Carbon fiber and method of forming the same

Patent metadata

Field	Value
Publication number	US-11898276-B2
Application number	US-202217827565-A
Country	US
Kind code	B2
Filing date	May 27, 2022
Priority date	May 27, 2021
Publication date	Feb 13, 2024
Grant date	Feb 13, 2024

Abstract

Carbon fiber and method of forming the same are provided. The method modifies proportion of a finishing oil to control a relation between a surface tension and a particle size of the finishing oil, and thus penetration of the finishing oil into an interior of the carbon fiber is avoided. Therefore, the carbon fiber can have both low oil residues and a high strength.

First claim

What is claimed is:

1. A method of forming a carbon fiber, comprising:
dissolving a polyacrylonitrile copolymer in a solvent to obtain a dope;
performing a spinning process to the dope, thereby obtaining a filament tow;
oiling the filament tow to obtain a filament with oil by using a finishing oil, wherein a surface tension (σ) is in a range of 30 mN/m to 70 mN/m, and the surface tension and a particle size (R) of the finishing oil satisfy following equation:
20<σ+( R/ 2) 0.5 <60;

performing a compacting drying process to the filament with oil, thereby obtaining a filament; and
performing a firing process to the filament, thereby obtaining the carbon fiber.

2. The method of claim 1 , wherein the polyacrylonitrile copolymer has a limiting viscosity in a range of 1.5 to 3.5.

3. The method of claim 1 , wherein the filament tow has a pore diameter in a range of 20 nm to 140 nm.

4. The method of claim 1 , wherein the finishing oil includes a silicone oil, an emulsifier and water.

5. The method of claim 1 , wherein the finishing oil has a particle size of 10 nm to 500 nm.

6. The method of claim 1 , wherein the solvent includes dimethylformamide (DMF), dimethylacetamide, dimethyl sulfoxide (DMSO), zinc chloride, or sodium thiocyanate.

7. The method of claim 1 , wherein the dope has a polymer concentration of 18 wt. % to 25 wt. %.

8. The method of claim 1 , wherein before oiling the filament tow, the method further comprises:
performing a drawing operation to the filament tow, wherein the drawing operation has a draw ratio not greater than 5.

9. The method of claim 1 , wherein a temperature of the compacting drying process is in a range of 100° C. to 200° C.

10. The method of claim 1 , wherein a residue of silicon within the carbon fiber is in a range of 500 ppm to 2500 ppm.

11. The method of claim 1 , wherein a ratio of an amount of silicon within an interior of the carbon fiber to an amount of silicon on a surface of the carbon fiber is less than or equal to 0.7.

12. The method of claim 1 , wherein a strength of the carbon fiber is greater than 5000 MPa.

13. A method of forming a carbon fiber, comprising:
performing a spinning process to a dope to obtain an as-spun fiber, wherein the dope comprises a polyacrylonitrile copolymer;
performing a first drawing operation to the as-spun fiber to obtain a filament tow;
oiling the filament tow to obtain a filament with oil by using a finishing oil, wherein a surface tension (a) and a particle size (R) of the finishing oil satisfy following equation: 20<σ+(R/2) 0.5 <60, the surface tension is in a range of 30 mN/m to 70 mN/m, and the finishing oil has a particle size of 10 nm to 500 nm;
performing a compacting drying process to the filament with oil, thereby obtaining a first filament;
performing a second drawing operation to the first filament, thereby obtaining a second filament; and
performing a firing process to the second filament, thereby obtaining the carbon fiber, wherein the firing process includes a stabilization treatment and a carbonization treatment.

14. The method of claim 13 , wherein the finishing oil includes a silicone oil, an emulsifier and water, and based on the finishing oil as 100 parts by weight, the silicone oil is 10 parts by weight to 60 parts by weight, the emulsifier is 10 parts by weight to 40 parts by weight, and the water is 30 parts by weight to 80 parts by weight.

15. The method of claim 13 , wherein the first drawing operation is performed in a rinsing compartment, and a temperature of the rinsing compartment is greater than 70° C.

16. The method of claim 13 , wherein a first draw ratio of the first drawing operation is less than 5, and a second draw ratio of the second drawing operation is not less than 2.

17. The method of claim 13 , wherein the stabilization treatment is performed at a temperature of 200° C. to 300° C.

18. The method of claim 13 , wherein a temperature of the carbonization treatment is greater than 1000° C.

Assignees

• Formosa Plastics Corp

Inventors

• Tsai Kun-Yeh
• Hung Chia-Chi
• Chou Wen-Ju
• Chen Ching-Wen
• Hsieh Chia-Chun
• Lin Shi-Jie
• Hwang Long-Tyan

Classifications

• D01F9/22 Primary

  from polyacrylonitriles · CPC title

• D01D5/06

  Wet spinning methods {(D01D5/0046 takes precedence)} · CPC title

• D02J1/223

  Stretching in a liquid bath · CPC title

• D02J1/228

  Stretching in two or more steps, with or without intermediate steps · CPC title

• D02J13/005

  by contact with at least one rotating roll · CPC title