Abstract An improved process is provided for the simultaneous conversion of a plurality of adjoining parallel ends of an organic polymeric fibrous material to a carbonaceous fibrous material. The parallel warp ends are provided and maintained during at least a portion of the conversion process an an integral tape possessing a high degree of structural integrity by the presence of a weft pick interlaced therewith in a sateen weave construction which floats a substantial number of the parallel warp ends as described. When the resulting carbonaceous tape is incorporated in a matrix material to form a composite article, the presence of the weft pick therein produces no substantial diminution in the composite properties.
An improved process according to claim 1 wherein said warp ends are an acrylonitrile homopolymer.
Claim 2
Dependent Claim
23 words
An improved process according to claim 1 wherein the composition of said weft pick is substantially identical to that of said warp ends.
Claim 3
Dependent Claim
34 words
An improved process according to claim 1 wherein said fibrous material is provided in the form of said tape of sateen weave construction while being passed through a stabilization zone and a carbonization zone.
Claim 4
Dependent Claim
37 words
An improved process according to claim 1 wherein said fibrous material is provided in the form of said tape of sateen weave construction while being passed through a stabilization zone, a carbonization zone, and a graphitization zone.
Claim 5
Dependent Claim
38 words
An improved process according to claim 1 wherein said fibrous material is provided in the form of said tape of sateen weave construction while being passed through a stabilization zone, a carbonization zone, and a surface treatment zone.
Claim 6
Dependent Claim
26 words
An improved process according to claim 1 wherein said warp ends are continuous multifilament yarns exhibiting a twist of about 0.1 to 5 turns per inch.
Claim 7
Dependent Claim
20 words
An improved process according to claim 7 wherein said weft pick possesses a twist of about 0.5 turn per inch.
Claim 8
Dependent Claim
24 words
An improved process according to claim 1 wherein said tape of sateen Weave construction includes 32 to 500 adjoining substantially parallel linear warp ends.
Claim 9
Dependent Claim
28 words
An improved process according to claim 1 wherein the total denier of said weft pick is equal to or less than that of each of said warp ends.
Claim 10
Dependent Claim
22 words
An improved process according to claim 1 wherein said weft pick possesses a twist of about 0.1 to 3 turns per inch.
Claim 11
Dependent Claim
41 words
An improved process according to claim 1 wherein said weft pick substantially floats from about 4 to 16 of said warp ends prior to each additional interlacing point in the main body of said tape as said warp ends are traversed.
Claim 12
Dependent Claim
27 words
An improved process according to claim 1 wherein said weft pick is provided at a frequency of about 1 to 3 picks per inch of said tape.