Method for manufacturing sized carbon fibers for composite applications

Various embodiments directed towards methods of applying sizing to fibers are disclosed herein. In some embodiments, solvent can be used to dissolve a sizing material into a solution, which can then be used to coat the fibers. In some embodiments, a water bath is used to coagulate a sizing on the fiber surface and to remove the remove solvent after coating the fibers, so that water vapor can be created during a subsequent drying step as opposed to solvent vapors. In some embodiments, strong acids or strong bases can be used as the solvent.

POLYACRYLONITRILE (PAN) POLYMERS WITH LOW POLYDISPERSITY INDEX (PDI) AND CARBON FIBERS MADE THEREFROM

A method for synthesizing polyacrylonitrile (PAN) polymer with a narrow molecular weight distribution is disclosed. The preferred PAN polymer has a PDI (Mw/Mn) of about 2 or less. Such PAN polymer is synthesized by controlled/living radical polymerization using a special RAFT (Reversible Addition-Fragmentation Chain Transfer) agent. Also disclosed is a method for producing carbon fibers from PAN polymer with low PDI. 2. The method of claim 1 , wherein the PAN polymer has a molecular weight within the range of 60 kg/mole to 500 kg/mole.3. The method of claim 2 , wherein the PAN polymer has a molecular weight within the range of 115 kg/mole to 180 kg/mole.4. The method according to claim 1 , wherein the PAN polymer has a PDI (Mw/Mn) of 1.2 to 1.9 (or an alternative PDI (Mz/Mw) of 1.2 to 1.7).5. The method according to claim 1 , wherein the solvent is selected from the group consisting of: dimethyl sulfoxide (DMSO) claim 1 , dimethyl formamide (DMF) claim 1 , and dimethyl acetamide (DMAc) claim 1 , ethylene carbonate (EC) claim 1 , a mixture of zinc chloride (ZnCl) and water claim 1 , and a mixture of sodium thiocyanate (NaSCN) and water.6. The method according to claim 1 , wherein the at least one co-monomer is selected from the group consisting of: vinyl-based acids claim 1 , vinyl-based esters claim 1 , and vinyl derivatives.7. The method of claim 6 , wherein the at least one co-monomer is selected from the group consisting of: methacrylic acid (MAA) claim 6 , acrylic acid (AA) claim 6 , itaconic acid (ITA) claim 6 , methacrylate (MA) claim 6 , methyl methacrylate (MMA) claim 6 , vinyl acetate (VA) claim 6 , ethyl acrylate (EA) claim 6 , butyl acrylate (BA) claim 6 , ethyl methacrylate (EMA) claim 6 , vinyl imidazole (VIM) claim 6 , acrylamide (AAm) claim 6 , diacetone acrylamide (DAAm).8. The method according to claim 1 , wherein the initiator is an azo compound or an organic peroxide.9. The method according to claim 8 , wherein the initiator is selected from the ...

POLYACRYLONITRILE (PAN) POLYMERS WITH LOW POLYDISPERSITY INDEX (PDI) AND CARBON FIBERS MADE THEREFROM

A method for synthesizing polyacrylonitrile (PAN) polymer with a narrow molecular weight distribution is disclosed. The preferred PAN polymer has a PDI (Mw/Mn) of about 2 or less. Such PAN polymer is synthesized by controlled/living radical polymerization using a special RAFT (Reversible Addition-Fragmentation Chain Transfer) agent. Also disclosed is a method for producing carbon fibers from PAN polymer with low PDI. 2. (canceled)3. The method of claim 1 , wherein the PAN polymer has a molecular weight within the range of 115 kg/mole to 180 kg/mole.4. The method according to claim 1 , wherein the PAN polymer has a PDI (Mw/Mn) of 1.2 to1.9.5. The method according to claim 1 , wherein the solvent is selected from the group consisting of: dimethyl sulfoxide (DMSO) claim 1 , dimethyl formamide (DMF) claim 1 , and dimethyl acetamide (DMAc) claim 1 , a mixture of zinc chloride (ZnCl) and water claim 1 , and a mixture of sodium thiocyanate (NaSCN) and water.6. The method according to claim 1 , wherein the at least one co-monomer is selected from the group consisting of: vinyl-based acids claim 1 , vinyl-based esters claim 1 , and vinyl derivatives.7. The method of claim 6 , wherein the at least one co-monomer is selected from the group consisting of: methacrylic acid (MAA) claim 6 , acrylic acid (AA) claim 6 , itaconic acid (ITA) claim 6 , methacrylate (MA) claim 6 , methyl methacrylate (MMA) claim 6 , vinyl acetate (VA) claim 6 , ethyl acrylate (EA) claim 6 , butyl acrylate (BA) claim 6 , ethyl methacrylate (EMA) claim 6 , vinyl imidazole (VIM) claim 6 , acrylamide (AAm) claim 6 , diacetone acrylamide (DAAm).8. The method according to claim 1 , wherein the initiator is an azo compound or an organic peroxide.9. The method according to claim 8 , wherein the initiator is selected from the group consisting of: azobisisobutyronitrile (AIBN) claim 8 , azobiscyanovaleric acid (ACVA) claim 8 , 2 claim 8 , 2′-azobis-(2 claim 8 ,4-Dimethyl) valeronitrile (ABVN) claim 8 , dilauroyl ...

Manufacture of intermediate modulus carbon fiber

The present disclosure relates generally to carbon fibers having high tensile strength and modulus of elasticity, as well as a process for the manufacture of such carbon fiber. The process comprises spinning a polymer/solvent solution into a solvent/water bath in the range of 78%-85% solvent, thereby producing a dense fiber structure, and subsequently carbonizing the polymer precursor fiber at a lower than typical carbonization temperature to form carbon fibers.

Method for producing carbon fibers from polyacrylonitrile (PAN) polymers with low polydispersity index (PDI)

A method for synthesizing polyacrylonitrile (PAN) polymer with a narrow molecular weight distribution is disclosed. The preferred PAN polymer has a PDI (Mw/Mn) of about 2 or less. Such PAN polymer is synthesized by controlled/living radical polymerization using a special RAFT (Reversible Addition-Fragmentation Chain Transfer) agent. Also disclosed is a method for producing carbon fibers from PAN polymer with low PDI.

CARBON FIBERS AND HIGH PERFORMANCE FIBERS FOR COMPOSITE APPLICATIONS

Various embodiments directed towards methods of applying sizing to fibers are disclosed herein. In some embodiments, solvent can be used to dissolve a sizing material into a solution, which can then be used to coat the fibers. In some embodiments, a water bath is used to coagulate a sizing on the fiber surface and to remove the remove solvent after coating the fibers, so that water vapor can be created during a subsequent drying step as opposed to solvent vapors. In some embodiments, strong acids or strong bases can be used as the solvent. 1. A method of applying a sizing onto an organic or inorganic fiber comprising the steps of:providing a quantity of fibers;contacting the quantity of fibers with a composition, wherein the composition comprises a polymer dissolved in a water-miscible solvent, thereby forming a solvent/polymer coating on the quantity of fibers;coagulating the polymer onto the quantity of fibers;removing the water-miscible solvent by washing the quantity of fibers having the solvent/polymer coating with water; andat least partially drying the resultant quantity of polymer-coated fibers to produce a quantity of sized fibers.2. The method of claim 1 , wherein the quantity of fibers is chosen from carbon fibers claim 1 , glass fibers claim 1 , ceramic fibers claim 1 , aramid fibers claim 1 , polyolefin fibers claim 1 , polyester fibers claim 1 , acrylic fibers and combinations thereof3. The method of claim 1 , wherein the quantity of fibers is a fabric.4. The method of claim 1 , wherein the water-miscible solvent is chosen from dimethyl sulfoxide (DMSO) claim 1 , N-methyl-2-pyrrolidone (NMP) claim 1 , dimethylformamide (DMF) claim 1 , hexamethylphosphoramide (HMPA) claim 1 , acetone claim 1 , methylethyl ketone claim 1 , butanone claim 1 , methyl alcohol claim 1 , ethyl alcohol claim 1 , isopropyl alcohol claim 1 , butyl alcohol claim 1 , di-chloro methane claim 1 , chloroform claim 1 , sodium thiocyanate and zinc chloride.5. The method of claim 1 , ...

MANUFACTURE OF INTERMEDIATE MODULUS CARBON FIBER

The present disclosure relates generally to carbon fibers having high tensile strength and modulus of elasticity, as well as a process for the manufacture of such carbon fiber. The process comprises spinning a polymer/solvent solution into a solvent/water bath in the range of 78%-85% solvent, thereby producing a dense fiber structure, and subsequently carbonizing the polymer precursor fiber at a lower than typical carbonization temperature to form carbon fibers. 1. A process for producing carbon fibers comprising:spinning a polymer solution having a concentration of about 19% to about 24% polymer in a coagulation bath at a coagulation bath concentration of about 70% to about 85% solvent and about 15% to about 30% water, thereby forming carbon fiber precursor fibers;drawing the carbon fiber precursor fibers through one or more draw and wash baths, wherein the carbon fiber precursor fibers are substantially free of solvent after the step of drawing the carbon fiber precursor fibers; andstabilizing and carbonizing the carbon fiber precursor fibers;wherein the carbon fiber precursor fibers are carbonized at a temperature of from about 1100° C. to about 1500° C.2. The process of claim 1 , wherein the bath temperature of the coagulation bath is from about 0° C. to about 10° C.3. The process of claim 1 , wherein the solvent in the coagulation bath is dimethyl sulfoxide.4. The process of claim 1 , wherein the polymer solution is a polyacrylonitrile polymer solution.5. The process of claim 1 , wherein the polymer has a weight averaged molecular weight (M) of about 120 claim 1 ,000 to about 180 claim 1 ,000.6. The process of claim 1 , wherein the polymer solution is spun by air-gap spinning.7. The process of claim 6 , wherein the air-gap spacing from a face of a spinneret to a surface of the coagulation bath is about 2.0 to about 10.0 mm.8. The process of claim 1 , wherein the carbon fiber precursor fibers from the coagulation bath have an average pore diameter of about 0.01 ...

Polyacrylonitrile (PAN) polymers with low polydispersity index (PDI) and carbon fibers made therefrom

A method for synthesizing polyacrylonitrile (PAN) polymer with a narrow molecular weight distribution is disclosed. The preferred PAN polymer has a PDI (Mw/Mn) of about 2 or less. Such PAN polymer is synthesized by controlled/living radical polymerization using a special RAFT (Reversible Addition-Fragmentation Chain Transfer) agent. Also disclosed is a method for producing carbon fibers from PAN polymer with low PDI.

Polyacrylonitrile (PAN) polymers with low polydispersity index (PDI) and carbon fibers made therefrom

A method for synthesizing polyacrylonitrile (PAN) polymer with a narrow molecular weight distribution is disclosed. The preferred PAN polymer has a PDI (Mw/Mn) of about 2 or less. Such PAN polymer is synthesized by controlled/living radical polymerization using a special RAFT (Reversible Addition-Fragmentation Chain Transfer) agent. Also disclosed is a method for producing carbon fibers from PAN polymer with low PDI.

POLYACRYLONITRILE (PAN) POLYMERS WITH LOW POLYDISPERSITY INDEX (PDI) AND CARBON FIBERS MADE THEREFROM

A method for synthesizing polyacrylonitrile (PAN) polymer with a narrow molecular weight distribution is disclosed. The preferred PAN polymer has a PDI (Mw/Mn) of about 2 or less. Such PAN polymer is synthesized by controlled/living radical polymerization using a special RAFT (Reversible Addition-Fragmentation Chain Transfer) agent. Also disclosed is a method for producing carbon fibers from PAN polymer with low PDI. 2. (canceled)3. The method of claim 1 , wherein the PAN polymer has a molecular weight within the range of 115 kg/mole to 180 kg/mole.4. The method according to claim 1 , wherein the PAN polymer has a PDI (Mw/Mn) of 1.2 to 1.9 (or an alternative PDI (Mz/Mw) of 1.2 to 1.7).5. The method according to claim 1 , wherein the solvent is selected from the group consisting of: dimethyl sulfoxide (DMSO) claim 1 , dimethyl formamide (DMF) claim 1 , and dimethyl acetamide (DMAc) claim 1 , ethylene carbonate (EC) claim 1 , a mixture of zinc chloride (ZnCl) and water claim 1 , and a mixture of sodium thiocyanate (NaSCN) and water.6. (canceled)7. The method of claim 1 , wherein the at least one co-monomer is selected from the group consisting of: methacrylic acid (MAA) claim 1 , acrylic acid (AA) claim 1 , itaconic acid (ITA) claim 1 , methacrylate (MA) claim 1 , vinyl acetate (VA) claim 1 , ethyl acrylate (EA) claim 1 , butyl acrylate (BA) claim 1 , vinyl imidazole (VIM) claim 1 , acrylamide (AAm) claim 1 , diacetone acrylamide (DAAm).8. (canceled)9. The method according to claim 1 , wherein the initiator is selected from the group consisting of: azobisisobutyronitrile (AIBN) claim 1 , azobiscyanovaleric acid (ACVA) claim 1 , 2 claim 1 ,2′-azobis-(2 claim 1 ,4-Dimethyl) valeronitrile (ABVN) claim 1 , dilauroyl peroxide (LPO) claim 1 , ditertbutul peroxide (TBPO) claim 1 , diisopropyl peroxydicarbonate (IPP).10. The method according to claim 1 , wherein the temperature at step (b) is within the range of 40° C.-85° C.12. (canceled)13. A method of producing a carbon ...

MANUFACTURE OF INTERMEDIATE MODULUS CARBON FIBER

The present disclosure relates generally to carbon fibers having high tensile strength and modulus of elasticity, as well as a process for the manufacture of such carbon fiber. The process comprises spinning a polymer/solvent solution into a solvent/water bath in the range of 78%-85% solvent, thereby producing a dense fiber structure, and subsequently carbonizing the polymer precursor fiber at a lower than typical carbonization temperature to form carbon fibers. 1. A process for producing carbon fibers comprising:spinning a polymer solution having a concentration of about 19% to about 24% polymer in a coagulation bath at a coagulation bath concentration of about 70% to about 85% solvent and about 15% to about 30% water, thereby forming carbon fiber precursor fibers;drawing the carbon fiber precursor fibers through one or more draw and wash baths, wherein the carbon fiber precursor fibers are substantially free of solvent after the step of drawing the carbon fiber precursor fibers; andstabilizing and carbonizing the carbon fiber precursor fibers;wherein the carbon fiber precursor fibers are carbonized at a temperature of from about 1100° C. to about 1500° C.2. The process of claim 1 , wherein the bath temperature of the coagulation bath is from about 0° C. to about 10° C.3. The process of claim 1 , wherein the solvent in the coagulation bath is dimethyl sulfoxide.4. The process of claim 1 , wherein the polymer solution is a polyacrylonitrile polymer solution.5. The process of claim 1 , wherein the polymer has a weight averaged molecular weight (M) of about 120 claim 1 ,000 to about 180 claim 1 ,000.6. The process of claim 1 , wherein the polymer solution is spun by air-gap spinning.7. The process of claim 6 , wherein the air-gap spacing from a face of a spinneret to a surface of the coagulation bath is about 2.0 to about 10.0 mm.8. The process of claim 1 , wherein the carbon fiber precursor fibers from the coagulation bath have an average pore diameter of about 0.01 ...

Polyacrylonitrile (pan) polymers with low polydispersity index (pdi) and carbon fibers made therefrom

A method for synthesizing polyacrylonitrile (PAN) polymer with a narrow molecular weight distribution is disclosed. The preferred PAN polymer has a PDI (Mw/Mn) of about 2 or less. Such PAN polymer is synthesized by controlled/living radical polymerization using a special RAFT (Reversible Addition-Fragmentation Chain Transfer) agent. Also disclosed is a method for producing carbon fibers from PAN polymer with low PDI.

Manufacture of intermediate modulus carbon fiber