Carbon fiber, as we know, is a high-performance material known for its expensive price. So, how is it produced?
Here is a general overview of the carbon fiber production process:
1. Raw Material Selection
The process begins with the selection of a suitable precursor material, which is typically a polymer-based substance such as polyacrylonitrile (PAN), rayon, or pitch. PAN is the most commonly used precursor due to its excellent carbonization properties.
2. Precursor Stabilization
The selected precursor material undergoes a stabilization process. In the case of PAN, it is heated in an oxygen-free environment at temperatures between 200 to 300 degrees Celsius. This process removes volatile elements and creates a thermoset material that is rigid and heat-resistant.
3. Carbonization
The stabilized precursor material is then subjected to high temperatures in a controlled environment, typically in the range of 1000 to 3000 degrees Celsius. This process, known as carbonization or pyrolysis, eliminates non-carbon elements, leaving behind a carbon-rich structure. The carbonization process strengthens the material and increases its carbon content.
4. Surface Treatment
The carbonized fiber undergoes surface treatment to improve its bonding properties. This step involves applying a sizing or coating material to protect the fibers and enhance their adhesion to matrix materials during composite manufacturing.
5. Fiber Spinning
The carbonized fibers are spun into yarns or threads through a process called fiber spinning. This can be done using various techniques, including wet spinning, dry spinning, or melt spinning, depending on the precursor material and desired fiber characteristics.
6. Fiber Prepregging (Optional)
In some cases, the carbon fibers are impregnated with a resin matrix, typically epoxy, to create a material called prepreg. Prepregs are commonly used in composite manufacturing processes, where the carbon fiber is combined with other materials to form a strong and lightweight composite structure.
7. Composite Manufacturing
The carbon fibers or prepregs are then used in various composite manufacturing techniques such as filament winding, hand lay-up, or automated lay-up processes to create carbon fiber-reinforced composites. These composites find applications in industries such as aerospace, automotive, sports equipment, and more.
The production of carbon fiber is a complex and highly challenging process, hence its relatively high price. However, it possesses numerous advantages and also offers great benefits in various industries, including the shoe insole industry.
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