# US 2018/0023220 A1 · Method for producing carbon fiber composite material

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- Number: US 2018/0023220 A1
- Document ID: US20180023220A1
- Status: Published application
- Kind: A1
- Application number: 15/720,725
- Filed: 2017-09-29
- Published: 2018-01-25
- Earliest claimed: 2015-03-31
- Assignees: National Institute of Advanced Industrial Science and Technology
- Applicants: National Institute of Advanced Industrial Science and Technology
- Inventors: Kenji HATA; Seisuke ATA; Shigeki TOMONOH; Howon YOON
- Web page: https://patentgrep.com/patent/US20180023220A1

## CPC

- D01F 9/12: Carbon filaments; Apparatus specially adapted for the manufacture thereof
- B29B 15/105: {of reinforcement of definite length with a matrix in solid form, e.g. powder, fibre or sheet form (calendering B29C70/506)}
- B32B 5/00: Layered products characterised by the non- homogeneity or physical structure {, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts}
- B32B 5/28: impregnated with or embedded in a plastic substance {(not used)}
- C01B 32/158: Carbon nanotubes
- C01B 32/159: single-walled
- C01B 32/174: Derivatisation; Solubilisation; Dispersion in solvents
- C08J 5/005: {Reinforced macromolecular compounds with nanosized materials, e.g. nanoparticles, nanofibres, nanotubes, nanowires, nanorods or nanolayered materials}
- C08J 5/042: {with carbon fibres}
- C08J 5/243: {using carbon fibres}
- C08K 3/041: {Carbon nanotubes}
- C08L 101/00: Compositions of unspecified macromolecular compounds
- B82Y 30/00: Nanotechnology for materials or surface science, e.g. nanocomposites
- B82Y 40/00: Manufacture or treatment of nanostructures
- C08J 2300/24: Thermosetting resins
- C08J 2363/00: Characterised by the use of epoxy resins; Derivatives of epoxy resins
- D01F: CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C}
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- B82Y: SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES

## Abstract

Provided are a carbon fiber composite material and a producing method thereof comprising an adhesive layer having excellent conductivity and high peeling strength. A carbon fiber composite material according to the present application includes a first carbon fiber dispersion layer having carbon fibers dispersed in a thermosetting resin, a carbon nanotube dispersion layer having carbon nanotubes dispersed in a thermosetting resin, and a second carbon fiber dispersion layer having carbon fibers dispersed in a thermosetting resin, wherein the carbon nanotube dispersion layer is arranged between the first carbon fiber dispersion layer and the second carbon fiber dispersion layer, and the carbon nanotubes in the carbon nanotube dispersion layer are arranged in close contact with the carbon fibers of the first carbon fiber dispersion layer and the carbon fibers of the second carbon fiber dispersion layer.

## Claims

### Claim 1

A carbon fiber composite material comprising:
a first carbon fiber dispersion layer having carbon fibers dispersed in a thermosetting resin;
a carbon nanotube dispersion layer having carbon nanotubes dispersed in a thermosetting resin; and
a second carbon fiber dispersion layer having carbon fibers dispersed in a thermosetting resin;
wherein
the carbon nanotube dispersion layer is arranged between the first carbon fiber dispersion layer and the second carbon fiber dispersion layer; and
the carbon nanotubes in the carbon nanotube dispersion layer are arranged in close contact with the carbon fibers of the first carbon fiber dispersion layer and the carbon fibers of the second carbon fiber dispersion layer.

### Claim 2

A carbon fiber composite material comprising:
a first carbon fiber dispersion layer having carbon fibers dispersed in a thermosetting resin;
a carbon nanotube dispersion layer having carbon nanotubes dispersed in a thermosetting resin; and
a second carbon fiber dispersion layer having carbon fibers dispersed in a thermosetting resin;
wherein
the carbon nanotube dispersion layer is arranged between the first carbon fiber dispersion layer and the second carbon fiber dispersion layer; and
the carbon fiber composite material has at least one of an interlayer peeling strength of 300 J/m2 or more, conductivity in a fiber axis direction of 0.1 S/cm or more, conductivity in a vertical direction with respect to the fiber axis direction of 10−5 S/cm or more, and a three-point bending strength of 500 MPa or more.

### Claim 3 (depends on 1)

The carbon fiber composite material according to claim 1, wherein the carbon nanotube dispersion layer has a film shape.

### Claim 4 (depends on 1)

The carbon fiber composite material according to claim 1, wherein a size of a carbon nanotube aggregate within the carbon nanotube dispersion layer is in a range of 5 μm or more and 50 μm or less of a median value of a particle size distribution at a volume standard.

### Claim 5 (depends on 1)

The carbon fiber composite material according to claim 1, wherein a carbon nanotube density of the carbon nanotube aggregate within the carbon nanotube dispersion layer is 0.1% by weight or more.

### Claim 6 (depends on 1)

The carbon fiber composite material according to claim 1, wherein an average length of the carbon nanotube of the carbon nanotube aggregate within the carbon nanotube dispersion layer is 1 μm or more.

### Claim 7 (depends on 1)

The carbon fiber composite material according to claim 1, wherein a thickness of the carbon nanotube dispersion layer is 0.1 μm or more.

### Claim 8

A producing method of a carbon fiber composite material comprising:
forming a first carbon fiber dispersion layer by dispersing carbon fibers in a thermosetting resin;
forming a carbon nanotube dispersion layer by dispersing carbon nanotubes in a thermosetting resin; and
forming a second carbon fiber dispersion layer by dispersing carbon fibers in a thermosetting resin;
wherein
the carbon fiber composite material is formed by arranging the carbon nanotube dispersion layer between the first carbon fiber dispersion layer and the second carbon fiber dispersion layer; and
the carbon nanotubes in the carbon nanotube dispersion layer are arranged in close contact with the carbon fibers of the first carbon fiber dispersion layer and the carbon fibers of the second carbon fiber dispersion layer.

### Claim 9

A producing method of a carbon fiber composite material comprising:
forming a first carbon fiber dispersion layer by dispersing carbon fibers in a thermosetting resin;
forming a carbon nanotube dispersion layer by dispersing carbon nanotubes in a thermosetting resin; and
forming a second carbon fiber dispersion layer by dispersing carbon fibers in a thermosetting resin;
wherein
the carbon fiber composite material is formed by being arranging the carbon nanotube dispersion layer between the first carbon fiber dispersion layer and the second carbon fiber dispersion layer; and
the carbon fiber composite material has at least one of an interlayer peeling strength of 300 J/m2 or more, conductivity in a fiber axis direction of 0.1 S/cm or more, conductivity in a vertical direction with respect to the fiber axis direction of 10−5 S/cm or more, and a three-point bending strength of 500 MPa or more.

### Claim 10 (depends on 8)

The producing method of a carbon fiber composite material according to claim 8, wherein the carbon nanotube dispersion layer has a film shape.

### Claim 11 (depends on 8)

The producing method of a carbon fiber composite material according to claim 8, wherein a size of a carbon nanotube aggregate within the carbon nanotube dispersion layer is in a range of 5 μm or more and 50 μm or less of a median value of a particle size distribution at a volume standard.

### Claim 12 (depends on 8)

The producing method of a carbon fiber composite material according to claim 8, wherein a carbon nanotube density of the carbon nanotube aggregate within the carbon nanotube dispersion layer is 0.1% by weight or more.

### Claim 13 (depends on 8)

The producing method of a carbon fiber composite material according to claim 8, wherein an average length of the carbon nanotube of the carbon nanotube aggregate within the carbon nanotube dispersion layer is 1 μm or more.

### Claim 14 (depends on 8)

The producing method of a carbon fiber composite material according to claim 8, wherein a thickness of the carbon nanotube dispersion layer is 0.1 μm or more.

### Claim 15 (depends on 1)

A paste type carbon nanotube contained resin material coated on the first carbon fiber dispersion layer and/or the second carbon fiber dispersion layer of the carbon fiber composite material according to claim 1, wherein the paste type carbon nanotube contained resin material has a viscosity measured by a rheometer of 50 Pa·s or more in a stationary state and/or 20 Pa·s or less under a condition of a sheer rate of 100 s−1 or more.