Polyacrylonitrile Precursor Polymerization for Carbon Fiber Production
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Solution Overview
Problem
The existing methods for manufacturing carbon-fiber precursor fibers are costly and lack productivity, and the flameproofing treatment process is time-consuming.
Innovation Solution
A method involving the preparation of a polyacrylonitrile-based polymer solution using specific polymerization terminators like ammonium hydroxide, tribenzylamine, and melamine, which allows for high productivity and reduced flameproofing treatment time by facilitating solvent and monomer recovery and optimizing the spinning process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional polymerization terminators are used in polyacrylonitrile-based polymer solution preparation, then the manufacturing process is simple, but the productivity is low and cost is high
Solution Approach 1:
The patent changes the chemical parameters of the polymerization terminator from conventional ammonia to specifically substituted ammonium hydroxide (C1-C6 alkyl or aromatic alkyl), amine (C1-C6 alkyl or aromatic alkyl), or melamine derivatives. This parameter change optimizes the polymerization process, enabling higher productivity and lower costs while maintaining process feasibility.
2Loss of time
If conventional polymerization terminators are used, then the manufacturing cost is high, but the flameproofing treatment time is long
Solution Approach 1:
The patent modifies the chemical composition parameters of the polymerization terminator to substituted ammonium hydroxide, amine, or melamine derivatives. These parameter changes result in a polyacrylonitrile-based polymer solution that produces precursor fibers with optimized properties, reducing flameproofing treatment time while maintaining cost-effectiveness.
3Productivity
If the polyacrylonitrile-based polymer solution is prepared with optimized terminators, then the flameproofing treatment time is reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The patent optimizes the chemical parameters of the polymerization terminator (using substituted ammonium hydroxide, amine, or melamine derivatives) to enhance production efficiency and reduce flameproofing treatment time. The patent demonstrates that these parameter changes improve productivity without proportionally increasing process complexity.
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 enhances the production efficiency of carbon-fiber precursor fibers, reduces the flameproofing treatment time, and results in high-quality carbon fibers with improved properties.
Implementation Method 1
polymerizing 85 mol % or more of acrylonitrile based on a total monomer and a balance of a monomer which is copolymerizable with the acrylonitrile, thus preparing a polyacrylonitrile-based polymer
Implementation Method 2
neutralized with at least one compound selected from among ammonium hydroxide substituted with C1 ̃C6 alkyl or C6 ̃C21 aromatic alkyl, amine substituted with C1 ̃C6 alkyl or C6 ̃C21 aromatic alkyl, and melamine unsubstituted or substituted with C1 ̃C6 alkyl as the polymerization terminator
Data Source
AI summary
Disclosed is a method for manufacturing carbon fiber which comprises the use of un-reacted raw material monomers in solution to prepare the precursor fiber for making the carbon fiber, and a relatively short passage period through hydrogen, which reduce production costs and increase returns. The present invention further comprises the carbon fiber precursors made thereby.