak intensity ratio of this peak in the range of from 1400 to 1500 cm -1 to the peak in the vicinity of 1580 cm -1 is increased,the proportion of the structure resembling that of the diamond-like carbon film is increased, and the desired high compressive strength and tensile strength of the single filament can be preferably obtained if the peak intensity ratio is at least 0.3. A more preferable peak intensity ratio is at least 0,5. In general, it is difficult to obtain a peak intensity ratio exceeding 1.5. The larger the peak intensity ratio, the more prominent is the improvement in the single filament tensile strength and single filament compressive strength. When the peak intensity ratio is at least 0.3, the carbon fiber made from an acrylic fiber is preferable, because this carbon fiber is characterized in that the tensile modulus of elasticity of the single filament is at least 340 GPa, the tensile strength of the single filament is at least 3.9 GPa, and the compressive strength σ cf of the single filament is at least 4.9 GPa. In contrast, in a diamond-type carbon film, an asymmetric peak having a shoulder in the region of 1350 to 1450 cm -1 is observed, with the region of 1500 to 1600 cm -1 as the center. Ions which can be implanted by the ion-implanting method are those of elements which are solid at room temperature, such as, for example, beryllium, boron, carbon, silicon, phosphorus, titanium, chromium, iron, nickel, cobalt, copper, zinc, germanium, silver, tin, molybdenum, tellurium, tantalum, tungsten, gold, and platinum; elements which are gaseous at normal temperature, such as hydrogen, nitrogen, neon, argon, krypton, fluorine, and chlorine; and molecular ions formed of these elements, such as boron fluoride. Particular examples are B, N, Ar, Si, Ti, Cr, Ni, Cu and C, especially B, N, Ar, Si, Ti, Cr, Ni and Cu and molecules containing these atoms. From an economical viewpoint and in view of the effect of improving the compressive characteristics by the implantation, nitrogen, boron, argon, carbon, silicon, titanium, chromium, nickel and copper are preferable, and nitrogen, boron, carbon, titanium and chromium are most preferable. A simultaneous or continuous implantation of at least two kinds of ion seeds effectively improves the treatment effect. Optimum implanting conditions such as the ion seed, acceleration voltage, and implantation quantity suitable for obtaining a desired structure, are selected while taking into consideration the relationship to the carbon fiber as the target. To effectively perform the ion implantation the vacuum degree at the implanting is preferably not larger than 10 -3 Torr, more preferably not larger than 10 -4 Torr, and most preferably not larger than 10 -5 Torr. The ion acceleration voltage is preferably at least 50 kV, more preferably at least 100 kV, and most preferably at least 150 kV. Since the implantation depth is determined by the combination of the ion seed and acceleration voltage, an optimum combination of the ion seed and acceleration voltage must be determined, to obtain a desired implantation depth. The implantation quantity is preferably at least 10 15 ions/cm 2 , more preferably at least 10 16 /cm 2 , and most preferably at least 10 17 /cm 2 , and an optimum implantation quantity is determined by the combination of the ion seed and acceleration voltage. The implantation time depends on the implantation quantity and the beam intensity of the implantation apparatus. To maintain an implantation quantity of at least 10 15 /cm 2 at a high productivity, the beam intensity is preferably at least 0.1 µA/cm 2 , more preferably at least 1 µA/cm 2 , and most preferably at least 5 µA/cm 2 . The implantation can be carried out at a beam intensity of at least 1 µA/cm 2 , for less than 10 minutes, preferably less than 1 minute. When feeding the carbon fiber for the implantation, the fiber bundle is preferably spread to disperse single filaments over a width, so that the thickness of the fiber bundle in the ion-implantation direction is 1 to 5 times, preferably 1 to 3 times, and most preferably 1 to 2 times, the diameter of the single filament. As the spreading method, a method can be adopted in which single filaments are separated and fixed to a metal frame, but preferably, a method is adopted in which a carbon fiber bundle is spread by an expanding guide to which a mechanical vibration such as an ultrasonic vibration or low frequency vibration is given. A flat guide or a convex guide is preferably used in combination with the expanding guide. If this method is adopted, a carbon fiber can be continuously supplied, and thus the method is advantageous from the viewpoint of productivity. When a carbon fiber is continuously supplied, the fiber is moved preferably at a constant moving speed. An implantation to the back side is difficult, even when single filaments are dispersed, and accordingly, the implantation is preferably effected by at least two implantations from different directions as a whole, for example, one from the front side and one from the back side. The implantations from different sides can be carried out simultaneously or one after the other. Different ion seeds can be used in these implantations. In the crystal structure of the carbon fiber obtained by the ion implantation, the crystallinity of the ion-implanted surface layer portion is lower than that of the central portion of the fiber, but the crystallinity of the unimplanted central portion is not changed, and therefore, the ion-implanted carbon fiber is characterized by having a clearly stepped crystal structure. The distribution of the crystallinity should be such that, in the above-mentioned laser Raman spectroscopy of the section of a single filament, the ratio (νa/νb) of the half width (νa) of the scattering peak in the vicinity of 1350 cm -1 of the Raman spectrum of the surface layer portion of the single filament to the half width (νb) of the scattering peak in the vicinity of 1350 cm -1 in the Raman spectrum of the central portion of the single filament is at least 1.5, preferably at least 2.0, and most preferably at least 3.0, to obtain the desired improvement of the compressive strength. In general, it is difficult to obtain a νa/νb ratio of 10 or more. The larger the νa/νb ratio value, the lower the crystallinity, and thus, the lower the crystallinity of the region in the surface layer portion. If an atom or molecule which is solid at room temperature is implanted, the surface layer portion of the carbon fiber has a -structure in which the implanted element is dispersed in the form of the atom or molecule, and this dispersion state can be determined by secondary ion mass spectroscopy (SIMS). This dispersion state is such that a maximum concentration region is present in the surface layer portion located about 0.1 to about 1 µm inside from the surface of the single filament, rather than on the surface thereof, and a distribution close to the normal distribution is manifested. The carbon fiber of the present invention is characterized in one aspect thereof by the specified distribution of crystallinity and the distribution of a foreign element implanted therein, which are determined by SIMS and elemental analysis. By the foreign element used herein is meant an element other than carbon. Preferably, the carbon fiber of the present invention does not contain any appreciable amount of a foreign element in the central portion of the single filament, and the content of the foreign element is highest in the surface layer portion thereof and the content of the foreign element on the surface thereof is lower than the highest content in the surface layer portion thereof. The content of the foreign element on the surface of the single filament is preferably not more than 1/2, more preferably not more than 1/5, of the highest content in the surface layer portion, in view of the enhanced adhesion to matrix resin. By the phrase "does not contain any appreciable amount of a foreign element" used herein is meant that the concentration of implanted foreign element is less than 0.05% in atomic ratio as determined by SIMS. However, where the foreign element is nitrogen, the above phrase means that the difference in the concentrations of nitrogen as measured before and after implantation is negligibly small. The crystallinity by laser Raman spectroscopy, the tensile strength, elastic modulus and compressive strength of a single filament, the crystal size, the degree of orientation and other properties are determined as follows. (1) Distribution of Crystallinity in Depth Direction of a Carbon Fiber A single filament is electrolessly plated with copper and embedded in an epoxy resin, and a section of the single filament is polished so that the inclination angle to the fiber axis is about 5°. The polished sample is subjected to analysis, and if the inclination angle is larger than 10°, the polished face of the section of the single filament is considered small, and the number of measurement points as decreased and precision is reduced by the analysis conducted at a beam diameter of 1 µm. A Ramanor U-1000 Raman system supplied by Jobin-Yvon, France, is used as the measurement apparatus. Using an argon ion laser (beam diameter = 1 µm) having an excitation wavelength of 5145 Å (514.5 nm), the Raman spectrum is measured at intervals of about 1 µm toward the central portion from the surface of the carbon fiber. With respect to each Raman spectrum, the peak division is carried out by curve fitting using a Gaussian function profile. When the peak division cannot be carried out by this method, Lorenz function profile is available. The distribution of half width in the vicinity of 1350 cm -1 is analyzed in the depth direction of a single filament. (2) Crystallinity on Surface of Carbon Fiber by Laser Raman Spectroscopy One single filament is collected from a sample fiber bundle and is subjected to analysis. A Ramanor U-1000 microscopic Raman system supplied by Jobin-Yvon, France, is used as the measurement apparatus. Using an argon ion laser (beam diameter = 1 µm) having an excitation wavelength of 5145 Å (514.5 nm), the Raman spectrum of the surface of the sample filament is measured, and with respect to each Raman spectrum, the peak division is carried out by curve fitting using a Gaussian functional profile, and the ratio of the intensity of the peak (peak height) observed within a range of 1400 to 1500 cm -1 to the intensity of the peak (peak height) observed in the vicinity of 1580 cm -1 is determined. When the peak division cannot be carried out by curve fitting using a Gaussian functional profile, for example, in the case of a non-ion-implanted graphite fiber, the peak division is carried out by curve fitting using a Lorenz functional profile. (3) Tensile Strength and Elastic Modulus of Single Filament The tensile strength and elastic modulus are determined by the single filament test method of JIS R-7601. The length of the sample single filament is set at 25 mm, and for one sample, 50 single filaments are measured and the mean value is calculated. The average single filament sectional area determined from the fineness and density of the sample fiber bundle, and the number of constituent single filaments, is used as the sectional area of the single filament. (4) Compressive Strength (σ cf ) of Single Filament A single filament having a length of about 10 cm is placed on a slide glass, one or two drops of glycerol are allowed to fall on the central portion, a loop is formed by twisting the single filament, and a preparate is placed on the loop. Then the assembly is placed under a microscope and projected on a monitor (CTR) by a video camera connected to the microscope. While the loop is within the visual field, the loop is pulled at a constant speed with both ends pressed by the fingers, to impose a strain on the loop. The behavior thereof is recorded by video until the single filament is broken. Stopping the recorded image, the short diameter (D) and lonq diameter () of the loop are measured on the CRT. The strain (ε) at point A in Fig. 7 is calculated from the diameter (d) of the single filament and D according to the formula ε = 1.07 x d/D, and ε is plotted on the abscissa and the long diameter/short diameter ratio (/D) is plotted on the ordinate (Fig. 8). The /D ratio shows a certain value (about 1.34) in the region where compression buckling does not occur, but this value is greatly increased after compression buckling occurs. The strain at which /D begins to increase greatly from the certain value corresponds to the strain at which the compression buckling occurs. This strain is preferred to as the compression yield strain (εcf). The measurement -is conducted for about 10 single filaments, and the mean value is calculated. The compressive strength of the single filament is determined by multiplying the obtained mean value by the tensile modulus of elasticity. The tensile modulus of elasticity is determined by impregnating the carbon fiber bundle with Bakelite ERL-4221/boron trifluoride monoethylamine (BF 3 .MEA)/acetone (weight ratio = 100/3/4), heating the resin-impregnated strand at 130°C for 30 minutes to effect curing, and carrying out the measurement by the resin-impregnated strand test method of JIS R-7601. (5) Elemental Analysis using CHN Corder Model MT-3 supplied by Yanagimoto Seisakusho, the carbon content is determined by the ratio of the carbon weight to the sample weight. The water content is the sample is determined and the sample weight is corrected from the water content. (6) Crystal Size Lc The fiber bundle is cut to a length of 40 mm, 20 mg of the cut fiber is precisely weighed and collected, and the filaments are arranged so that the axes are precisely in parallel to one another. By using a sample-preparing tool, a uniform sample fiber bundle having a width of 1 mm is formed and impregnated with a dilute collodion solution, so that the fiber bundle is fixed and is not deformed. Then the fiber bundle is fixed to a sample stand for wide angle X-ray diffractometry. An X-ray generator supplied by Rigaku Denki is used as the X-ray source, and a CuKα ray (Ni filter is used) having an output of 35 kV-15 mA is also used. By using a goniometer supplied by Rigaku Denki, the diffraction peak in the vicinity of 2 - 26°, which corresponds to the plane index (002) of graphite, is detected by the permeation method by a scintillation counter. The crystal size Lc is determined from the half width in the diffraction peak, according to the following formula: Lc = λ/β O cos wherein λ is the wavelength (Å) (10 -1 nm) of the used X-ray (since CuKα is used, λ is 1.5418 Å, ie. 0.5418 nm), β O is determined by β O 2 = β E 2 - β I 2 (in which β E is the measured apparent half width and β I is the apparatus constant which is 1.05 x 10 -2 rad in this case), and  is Bragg's diffraction angle. (7) Orientation Degree π 002 in Direction of Fiber Axis The crystal orientation degree is calculated from the half width (H°) of the expansion of the profile in the meridional direction including the maximum intensity of the (002) diffraction, according to the following formula: Crystal orientation degree (π 002 )(%) = 180° - H° 180° x 100 The torsional modulus of elasticity, ΔL, the element distribution by SIMS and the 0° compressive strength of a composite are determined by the following methods. (8) Torsional Modulus of Elasticity (Gf) As illustrated in Fig. 9, one end of a single filament (2) having a length of about 10 cm is inserted into a fine hole formed at the center of a glass weight (1) having a mass of about 0.5 g, a length of 8 mm and a diameter of 6 mm, and is bonded by an instant adhesive, and the other end is fixed by a clip (3) through a cushion paper and allowed to hang down on a frame (4) of a stand. The weight (1) is twisted by about +10 turns to impart torsions to the single filament, and then the weight is freed. The time required for the weight to reversely rotate by about -10 turns, and to stop and to further rotate by about +10 turns to the original torsion state and stop, is designated as one frequency T (sec), and the measurement is continuously made for 5 frequencies to determine a mean value thereof. This measurement is conducted for about 5 single filaments, and the mean value is calculated, and the torsional modulus of elasticity Gf (GPa) is determined according to the following formulae: Gf = 125πℓI/(d 4 T 2 ) x 10 -5 and I = MD 2 /(8 g) wherein ℓ represents the length (mm) of the fiber, d represents the diameter (mm) of the single filament, M represents the mass (g) of the weight, D represents the diameter (mm) of the weight, g represents the acceleration (m/sec 2 ) due to gravity, and I represents the torsional moment. (9) ΔL by Iodine Adsorption Method About 0.5 g of a dry sample having a fiber length of 5 to 7 cm is precisely weighed and introduced into a plugged Erlenmeyer flask having an inner volume of 200 ml. Then, 100 ml of an iodine solution (prepared by placing 51 g of I 2 , 10 g of 2,4-dichlorophenol, 90 g of acetic acid and 100 g of potassium iodine in a graduated flask having an inner volume of 1 ℓ and dissolving them in water to form a predetermined amount of a solution) is added to the flask. The adsorption treatment is carried out at 60°C for 50 minutes while shaking. The iodine-adsorbed sample is water-washed for 30 minutes in running water, subjected to centrifugal dehydration at 2000 rpm for 1 minute, and promptly air-dried. The sample is opened and the lightness L 1 is measured by a Hunter type color difference meter (Model CM-25 supplied by Color Machine). Separately, a corresponding sample which has not been subjected to the iodine adsorption treatment is opened, the lightness (L 0 ) is measured by the above-mentioned Hunter type colqr difference meter, and the lightness difference ΔL is determined from L 0 - L 1 . (10) Elementary Distribution Analysis by SIMS A Model A-DIDA 3000 supplied by ATOMIKA, West Germany, is used as the evaluation apparatus. Oxygen ions (0 2 + ) are caused to impinge against the surface of the carbon fiber under a high vacuum of 10 -9 Torr and an acceleration voltage of 12 kV at an ion current of 70 µA, and the secondary ions formed by sputtering are subjected to mass analysis. The sample is prepared by arranging the filaments so that the axes are in parallel to one another, and the measurement is carried out in an analysis region having a 120 µm x 120 µm size. With regard to the depth, the relationship between the sputtering time and the depth is determined by a surface roughness meter on glassy carbon calcined at 1500°C, and the depth is determined from the thus obtained sputtering rate and the sputtering time. (11) 0° Compressive Strength of Composite Carbon filaments are arranged in parallel to one another and impregnated with #3620 resin supplied by Toray to prepare prepregs. The prepregs are laminated, and the determination is carried out using a specimen size and method according to ASTM-D695. Embodiments of the present invention will now be described in more detail with reference to the following Examples. Example 1 and Comparative Example 1 A DMSO solution containing 20% by weight of a copolymer comprising 99.4 mole% of acrylonitrile (AN) and 0.6 mole% of methacrylic acid was prepared. The temperature of the solution was adjusted to 35°C and the solution was extruded into air through a spinneret with 3,000 orifices, each having a diameter of 0.12 mm, allowed to travel through a space having a length of about 4 mm and coagulated in a 30% aqueous solution of DMSO maintained at a temperature of 5°C. The coagulated fiber was washed with water and drawn at a draw ratio of 3.5 in a three-stage drawing bath, a silicone type oiling agent was applied to the drawn fiber, and the fiber was brought into contact with a roller surface heated at 130 to 160°C to dry and densify the fiber. The fiber was drawn at a draw ratio of 3 in compressed steam under 3.7 kg/cm 2 to obtain a fiber bundle having a single filament fineness of 0.8 denier and a total fineness of 2,400 denier. The ΔL value of the obtained fiber bundle was 28. The obtained fiber bundle was heated at a draw ratio of 1.05 in air maintained at 240 to 280°C, to obtain an oxidized fiber having a density of 1.35 g/cm 3 , and then the fiber was carbonized at 1,400°C in a nitrogen atmosphere, while the fiber was drawn by 8% in a temperature range of 350 to 500°C at a temperature-elevating rate of 200°C/min. The Lc value of the obtained carbon fiber was 18 Å (1.8 nm). About 100 single filaments of the obtained carbon fiber were divided and fixed on a square aluminum frame having a side length of 10 cm, and 1 x 10 16 /cm 2 of boron ions were implanted under a vacuum degree of 3 x 10 -6 Torr and an acceleration voltage of 150 kV. This treatment was conducted from both of the front and back surfaces. The beam intensity was 0.2 µA/cm 2 and the treatment time was about 20 minutes for each surface. The Lc value of the ion implanted fiber was 17 Å (1.7 nm). The ion-implanted carbon fibers had regions with a lower crystallinity in the surface layer portion than that of the central portion. With respect to the carbon fiber before or after the ion implantation, the compressive strength of the single filament, the torsional modulus of elasticity, and the tensile properties of the single filament were determined. The results are shown in Table 1. As seen from Table 1, the compressive strength cf of the single filament was greatly increased from 7.55 GPa to 10.0 GPa, the torsional modulus of elasticity was increased from 20.6 GPa to 31.4 GPa, i.e., by about 1.5 times, and the tensile strength was increased from 5.39 GPa to 6.37 GPa. Thus, the properties desirable for carbon fibers were greatly improved. Examples 2-4 The carbon fiber before ion implantation obtained in Example 1 was treated in the same manner as described in Example 1 except that the ion-implanting conditions were changed as shown in Table 2. The properties of the obtained ion-implanted carbon fibers are shown in Table 2. The ion-implanted carbon fibers had regions with a lower crystallinity in the surface layer portion than that of the central portion. Example 5 The carbon fiber bundle before ion implantation, as used in Example 1, was spread under ultrasonic vibration using convex and flat vibrating guides and an aluminum foil as a lead paper, so that the thickness was 1 to 3 times the diameter of the single filament, and the spread fiber was wound. The fiber wound on a bobbin was set to a vacuum system, the fiber was withdrawn together with the lead paper and wound on another bobbin at a speed of 1 cm/min. Then, nitrogen ions were continuously implanted in the travelling fiber vertically thereto. The vacuum degree was 1 x 10 -6 Torr, the acceleration voltage was 150 kV, and the implantation quantity was 1 x 10 16 /cm 2 . The wound carbon fiber was unwound in the opposite direction and the carbon fiber was again similarly treated. Thus, the ion implantation was effected from both the front and back surfaces. In the obtained carbon fiber, the compressive strength of the single filament was 9.61 GPa, and the obtained carbon fiber was a high-performance carbon fiber substantially comparable to the carbon fiber obtained by batchwise implantation into single filaments (Example 1). The crystal size Lc was 17 Å (1.7 nm), i.e., the same as that in Example 1. The ion-implanted carbon fibers had regions with a lower crystallinity in the surface layer portion than that of the central portion. Example 6 and Comparative Example 2 The carbon fiber bundle before ion implantation, as used in Example 1, was graphitized by elevating the temperature to 2,400°C. Boron ions were implanted into the thus-obtained graphite fiber in the same manner as described in Example 1. The characteristics of the graphite fiber before and after the ion implantation are shown in Table 3. As seen from Table 3, in the graphite fiber, the νa/νb was increased from 1.0 to 4.8, i.e., the crystallinity in the surface layer portion was decreased, the single filament compressive strength σ cf was increased from 3.53 GPa to 7.45 GPa, i.e., by about 2 times, the tortional modulus of elasticity was increased from 14.7 GPa to 27.4 GPa, i.e., by almost 2 times, and the tensile strength was increased from 3.23 GPa to 4.21 GPa, by the ion implantation. With respect to the ion-implanted carbon fiber, the distribution of boron atoms was analyzed by SIMS. It was found that the boron concentration was highest in a portion about 0.5 µm from the surface. The distribution of boron atoms is illustrated in Fig. 11. From the analysis of crystalline distribution in the radial direction in the cross-section perpendicular to the fiber axis according to the laser Raman spectroscopy, it was revealed that, as shown in Fig. 3, the ion implanted graphite fiber had a region spanning from the surface of single filament to a depth of 0.8 µm, in which the degree of crystallinity was reduced. In Fig. 3, curves A and B correspond to the graphite fiber after ion implantation and the graphite fiber before ion implantation, respectively. In this analysis, laser Raman spectral data were obtained on seven points in the region spanning from the filament surface to a depth of 0.8 µm, and νa was determined from an average value of the seven spectral data. The other characteristics of the graphite fiber before and after the ion implantation are shown in Table 4. Examples 7 and 8 Ion-implanted graphite fibers were produced in the same manner as described in Example 6 except that the ion-implanting conditions were changed as shown in Table 4. The properties of the obtained ion-implanted graphite fibers are shown in Table 4. Example 9-11 Using the same oxidized fiber as that used in Example 1, various carbon fibers and graphite fibers were produced wherein the temperature elevating rate was 200°C/min in a temperature range of 350 to 500°C in a nitrogen atmosphere, the drawing ratio was 8%, and the highest carbonization temperature was set at 1,600, 1,800 and 2,000°C with all other conditions remaining substantially the same, and ion implanting treatment was carried out in the same manner as described in Example 1. The results are shown in Table 5. Examples 12-16 Ion-implanted graphite fibers were produced in the same manner as described in Example 6 except that the ion-implanting conditions were varied as shown in Table 6. Example 17 and Comparative Example 3 The carbon fiber bundle before ion implantation as used in Example 1 was graphitized at a temperature of 2,850°C to prepare a graphite fiber having a crystal size Lc of 57 Å (5.7 nm). The graphite fiber was implanted with boron ions in the same manner as described in Example 1 except that the implantation quantity was varied to 5 x 10 6 /cm 2 . The ion-implanted graphite fiber had a crystal size Lc of 54 Å (5.4 nm). By the ion implantation, the compressive strength of the single filament was increased from 3.63 GPa to 5.78 GPa. Example 18 and Comparative Example 4 The graphite fiber bundle before ion implantation, used in Example 6, was spread by low-frequency vibrations using convex and flat vibrating guides, so that the thickness was 1 to 3 times the diameter of the single filament, and the spread fiber was wound on a bobbin together with an aluminum foil used as a lead paper. The fiber wound on the bobbin was set in a vacuum system, withdrawn together with the lead paper, and then wound on another bobbin at a speed of 1 cm/min. Boron ions were continuously implanted vertically to the travelling fiber. The vacuum degree was 1 x 10 -6 Torr, the acceleration voltage was 150 kV, and the implantation quantity was 1 x 10 16 /cm 2 . The wound carbon fiber was unwound in the reverse direction and was ion-implanted again, and thus ions were implanted from both the front and back surfaces. The 0° composite compressive strength of the obtained graphite fiber was 1.35 GPa (Example 18), which was much higher than the composite compressive strength, 1.05 GPa, of the graphite fiber before ion-implantation (Comparative Example 4). The crystal size Lc of the graphite fiber was 43 Å (4.3 nm) before ion-implantation (Comparative Example 4) and 41 Å (4.1 nm) after ion-implantation (Example 18). Comparative Example 5 The carbon fiber bundle before ion implantation, as used in Example 1, was wound on a Pyrex glass frame and heat-treated in hot 60% nitric acid at 120°C for 45 minutes. Then the treated carbon fiber was washed with water for about 60 minutes, dried in an oven at 120°C, and heat-treated for 1 minute in a nitrogen atmosphere at 700°C. The properties of the obtained carbon fiber are shown in Table 7. The crystal size Lc of the carbon fiber was 18 Å (1.8 nm) both before and after ion implantation. In the carbon fiber obtained by the above treatment, the tensile strength was better than that of the untreated fiber (Comparative Example 1), but νa/νb was 1.0, and the lowering of the crystallinity was unsatisfactory. Accordingly, there was little improvement of the compressive strength of the single filament. Comparative Example 6 The carbon fiber bundle before ion implantation as used in Example 6 was treated in the same manner as described in Comparative Example 5. The results are shown in Table 7. The value of νa/νb of the carbon fibers treated as above was 1.0 so the crystallinity by the laser Raman spectroscopy was the same as untreated carbon fibers. The compressive strength of single filament was improved only to a very slight extent by the implantation treatment. Comparative Example 7 The carbon fiber bundle before ion implantation used in Example 1, was introduced into a tank filled with 30% nitric acid maintained at 50°C through a ceramic guide, and the fiber was continuously fed at a speed of 0.4 m/min. An electric current was passed through the carbon fiber at an electricity quantity of 200 coulomb/g of the fiber by a metallic roller disposed just before the tank. The obtained carbon fiber was washed with water, dried, and heat-treated for about 1 minute in a nitrogen atmosphere maintained at 700°C. The properties of the obtained carbon fiber are shown in Table 8. The crystal size Lc of the carbon fiber was 18 Å (1.8 nm) both before and after ion implantation. In the carbon fiber obtained by the above treatment, νa/νb was 1.0 and the same as that of the untreated fiber. There was no appreciable difference between the untreated fiber and the treated fiber in crystallinity determined by the laser Raman spectroscopy. There was little improvement of the compressive strength of the single filament. Comparative Example 8 The carbon fiber bundle before ion implantation as used in Example 6 was treated in the same manner as described in Comparative Example 7. The results are shown in Table 8. The values of νa/νb of the carbon fibers treated as above was 1.0 so the crystallinity by laser Raman spectroscopy was the same as the untreated carbon fibers. The compressive strength of single filament was improved only to a very slight extent by the implantation treatment. N.B. To convert from: denier to: tex, multiply by: 0.1111.

Claims: A carbon fiber which (a) is made from an acrylic fiber; (b) has a crystal size Lc of 15 to 65 angstroms (1.5 to 6.5 nm) as determined by wide angle X-ray diffractometry, and (c) has regions with a lower crystallinity in the surface layer portion thereof than that in the central portion thereof, as provided by a νa/νb ratio of at least 1.5, where νa is a half width of the scattering peak at 1320 to 1380 cm -1 of the laser Raman spectrum of at least part of the regions in the surface layer portion of a single filament and νb is a half width of the scattering peak at 1320 to 1380 cm -1 of the laser Raman spectrum of the central portion of the single filament, whereby the carbon fiber has a compressive strength (σ cf ) of the single filament determined by the loop method which satisfies the requirement represented by the following formula (I): σ cf ≥ 10.78 - 0.1176 x Lc with σ cf expressed in GPa and Lc expressed in angstroms (10 -1 nm). A carbon fiber according to claim 1, which contains an ion-implanted material but does not contain any appreciable amount of ion-implanted material in the central portion of the single filament, and wherein the content of the ion-implanted material is highest in the surface layer portion thereof. A carbon fiber according to claim 1 or claim 2, wherein the ratio νa/νb is at least 2.0. A carbon fiber according to any preceding claim, wherein the carbon content determined by elemental analysis is at least 98%, the crystal size Lc determined by wide angle X-ray diffractometry is at least 22 angstroms (2.2 nm), the orientation degree π 002 in the direction of the fiber axis is at least 85%, the peak of modified graphite is observed in the range of 1400 to 1500 cm -1 of the laser Raman spectrum of the surface of a single filament, and the intensity of said peak is at least 0.3 times the intensity of the peak of graphite present at 1550 to 1610 cm -1 . A carbon fiber according to any preceding claim, wherein the tensile modulus of elasticity of a single filament is at least 340 GPa, the tensile strength of the single filament is at least 3.9 GPa, and the compressive strength σ cf of the single filament is at least 4.9 GPa. A method of producing carbon fibers containing ion-implanted material, in which method carbon fiber is made from an acrylic fiber and then subjected to an ion implantation process comprising ionizing in vacuo an atom or molecule which is solid or gaseous at room temperature, accelerating the ionized atom or molecule by an electric field, and implanting the accelerated ionized atom or molecule in a bundle of the carbon fibers through the surface thereof. A method according to claim 6, wherein prior to implantation into the bundle of carbon fibers of the accelerated ionized atom or molecule, the bundle of carbon fibers is spread to an extent such that the thickness of the fiber bundle in the ion implanting direction is up to 5 times the diameter of a single filament of the carbon fiber. A method according to claim 6 or claim 7, wherein accelerated ionized atoms or molecules are implanted in two opposite directions through the front and back surfaces of the carbon fiber. A method according to any one of claims 6 to 8, wherein the ionized material is continuously implanted while the carbon fiber is continuously moved. A method according to claim 9, wherein the carbon fiber is moved at a constant speed. A method according to any one of claims 6 to 10, wherein the quantity of the implanted ionized material is at least 10 15 /cm 2 . A method according to any one of claims 6 to 11, wherein the ionized material is implanted under a vacuum degree of not larger than 10 -3 Torr. A method according to any one of claims 6 to 12, wherein the atom or molecule to be ionized is selected from B, N, Ar, Si, C, Ti, Cr, Ni and Cu atoms, and molecules containing these atoms. A method according to any one of claims 6 to 13, wherein the bundle of carbon fibers is prepared by calcining acrylic fiber having a lightness difference AL, determined by the iodine adsorption method, of not larger than 45 at a temperature of at least 1,000°C in an inert gas atmosphere. A method according to claim 14, wherein the acrylic fiber is heated at a temperature of at least 1,800°C to be thereby graphitized.

Inventors: HIRAMATSU TORU, KATAGIRI GEN, MATSUHISA YOJI, YOSHIDA KAZUO, HIRAMATSU, TORU, KATAGIRI, GEN, MATSUHISA, YOJI, YOSHIDA, KAZUO
Applicants: TORAY INDUSTRIES, TORAY RESEARCH CENTER INC, TORAY INDUSTRIES, INC., TORAY RESEARCH CENTER, INC.
Application year: 1989
Main classification: D01F9
IPC codes: D01F9