Modification of continuous carbon fibers during precursor formation for composites having enhanced moldability

Abstract

Methods of producing continuous carbon fibers for composites having enhanced moldability are provided. Discrete regions are introduced into a continuous precursor fiber comprising an acrylic polymer material, such as polyacrylonitrile (PAN), as the precursor fiber is formed. The precursors may be heterogeneous fibers having a second distinct material interspersed in discrete regions with the acrylic polymer material. Alternatively, the precursors may be heterogeneous fibers where laser is applied to the acrylic polymer material in discrete regions to cause localized molecular disruptions. After the continuous precursor fiber is heated for carbonization and/or graphitization, the precursor forms a continuous carbon fiber having a plurality of discrete weak regions. These relatively weak regions provide noncontiguous break points that reduce stiffness and improve moldability for carbon fiber polymeric composites, while retaining high strength levels. Carbon fiber polymeric composites incorporating continuous carbon fibers having the plurality of discrete noncontiguous weak regions are also provided.

Dependencies are inferred from the claim text.