Patent Grant
8839492
The present application is a 35 U.S.C. §371 national stage patent application of International patent application PCT/JP2012/050777, filed on Jan. 17, 2012, published as WO/2012/108230 on Aug. 16, 2012, the text of which is incorporated by reference, and claims the benefit of the filing date of Japanese application nos. 2011-026960, filed on Feb. 10, 2011, and 2011-167343, filed on Jul. 29, 2011, the text of both of which is also incorporated by reference.
The invention relates to a pressure steam treatment apparatus preferably applied when fibers are drawn, specifically, to a pressure steam treatment apparatus in which fiber bundles are drawn under a pressure steam atmosphere, and particularly, to a pressure steam treatment apparatus capable of continuously treating a plurality of fiber bundles collectively in pressure steam treatment of a plurality of fiber bundles under a pressure steam atmosphere and to a method for producing acryl fiber bundles.
In the production of carbon fibers and such, fiber bundles made of a polyacrylonitrile type polymer and such are used as raw threads. These fiber bundles need to have excellent strength and high degree of orientation. Such a fiber bundle, for example may be obtained by spinning a yarn raw solution containing a polyacrylonitrile polymer to form, a solidified fiber, which is then drawn in a bath, followed by drying to densify, thereby obtaining a fiber bundle, which is then subjected to a secondary drawing process carried out under a pressure steam atmosphere.
For the treatment of the fiber bundle under a pressure steam environment, a treatment apparatus is used which makes fiber bundles run inside thereof and supplies pressure steam to the fiber bundle. In such a treatment apparatus, there was the case where the pressure, temperature and humidity in the apparatus became unstable, causing the raise of fuzz on the fiber bundle and fiber bundle breakage, if the pressure steam supplied to the inside of the apparatus leaked in a large amount externally from the inlet and outlet of the pressure steam treatment apparatus. Also, a large amount of pressure steam is required to suppress the influence of the leakage of steam from the apparatus, leading to increase in energy cost.
As a treating apparatus that restrains the leakage of pressure steam from the inside of the apparatus, a pressure steam treating apparatus is known which is provided with a pressure steam treating section for treating fiber bundles running in a fixed direction and two labyrinth sealing chambers extending from the front and back of the pressure steam treating section. The above labyrinth sealing chambers were each provided with a plurality of labyrinth nozzles made of plate fragments extending at right angle from the internal wall surface thereof to the fiber bundles wherein steam energy is consumed when steam passes through each space (expansion room) between these labyrinth nozzles, to thereby reduce the leak amount of pressure steam.
Specifically, Japanese Patent Application Laid-Open No. 2001-140161 (Patent Document 1) discloses a pressure steam treatment apparatus which is provided with a pressure steam treating section and two labyrinth sealing chambers extending from the front and back of the pressure steam treating section, wherein each labyrinth sealing chamber is provided with labyrinth nozzles in 80 to 120 stages, and the ratio (L/P) of the length L of the labyrinth nozzle extended from the inside wall to the pitch P between adjacent labyrinth nozzles is from 0.3 to 1.2.
Patent Document 1: Japanese Patent Application Laid-Open No. 2001-140161
However, in the pressure steam treating apparatus of Patent Document 1, no attention is paid at all to the influence of heat and pressure on the pressure steam treatment apparatus itself and no study has been even made on the influence. According to this type of pressure steam treatment apparatus, the occurrences of fuzz on the fiber bundle and fiber bundle breakage tend to increase by long-time continuous treatment. When examining the reasons, one of the reasons is the deformation of the pressure steam treatment apparatus because of continuous operation of the pressure steam treatment apparatus. The deformation is typified by the pressure deformation of the apparatus due to the pressure of the pressure steam and thermal deformation due to a rise of the temperature of the members of the apparatus caused by high temperature of the pressure steam.
With regard to the pressure deformation of the apparatus, the body constituting the pressure steam treatment chamber and labyrinth sealing chamber is fixedly installed in such a manner that it is covered with an external wall member constituted of rectangular-shaped members arranged lengthwise and crosswise along the upper and lower surfaces of the body of the apparatus to thereby provide pressure resistance to the apparatus. However, when only the frame structure is adopted, the body constituting the pressure steam section and labyrinth sealing chamber is heated and expanded, whereas a beam member of the prismatic member and external wall member are cooled because of the temperature difference between these members and the peripheral atmosphere and therefore reduced in thermal expansion as compared with the body constituting these pressure steam treatment chamber and labyrinth sealing chamber. Accordingly, the difference in thermal expansion between the body constituting these pressure steam treatment and labyrinth sealing chamber and the prismatic member and external wall member causes a warpage of the whole apparatus.
In multi-spindle batch process in which a plurality of fiber bundles are made to run, the leakage of steam from the fiber bundle inlet and outlet is restrained to stabilize the treatment by limiting the number of labyrinth nozzles to be installed and intervals between the nozzles like the invention disclosed in the above Patent Document 1. However, the interference between adjacent fiber bundles running together cannot be reduced. Though it is considered to be better to widen the width of the opening section of running fiber bundles to avoid this interference, the warpage of the pressure steam treatment apparatus due to thermal deformation is increased if the width is widened, and therefore, such a phenomenon is observed that the height of the opening section at the center of the section of the opening section largely differs from that at each end of the opening section. As a result, the opening height required for the passing of fiber bundles cannot be secured in a part of the opening height, and there is therefore the case where the fiber bundles are brought into contact with the labyrinth nozzle, causing the raise of fuzz on the fiber bundle and fiber bundle breakage.
Also, if it is intended to increase the width of the opening section in the pressure steam treatment apparatus described in the above Patent Document 1, it is inevitable to increase the height of the opening section to a level higher than a desired opening height to secure the opening height necessary to pass the fiber bundles, resulting in increase in the amount of pressure steam leaked from the pressure steam treatment apparatus, giving rise to the problem concerning increased cost on the contrary.
The invention has been made to solve the aforementioned problems at the same time and it is an object of the invention to provide a pressure steam treatment apparatus provided with a pressure steam treatment chamber, and two labyrinth sealing chambers extending from the front and back of the pressure steam treatment chamber, the apparatus treating a plurality of fiber bundles running side by side sheet-wise along the running path collectively in a pressure steam atmosphere, and ensuring that the energy cost necessary due to the leakage of pressure steam can be reduced, thermal deformation of the apparatus can be prevented, and also, the raise of fuzz on the fiber bundle and fiber bundle breakage can be prevented.
Another object of the invention is to provide a pressure steam treatment apparatus provided with a pressure steam treatment chamber, and two labyrinth sealing chambers extending from the front and back of the pressure steam treatment chamber, the apparatus treating a plurality of fiber bundles running side by side sheet-wise along the running path collectively in a pressure steam atmosphere, and ensuring that the energy cost necessary due to the leakage of pressure steam can be reduced, and also, the raise of fuzz on the fiber bundle and fiber bundle breakage can be prevented without fail.
A pressure steam treatment apparatus for a carbon fiber precursor acryl fiber bundle of the present invention includes a pressure steam treatment chamber and a first and a second labyrinth sealing chamber arranged adjacent to the front and back of a pressure steam treatment chamber in the running direction of fiber bundles, the apparatus being characterized in that the labyrinth sealing chambers are respectively arranged on a fiber bundle inlet and on a fiber bundle outlet of the steam treatment apparatus, having a running path of the fiber bundle in a horizontal direction and having plural labyrinth nozzles on top and bottom of the running path, and the labyrinth nozzles are comprised by having top side labyrinth nozzle and bottom side labyrinth nozzle located by opposing each other, the difference (ΔH) between a maximum value and a minimum value of the distance in the perpendicular direction of the top and bottom side labyrinth nozzles, of a pair of opposing labyrinth nozzles is 0.5 mm or smaller when the ambient temperature of the labyrinth sealing chambers is 140° C.
Here, the apparatus includes an external wall member on an upper surface of the pressure steam treatment apparatus excluding a steam inlet, having a plate member extending toward a top board of the pressure steam treatment apparatus, an external wall member on an lower surface of the pressure steam treatment apparatus excluding a steam inlet, and having a plate member extending toward a bottom board of the pressure steam treatment apparatus, and when the ambient temperature of the pressure steam treatment chamber or labyrinth sealing chamber is 140° C., a difference in temperature between an optional point on the top or bottom boards of the pressure steam treatment chamber and a point on the external wall member opposite to the optional point is 30° C. or less.
The external wall member may be a member having a linear expansion coefficient higher than those of the top board and bottom board.
It is preferable that a heat conductive member be disposed in a space part formed between at least the upper surface of the pressure steam treatment chamber and the labyrinth sealing chamber and the external wall member.
A pressure steam treatment apparatus according to another embodiment of the invention includes a pressure steam treatment chamber and a labyrinth sealing chamber, the apparatus being characterized in that the labyrinth sealing chamber is respectively arranged on a fiber bundle inlet and a fiber bundle outlet of the steam treatment apparatus, having a running path of the fiber bundle in a horizontal direction, and it includes an external wall member on an upper surface of the pressure steam treatment apparatus excluding a steam inlet, having a plate member extending toward a top board of the pressure steam treatment apparatus, an external wall member on an lower surface of the pressure steam treatment apparatus excluding a steam inlet, and having a plate member extending toward a bottom board of the pressure steam treatment apparatus, and a heat conductive member is disposed in a space part between at least the top board of the pressure steam treatment chamber and the external wall member on the upper surface of the top board.
With regard to an optional section having the above space part parallel to the above top board in the space part, the ratio (A2/A1) of the sectional area A2 of the above heat conductive member to the area A1 enclosed by the above plate member is preferably 5% or more.
As the above heat conductive member, a material having a heat conductivity of 16 W/(mK) or more is preferably used. Also, the ratio (H/W) of the height H to width W of the rectangular-shaped opening section formed between the opposing top and bottom labyrinth nozzles in the labyrinth sealing chamber is preferably 1/2000 to 1/60.
As to the above heat conductive member, one or two or more heat conductive members may be arranged at a right angle to the external wall member (40) and also at a right angle to the opening section and/or parallel to the opening section. Also, when two or more of the heat conductive members are arranged, the heat conductive members are preferably arranged at intervals of 100 mm to 500 mm. This structure ensures that the heat given from pressure steam used to treat fiber bundles to the structural members constituting the pressure steam treatment chamber and labyrinth sealing chamber can be efficiently conducted to the external wall member, thereby making possible to reduce the heat deformation of the pressure steam treatment apparatus.
In this description of the invention, a typical example is shown in which the heat conductive members are arranged grid-wise in a space formed between the pressure steam treatment chamber and labyrinth sealing chamber and the external wall member through the plate member. One or a plurality of first heat conductive members may be arranged at a right angle to the pressure steam treatment chamber and labyrinth sealing chamber and in parallel to the direction of running fiber bundles and, at the same time, one or a plurality of second heat conductive members may be arranged at a right angle to the pressure steam treatment chamber and labyrinth sealing chamber and in parallel to a direction in which the row of fiber bundles are arranged. When a plurality of heat conductive members is arranged, they are preferably arranged at intervals of 100 mm to 500 mm. This structure ensures that the heat given from pressure steam used to treat fiber bundles to the members constituting the pressure steam treatment chamber and labyrinth sealing chamber can be efficiently conducted to the external wall member, thereby making possible to reduce the heat deformation of the pressure steam treatment apparatus.
Also, as the heat conductive member, one or a plurality of third heat conductive members may be arranged at a right angle to the external wall member and also diagonally to the direction of opening section. Further, one or two or more heat conductive members may be arranged at a right angle to the external wall member and also at a right angle to the opening section and diagonally to the opening section.
Also, the pressure steam treatment apparatus is preferably provided with a heating device (for example, a heater) for heating the external wall member. It is preferable that the pressure steam treatment apparatus be further provided with a device for detecting the temperature of the external member heated by the heating device and with a temperature control device for controlling the heating temperature of the heating device.
Moreover, a pressure steam treatment apparatus according to another embodiment of the invention includes a pressure steam treatment chamber and a labyrinth sealing chamber, the apparatus being characterized in that the labyrinth sealing chambers are respectively arranged on a fiber bundle inlet and a fiber bundle outlet of the steam treatment apparatus, having a running path of the fiber bundle in a horizontal direction, and it includes an external wall member on an upper surface of the pressure steam treatment apparatus excluding a steam inlet, having a plate member extending toward a top board of the pressure steam treatment apparatus, an external wall member on an lower surface of the pressure steam treatment apparatus excluding a steam inlet, and having a plate member extending toward a bottom board of the pressure steam treatment apparatus, and is provided with a heating device that heats the external wall member. Further, the apparatus is preferably provided with a device that detects the temperature of the external wall member heated by the heating device and a control device that controls the heating temperature of the heating device based on the results of detection of the temperature control device.
According to the invention, there is provided a method for producing an acryl fiber bundle, the method including performing drawing treatment of acryl fiber bundles by a pressure steam treatment apparatus for acryl fiber bundles which has the above structure.
In the pressure steam treatment apparatus of the invention which adopts the above structure, fiber bundles are treated with pressure steam, thereby enabling the prevention of the raise of fuzz on the fiber bundle and fiber bundle breakage, and therefore, high quality fiber bundles can be obtained. Also, the heat given from pressure steam used to treat fiber bundles to the members forming the pressure steam treatment chamber and labyrinth sealing chamber can be efficiently conducted to the external wall member, thereby making possible to reduce the heat deformation of the pressure steam treatment apparatus.
Also, in the pressure steam treatment apparatus according to another embodiment of the invention, an external wall member including a plate member is fixedly installed so as to cover the body of the apparatus to thereby secure the strength of the whole apparatus, and a heating device is provided in the external wall member to thereby eliminate the temperature difference between the body of the apparatus and the external wall member, with the result that pressure deformation and temperature deformation of the whole apparatus can be restrained, the energy cost necessary due to the leakage of pressure steam can be reduced, and also, the raise of fuzz on the fiber bundle and fiber bundle breakage can be prevented at the same time.
(Pressure Steam Treatment Apparatus)
A pressure steam treatment apparatus (hereinafter referred to as a treatment apparatus) 1 in this embodiment is provided with a pressure steam treatment chamber 10 for treating acryl fiber bundles (hereinafter referred to simply as fiber bundles) Z which are precursors of carbon fibers running in a fixed direction by pressure steam and with two labyrinth sealing chambers extending to the fiber bundle inlet and fiber bundle outlet (in front and back of the fiber bundle running direction) respectively. There is no substantial difference between the structures of the pressure steam treatment chamber 10 and labyrinth sealing chamber 20 and those of the pressure steam treatment chamber and labyrinth sealing chamber of the pressure steam treatment apparatus disclosed in the above Patent Document 1. For this, specific structures and detailed explanations of the pressure steam treatment chamber 10 and labyrinth sealing chamber 20 are committed to the quotation from the descriptions of the above Patent Document 1 in the following explanations.
According to the illustrated example, the pressure steam treatment chamber 10 and labyrinth sealing chamber 20 are provided with a top board 11a and a bottom board 11b which are made of upper and lower single plane plates. The pressure steam treatment chamber 10 is located in the center part between the top board 11a and bottom board 11b and the labyrinth sealing chambers 20 are disposed adjacent to the front and back of the pressure steam treatment chamber 10. The pressure steam treatment chamber 10 disposed in the center part between the top board 11a and the bottom board 11b is provided with a porous plate 14 made of two porous plate materials which are to be disposed on the upper and lower sides of a fiber bundle running path 18 of the fiber bundles Z sandwiched therebetween. Pressure rooms 16 and 17 are formed between the top and bottom boards 11a and 11b and each porous plate 14. This pressure room 16 is provided with a pressure steam inlet 12 for supplying steam from the outside on each of the upper and lower side thereof. The pressure steam inlet 12 is formed on each of the upper and lower parts of the center of the pressure steam treatment chamber 10. This pressure steam inlet 12 may be formed on either the upper or lower part.
Any material may be used as the material constituting the pressure steam treatment chamber 10 insofar as it has mechanical strength high enough to stand against the pressure of pressure steam. Examples of the material include stainless steel having corrosion resistance and iron steel materials provided with anticorrosive coat.
The labyrinth sealing chamber 20 is provided with a plurality of labyrinth nozzles 24 made of plate fragments projecting perpendicularly in a direction decreased in the distance between the upper and lower fragments, from each internal wall surface 22 of the top board 11a and bottom board 11b towards the fiber bundles Z. An opening section 26 which is to be the fiber bundle running path inside of the labyrinth sealing chamber 20 is formed by the labyrinth nozzles 24 and an expansion room 28 is formed between adjacent labyrinth nozzles 24. Also, a fiber bundle inlet 30 for introducing the fiber bundles Z is formed in a first labyrinth sealing chamber 31 on the primary (rear part) side of the pressure steam treatment chamber 10 and a fiber bundle outlet 32 from which the fiber bundles Z are discharged is formed in a second labyrinth sealing chamber 33 on the secondary (front part) side of the pressure steam treatment 10.
Examples of the material of the plate fragment constituting the labyrinth nozzle 24 include, though not particularly limited to, stainless, titanium, titanium alloys, andiron steel material surface-treated by hard chromium plating in the point that these materials each have corrosion resistance and can reduce damages to the fiber bundles when they are in contact with the fiber bundles.
The formation of the expansion room 28 between adjacent labyrinth nozzles 24 in the labyrinth sealing chamber 20 causes the generation of eddy current in the flow of pressure steam in the expansion room 28 to consume energy, thereby dropping the pressure, leading to reduction in the amount of pressure steam leakage.
The labyrinth nozzle 24 is made of a narrow plate fragment and is formed so as to project at right angle with the fiber bundles Z running through the opening section 26 of the labyrinth section 20 from the internal wall surface 22 of the top and bottom boards 11a and 11b. The labyrinth nozzle 24 is preferably a plate fragment having a rectangular frame form, though no particular limitation is imposed on the shape of the labyrinth nozzle 24.
This labyrinth nozzle 24 may be projected from all of the internal wall surface 22 in all regions of the labyrinth sealing chamber 20 or may be projected from the internal wall surface 22 excluding that of a part of the labyrinth sealing chamber 20. Specifically, as shown in
Although the ratio (L/P) of the projected length L (
The pitch P between adjacent labyrinth nozzles 24 is preferably 16 to 29 mm, though no particular limitation is imposed on the pitch.
Though the thickness a (
Although the number of stages of the labyrinth nozzle 24 is preferably 20 to 80, no particular limitation is imposed on that number.
Also, the shape of the labyrinth nozzle 24 is not limited to a flat plate form illustrated in
The opening section 26 formed by the labyrinth nozzle 24 is preferably made into a rectangular-shaped form extending in a horizontal direction as shown in
Also, the opening section 26 is preferably formed in the center in the direction of the height of the labyrinth sealing chamber 20. This easily prevents the occurrence of such a phenomenon that the flow streams of pressure steam in the upper and bottom regions partitioned by the fiber bundles Z running in the labyrinth sealing chamber 20 of the expansion room 28 differ from each other, which makes unstable the running of the fiber bundles Z.
The ratio (H/W) (
The treatment apparatus 1 is preferably so designed that it is divided into two sections, that is, the upper section and lower section with the fiber bundles Z running in the apparatus as its center. This makes it possible to carry out threading work in a short time with ease when, particularly, a plurality of fiber bundles is collectively drawn under a pressure steam atmosphere while the fiber bundles Z are made to run in parallel in the treatment apparatus 1.
When adopting the structure obtained by dividing the treatment apparatus 1 into two sections, there is no particular limitation to an opening/closing mechanism of the divided apparatus bodies, and, for example, a mechanism in which the divided apparatus bodies are linked by a hinge to switch the opening/closing of the both may be adopted. Also, a method may be adopted in which the divided upper apparatus body section is lifted to open/close. In such a case, it is preferable to make a structure in which the joint part between the divided apparatus bodies is sealed by a cramp to prevent pressure steam from leaking from the joint part between the apparatus bodies.
Also, a plate member 50 enclosed by a plate material and an external wall member 40 are arranged so as to cover the structural members constituting the pressure steam treatment 10 and labyrinth sealing chamber 20 of the treatment apparatus 1 shown in
If, in the rectangular-shaped opening section 26, the height of the center is the same as that of the end in the direction of the width of the opening section 26, as shown in
In the treatment apparatus 1, when the temperature of the labyrinth sealing chamber 20 is 120° C. to 160° C. (particularly in the situation when the ambient temperature of the labyrinth sealing chamber 20 is 140° C.), the above ΔH can be reduced to 0.5 mm or less by efficiently conducting the heat of the pressure steam treatment chamber 10 and labyrinth sealing chamber 20 to the external wall member 40. This brings about difficulty in the rise of difference in the flow of pressure steam in the center and the end in the direction of the width of the rectangular-shaped opening section 26, so that heat is uniformly applied to a fiber flux, with the result that a fiber flux having uniform quality is easily obtained. In this point, ΔH is designed to be more preferably 0.25 mm or less.
If a difference in temperature between an optional point on the top and bottom boards 11a and 11b of the pressure steam treatment chamber 10 and the labyrinth sealing chamber 20 and a point on the external wall member opposite to the above optional point is 30° C. or less when the temperature of the pressure steam treatment chamber 10 and labyrinth sealing chamber 20 is 100° C. to 160° C. (particularly in the situation when the ambient temperature of the labyrinth sealing chamber 20 is 140° C.), this is preferable because warpage caused by thermal expansion is limited. In this point, the temperature difference is more preferably 25° C. or less and even more preferably 20° C. or less.
Also, the external wall member 40 is preferably a member having a higher linear expansion coefficient than each linear expansion coefficient of the members of the top and bottom boards 11a and 11b to limit the difference in thermal expansion and restrain the warpage even if a temperature difference between the top board 11a or bottom board 11b and the external wall member 40 arises. Which member to select as the member having a different linear expansion coefficient may be optionally selected based on a temperature difference between the top board 11a or bottom board 11b and the external wall member 40.
Also, in the plate member 50, heat conductive members 44 and 46 are installed between the member constituting the pressure steam treatment chamber 10 and labyrinth sealing chamber 20 and the external wall member 40. Although a material having a heat conductivity of 16 W/(m·K) or more is preferably used as the material of the heat conductive members 44 and 46 and iron steel, stainless steel, aluminum alloy, or the like may be used, no particular limitation is imposed on it.
The temperature difference between the structural members constituting the pressure steam treatment chamber 10 and labyrinth sealing chamber 20 and the external wall member 40 is dropped by the heat conductive effect of the heat conductive members 44 and 46, so that the warpage of the apparatus is decreased, and therefore, the uniform height H of the opening section 26 is kept, thereby more reducing the difference ΔH between the height H1 at the center and the height H2 of the end in the direction of the width of the opening section 26.
The heat conductive members 44 and 46 disposed between the structural members (top and bottom boards 11a and 11b) constituting the pressure steam treatment chamber 10 and labyrinth sealing chamber 20 and the external wall member 40 are preferably formed such that the ratio (A2/A1) of the sectional area A2 of the heat conductive member to the area A1 enclosed by the plate member 50 with respect to an optional sectional surface parallel to the external wall member 40 is 5% or more. Also, the heat conductive members 44 and 46 are preferably formed such that the above ratio (A2/A1) is 33% or less.
In the treatment apparatus 1, the heat conductive members are projected from and perpendicularly to the above top board 11a and bottom board 11b of the pressure steam treatment chamber 10 and labyrinth sealing chamber 20. The heat conductive members in the illustrated example (reference numerals 44 and 46 in
When the heat conductive members 44 and 46 are each arranged in parallel to the direction of running fiber bundles and to a direction in which the row of fiber bundles are arranged in the plate member 50, the difference between the amount of thermal expansion of the structural members constituting the pressure steam treatment chamber 10 and labyrinth sealing chamber 20 and that of the external wall member 40 is reduced, enabling reduction in the warpage of the apparatus, and therefore, an opening section 26 having a uniform height H is obtained.
Also, the interval between the heat conductive members 44 and 46 each arranged in parallel to the direction of running fiber bundles and to a direction in which the row of fiber bundles are arranged is preferably 100 mm to-500 mm. When the interval between the heat conductive members 44 and 46 is 500 mm or less, the heat given from pressure steam used to treat fiber bundles Z to the structural members forming the pressure steam treatment chamber 10 and labyrinth sealing chamber 20 can be efficiently conducted to the external wall member 40, thereby making possible to reduce the heat deformation of the pressure steam treatment apparatus. When the heat conductive member 48 arranged diagonally is further added, the deformation of the pressure steam treatment apparatus can be more reduced because the heat is evenly transferred to the external wall member 40. When the interval between the heat conductive members 44 and 46 is 100 mm or more, the amount of the structural materials to be used can be decreased to a minimum, and a rise in apparatus cost can be suppressed because increase in the size of the opening/closing mechanism with increase in the weight of the apparatus itself can be limited.
It is preferable to fill the space formed by the plate member 50, pressure steam treatment chamber 10, and labyrinth sealing chamber 20 with insulation material to restrain heat radiation to the air from the plate member 50 and external wall member 40. As the insulation material to be filled, glass wool, rock wool, and the like may be used, though no particular limitation is imposed on the insulation material. The existence of the insulation material can improve the heat efficiency of the pressure steam treatment chamber 10 and labyrinth sealing chamber 20 in the inside and at the same time, efficiently restrain heat radiation to the air from the plate member 50 and external wall member 40.
Any material may be used as the material of the plate member 50 and external wall member 40 without any particular limitation insofar as it is a material having mechanical strength enough to stand against the pressure of the pressure steam. An iron steel material with antirust coat, stainless steel, specific Invar alloys having a low linear expansion coefficient, and the like may be used.
Any material may be used as the material of the heat conductive members 44, 46 and 48 without any particular limitation insofar as it is a material having mechanical strength enough to stand against the pressure of the pressure steam and high heat conductivity. An iron steel material with antirust coat, stainless steel, specific Invar alloy having a low linear expansion coefficient, and the like may be used.
Next, a pressure steam treatment apparatus according to a second embodiment will be explained.
A pressure steam treatment apparatus 101 shown in
When adopting the structure obtained by dividing the treatment apparatus 101 into two bodies, there is no particular limitation to an opening/closing mechanism of the divided apparatus bodies 61 and 62, and, for example, a mechanism in which the divided apparatus bodies 61 and 62 are linked by a hinge to switch the opening/closing of the both may be adopted. Also, a method may be adopted in which the divided upper apparatus body section 61 is lifted to open/close. In such a case, it is preferable to make a structure in which the joint part between the divided apparatus bodies is sealed by a cramp to prevent pressure steam from leaking from the joint part between the apparatus bodies.
Also, the apparatus body constituting the pressure steam treatment chamber 10 and labyrinth sealing chamber 20 of the treatment apparatus 101 is enclosed by a plate-shaped upper and lower frame material (plate member) 50 in such a manner as to cover the apparatus body along the upper and lower peripheral surfaces, and the same prismatic members 44 and 46 are assembled grid-wise in a space part enclosed by the above upper and lower frame member 50 excluding a pressure steam inlet 12. Also, external wall members 40A and 40B are fixedly disposed on the upper and lower external side surfaces of the upper and lower frame materials and the prismatic members 44 and 46 respectively.
Here, either the same or different material may be used for the prismatic members 44, 46 and 48 with great heat conductivity which are arranged on the upper and lower external surfaces and left and right external surfaces of the apparatus body. With regard to the prismatic members arranged grid-wise on the upper and lower external surfaces and left and right external surfaces of the apparatus body, the same raw material or different raw material may be combined prior to use.
A heating device is arranged in each of the above upper and lower external wall members 40A and 40B. In the pressure steam treatment apparatus 101 in this embodiment, a steam heater 52 is used as the above heating device. However, there is no particular limitation to the heating device and any heating method may be used insofar as it can heat a member to be heated to a desired temperature. For example, besides the steam heater 52, a cease heater, aluminum casting heater, brass casting heater, or rubber heater may be adopted. The space between the heater 52 and the treatment apparatus 101 may be filled with thermo-cement or the like to improve the efficiency of heat conductivity to the upper and lower external wall members 40A and 40B from these heaters.
Also, in the treatment apparatus 101 according to this embodiment, a heating device is disposed on the entire surface of the upper and lower external members 40A and 40B. However, no particular limitation is imposed on the arrangement of the heating device insofar as the heating device are arranged at the position where the upper and lower wall members 40A and 40B are cooled due to a temperature difference from that of the peripheral atmosphere. For example, heating device are arranged inside of the upper and lower external wall members 40A and 40B. Specifically, the heating device may be arranged either only in the upper external wall member 40A on the upper side of the apparatus body or only in the lower external wall member 40B on the lower side of the apparatus body. Also, a heating device may be formed only in a part of the upper and lower external wall members 40A and 40B. The formation of heating devices other than pressure steam for the pressure steam treatment apparatus makes it possible to compensate temperature drop caused by the heat radiation of the upper and lower external wall members 40A and 40B, so that the whole apparatus is thermally expanded uniformly, with the result that the unevenness caused by a variation in the height of the opening section 26 formed by the labyrinth nozzle 24 can be reduced.
Though no particular limitation is imposed on the heating temperatures of the upper and lower external wall members 40A and 40B heated by the heating device, it is preferable to select a temperature optimum to secure a desired height of the opening section from the temperature of the steam supplied to the inside of the pressure steam treatment chamber 10, the width of the opening section 26, and sum of all length of the pressure steam treatment chamber 10 in the direction of running fiber bundles and all length of the primary side and secondary side labyrinth sealing chambers 20a and 20b. Also, a method may be adopted in which the distribution of the heating temperature of the member to be heated by the heating device is all fixed or a method may be adopted in which the temperature of only part of the members is dropped, or a method may be adopted in which the temperature of the members is continuously varied corresponding to the temperature of the steam in the labyrinth sealing chamber 20. A temperature control device that receives detection signals from the above various positions and controls the temperature of a necessary position in the labyrinth sealing chamber 20 to a desired temperature is disposed outside of the treatment apparatus 101.
In this embodiment, a temperature detection device that detects the heating temperature of a member to be heated is installed to control the temperature in the above-mentioned labyrinth sealing chamber 20. This temperature detection device is preferably installed at a position where the temperature of the body can be directly measured in the upper and lower external wall members 40A and 40B. For this, in this embodiment, a temperature detection device is installed at one or plural positions in the labyrinth sealing chamber 20. As a method of detecting the heating temperature of the heating device, for example, many thermocouples are used. However, the detection method is not limited to this and any method may be used without any particular limitation insofar as it can detect the temperature exactly in a desired temperature range.
The treatment apparatuses 1 and 101 are not limited to the treatment apparatuses 1 and 101 illustrated in
The fiber bundles Z may be properly selected corresponding to use, and examples of the fiber bundles Z include fiber bundles used to manufacture carbon fibers such as fiber bundles obtained by spinning a yarn raw solution containing a polyacrylonitrile polymer to form spun fibers, which are then drawn in a bath, followed by drying to densify. In this embodiment, a yarn raw solution containing a polyacrylonitrile polymer is spun to form a solidified fibers, which are then drawn in a bath, followed by drying to densify, thereby obtaining fiber bundles which are precursor fibers of carbon fiber and the fiber bundles are then subjected to a secondary drawing process performed under a pressure steam atmosphere to obtain fiber bundles Z of a polyacrylonitrile type fiber flux made of multifilament.
Although the treatment apparatuses 1 and 101 are not particularly limited by the type of the fiber bundles Z of fibers made of a polyacrylonitrile type polymer to be applied and treatment processes, they may be preferably used for a drawing apparatus or drawing method in the case of obtaining fine size fibers or fibers having high orientation and in the case where high spinning speed is required. Particularly, the treatment apparatuses 1 and 101 maybe preferably used in a drawing process in the production of polyacrylonitrile type polymer fibers for carbon fibers.
The invention will be explained in detail by way of examples and comparative examples. However, the invention is not limited by the following descriptions. In the following Examples 1 to 14 and Comparative Example 1 and 2, a difference ΔH (=H2−H1) between the height H1 of the section at the center 34 of the opening section shown in
In Examples 15 to 26, the influence of unevenness of the height H of the opening section 26 caused by the deformation of the pressure steam treatment apparatus 101 was evaluated by measuring the frequency of the raise of fuzz on the fiber bundle. The evaluation of the frequency of the raise of fuzz on the fiber bundle was made according to the following method. Specifically, the number of fuzz generated per hour in plurality of running fiber bundles drawn and discharged from the pressure steam treatment apparatus was measured visually to calculate an average number of raises of fuzz per fiber bundle. The standard of evaluation is shown in Table 2. The average number of raises of fuzz on the fiber bundle was calculated by the following equation. (Average number of raises of fuzz on the fiber bundle)=(Total number of fuzz raised per hour in a plurality of running fiber bundles drawn and discharged from the pressure steam treatment apparatus)/(Number of fiber bundles charged to the pressure steam treatment apparatus)
The unevenness of the height of the opening section 26 in the direction of the width in each of Examples 15 to 26 was a maximum among the differences ΔH=(H2−H1) between the height H1 of the section at the center 34 of the section of the opening section 26 and the height H2 of the section at each end 36 of the section of the opening section 26, these heights being found, as shown in
A polyacrylonitrile type polymer obtained by copolymerizing acrylonitrile (AN), methylacrylate (MA) and methacrylic acid (MAA) in a molar ratio of AN/MA/MAA=96/2/2 was dissolved in a dimethylacetamide (DMAc) solution (polymer concentration: 20 mass %, viscosity: 50 Pa·s, temperature: 60° C.) to prepare a yarn raw solution. The yarn raw solution was discharged in an aqueous DMAc solution having a concentration of 70% by mass and a liquid temperature of 35° C. through a spinneret having 12000 holes. The obtained spun fiber was washed with water, then drawn at a draw ratio of 3 times, and dried at 135° C. to obtain densified fiber bundles Z.
The treatment apparatus 1 illustrated in
As the heat conductive member 44 arranged in parallel to the direction of the running fiber bundles Z, two plate materials having a plate thickness of 21 mm were disposed rib-like at equal intervals (350 mm pitch), and as the heat conductive member 46 arranged in parallel to a direction in which the row of fiber bundles are arranged. 12 plate materials having a plate thickness of 12 mm were disposed at equal intervals (300 mm pitch) so as to cross with the heat conductive member 44. A plate material having a plate thickness of 25 mm was used as the plate member 50, a plate material having a plate thickness of 21 mm was used as the external wall member 40 and a plate material having a plate thickness of 25 mm was used as the structural members of the pressure steam treatment chamber 10 and labyrinth sealing chamber 20. The treatment apparatus enclosed by the structural members of the pressure steam treatment chamber 10 and labyrinth sealing chamber 20, the plate member 50 and the external wall member 40 was designed to have a height of 300 mm. The ratio (A2/A1) of the sectional area A2 of the heat conductive member to the area A1 enclosed by the plate member 50 in this treatment apparatus was designed to be 7.5%. In this case, the labyrinth nozzle 24 and porous plate 14 were neglected in order to simplify the calculation.
As the physical properties of each of the plate member 50, external wall member 40, heat conductive members 44 and 46, pressure steam treatment chamber 10, and labyrinth sealing chamber 20, the physical properties of general iron steel (modulus of longitudinal elasticity=206 GPa, modulus of transverse elasticity=79 GPa, and linear expansion coefficient γ=11.7×10−6 [/° C.]) were used.
The pressure and temperature in the structural member of the pressure steam treatment chamber 10 were set to 300 KPaG and 142° C. respectively and the pressure applied to the inside of the structural member of the labyrinth sealing chamber 20 descends towards the fiber bundle inlet 30 and fiber bundle outlet 32 from the first and second labyrinth sealing chambers 31 and 33. The temperature applied to the inside of the member forming the labyrinth sealing chamber 20 was made to be steam saturation temperature at the above proportionally descending pressure. In this example, the pressure proportionally descends such that the pressure of the first and second labyrinth sealing chambers 31 and 33 is 300 KPaG and the pressure of the fiber bundle inlet 30 and fiber bundle outlet 32 is 0 KPaG. Also, the temperature of the first and second labyrinth sealing chambers 31 and 33 is set to 142° C. and the temperature of the fiber bundle inlet 30 and fiber bundle outlet 32 is set to 100° C.
The heat transfer coefficient between the inner surface of the plate member 50, the surface of the heat conductive member 44 parallel to the direction of running fiber bundles, and the surface of the heat conductive member 46 parallel to a direction in which the row of fiber bundles are arranged and the space section was set to 3 W/(m2/K) and the temperature of the space section was set to 80° C. The heat transfer coefficient between the external surface of the plate member 50 and the space section was set to 10 W/(m2/K) and the temperature of the space section was set to 60° C. Here, W is the width of the rectangular-shaped opening section of the labyrinth nozzle.
Numerical analysis of an analog having a size of 1/8 that of the aforementioned form was made, and as a result, ΔH was 0.212 mm and ΔT=18° C. (See
Numerical analysis was made using the same condition as that of Example 1 except that the thicknesses and number of the heat conductive members 44 and 46 and the ratio (A2/A1) of the sectional area A2 of the heat conductive member to the area A1 enclosed by the plate member 50 with respect to an optional section parallel to the external wall member 40 were altered to those shown in
Numerical analysis was made using the same condition as that of Example 1 except that all region of the space section formed between the plate member 50 of the treatment apparatus 1 as indicated by the fine shaded hatch in
Numerical analysis was made using the same condition as that of Example 1 except that as illustrated in
Numerical analysis was made using the same condition as that of Example 1 except that as illustrated in
Numerical analysis was made using the same condition as that of Example 1 except that as illustrated in
Numerical analysis was made using the same condition as that of Example 1 except that as illustrated in
Numerical analysis was made using the same condition as that of Example 1 except that the total length X of the treatment apparatus 1 was altered to that shown in
Numerical analysis was made using the same condition as that of Example 1 except that as illustrated in
Numerical analysis was made using the same condition as that of Example 1 except that as illustrated in
Numerical analysis was made using the same condition as that of Example 1 except that the width Y of the treatment apparatus 1 and the width W of the rectangular-shaped opening section of the labyrinth nozzle 24 were altered to those shown in
A treatment apparatus 104 was used having the same structure as the treatment apparatus 104 illustrated in
A K-type thermocouple was attached to the surface opposite to the heating surface of the external wall member of the K-type thermocouple to detect the temperature of the external wall member heated by the heater 52.
Using the above treatment apparatus 104, the fiber bundles Z obtained in Production Example 1 was introduced from the fiber bundle inlet on five spindles to carry out pressure steam treatment. The pressure in the pressure room was set to 300 kPa and the pressure and temperature of pressure steam supplied to the heater 52 were controlled such that the temperature of the upper and lower external wall member was 142° C.
The frequency of the raise of fuzz on the fiber bundle after drawn by pressure steam during drawing in the pressure steam treatment apparatus 104 and unevenness of the height of the opening section in the direction of the width were evaluated. The results are shown in
Pressure steam treatment of the fiber bundles Z was carried out in the same manner as in Example 15 except that the prismatic members 44, 46 and 48 in the treatment apparatuses 104, 107, 110, 101 and 113 were altered as shown in
The condition of the raise of fuzz on the fiber bundle after the pressure steam drawing was observed while drawing process was performed in the pressure steam treatment apparatus to evaluate the frequency of the raise of fuzz on the fiber bundle and the unevenness of the height in the direction of the width of the opening section. The results are shown in
Pressure steam treatment of the fiber bundles Z was carried out in the same manner as in Example 15 except that a treatment apparatus 105 was used in which a heater 52 with one surface having a plane form is stuck only to the upper external wall member 40A as the heating device of the treatment apparatus other than the pressure steam treatment chamber as shown in
The condition of the raise of fuzz on the fiber bundle after the pressure steam drawing was observed while drawing process was performed in the pressure steam treatment apparatus 105 to evaluate the frequency of the raise of fuzz on the fiber bundle and the unevenness of the height in the direction of the width of the opening section 26. The results are shown in
Pressure steam treatment of the fiber bundles Z was carried out in the same manner as in Example 21 except that the prismatic members 44, 46 and 48 in the treatment apparatuses 105, 108, 111, 102 and 114 were altered as shown in
The condition of the raise of fuzz on the fiber bundle after the pressure steam drawing was observed while drawing process was performed in the pressure steam treatment apparatus to evaluate the frequency of the raise of fuzz on the fiber bundle and the unevenness of the height in the direction of the width of the opening section 26. The results are shown in
Pressure steam treatment of the fiber bundles Z was carried out in the same manner as in Example 15 except that a treatment apparatus was used which had the same structure as the treatment apparatuses 101, 104, 107, 110, and 113 except that the heater for heating the upper and lower external wall members was not disposed and the temperature of the external wall member 40A was altered to that shown in
The condition of the raise of fuzz on the fiber bundle after the pressure steam drawing was observed while drawing process was performed in the pressure steam treatment apparatus to evaluate the frequency of the raise of fuzz on the fiber bundle and the unevenness of the height in the direction of the width of the opening section 26. The results are shown in
| Number | Date | Country | Kind |
|---|---|---|---|
| 2011-026960 | Feb 2011 | JP | national |
| 2011-167343 | Jul 2011 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2012/050777 | 1/17/2012 | WO | 00 | 8/9/2013 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2012/108230 | 8/16/2012 | WO | A |
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| Number | Date | Country | |
|---|---|---|---|
| 20140123713 A1 | May 2014 | US |
