Preparation of carbon fiber fabrics from phenolic resin by electrospray deposition

Abstract

Flexible carbon fiber fabrics of 1.7 μm diameter fiber were prepared by electrospray deposition (ESD) from phenolic resin/poly(vinyl butyral) and successive curing and carbonization. In the present study, phenolic resin (thermostable 3-dimensional cross-linked polymer) was used for ESD and successive carbonization. The bead-free fiber was obtained by ESD from a phenolic resin solution with concentration above 55 wt %. The as-deposited fabrics, however, were very brittle. The addition of poly (vinyl butyral) (Mw = 110,000) improved the dimensional stability of the as-deposited fabrics. After carbonization of the as-deposited fabrics, the flexible carbon fiber fabrics were obtained. The carbon fiber fabrics showed relatively high electrical conductivity and a large specific surface area (BET surface area = 495 m2/g). This indicates that the flexible carbon fiber fabrics are applicable not only for adsorbent and composite materials but also for materials for electronic device use. © 2007 The Society of Polymer Science.