At present, carbon fiber products are mainly made into carbon fiber reinforced plastic composite materials to apply carbon fiber is a fibrous carbon material. It is a new material with greater strength than steel, smaller density than aluminum, corrosion resistance than stainless steel, high temperature resistance than heat-resistant steel, and conductivity like copper, with many valuable electrical, thermal and mechanical properties.
A brief history of carbon fiber development.
1860 Swan makes carbon filament light bulb
In 1878, Swan tried to produce carbon silk from cotton yarn
In 1879, Edison tried to produce carbon silk from oil smoke and tar, cotton yarn and bamboo silk (lasted 45 hours)
In 1882, the carbon wire lamp was practical in 1911, the tungsten wire lamp was practical
In 1950, the United States Wright- Patterson Air Force Base began to develop adhesive based carbon fiber
In 1959, the United States UCC company produced low modulus adhesive based carbon fiber "Thornel-25", Japan Osaka Industrial test Institute Akio Shindo invented PAN-based carbon fiber
In 1962, Nippon Carbon Corporation began to produce low modulus PAN-based carbon fiber (0.5 tons/month)
In 1963, Watt and Johnson of the Royal Institute of Aeronautical Research (RAE) in the United Kingdom successfully opened up the technical way to make high performance PAN-based carbon fibers (by applying tension during heat treatment).
In 1964, British Courtaulds,Morganite and RoII-Roys company used RAE technology to produce PAN-based carbon fiber
In 1965, Otani Sugiro of Gunma University in Japan invented asphalt based carbon fiber. UCC Company began to produce high modulus adhesive based carbon fiber (drawn during graphitization)
In 1970, the Japanese Kureha Chemical Company produced bitum-based carbon fiber (10 tons/month), and the Japanese Toray Company and the United States UCC technical cooperation
In 1971, Japan Toray industrial scale production of PAN based carbon fiber (1 ton/month), carbon fiber grade T300, graphite fiber M40
In 1972, the United States Hercules company began to produce PAN-based carbon fiber Japan with carbon fiber manufacturing fishing rods, the United States with carbon fiber manufacturing golf clubs
In 1973, Japan Tobang Rayon Company began to produce PAN-based carbon fiber (0.5 tons/month) Japan Toray Company expanded production by 5 tons/month
1974, carbon fiber fishing rod, golf clubs rapid development of Japan Toray company expanded production 13 tons/month
1975, the commercialization of carbon fiber tennis racket UCC company announced the use of meso-phase asphalt to manufacture high modulus asphalt based carbon fiber "THORNEL-P" UCC high performance asphalt based carbon fiber commercialization
In 1976, Tobang Rayon Company and the United States Celanes technical cooperation Sumitomo Chemical and the United States Hercules (Hercules) established a joint company
In 1979, Japan Carbon Corporation and Asahi Kasei Industrial Corporation established the Rising Sun Carbon Fiber Company
In 1980, the United States Boeing Company proposed the demand for high strength, large elongation of carbon fiber
In 1981, Taiwan Plastics set up a carbon fiber research center, Japan's Mitsubishi Rayon Company and the United States Hitco company for technical cooperation
In 1984, Taiwan Formosa Plastics and the United States Hitco company for technical cooperation, Japan Toray company successfully developed high-strength carbon fiber T800
In 1986, Japan Toray Company successfully developed high-strength carbon fiber T1000
In 1989, Japan Toray Company successfully developed high mold medium strength carbon fiber M60
In 1992, Japan Toray Company successfully developed high mold medium strength carbon fiber M70J, Yang's touch up to 690GPa;
In 1971, TORAY became the world's first human manufacturer, engaged in the human industrial production of PAN-based carbon fiber, and named its product "TORAYCA", which is short for TORAY carbon fiber. TORAY is the world leader in the production and marketing of carbon fiber.
At present, the world mainly produces two kinds of carbon fiber. One is PAN-based carbon fiber with polyacrylonitrile as raw material, and the other is asphalt-based carbon fiber, which is distilled from coal and petroleum synthetic asphalt to form asphalt, and then polymerized into fiber.
Pan-based carbon fibers are superior to bitumen based carbon fibers in strength, so they have a positive and overwhelming advantage in carbon fiber production around the world.
The company began to contact carbon fiber heating element as early as 1993, and in 1994 for a large iron and steel enterprise in the north of China, the constant temperature industrial control unit designed and installed carbon fiber heating plate material. In 1995, began to study carbon fiber ground heating materials, to 2002, developed a variety of forms of carbon fiber heating elements, and obtained a number of Chinese patents. During this period, we have been cooperating with TORAY on technology and made outstanding contributions to the development of carbon fiber heating materials. At present, the products sold are the third generation of carbon fiber heating products, carbon fiber heating technology has also been tested for more than ten years, we believe that the current third generation of products in form, function, effect and efficiency belong to the industry's high level, is a scientific and reasonable form of carbon fiber heating materials.
1. Carbon fiber production process
For the production process of carbon fiber, when the PAN-based carbon fiber is produced, the polyacrylonitrile fiber, known as the "parent", is first processed by the polymerization and spinning process. The matrix is then oxidized in an oxidation furnace at 200 to 300 degrees Celsius. In addition, carbon fiber is also carbonized in a carbonization furnace at a temperature between 1000 and 2000 degrees Celsius. In addition to conventional types of fine carbon fibers, PAN-based carbon fibers also include coarse fibers, known as "rayon tow type carbon fibers," which are relatively low-cost to produce.
2. Properties of carbon fiber
As is often said, carbon fibers are lighter than aluminum and harder than steel, their specific gravity is a quarter of iron, and their specific strength is ten times that of iron. By comparing this with other fibers, you can get an idea of the properties of carbon fibers. Also, carbon fiber is first and foremost a substance, made of the same carbon as diamonds. For this reason, in addition to the superior tensile strength and tensile modulus, carbon fiber is very stable in chemical composition and has high corrosion resistance. Other properties of carbon fiber include high X-ray penetration, high chemical, heat and low temperature resistance.
These properties of carbon fiber mean that it can be used in many fields besides heating. Includes mainly sports, such as golf clubs and fishing rods; Aviation applications include aircraft components and industrial applications. With the continuous progress of industry, people are looking for many new materials with new capabilities, and the demand for carbon fiber is gradually increasing, and it is widely used in medical equipment, pressure vessels, civil engineering and building materials, energy, and other new industrial applications. The production cost of carbon fiber is also gradually reducing, and the processing technology is diversified and differentiated, and manufacturers can provide a series of carbon fiber products according to the specific application. All of this supports new types of applications centered on industrial applications.
3. Form and manufacturing process of carbon fiber products
Carbon fiber comes in four product forms: fiber, cloth, prepreg billet, and cut fiber. Fabric refers to fabric made of carbon fiber. Prepreg billet is a product that arranges carbon fibers in one direction and converts the carbon fibers or fabric into sheets by soaking them in resin. Staple fibers refer to short strands. In different ratios, these products are combined with resins to form carbon fiber reinforced plastics (CFRP).
Pressure vessels can be made by attaching resins to fibers and rolling them around a core, which is then plasticized or hardened. This method is called "winding forming".
The fabric is put into a model and then soaked in resin, which can be used to produce cardstock and body parts of rowboats. This is known as the "Resin transfer molding method (RTM)".
Aircraft components are manufactured by heating, pressurizing and plasticizing prepreg billets in autoclaves. The prepreg blank is wrapped around a core and then heated and plasticized, which is called the "wafer winding method" and can be used to make golf clubs. Short filaments are mixed with resins to form mixtures that can be processed to produce machine components and other products.
In the past, prepreg billets were widely used in the form of carbon fiber, which was prefabricated in the reactor using a sheet winding method. Recently, however, with the development of new industrial applications, fiber winding forming methods, mixtures and other prefabrication methods have been more widely developed. The application of molding methods such as RTM allows manufacturers to make large products more efficiently. The combination of carbon fiber with suitable resins and prefabrication processes makes the application of carbon fiber more attractive.
4. Development of other applications.
At present, various other applications account for the following percentage of the annual demand for carbon fiber: approximately 30% for sports applications, 10% for aviation applications, and 60% for industrial applications.
Three important applications in sports applications are golf clubs, fishing rods and tennis racquet frames. At present, it is estimated that the annual production of golf clubs is 34 million. According to the National region classification, these golf clubs are mainly produced in the United States, China, Japan and Chinese Taipei, and the United States and Japan are the main consumption places of golf clubs, accounting for more than 80%. 40% of the world's carbon fiber golf accessories are made of TORAY carbon fiber.
The worldwide production of carbon fiber fishing rods is about 20 million pairs per year, which means that there is a steady demand for carbon fiber for this application.
The market capacity for tennis racket frames is about 6 million per year. Other sports applications include ice hockey sticks, ski poles, archery, and cycling, while carbon fiber products are also used in rowing, rowing, surfing, and other Marine sports.
In 1992, the demand for carbon fiber in the aviation industry began to decline, mainly due to the decline of the commercial aircraft industry, but it recovered rapidly in early 1995. The main reason for the recovery is that since production efficiency has been improved overall and production of the Boeing 777 has begun at full capacity, TORAY's carbon fiber is used as a structural material, including the horizontal and vertical transverse tail fins and beams, which are so important that if they are damaged, the entire plane could crash during flight. These materials are called "primary structural materials" because they are so important that the quality requirements for them are extremely demanding. For the Boeing 777 aircraft, TORAY is one of the certified carbon fiber manufacturers designated by Boeing.
Europe's Airbus also uses a lot of carbon fiber in their aircraft, and TORAY's TORAYCA carbon fiber will be used in large quantities in their new passenger aircraft, the A380.
In the industrial field, the application of carbon fiber is also quite extensive, as a material, they are replacing metal and concrete to meet the environmental, safety and energy requirements, the demand for carbon fiber products in the industrial field is showing an upward trend.
In the field of civil engineering and construction, the application of carbon fiber seismic repair and strengthening method is a major breakthrough, and is being more widely promoted in this field. In railway construction, large roof systems and sound insulation walls will have good applications in the future, and these will also be very promising applications. Pressure vessels are mainly used in the pressurized natural gas (CNG) tank of automobiles, as shown in the figure, and in the fixed breathing apparatus (SCBA) of firefighters. CNG tanks originated in the United States and Europe, and now Japan and other Asian regions are also showing great interest in this application.
Other applications of carbon fiber include the production of composite materials for machine components, household appliances, microcomputers, and semiconductor-related equipment, which can be used for sword strengthening, anti-static, and electromagnetic wave protection. In addition, in the X-ray instrument market, the application of carbon fiber can reduce human exposure to X-rays.
With the continuous reduction of the cost of carbon fiber, and the improvement of environmental protection requirements in the world, carbon fiber has begun to be applied to the automotive field, and in the future, they will be applied to the tail boiler, engine, drive shaft and fuel tank materials, which will have a good prospect in the future.
5. History of the carbon fiber market. The full commercialization of carbon fiber began in the 1970s, and the 1970s was the period of introduction and development of golf clubs and fishing rod applications, mainly in Japan. In the early 1980s, carbon fiber began to be widely used as a structural material in passenger aircraft and aircraft, mainly in Europe and North America.
Then, people raised awareness of carbon fiber and began to see it as a high-quality material, and it gained rapid growth in the mid-1980s. In the mid-1980s, Airbus began using CFRP as the primary structural material in their aircraft, and the market for carbon fiber has steadily expanded with its use in tennis and new sports. Since the mid-1990s, the carbon fiber industry has only just begun to emerge as a new source of demand growth, despite a downturn in aviation after the 1991 Gulf War and a slowing global economy. In particular, Europe and North America began to apply carbon fiber to pressure vessels, this growth is very significant, and heating materials using carbon fiber's outstanding electric heating characteristics have also begun to appear. The 1995 Kobe earthquake accelerated the need for seismic reinforcement applications. In the future, it is expected that the main application areas of carbon fiber will focus on industrial applications, and this demand will steadily increase; The proportion of application of carbon fiber heating materials in industrial and civil fields will also increase rapidly with the soaring price of oil and natural gas year by year. In addition, the new space program and steam related applications will promote the industrial application of carbon fiber.
6. Supply and demand conditions
In 2004, the production capacity of conventional carbon fiber was about 25,000 tons, of which 75% was produced by Japanese-related manufacturers. In addition, the production of low-cost crude carbon fiber, known as the "rayon tow type" of carbon fiber is also thousands of tons, which has begun to be used in low-end sports and industrial applications, but also is used