# US 7,610,743 B2 · Carbon fiber spun yarn and woven fabric thereof

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- Number: US 7,610,743 B2
- Document ID: US7610743B2
- Status: Granted
- Kind: B2
- Application number: 10/581,254
- Filed: 2004-11-30
- Published: 2008-12-18
- Granted: 2009-11-03
- Earliest claimed: 2003-12-01
- Assignees: Kureha Corporation
- Inventors: Tatsuo Kobayashi; Naohiro Sonobe
- Web page: https://patentgrep.com/patent/US7610743B2

## CPC

- D02G 3/16: Yarns or threads made from mineral substances
- D02G 3/447: {Yarns or threads for specific use in general industrial applications, e.g. as filters or reinforcement}
- D03D 15/275: Carbon fibres
- D03D 15/41: with specific twist
- D03D 15/573: Tensile strength
- D10B 2101/12: Carbon; Pitch
- D10B 2201/24: Viscose
- D10B 2321/10: polymers of unsaturated nitriles, e.g. polyacrylonitrile, polyvinylidene cyanide
- D10B 2401/063: high strength
- D10B 2401/16: antistatic; conductive
- Y10T 442/3065: Including strand which is of specific structural definition
- D02G: CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D03D: WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D10B: INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A carbon fiber spun yarn, which is a spun yarn of a carbon fiber that has an average (002)-interlayer spacing of 0.340-0.380 nm as measured by X-ray diffraction method, has a specific gravity of 1.55-1.80 as measured by a density gradient tube method, a hydrogen-to carbon atomic ratio (H/C) as measured by elementary analysis of at most 0.1 and contains 3-30 wt. % of carbon fiber having a fiber length of at least 150 mm, wherein the spun yarn has a weight per 1000 m (tex) of 30-150 g, a number of primary twist of 50-400 turns/m and a tensile strength of at least 0.15 N/tex. The carbon fiber spun yarn may be woven to provide a carbon fiber woven fabric suitable as a gas diffuser (electroconductive substrate) of a solid polymer electrolyte fuel cell.

## Claims

### Claim 1

A carbon fiber spun yarn, which is a spun yarn of a carbon fiber that has an average (002)-interlayer spacing of 0.340-0.380 nm as measured by X-ray diffraction method, has a specific gravity of 1.55-1.80 as measured by a density gradient tube method, a hydrogen-to carbon atomic ratio (H/C) as measured by elementary analysis of at most 0.1 and contains 3-30 wt. % of carbon fiber having a fiber length of at least 150 mm, wherein the spun yarn has a weight per 1000 m (tex) of 30-150 g, a number of primary twist of 50-400 turns/m and a tensile strength of at least 0.15 N/tex and where the carbon fiber has an average diameter of 5-20 μm.

### Claim 2 (depends on 1)

A carbon fiber spun yarn according to claim 1, wherein the carbon fiber is an isotropic pitch-based carbon fiber.

### Claim 3 (depends on 1)

A carbon fiber spun yarn according to claim 1, wherein the carbon fiber is a polyacrylonitrile-based carbon fiber or a rayon-based carbon fiber.

### Claim 4 (depends on 1)

A carbon fiber spun yarn according to claim 1, containing 70-97 wt. % of carbon fiber having a fiber length of 50-150 mm.

### Claim 5 (depends on 1)

A carbon fiber spun yarn according to claim 1, which is in a single-twist state.

### Claim 6 (depends on 1)

A carbon fiber woven fabric, comprising at least 30 wt. % thereof of a carbon fiber spun yarn according to claim 1.

### Claim 7 (depends on 6)

A carbon fiber woven fabric according to claim 6, having a fiber area weight (FAW) of at least 50 g/m2 and below 200 g/m2, and a thickness of 0.20-0.60 mm.

### Claim 8 (depends on 6)

A carbon fiber woven fabric according to claim 6, having a volume resistivity of 20-1500 μΩ·m.

### Claim 9 (depends on 6)

A carbon fiber woven fabric according to claim 6, which is in a state of plain weave.

### Claim 10 (depends on 6)

A gas diffuser for a solid polymer electrolyte fuel cell, comprising a carbon fiber woven fabric according to claim 6.