Preparation of monolithic carbon fiber composite material

• US 5,972,253 A
• Filed: 09/23/1997
• Issued: 10/26/1999
• Est. Priority Date: 09/30/1996
• Status: Expired due to Fees

• Current Assignee: University Of Kentucky Research Foundation (University of Kentucky)
• Original Assignee: University Of Kentucky Research Foundation (University of Kentucky)
• Inventors: Kimber, Geoffrey M.
• Primary Examiner(s): Ramsuer, Robert W.
• Assistant Examiner(s): Keating, Dominic
• Application Number:
  US08/935,631
• Time in Patent Office: 763 Days
• Field of Search: 428/295, 264/29.7
• US Class Current: 264/29.7
• CPC Class Codes: C01B 32/382 Making shaped products, e.g. fibres, spheres, membranes or foam
• CPC Class Codes: Y10T 442/624 Microfiber is carbon or carbonaceous

Abstract

A process for preparing an activated carbon fiber composite material includes the steps of mixing carbon fibers, binder and water to form a slurry, molding the slurry to produce a green monolithic body, curing the monolithic body, carbonizing the cured monolith to produce a carbon fiber composite with an open, permeable structure and activating the composite. If pre-activated carbon fibers are utilized in the mixing step the carbonizing and activating steps are eliminated.

Claims

1. A process for preparing an activated carbon fiber composite material comprising the steps of:

mixing between about 5-about 12 weight percent of carbon fibers having a diameter between about 5-about 100 μ

m and a length between about 0.1-about 5.0 mm with between about 1.25-about 3.0 weight percent binder and water in order to produce a slurry;

placing said slurry in a molding vessel;

filtering said slurry thereby producing a green monolithic body;

dewatering and drying said green monolithic body;

curing said green monolithic body thereby producing a cured monolithic body;

carbonizing said cured monolithic body thereby producing a carbon fiber composite defining an open permeable structure resistant to delamination; and

activating said carbon fiber composite whereby said carbon fibers are made porous.

2. A process for preparing an activated carbon fiber composite material comprising the steps of:

mixing between 5-12 weight percent of carbon fibers having a diameter between 5-100 μ

m and a length between 0.1-5.0 mm with between 1.25-3.0 weight percent binder and water in order to produce a slurry;

placing said slurry in a molding vessel;

filtering said slurry thereby producing a green monolithic body;

dewatering and drying said green monolithic body;

curing said green monolithic body thereby producing a cured monolithic body;

carbonizing said cured monolithic body thereby producing a carbon fiber composite defining an open permeable structure resistant to delamination; and

activating said carbon fiber composite whereby said carbon fibers are made porous.

3. A process for preparing a pre-activated carbon fiber composite material comprising the steps of:

mixing between about 5-about 12 weight percent of pre-activated carbon fibers having a diameter between about 5-about 100 μ

m and a length between about 0.1-about 5.0 mm with between about 1.25-about 3.0 weight percent binder and water in order to produce a slurry;

placing said slurry in a molding vessel;

filtering said slurry thereby producing a green monolithic body;

dewatering and drying said green monolithic body; and

curing said green monolithic body thereby producing a cured, pre-activated carbon fiber composite defining an open permeable structure resistant to delamination.

4. The process set forth in claim 3, including retaining at least a portion of said mold about said carbon fiber composite to serve as a mechanical support.

5. A process for preparing a pre-activated carbon fiber composite material comprising the steps of:

mixing between 5-12 weight percent of pre-activated carbon fibers having a diameter between 5-100 μ

m and a length between 0.1-5.0 mm with between 1.25-3.0 weight percent binder and water in order to produce a slurry;

placing said slurry in a molding vessel;

filtering said slurry thereby producing a green monolithic body;

dewatering and drying said green monolithic body; and

curing said green monolithic body thereby producing a cured, pre-activated carbon fiber composite defining an open permeable structure resistant to delamination.

6. The process set forth in claim 5, including retaining at least a portion of said mold about said carbon fiber composite to serve as a mechanical support.