Highly Chlorinated Polyvinyl Chloride as a Novel Precursor for Fibrous Carbon Material.

Pure, highly chlorinated polyvinyl chloride (CPVC), with a 63 wt % of chlorine, showed a unique-thermal-pyrolytic-phenomenon that meant it could be converted to carbon material through solid-phase carbonisation rather than liquid-phase carbonisation. The CPVC began to decompose at 270 °C, with a rapid loss in mass due to dehydrochlorination and novel aromatisation and polycondensation up to 400 °C. In this study, we attempted to prepare carbon fibre (CF) without oxidative stabilisation, using the aforementioned CPVC as a novel precursor. Through the processes of solution spinning and solid-state carbonisation, the spun CPVC fibre was directly converted to CF, with a carbonisation yield of 26.2 wt %. The CPVC-derived CF exhibited a relatively smooth surface; however, it still demonstrated a low mechanical performance. This was because the spun fibre was not stretched during the heat treatment. Tensile strength, Young's modulus and elongation values of 590 ± 84 MPa, 50 ± 8 GPa, and 1.2 ± 0.2%, respectively, were obtained from the CPVC spun fibre, with an average diameter of 19.4 µm, following carbonisation at 1600 °C for 5 min.

Shortening Stabilization Time Using Pressurized Air Flow in Manufacturing Mesophase Pitch-Based Carbon Fiber.

Oxidation-stabilization using pressurized air flows of 0.5 and 1.0 MPa could successfully shorten the total stabilization time to less than 60 min for manufacturing mesophase pitch-based carbon fibers without deteriorating mechanical performance. Notably, the carbonized fiber heat-treated at 1000 °C for 30 min, which was oxidative-stabilized at 260 °C without soaking time with a heating rate of 2.0 °C/min using 100 mL/min of pressurized air flow of 0.5 MPa (total stabilization time: 55 min), showed excellent tensile strength and Young's modulus of 3.4 and 177 GPa, respectively, which were higher than those of carbonized fiber oxidation-stabilized at 270 °C without soaking time with a heating rate of 0.5 °C/min using 100 mL/min of atmospheric air flow (total stabilization time: 300 min). Activation energies for oxidation reactions in stabilization using pressurized air flows were much lower than those of oxidation reactions using atmospheric air flow because of the higher oxidation diffusion from the outer surface into the center part of pitch fibers for the use of the pressurized air flows of 0.5 and 1.0 MPa than the atmospheric one. The higher oxygen diffusivities resulted in a more homogeneous distribution of oxygen weight uptake across the transverse section of mesophase pitch fibers, and allowed the improvement of the mechanical properties.