Constructing the Bridge from Isotropic to Anisotropic Pitches for Preparing Pitch-Based Carbon Fibers with Tunable Structures and Properties.

Synthetic naphthalene pitches (SNPs) with isotropy and anisotropy were prepared by a simple thermal polycondensation method to fabricate pitch-based carbon fibers. The structural characteristic, thermal stability, phase-separation behavior, and melt-spinnability of the SNPs and the structural properties of the derived carbon fibers were systematically investigated. The results show that spinnable SNPs with controllable mesophase contents ranging from 0 to 100 vol % and softening points (210-290 °C) could be easily obtained by a nitrogen-bubbling treatment to improve their thermal stability and melt-spinnability by avoiding the phase separation of liquid crystal (LC) in the pitch. An experimental phase diagram of spinnability and mesophase content is newly proposed for predicting the spinnability of a mesophase-containing pitch. The LC has a significant influence not only on the constituents, structure, and physical properties of the SNPs but also on the final structure and properties of the corresponding pitch-based carbon fibers. The low ash content (less than 0.15 wt %) in the pitch precursor is found to have no obvious effect on the pitch spinnability and the mechanical properties of derivative large-diameter carbon fibers.

Effect of Liquid Crystalline Texture of Mesophase Pitches on the Structure and Property of Large-Diameter Carbon Fibers.

Two types of carbon fibers with a large diameter of ∼22 µm, derived from unstirred and vigorously stirred mesophase pitch melts with different liquid crystalline mesophase textures, were prepared by melt-spinning, stabilization, carbonization, and graphitization treatments. The morphology, microstructure, and physical properties of the carbon fibers derived from the two kinds of mesophase precursors after various processes were characterized in detail. The results show that the optical texture (i.e., size and orientation) of the liquid crystalline mesophase in the molten pitch is obviously modified by thermomechanical stirring treatment, which has a significant effect on the texture of as-spun pitch fibers, and finally dominates the microstructure and physical properties of the resulting carbon and graphite fibers. These large-diameter fibers expectedly maintain their morphological and structural integrity and effectively avoid shrinkage cracking during subsequent high-temperature heat treatment processes, in contrast to those derived from the unstirred pitch. This is due to the smaller crystallite sizes and lower orientation of graphene layers in the former. The tensile strength and axial electrical resistivity of the 3000 °C-graphitized large fibers derived from the unstirred pitch are about 1.8 GPa and 1.18 µΩ m, respectively. In contrast, upon melt stirring treatment of the pitch before spinning, the resulting large-diameter graphite fibers possess the corresponding values of 1.3 GPa and 1.86 µΩ m. Despite the acceptable decrease of mechanical properties and axial electrical and thermal conduction performance, the latter possesses relatively high mechanical stability (i.e., low strength deviation) and ideal morphological and structural integrity, which is beneficial for the wide applications in composites.

Graphite nanoplatelets produced by oxidation and thermal exfoliation of graphite and electrical conductivities of their epoxy composites.

Graphite nanoplatelets were produced by sonication of thermally reduced graphite oxide produced from three precursor graphites. The thicknesses of the resulting graphite nanoplatlets were measured by X-ray diffraction and transmission electron microscopy. The type and size of the precursor graphite plays an important role in the final graphite nanoplatelet quality. The thinnest graphite nanoplatelets (average thickness of 4-7 nm) were obtained from Sri Lankan powdered graphite (average particle size of 0.1-0.2 mm). Thicker graphite nanoplatelets (average thickness of 30-60 nm), were obtained from a Canadian graphite (with an average flake size of 0.5-2 mm). Graphite nanoplatelets obtained by acid intercalation of Sri Lankan graphite were much thicker (an average thickness of 150 nm). Graphite nanoplatelet/epoxy composites containing 4 wt.% graphite nanoplatelets derived from Canadian or Sri Lankan natural graphite have electrical conductivities significantly above the percolation conductivity threshold. In contrast, corresponding composites, produced with (4 wt.%) commercial graphite nanoplatelets, either as-received or re-exfoliated, were electrically insulating. This behaviour is attributed to the highly wrinkled morphology, folded edges and abundant surface functional groups of the commercial graphite nanoplatelets. Thermal reduction of graphite oxide produced from natural flake graphite is therefore a promising route for producing graphite nanoplatelets fillers for electrically-conducting polymer composites.