Preparation of Carbon Fiber Fabrics from Phenolic Resin by Electrospray Deposition

Flexible carbon fiber fabrics of 1.7 mu m 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) (M-w = 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 m(2)/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. [doi:10.1295/polymj.PJ2007091]