Melt-Processable Carbon Fiber Precursor Composition

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Solution Overview

Problem

Traditional carbon fiber precursors are costly and limited in application due to solvent toxicity and high processing costs associated with solution spinning, restricting their use beyond aerospace and sporting goods industries.

Innovation Solution

Development of melt-processable carbon fiber precursors through a method involving combining acrylonitrile monomers with co-monomers, adding plasticizers, melt-spinning, annealing, stabilizing, and carbonizing the fibers, which allows for thermal cross-linking in air, eliminating the need for toxic solvents and reducing processing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If solution spinning is used to produce carbon fiber precursors, then the precursor fibers can be formed with adequate structural properties, but solvent toxicity and higher processing costs occur which restrict applications

Engineering Contradiction:

Improvestructural properties of precursor fibersVSAvoidsolvent toxicity and processing costs

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the physical state parameter of the precursor from solution-based to melt-based. By formulating a melt-processable composition with acrylonitrile (70-90 wt%), co-monomer (5-20 wt%), and plasticizer (5-20 wt%), the invention enables processing without toxic solvents while maintaining fiber structural integrity through controlled thermal processing

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention utilizes phase transition of the polymer composition from solid to melt state during processing. The composition is heated to melt the plasticizer and polymer matrix, allowing fiber formation through melt spinning, then cooled to solidify the fiber structure, eliminating the need for solvent evaporation and recovery

Inventive Principle:

Principle #36Phase transitions

2Strength

If traditional carbon fiber precursors are used, then high strength and stiffness are achieved, but the processing cost increases due to solvent recovery requirements

Engineering Contradiction:

Improvespecific strength and stiffnessVSAvoidprocessing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent extracts and eliminates the toxic solvent component from the traditional solution spinning process. By developing a melt-processable composition that uses no solvent, the invention removes the need for expensive solvent recovery systems while maintaining carbon fiber precursor quality

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention replaces expensive, environmentally problematic solvent systems with a simpler, cheaper melt processing approach. The plasticizer serves as a temporary processing aid that is consumed during processing to enable melt flow, then remains as part of the final fiber structure without requiring recovery

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of manufacture

If melt processable precursors are developed, then processing cost is reduced and applications are expanded, but thermal stabilization capability in air must be achieved

Engineering Contradiction:

Improveprocessing costVSAvoidthermal stabilization capability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent introduces a co-monomer as an intermediary component that facilitates thermal stabilization. The co-monomer (5-20 wt%) acts as a crosslinking agent that promotes ladder polymer formation during oxidative stabilization in air, enabling melt-spun fibers to achieve the structural stability required for high-quality carbon fiber production

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention creates a composite polymer system combining acrylonitrile, co-monomer, and plasticizer that exhibits synergistic properties. The co-monomer provides thermal stabilization functionality while the plasticizer enables melt processability, and acrylonitrile provides the carbon fiber backbone, achieving multiple requirements simultaneously

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method produces cost-effective carbon fibers with high strength and heat resistance, expanding their applications to sectors like sports and automobile industries by eliminating solvent toxicity and reducing processing costs, while maintaining high mechanical properties.

Implementation Method 1

stabilization typically occurs around 200-300° C. in air, which leads to the formation of a ladder polymer

Methodology Applied

Scientific EffectOxidation: Oxidation

Implementation Method 2

The claimed invention provides a method for forming a carbon fiber precursor by melt spinning, which can be thermally cross-linked in air

Methodology Applied

Scientific EffectThermal cross-linking:

Implementation Method 3

carbonization is carried out at temperature of 1000-1400° C. in an inert atmosphere which removes nearly all of the non-carbon elements

Methodology Applied

Scientific EffectCarbonization: Pyrolysis

Implementation Method 4

melt-spinning the composition to form fibers

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS10435821B2Carbon fiber compositions and methods of making

Publication Date: 2019.10.08 BOARD OF RGT THE UNIV OF TEXAS SYST

AI summary

The invention is directed to melt-processable carbon fiber precursors which have the capability of thermal stabilization in air followed by carbonization in inert atmosphere which make them cost effective and widen their applications.