Production of activated carbon fibers from acid contacted polybenzimidazole fibrous material

Claim 2

An improved process for forming activated carbon fibers comprising: (a) contacting polybenzimidazole fibrous material with a solution of an acid having a pK A value below about 4.5 to transform at least a portion of the polybenzimidazole to a polybenzimidazonium salt wherein the anion of said salt is derived from said acid, (b) preoxidizing said polybenzimidazole fibrous material containing said polybenzimidazonium salt by heating in an oxygen-containing gaseous atmosphere at a temperature of approximately 400° to 550° C., (c) carbonizing said resulting preoxidized fibrous material by heating in a non-oxidizing gaseous atmosphere at a temperature of approximately 650° to 875° C. until a carbonaceous fibrous material is formed which contains at least 60 percent carbon by weight, and (d) heating said resulting carbonaceous fibrous material in an oxidizing gas at a temperature of approximately 450° to 600° C. until an activated carbonaceous fibrous material is formed having a dynamic weight absorptivity of at least 100 mg. of CCl 4 per gram.

Claim 3

An improved process for forming activated carbon fibers in accordance with claim 1 wherein said polybenzimidazole fibrous material consists essentially of recurring units of the formula: ##STR5## wherein R is a tetravalent aromatic nucleus, with the nitrogen atoms forming the benzimidazole rings paired upon adjacent carbon atoms of said aromatic nucleus, and R' is selected from the group consisting of (1) an aromatic ring, (2) an alkylene group having from 4 to 8 carbon atoms, and (3) a heterocyclic ring selected from the group consisting of (a) pyridine, (b) pyrazine, (c) furan, (d) quinoline, (e) thiophene, and (f) pyran.

Claim 4

An improved process for forming activated carbon fibers in accordance with claim 1 wherein said polybenzimidazole fibrous material is poly-2,2'-(m-phenylene)-5,5'-bibenzimida- zole.

Claim 5

An improved process for forming activated carbon fibers in accordance with claim 1 wherein said polybenzimidazole fibrous material is in the form of a woven cloth.

Claim 6

An improved process for forming activated carbon fibers in accordance with claim 1 wherein said polybenzimidazole fibrous material prior to contact with said acid has a denier per filament of approximately 1 to 4.

Claim 7

An improved process for forming activated carbon fibers in accordance with claim 1 wherein said acid is sulfuric acid and polybenzimidazonium sulfate is formed in step (a).

Claim 8

An improved process for forming activated carbon fibers in accordance with claim 1 wherein said solution of said acid when utilized in step (a) is provided at a temperature of approximately 20° to 80° C.

Claim 9

An improved process for forming activated carbon fibers in accordance with claim 7 wherein the contact of said fibrous material with said acid in step (a) is accomplished by immersing said fibrous material in said acid solution for at least about 1 second.

Claim 10

An improved process for forming activated carbon fibers in accordance with claim 1 wherein said fibrous material is washed immediately following step (a) to substantially remove any adhering free acid.

Claim 11

An improved process for forming activated carbon fibers in accordance with claim 1 wherein said oxygen-containing gaseous atmosphere of step (b) is air.

Claim 12

An improved process for forming activated carbon fibers in accordance with claim 1 wherein said oxidizing gas of step (d) is selected from the group consisting of water vapor, carbon dioxide, nitrogen dioxide, and mixtures of the foregoing.

Claim 13

An improved process for forming activated carbon fibers comprising: (a) contacting a polybenzimidazole fibrous material with a solution of sulfuric acid provided at a temperature of approximately 20° to 80° C. to transform at least a portion of the polybenzimidazole to polybenzimidazonium sulfate, (b) preoxidizing said polybenzimidazole fibrous material containing said polybenzimidazonium sulfate by heating in air at a temperature of approximately 400° to 550° C. for approximately 1 to 60 minutes, (c) carbonizing said resulting preoxidized fibrous material by heating in a non-oxidizing gaseous atmosphere at a temperature of approximately 650° to 875° C. for approximately 0.5 to 5 minutes to form a carbonaceous fibrous material which contains at least 60 percent carbon by weight, and (d) heating said resulting carbonaceous fibrous material in a gaseous atmosphere containing water vapor at a temperature of approximately 450° to 600° C. for approximately 3 to 20 minutes to form an activated carbonaceous fibrous material having a dynamic weight absorptivity of at least 100 mg. of CCl 4 per gram.

Claim 14

An improved process for forming activated carbon fibers comprising: (a) contacting a polybenzimidazole fibrous material with a solution of sulfuric acid provided at a temperature of approximately 20° to 80° C. to transform at least a portion of the polybenzimidazole to polybenzimidazonium sulfate, (b) preoxidizing said polybenzimidazole fibrous material containing said polybenzimidazonium sulfate by heating in air at a temperature of approximately 400° to 550° C. for approximately 1 to 60 minutes, (c) carbonizing said resulting preoxidized fibrous material by heating in a non-oxidizing gaseous atmosphere at a temperature of approximately 650° to 875° C. for approximately 0.5 to 5 minutes to form a carbonaceous fibrous material which contains at least 60 percent carbon by weight, and (d) heating said resulting carbonaceous fibrous material in a gaseous atmosphere containing water vapor at a temperature of approximately 450° to 600° C. for approximately 3 to 20 minutes to form an activated carbonaceous fibrous material having a dynamic weight absorptivity of at least 100 mg. of CCl 4 per gram.

Claim 15

An improved process for forming activated carbon fibers in accordance with claim 12 wherein said polybenzimidazole fibrous material consists essentially of recurring units of the formula: ##STR6## wherein R is a tetravalent aromatic nucleus, with the nitrogen atoms forming the benzimidazole rings paired upon adjacent carbon atoms of said aromatic nucleus, and R' is selected from the group consisting of (1) an aromatic ring, (2) an alkylene group having from 4 to 8 carbon atoms, and (3) a heterocyclic ring selected from the group consisting of (a) pyridine, (b) pyrazine, (c) furan, (d) quinoline, (e) thiophene, and (f) pyran.

Claim 16

An improved process for forming activated carbon fibers in accordance with claim 12 wherein said polybenzimidazole fibrous material is poly-2,2'-(m-phenylene)-5,5'-bibenzimidazole.

Claim 17

An improved process for forming activated carbon fibers in accordance with claim 12 wherein said polybenzimidazole fibrous material is in the form of a woven cloth.

Claim 18

An improved process for forming activated carbon fibers in accordance with claim 12 wherein said polybenzimidazole fibrous material prior to contact with said acid has a denier per filament of approximately 1 to 4.

Claim 19

An improved process for forming activated carbon fibers in accordance with claim 12 wherein the contact of said fibrous material with said acid in step (a) is accomplished by immersing said fibrous material in said acid solution for at least about 30 seconds.

Claim 20

An improved process for forming activated carbon fibers in accordance with claim 12 wherein said fibrous material is washed immediately following step (a) to substantially remove any adhering free acid.

Claim 21

An improved process for forming activated carbon fibers comprising: (a) contacting a polybenzimidazole fibrous material comprising poly-2,2'-(m-phenylene)-5,5'-bibenzimidazole having a denier per filament of approximately 1 to 4 with a solution of sulfuric acid provided at a temperature of approximately 20° to 80° C. to transform at least a portion of the polybenzimidazole to polybenzimidazonium sulfate, (b) preoxidizing said polybenzimidazole fibrous material containing said polybenzimidazonium sulfate by heating in air at a temperature of approximately 450° to 500° C. for approximately 5 to 10 minutes, (c) carbonizing said resulting preoxidized fibrous material by heating in a nitrogen atmosphere at a temperature of approximately 700° to 800° C. for approximately 0.7 to 2 minutes to form a carbonaceous fibrous material which contains at least 63 percent carbon by weight, and (d) heating said resulting carbonaceous fibrous material in a gaseous atmosphere containing water vapor at a temperature of approximately 500° to 550° C. for approximately 8 to 12 minutes to form an activated carbonaceous fibrous material having a dynamic weight absorptivity of at least 125 mg. of CCl 4 per gram.

Claim 22

An improved process for forming activated carbon fibers comprising: (a) contacting a polybenzimidazole fibrous material comprising poly-2,2'-(m-phenylene)-5,5'-bibenzimidazole having a denier per filament of approximately 1 to 4 with a solution of sulfuric acid provided at a temperature of approximately 20° to 80° C. to transform at least a portion of the polybenzimidazole to polybenzimidazonium sulfate, (b) preoxidizing said polybenzimidazole fibrous material containing said polybenzimidazonium sulfate by heating in air at a temperature of approximately 450° to 500° C. for approximately 5 to 10 minutes, (c) carbonizing said resulting preoxidized fibrous material by heating in a nitrogen atmosphere at a temperature of approximately 700° to 800° C. for approximately 0.7 to 2 minutes to form a carbonaceous fibrous material which contains at least 63 percent carbon by weight, and (d) heating said resulting carbonaceous fibrous material in a gaseous atmosphere containing water vapor at a temperature of approximately 500° to 550° C. for approximately 8 to 12 minutes to form an activated carbonaceous fibrous material having a dynamic weight absorptivity of at least 125 mg. of CCl 4 per gram.

Claim 23

An improved process for forming activated carbon fibers in accordance with claim 19 wherein said polybenzimidazole fibrous material is in the form of a woven cloth.

Claim 24

An improved process for forming activated carbon fibers in accordance with claim 19 wherein the contact of said fibrous material with said acid in step (a) is accomplished by immersing said fibrous material in said acid solution for at least about 1 second.

Claim 25

An improved process for forming activated carbon fibers in accordance with claim 19 wherein said fibrous material is washed immediately following step (a) to substantially remove any adhering free acid.