High temperature, low oxidation stabilization of pitch fibers

Abstract

The present invention provides a process for thermosetting pitch fibers in reduced times, at low concentrations of oxygen and at higher temperatures than previously possible. Additionally, the present invention provides a pitch fiber which has an oxygen diffusion rate to the center of the fiber which is competitive with the rate of oxidation at the fiber's surface. Further, the present invention provides a high density pitch fiber batt which thermosets without loss of fiber structure.

Description

I. BACKGROUND OF THE INVENTION[0001] This invention relates to the field of preparing carbon fibers from carbonaceous pitches. A typical process for manufacturing pitch based carbon fibers may include the following steps: (1) preparing a suitable pitch for spinning; (2) spinning the pitch into as-spun pitch fibers; (3) thermosetting (stabilizing) the pitch fibers to render them infusible, i.e. unmeltable; and, (4) carbonizing the fibers by heating the stabilized fibers to carbonization temperatures.[0002] In the described process, the as-spun pitch fiber of step (2) is a thermoplastic material. Thus, additional heating of the fiber results in melting and loss of fiber structure. Therefore, prior to carbonization, the fiber must be rendered unmeltable, i.e. thermoset. The thermosetting process is commonly known as oxidative stabilization due to the heating of the fiber in the presence of an oxidizing agent. Typical stabilization processes expose the as-spun fibers to a high concentra...

AI Technical Summary

Benefits of technology

[0009] Additionally, the present invention provides a process for stabilizing pitch fibers using continuous heating in the presence of a stream of gas. This process provides a means of significantly reducing the risk of uncontrolled exothermic reactions. According to this novel process, the pitch fibers are heated to a temperature at least equal to the spinning temperature of the fibers. During the heating process, the fibers are contacted with a flowing gas which contains an oxidizing agent. The flow rate of the gas is sufficient to remove excess heat from the fibers during the stabilization process thereby controlling the exotherm of the reaction. Exposure of the fibers to the oxidizing agent is maintained for a period of time sufficient to stabilize the fibers.

[0010] Further, the present invention provides a pitch fiber having a softening point of at least 300.degree. C. The novel fiber has an oxygen diffusion rate to its center which is approximately equal to, or greater than, the oxidation rate at the fiber's surface. Thus, the fiber's center becomes oxidatively stabilized at a rate ranging from slightly less than, to greater than the rate of consumption of carbon by oxygen at the fiber's surface. In this manner, the current invention precludes excess loss of carbon at the surface of the fiber. Oxidative stabilization of the fiber may be carried out at temperatures equal to or greater than the fiber's spinning temperature in an atmosphere containing up to ten percent oxidizing agent by volume. Preferably, the concentration of oxidizing agent will be less than eight percent by volume. Finally, depending upon operating conditions and raw material used, these fibers may be oxidatively stabilized in less than ten minutes.

[0011] The current invention additionally provides a pitch fiber batt having a density of at least 900 g / m.sup.2 which is capable of being oxidatively stabilized. Despite the high density of fibers, the novel pitch fiber batt oxidatively stabilizes without loss of fiber structure when heated in a flowing gas stream containing an oxidizing agent.III.

Problems solved by technology

Thus, additional heating of the fiber results in melting and loss of fiber structure.

Generally, low softening point pitches require long periods of time and more oxygen to complete the stabilization process.

Unfortunately, high oxygen concentrations and elevated temperatures increase the possibility of uncontrolled exothermic oxidation reactions.

Reactions of this type are particularly hazardous when highly volatile hydrocarbons are present.

Clearly, when treating a large amount of fiber over a short period of time the current manufacturing methods have significant drawbacks.

The need to limit temperature, oxidant concentration and quantity of fiber in the stabilization process creates higher than desirable costs, diminishes the value and strength of the fiber and creates obvious operating risks.