METHOD FOR MAKING CARBON FABRIC AND PRODUCT THEREOF

• US 20100112206A1
• Filed: 01/11/2010
• Published: 05/06/2010
• Est. Priority Date: 12/03/2003
• Status: Active Grant

• Current Assignee: Feng Chia University
• Original Assignee: Feng Chia University
• Inventors: KO, Tse-Hao
• Granted Patent: US 7,927,575 B2
• Time in Patent Office: Days
• US Class Current: 427/227
• CPC Class Codes: D03D 15/275 Carbon fibres
• CPC Class Codes: D03D 15/283 synthetic polymer-based, e.g. polyamide or polyester fibres cellulose-based artificial fibres D03D15/225
• CPC Class Codes: D06C 7/04 Carbonising or oxidising processes comprising combined chemical and mechanical treatment D06M
• CPC Class Codes: D10B 2101/12 Carbon; Pitch
• CPC Class Codes: D10B 2321/022 polypropylene
• CPC Class Codes: D10B 2401/16 antistatic; conductive
• CPC Class Codes: Y10T 428/249945 Carbon or carbonaceous fiber
• CPC Class Codes: Y10T 428/2913 Rod, strand, filament or fiber
• CPC Class Codes: Y10T 428/2915 including textile, cloth or fabric
• CPC Class Codes: Y10T 428/2918 including free carbon or carbide or therewith [not as steel]
• CPC Class Codes: Y10T 442/3146 Strand material is composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
• CPC Class Codes: Y10T 442/3171 Strand material is a blend of polymeric material and a filler material
• CPC Class Codes: Y10T 442/3976 Including strand which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous composition, water solubility, heat shrinkability, etc.]
• CPC Class Codes: Y10T 442/3984 Strand is other than glass and is heat or fire resistant

Abstract

A carbon fabric of high conductivity and high density is formed of oxidized fibers of polypropylene. The oxidized fibers have a carbon content at least 50 wt %, an oxygen content at least 4 wt %, and a limiting oxygen index at least 35%. The carbon fabric is made by preparing a raw fabric obtained from oxidized fibers of polypropylene by weaving and then carbonizing the raw fabric.

Claims

1. A method for making a carbon fabric comprising:

(a) preparing a raw fabric from raw fibers by weaving the raw fibers;

(b) carbonizing said raw fabric to form a carbon fabric;

wherein the raw fibers are oxidized polypropylene having a carbon content of at least 50 wt %, an oxygen content of at least 4 wt % and a limiting oxygen index of at least 35%.

2. The method according to claim 1, wherein the carbon content of said raw fibers is more than 55 wt %.

3. The method according to claim 1, wherein the oxygen content of said raw fibers is more than 8 wt %.

4. The method according to claim 1, wherein the oxygen limiting index of said raw fibers is more than 50 %.

5. The method according to claim 1, wherein the raw fabric is carbonized at 700-2500 °

C.

6. The method according to claim 1, wherein the raw fabric is carbonized at 900-2500 °

C.

7. The method according to claim 1, wherein the raw fabric is carbonized in at least one high temperature oven in the presence of an inert gas.

8. The method according to claim 7, wherein the raw fabric is carbonized in a plurality of high temperature ovens connected in series.

9. The method according to claim 7, wherein the inert gas is helium.

10. The method according to claim 1, wherein said raw fabric is carbonized at a constant temperature.

11. The method according to claim 1, wherein said raw fabric is carbonized continuously at different temperatures.

12. The method according to claim 1, wherein said raw fabric is carbonized in an interrupted fashion at varying temperatures.

13. The method according to claim 1, wherein said raw fabric is subjected to carbonization for 2-240 minutes.

14. The method according to claim 13, wherein said raw fabric is subjected to carbonization for 10-100 minutes.

15. The method according to claim 1, wherein shrinkage of the raw fabric during carbonization is below 30%.