Process for producing carbon fibers from heat treated pitch

Claim 2

The process for producing a carbonaceous pitch fiber capable of being thermoset and converted thermally to carbon fiber comprising: heating a non-Newtonian carbonaceous pitch selected from the group consisting of anisotropic pitch, isotropic pitch, and mixtures thereof to spinning temperatures; subjecting said carbonaceous pitch to shearing forces for spinning said heated pitch to form said fiber, said shearing forces being at least sufficient at spinning temperatures to orient large domains in said pitch into a fine domain structure parallel to the shear direction and to cause gel breakdown.

Claim 3

The process of claim 1 wherein said heated pitch is spun at right angles to the direction of shearing forces.

Claim 4

The process of claim 1 wherein said carbonaceous pitch has a viscosity in the range of 10 to 200 poise at temperatures in the range of 230° to 450° C.

Claim 5

The process of claim 3 wherein said carbonaceous pitch contains greater than 65 wt. % optically anisotropic liquid crystalline domains.

Claim 6

The process of claim 4 wherein said pitch contains greater than 90 wt. % optically anisotropic liquid crystalline domains.

Claim 7

The process of claim 5 wherein said spinning temperatures are in the range of from about 230° C. to 450° C.

Claim 8

The process of claim 1 wherein said pitch is an isotropic pitch.

Claim 9

A process for producing a carbonaceous pitch fiber capable of being thermoset and converted thermally to a carbon fiber, said pitch fiber having an optically anisotropic content greater than 90% by weight comprising: subjecting an anisotropic, non-Newtonian pitch containing greater than 90% optically anisotropic domains at spinning temperatures to a shearing force and spinning said heated pitch to form said fiber, said shearing forces being at least sufficient at spinning temperatures to orient large optically anisotropic domains into a fine domain structure parallel to the shear direction and to cause gel breakdown.

Claim 10

A process for producing a carbonaceous pitch fiber capable of being thermoset and converted thermally to a carbon fiber, said pitch fiber having an optically anisotropic content greater than 90% by weight comprising: subjecting an anisotropic, non-Newtonian pitch containing greater than 90% optically anisotropic domains at spinning temperatures to a shearing force and spinning said heated pitch to form said fiber, said shearing forces being at least sufficient at spinning temperatures to orient large optically anisotropic domains into a fine domain structure parallel to the shear direction and to cause gel breakdown.

Claim 11

The process of claim 8 wherein said heated pitch is spun at right angles to the direction of shearing forces.

Claim 12

The process for forming a pitch fiber comprising: providing an isotropic carbonaceous pitch which is insoluble in benzene at ambient temperatures and which pitch when heated to a temperature in the range from about 230° C. to 450° C. is converted to an optically anisotropic pitch containing greater than 90% optically anisotropic domains; heating said isotropic pitch at a temperature in the range of from about 230° C. to about 450° C. for a time sufficient to convert said isotropic pitch to an optically, non-Newtonian, anisotropic pitch containing greater than 90% optically anisotropic domains; maintaining the temperature of said optically anisotropic pitch in the temperature range of between about 230° C. to 450° C. in the spinning die; subjecting said heated pitch to shearing forces for spinning said pitch whereby a pitch fiber is obtained, said shearing forces being at least sufficient at spinning temperatures to orient large optically anisotropic domains into a fine domain structure parallel to the shear direction and to cause gel breakdown.

Claim 13

The process for forming a pitch fiber comprising: providing an isotropic carbonaceous pitch which is insoluble in benzene at ambient temperatures and which pitch when heated to a temperature in the range from about 230° C. to 450° C. is converted to an optically anisotropic pitch containing greater than 90% optically anisotropic domains; heating said isotropic pitch at a temperature in the range of from about 230° C. to about 450° C. for a time sufficient to convert said isotropic pitch to an optically, non-Newtonian, anisotropic pitch containing greater than 90% optically anisotropic domains; maintaining the temperature of said optically anisotropic pitch in the temperature range of between about 230° C. to 450° C. in the spinning die; subjecting said heated pitch to shearing forces for spinning said pitch whereby a pitch fiber is obtained, said shearing forces being at least sufficient at spinning temperatures to orient large optically anisotropic domains into a fine domain structure parallel to the shear direction and to cause gel breakdown.

Claim 14

The process of claim 10 wherein said heated pitch is spun at right angles to the shear direction.

Claim 15

The process of claim 10 including the steps of heating said pitch fiber in a temperature range of between about 250° C. to 400° C. and an oxidizing atmosphere to render the fibers infusible and thereafter carbonizing said oxidizing fiber by heating at temperatures up to 2000° C. whereby a carbon fiber is obtained.