ABSTRACT:Flexible carbon fiber fabrics of 1.7 mm 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 ¼ 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 Recently, increasing attention to nanomaterials has been focused on the carbon-based ones such as carbon nanotube (CNT), carbon nanofiber, and fullerene due to their electrical, thermal, and mechanical properties. Particularly, carbon nanofiber has a high surface area, lightweight, high electrical conductivity (comparable to CNT), 1 and is low-cost in the production process.
2-4In addition, it is pointed out that carbon fibers with thinner diameters have a higher specific surface area and a higher electrical conductivity. In the cases of both carbon nanofibers and assemblies of carbon nanofibers, a free-standing carbon fibrous fabric is required for the applications such as electrodes, super capacitors, catalyst supports, emitter, sensor substrates, filter media, and reinforcements. If this fabric is flexible, its application is expanded much more. Conventional carbon fibers are produced by melt spinning and chemical vapor deposition (CVD). The melt spinning produces carbon fibers with diameters of more than 5 mm. The CVD method, on the other hand, synthesizes carbon fibers with diameters ranging from 10 nm to several microns. 5,6 CVD, however, is not suitable for producing long fibers and nonwoven fabrics.Electrospray deposition (ESD) has been expected to prepare a free-standing carbon fibrous fabric. ESD is a straightforward and versatile method for forming thin films.7 One major advantages of ESD is easily forming nano-microscaled fibrous fibers (typically nonwoven fabrics) from organic and inorganic materials.
8-11The ESD methods consist of the following steps; (i) a strong electric field is applied between a nozzle containing the polymer solution and a conductive substrate, (ii) when the voltage reaches a critical value, electrostatic forces overcome the surface tension of the solution, (iii) charged droplets (or jets) are sprayed from the tip of the nozzle, in a dry atmosphere; and (iv) the dried droplets (or jets) are finally collected on the substrate to form a thin film. [12][13][14] We can control the fiber diameter by changing the solution properties (e.g., viscosity) and operational conditions (e.g., the distance between the nozzle tip and the substrate surface, the flow rate, an...