Method of manufacturing a high bulk density carbon fiber felt
AssigneesOsaka Gas Co., Ltd., Japan Felt Industrial Company Limited
InventorsHirofumi Kyutoku, Kouichi Yamamoto, Yoshihisa Otani
Life of this patent
Estimating the term…
Abstract
Polymer-type fibers longitudinally shrinkable by calcination and other carbon fibers are mixed and mechanically compressed and integrated by a needle punch, and the polymer-type fibers are then shrunk when calcined. Thus, there is obtained high bulk density carbon fiber felt having average bulk density of 0.1 g/cm.sup.3 or more without the carbon fiber felt impregnated with, resin and compressingly molded. The density of carbon fiber felt may change in the thickness direction thereof. The high bulk density carbon fiber felt may be used as a thermal insulator for a high-temperature furnace, a heat-resisting cushioning material, and a material for the electrode of a secondary battery.
Claims13
A method of manufacturing high bulk density carbon fiber felt, comprising the steps of:
- mixing together (i) first fibers of at least one of fibers selected from the group consisting of carbon fibers, pitch fibers subjected to an infusible treatment, rayon fibers, polyacrylonitrile fibers and cellulose fibers subjected to an infusible treatment, and (ii) phenol resin fibers which are longitudinally shrunk by calcination and which can be carbonized and/or graphitized;
- mechanically compressing and entangling said first fibers with said phenol resin fibers to prepare a felt;
- and
- calcining said felt to shrink said phenol resin fibers and obtain a high bulk density carbon fiber felt having a bulk density of at least about 0.1 g/cm.sup.3.
Dependencies are inferred from the claim text.