US3769144A - Quilted fabric containing high surface area carbon fibers - Google Patents

Quilted fabric containing high surface area carbon fibers Download PDF

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Publication number
US3769144A
US3769144A US00237836A US3769144DA US3769144A US 3769144 A US3769144 A US 3769144A US 00237836 A US00237836 A US 00237836A US 3769144D A US3769144D A US 3769144DA US 3769144 A US3769144 A US 3769144A
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fabric
carbon fibers
quilted fabric
quilted
flexible
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US00237836A
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J Economy
R Lin
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Stemcor Corp
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Carborundum Co
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Assigned to KENNECOTT CORPORATION reassignment KENNECOTT CORPORATION MERGER (SEE DOCUMENT FOR DETAILS). EFFECTIVE DEC. 31, 1980 NORTH DAKOTA Assignors: BEAR CREEK MINING COMPANY, BEAR TOOTH MINING COMPANY, CARBORUNDUM COMPANY THE, CHASE BRASS & COPPER CO. INCORPORATED, KENNECOTT EXPLORATION, INC., KENNECOTT REFINING CORPORATION, KENNECOTT SALES CORPORATION, OZARK LEAD COMPANY, PLAMBEAU MINING CORPORATION, RIDGE MINING CORPORATION (ALL MERGED INTO)
Assigned to KENNECOTT MINING CORPORATION reassignment KENNECOTT MINING CORPORATION CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). EFFECTIVE DEC. 31, 1986. (SEE DOCUMENT FOR DETAILS) Assignors: KENNECOTT CORPORATION
Assigned to STEMCOR CORPORATION, 200 PUBLIC SQUARE, CLEVELAND, OHIO 44114 A DE. CORP. reassignment STEMCOR CORPORATION, 200 PUBLIC SQUARE, CLEVELAND, OHIO 44114 A DE. CORP. ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: KENNECOTT MINING CORPORATION
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    • A—HUMAN NECESSITIES
    • A62—LIFE-SAVING; FIRE-FIGHTING
    • A62D—CHEMICAL MEANS FOR EXTINGUISHING FIRES OR FOR COMBATING OR PROTECTING AGAINST HARMFUL CHEMICAL AGENTS; CHEMICAL MATERIALS FOR USE IN BREATHING APPARATUS
    • A62D5/00—Composition of materials for coverings or clothing affording protection against harmful chemical agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2571/00—Protective equipment
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S264/00—Plastic and nonmetallic article shaping or treating: processes
    • Y10S264/29—Mixed resin filaments
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S273/00—Amusement devices: games
    • Y10S273/23—High modulus filaments
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2904—Staple length fiber
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/30—Self-sustaining carbon mass or layer with impregnant or other layer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
    • Y10T442/102—Woven scrim
    • Y10T442/153—Including an additional scrim layer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3472—Woven fabric including an additional woven fabric layer
    • Y10T442/348—Mechanically needled or hydroentangled
    • Y10T442/3496—Coated, impregnated, or autogenously bonded

Definitions

  • ABSTRACT A quilted fabric containing high surface area carbon 11 Niagara Falls, NY.
  • the quilted fabric thus made is 423 447 ful for fabricating protective clothing or gas masks for ,ll2/420, l6l/79,l61/92, 161/182 51 110.0321) 7/08 use y Personnel who must enter areas which y contain noxious gases, or for face masks for combat- 423 447 ting the air pollution problem.
  • the quilted fabric makes possible the use of spun yarns of activated carbon fabric which have,
  • activated carbon fibers for such purposes has been considered both from the viewpoint of continuous filaments and yarns spun from staple fibers.
  • the continuous filaments are strong, if made of sufficient filament diameter, but are difficult and expensive to produce, and alsoare at larger filament diameters, rela tively inflexible.
  • Yarns of activated carbon spun from staple fibers are relatively weak, even though the individual filaments may have a high tensile strength, due to a .variety of factors which influence the yarn strength, such as the tendency of activated carbon filaments to slip upon each other easily when spun into a yarn.
  • an object of this invention to provide a fabric containing high surface area carbon fibers (activated carbon" fibers), i.e.,fibers having a surface area of at least 300 m /g, which overcomes these various disadvantages of the prior art.
  • a quilted fabric containing high surface area carbon fibers comprises in combination (I) at least one central layer of flexible carbon fibers having a surface area of at least about 300 square meters per gram (m /g); (2) a pair of outer layers of reinforcing fabric. positioned on each side of the layer of flexible carbon fibers; and (3) a network of quilting stitching, uniting thecentral layer of flexible carbon fibers and the outer layers of reinforcing fabric into an integral quilted fabric.
  • FIGURE of the drqwing illustrates a quilted fabric containing high surface area carbon fibers-in accordance with the present invention.
  • the quilted fabric containing high surface area carbon fibers begins with at least one central layer of flexible carbon fibers having a surface area of at least 300 m /g. It is convenient to use for this central layer of flexible carbon fibers a layer of woven carbon cloth; however, other forms of fibers can also be used, such as carbon felt, resin' bonded carbon batting, or a multiplicity of loose staple fibers of carbon.
  • a preferred method for producing the carbon fibers comprises the steps of l) heating an infusible cured phenol-formaldehyde novolac (CA-0001) fiber in air from about room temperature up to an intermediate temperature in the range of 1 from about 250C to about 450C, at a rate of temperature rise of from about 50C/hr to about 200C/hr, and (2) further heating said fiber in a nonoxidizingatmosphere from said intermediate temperature to a final temperature in the range of from about 700C to about 900C, at a rate of temperature rise offrom about 50C/hr to about 200C/hr.
  • CA-0001 infusible cured phenol-formaldehyde novolac
  • CA-000i for temporary use in describing the cross-linked novolac fiber, and it is sold by The Carborundum Company of Niagara Falls, New York, as Kynol CA-000l fiber. It is preferred to form the layer of woven carbon cloth, carbon-felt, resin bonded carbon atting, or loose staple fibers of carbon by first forming the respective shape of CA-000l fibers, and then applyingthe above-described 5 min. at 900C for carbon fibers made from combinations of pitch and novolac), and such fibers can also be used in the present invention. Other flexible carbon fibers having high surface area, if available, can also be used.
  • a plurality of central layers of flexible carbon fibers can be utilized, such as two or more layers of carbon cloth, or a layer of carbon cloth in combination with a multiplicity of loose staple fibers of carbon, or the like.
  • the quilting stitching pattern should of course be chosen with the number and type of layers of flexible carbon fibers in mind. Thus, ifa multiplicity of loose staple fibers of carbon is used, it is preferred that the quilting stitching be relatively close together, e.g., several centimeters apart. On the other hand, if felt,
  • the quilting stitching can be somewhat further apart e.g., 5-10 cm apart.
  • the outer layers of reinforcing fabric can be any suitable material.
  • Nylon cloth is a preferred material for this purpose, since it is a relatively strong fabric and can be formulated with a loose mesh and still retain a high degree of strength. Loose meshes are preferred for these outer reinforcing fabric layers for some applications, for ease of stitching.
  • An especially preferred nylon for the outer layers of reinforcing fabric is that nylon which is a wholly aromatic polyamide. This type of fiber is available commercially under the trademark NOMEX" (E. l. duPont de Nemours & Co.), and details of manufacture of such wholly aromatic polyamides are disclosed in U.S. pat. Nos. 3.063.966 and 3,287,324. A process for the dry spinning of such aromatic polyamides into fibers is disclosed in U.S. pat. No. 3.360.598.
  • Another fiber which is preferred for use in fabricating the outer layers of reinforcing fabric is uncarbonized Kynol CA-OOOl cloth. described in U.S. pat. No. 3.650.102 and available commercially from The Carborundum Company.
  • the use of wholly aromatic polyamides and uncarbonized (TA-0001 cloth for the outer layers of reinforcing fabric have the advantage of providing a protective fabric for clothing which combines the heat resistance of wholly aromatic polyamide or CA-OOOl cloth with the property of gas absorption and adsorption of high surface area flexible carbon fibers, so that an individual who may face one or both of these hazards can protect himself with a single garment.
  • the single figure of drawing illustrates a portion of quilted fabric containing high surface area carbon fibers in accordance with the present invention.
  • This quilted fabric comprisesin combination at least one central layer 11 of flexible carbon fibers having a surface area of at least about 300 m /g; and a pair of outer layers 12 of reinforcing fabric positioned on each side of the layer of flexible carbon fibers.
  • a network of quilting stitching l3.unites the central layer of flexible carbon fibers and the outer layers of reinforcing fabric into an integral quilted fabric.
  • layer 11 of flexible carbon fibers although illustrated as woven carbon cloth, can
  • the resulting carbonized and activated carbon fabric had a weight of about 4.24 ounces per square yard, and a surface area of at least about 300 m lg.
  • This activated carbon cloth constituting a layer 11 of flexible carbon fibers. was then placed between two layers 12 of nylon mesh fabric having a 27 X 48 square weave construction. The. three layers were then united by a network of quilting stitching 13 into an integral quilted fabric.
  • the quilted fabric was found to be substantially stronger than the carbonized activated carbon fabric layer 11 by itself, yet it retains its flexibility.
  • the composite quilted fabric, as thus constituted, can be used 7 to fabricate protective clothing, which is highly effective as a scavenger for poisonous or other noxious gases.
  • a quilted fabric containing high surface area carbon fibers. comprising in combination l. at least one central layer of flexible carbon fibers having a surface area of at least about 300 m /g;
  • the quilted fabric of claim 1 comprising a plural- I ity of central layers 'of flexible carbon fibers.

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • General Health & Medical Sciences (AREA)
  • Materials Engineering (AREA)
  • Toxicology (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Business, Economics & Management (AREA)
  • Emergency Management (AREA)
  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

A quilted fabric containing high surface area carbon fibers is made by uniting a central layer of flexible activated carbon fibers between a pair of outer layers of reinforcing fabric, positioned on each side of the layer of activated flexible carbon fibers, with a network of quilting stitching. The quilted fabric thus made is useful for fabricating protective clothing or gas masks for use by personnel who must enter areas which may contain noxious gases, or for face masks for combatting the air pollution problem. The quilted fabric makes possible the use of spun yarns of activated carbon fabric which have, per se, low tensile strength, but which can be made more economically than continuous filaments of higher tensile strength.

Description

[ Oct. 30, 1973 Economy et al.
[ 1 QUILTED FABRIC CONTAlNlNG 111G111 SURFACE AREA CARBON FIBERS Primary Examiner-Harold Ansher Assistant ExaminerM. E. McCamish [75] Inventors. James Economy, Eggertsvllle, Huey Atmmey David E g y et Y. Lin, Williamsville, both of N.Y.
[73] I Assignee: The Carborundum Company,
[57] ABSTRACT A quilted fabric containing high surface area carbon 11 Niagara Falls, NY.
Mar. 24, 1972 3 hers is made by uniting a central layer of flexible ac- [21] Appl. No.: 237,836
tivated carbon fibers between a pair of outer layers of reinforcing fabric, positioned on each side of the layer of activated flexible carbon fibers, with a network of 52 us. 161/50, 112/402, 112 417, qu stilchihg- The quilted fabric thus made is 423 447 ful for fabricating protective clothing or gas masks for ,ll2/420, l6l/79,l61/92, 161/182 51 110.0321) 7/08 use y Personnel who must enter areas which y contain noxious gases, or for face masks for combat- 423 447 ting the air pollution problem. The quilted fabric makes possible the use of spun yarns of activated carbon fabric which have,
[58] Field of Search per se, low tensile strength, but
[56] References Cited UNITED STATES PAT ENTS laments of higher tensile strength.
10 Claims, 1 Drawing Figure 3,203,849 8/1965 Katz 10/1968 Coates QUILTED FABRIC CONTAINING HIGH SURFACE AREACARBON FIBERS BACKGROUND OF THE INVENTION tection for personnel who must enter areas which may contain such noxious gases.
One approach which has been considered is to bond granular activated carbon with a resin to a fabric backing from which clothing is made. This system has the disadvantage, however, that the resin which is used to bond the activated carbon particles can enter into the particles and in part destroy the high surface area which is desired in the activated carbon.
The use of activated carbon fibers for such purposes has been considered both from the viewpoint of continuous filaments and yarns spun from staple fibers. The continuous filaments are strong, if made of sufficient filament diameter, but are difficult and expensive to produce, and alsoare at larger filament diameters, rela tively inflexible. Yarns of activated carbon spun from staple fibers are relatively weak, even though the individual filaments may have a high tensile strength, due to a .variety of factors which influence the yarn strength, such as the tendency of activated carbon filaments to slip upon each other easily when spun into a yarn.
To overcome this weakness problem, it has been proposed to weave fabric using alternating activated car- I bon yarns and others yarns of higher strength. This system, however has the disadvantage that the activated carbon fibers are relatively far apart so that noxious fumes can penetrate the garment without coming into contact with an activated carbon surface, thereby causing the garment made from such a fabric to fail in its essential purpose of protecting the wearer from the noxious fumes.
It is therefore, an object of this invention to provide a fabric containing high surface area carbon fibers (activated carbon" fibers), i.e.,fibers having a surface area of at least 300 m /g, which overcomes these various disadvantages of the prior art.
SUMMARY OF THE INVENTION According to the present invention, a quilted fabric containing high surface area carbon fibers comprises in combination (I) at least one central layer of flexible carbon fibers having a surface area of at least about 300 square meters per gram (m /g); (2) a pair of outer layers of reinforcing fabric. positioned on each side of the layer of flexible carbon fibers; and (3) a network of quilting stitching, uniting thecentral layer of flexible carbon fibers and the outer layers of reinforcing fabric into an integral quilted fabric.
BRIEF DESCRIPTION OF THE DRAWING The single FIGURE of the drqwing illustrates a quilted fabric containing high surface area carbon fibers-in accordance with the present invention.
DETAILED DESCRIPTION According to the present invention, the quilted fabric containing high surface area carbon fibers begins with at least one central layer of flexible carbon fibers having a surface area of at least 300 m /g. It is convenient to use for this central layer of flexible carbon fibers a layer of woven carbon cloth; however, other forms of fibers can also be used, such as carbon felt, resin' bonded carbon batting, or a multiplicity of loose staple fibers of carbon. For any of these four formscloth, felt, batting or staple fibers-a preferred method for producing the carbon fibers comprises the steps of l) heating an infusible cured phenol-formaldehyde novolac (CA-0001) fiber in air from about room temperature up to an intermediate temperature in the range of 1 from about 250C to about 450C, at a rate of temperature rise of from about 50C/hr to about 200C/hr, and (2) further heating said fiber in a nonoxidizingatmosphere from said intermediate temperature to a final temperature in the range of from about 700C to about 900C, at a rate of temperature rise offrom about 50C/hr to about 200C/hr. Further details of this method of producing carbon fibers, and preferred features of the method of production, are set forth in commonly assigned, copending U.S. pat. application Ser. No. 182,865, filed Sept. 22, I971, by 1. Economy and R. Y. Lin, the disclosure of which is incorporated herein by reference. The starting material, namely the infusible cured (cross-linked) phenol-formaldehyde novolac fiber, is produced as described in U.S. pat. No. 3,650,102, issued Mar. 21, I972 to 1. Economy and R. Clark, assignors to The Carborundum Company of Niagara Falls, New York. The U.S. Federal .Trade Commission has assigned the symbol CA-000i" for temporary use in describing the cross-linked novolac fiber, and it is sold by The Carborundum Company of Niagara Falls, New York, as Kynol CA-000l fiber. It is preferred to form the layer of woven carbon cloth, carbon-felt, resin bonded carbon atting, or loose staple fibers of carbon by first forming the respective shape of CA-000l fibers, and then applyingthe above-described 5 min. at 900C for carbon fibers made from combinations of pitch and novolac), and such fibers can also be used in the present invention. Other flexible carbon fibers having high surface area, if available, can also be used.
If desired,-a plurality of central layers of flexible carbon fibers can be utilized, such as two or more layers of carbon cloth, or a layer of carbon cloth in combination with a multiplicity of loose staple fibers of carbon, or the like. The quilting stitching pattern should of course be chosen with the number and type of layers of flexible carbon fibers in mind. Thus, ifa multiplicity of loose staple fibers of carbon is used, it is preferred that the quilting stitching be relatively close together, e.g., several centimeters apart. On the other hand, if felt,
batting or woven carbon cloth is used, the quilting stitching can be somewhat further apart e.g., 5-10 cm apart.
The outer layers of reinforcing fabric can be any suitable material. Nylon cloth is a preferred material for this purpose, since it is a relatively strong fabric and can be formulated with a loose mesh and still retain a high degree of strength. Loose meshes are preferred for these outer reinforcing fabric layers for some applications, for ease of stitching. An especially preferred nylon for the outer layers of reinforcing fabric is that nylon which is a wholly aromatic polyamide. This type of fiber is available commercially under the trademark NOMEX" (E. l. duPont de Nemours & Co.), and details of manufacture of such wholly aromatic polyamides are disclosed in U.S. pat. Nos. 3.063.966 and 3,287,324. A process for the dry spinning of such aromatic polyamides into fibers is disclosed in U.S. pat. No. 3.360.598.
Another fiber which is preferred for use in fabricating the outer layers of reinforcing fabric is uncarbonized Kynol CA-OOOl cloth. described in U.S. pat. No. 3.650.102 and available commercially from The Carborundum Company. The use of wholly aromatic polyamides and uncarbonized (TA-0001 cloth for the outer layers of reinforcing fabric have the advantage of providing a protective fabric for clothing which combines the heat resistance of wholly aromatic polyamide or CA-OOOl cloth with the property of gas absorption and adsorption of high surface area flexible carbon fibers, so that an individual who may face one or both of these hazards can protect himself with a single garment.
Referring now to the drawing, the single figure of drawing illustrates a portion of quilted fabric containing high surface area carbon fibers in accordance with the present invention. This quilted fabric comprisesin combination at least one central layer 11 of flexible carbon fibers having a surface area of at least about 300 m /g; and a pair of outer layers 12 of reinforcing fabric positioned on each side of the layer of flexible carbon fibers. A network of quilting stitching l3.unites the central layer of flexible carbon fibers and the outer layers of reinforcing fabric into an integral quilted fabric. As mentioned above, layer 11 of flexible carbon fibers. although illustrated as woven carbon cloth, can
also be carbon felt, resin bonded carbon batting. or loose staple fibers of carbon. The network of a quilting stitching 13 will of course be modified to take into account the physical form of central layer 11 of flexible carbon fibers. g
The invention will now be illustrated with an example.
EXAMPLE percent. The resulting carbonized and activated carbon fabric had a weight of about 4.24 ounces per square yard, and a surface area of at least about 300 m lg. This activated carbon cloth constituting a layer 11 of flexible carbon fibers. was then placed between two layers 12 of nylon mesh fabric having a 27 X 48 square weave construction. The. three layers were then united by a network of quilting stitching 13 into an integral quilted fabric. The quilted fabric was found to be substantially stronger than the carbonized activated carbon fabric layer 11 by itself, yet it retains its flexibility. The composite quilted fabric, as thus constituted, can be used 7 to fabricate protective clothing, which is highly effective as a scavenger for poisonous or other noxious gases.
We claim;
l. A quilted fabric containing high surface area carbon fibers. comprising in combination l. at least one central layer of flexible carbon fibers having a surface area of at least about 300 m /g;
2. a pair of outer layers of reinforcing fabric. one
layer being positioned on each side of the layer of flexible carbon fibers; and
3. a network of quilting stitching. uniting the central layer of flexible carbon 'fibersand the outer layers of reinforcing fabric into an integral quilted fabric.
2. The quilted fabric of claim 1, wherein the central layer of flexible carbon fibers is woven carbon cloth.
3. The 'quilted fabric of claim 1, wherein the central layer of flexible carbon fibers is carbon felt.
4. The quilted fabric of claim 1, wherein the central layer of flexible carbon fibers is resin bonded carbon batting.
5. The quilted fabric of claim 1, wherein the central layer of flexible carbon fibers is a multiplicity of loose staple fibers of carbon.
6. The quilted fabric of claim 1, comprising a plural- I ity of central layers 'of flexible carbon fibers.
7. The quilted fabric of claim 1, wherein the outer layers of reinforcing fabric are nylon cloth.
8. The quilted fabric of claim 7, wherein the nylon is a wholly aromatic polyamide.
9. The quilted fabric of claim 1. wherein the outerlayers of reinforcing fabric are uncarbonized CA-00Ol cloth.
10. The quilted fabric of claim l, wherein the method of producing the central layer of flexible carbon fibers

Claims (12)

  1. 2. further heating said fiber in a nonoxidizing atmosphere from said intermediate temperature to a final temperature in the range of from about 700*C to about 900*C, at a rate of temperature rise of from about 50*C/hr to about 200*C/hr.
  2. 2. The quilted fabric of claim 1, wherein the central layer of flexible carbon fibers is woven carbon cloth.
  3. 2. a pair of outer layers of reinforcing fabric, one layer being positioned on each side of the layer of flexible carbon fibers; and
  4. 3. a network of quilting stitching, uniting the central layer of flexible carbon fibers and the outer layers of reinforcing fabric into an integral quilted fabric.
  5. 3. The quilted fabric of claim 1, wherein the central layer of flexible carbon fibers is carbon felt.
  6. 4. The quilted fabric of claim 1, wherein the central layer of flexible carbon fibers is resin bonded carbon batting.
  7. 5. The quilted fabric of claim 1, wherein the central layer of flexible carbon fibers is a multiplicity of loose staple fibers of carbon.
  8. 6. The quilted fabric of claim 1, comprising a plurality of central layers of flexible carbon fibers.
  9. 7. The quilted fabric of claim 1, wherein the outer layers of reinforcing fabric are nylon cloth.
  10. 8. The quilted fabric of claim 7, wherein the nylon is a wholly aromatic polyamide.
  11. 9. The quilted fabric of claim 1, wherein the outer layers of reinforcing fabric are uncarbonized CA-0001 cloth.
  12. 10. The quilted fabric of claim 1, wherein the method of producing the central layer of flexible carbon fibers comprises the steps of
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Cited By (44)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3903220A (en) * 1972-12-04 1975-09-02 Carborundum Co Method for producing carbon fibers
US3966887A (en) * 1971-11-08 1976-06-29 Charbonnages De France Process for production of carbon fibers and the resultant fibers
US4014725A (en) * 1975-03-27 1977-03-29 Union Carbide Corporation Method of making carbon cloth from pitch based fiber
US4032607A (en) * 1974-09-27 1977-06-28 Union Carbide Corporation Process for producing self-bonded webs of non-woven carbon fibers
US4217386A (en) * 1979-06-07 1980-08-12 The United States Of America As Represented By The Secretary Of The Army Laminated, highly sorbent, active carbon fabric
US4234326A (en) * 1972-07-05 1980-11-18 The Secretary Of State For Defence In Her Britannic Majesty's Government Of The United Kingdom Of Great Britain And Northern Ireland Filter assemblies with layers of activated carbon fibrous cloth
US4433024A (en) * 1982-07-23 1984-02-21 Minnesota Mining And Manufacturing Company Reduced-stress vapor-sorptive garments
US4500581A (en) * 1981-03-20 1985-02-19 Boseki Kabushiki Kaisha Material for protecting human bodies from harmful or poisonous chemical substance
US4513047A (en) * 1984-01-23 1985-04-23 Burlington Industries, Inc. Sorbent internally ribbed carbon-containing material and protective garment fabricated therefrom
US4520623A (en) * 1982-07-17 1985-06-04 Toho Beslon Co., Ltd. Activated carbon fiber spun yarn
EP0144553A1 (en) * 1983-09-12 1985-06-19 American Cyanamid Company Non-woven activated carbon fabric
US4538303A (en) * 1982-09-16 1985-09-03 Romer Gmbh Protective helmet
US4539249A (en) * 1983-09-06 1985-09-03 Textile Products, Incorporated Method and apparatus for producing blends of resinous, thermoplastic fiber, and laminated structures produced therefrom
US4565727A (en) * 1983-09-12 1986-01-21 American Cyanamid Co. Non-woven activated carbon fabric
US4681801A (en) * 1986-08-22 1987-07-21 Minnesota Mining And Manufacturing Company Durable melt-blown fibrous sheet material
EP0264131A2 (en) * 1986-10-17 1988-04-20 Akira Hayashi Diaphragm for producing sound
US4772508A (en) * 1986-01-24 1988-09-20 Brassell Gilbert W Activated carbon-carbon composite of high surface area and high compressive strength
WO1988010134A1 (en) * 1987-06-22 1988-12-29 Charcoal Cloth Limited Protective clothing against chemical and biological agents
US4868032A (en) * 1986-08-22 1989-09-19 Minnesota Mining And Manufacturing Company Durable melt-blown particle-loaded sheet material
US4869947A (en) * 1988-12-21 1989-09-26 E. I. Du Pont De Nemours And Company Laminated fabric for protective clothing
US4943475A (en) * 1986-07-23 1990-07-24 Membrane Technology & Research, Inc. Multilayer composite protective fabric material and use in protective clothing
US5024594A (en) * 1986-07-23 1991-06-18 Membrane Technology & Research, Inc. Protective clothing material
EP0439184A2 (en) * 1990-01-26 1991-07-31 PETOCA Ltd. Carbon fiber structure and process for producing the same
US5082701A (en) * 1987-12-09 1992-01-21 Quadrax Corporation Multi-directional, light-weight, high-strength interlaced material and method of making the material
US5229177A (en) * 1987-12-09 1993-07-20 Quadrax Corporation Multi-directional, light-weight, high-strength interlaced material
US5265981A (en) * 1992-06-05 1993-11-30 Mcneil Ronald A System and method for rehabilitating a manhole, and manhole rehabilitated thereby
US5490744A (en) * 1993-12-08 1996-02-13 Mcneil; Ronald A. Method and apparatus for inflating and curing a resin impregnated manhole liner
US6237160B1 (en) * 1998-04-01 2001-05-29 Thierry Bouville Trousers belt for a cook
US6503856B1 (en) 2000-12-05 2003-01-07 Hexcel Corporation Carbon fiber sheet materials and methods of making and using the same
US6521200B1 (en) * 1998-05-14 2003-02-18 University Of Waterloo Catalyst and process for oxidation of sulphur dioxide
US6696374B2 (en) 2000-07-25 2004-02-24 William M. Bridgeman Carbon-based weld blanket
US20040092188A1 (en) * 2002-11-08 2004-05-13 Shih-Ju Hsieh Clothing material structure of fiber cloth containing PAN series activated carbon
US20050113771A1 (en) * 2003-11-26 2005-05-26 Kimberly-Clark Worldwide, Inc. Odor control in personal care products
US20050142966A1 (en) * 2003-12-31 2005-06-30 Kimberly-Clark Worldwide, Inc. Odor control materials and face masks including odor control materials
US20050183727A1 (en) * 2004-02-23 2005-08-25 Chou Su J. Mask having anti-virus and anti-germ effect
US6966918B1 (en) * 1999-08-31 2005-11-22 Ethicon G.M.B.H. Reinforced areal implant
US20050262620A1 (en) * 2004-05-26 2005-12-01 Shulong Li Protective garment system having activated carbon composite with improved adsorbency
US20050266750A1 (en) * 2004-05-26 2005-12-01 Shulong Li Treated activated carbon and process for making same
GB2452471A (en) * 2007-09-07 2009-03-11 Oeztek Tekstil Terbiye Tesisle Three layer fabric for nuclear, biological and chemical protective clothing
ITMI20081354A1 (en) * 2008-07-24 2010-01-25 Roberto Fantino LAYERED PRODUCT WITH HIGH CAPACITY OF THERMAL INSULATION AND AUTOESTINGUENCE.
US7655829B2 (en) 2005-07-29 2010-02-02 Kimberly-Clark Worldwide, Inc. Absorbent pad with activated carbon ink for odor control
WO2010016085A1 (en) 2008-08-05 2010-02-11 Maria Cristina Tommasino New methods and apparatus for the measurements of radon concentrations indoors, in soil, in water, and/or aqueous media
US20130045252A1 (en) * 2010-05-06 2013-02-21 Thomas Douglas Rawlings Apparatus for the Arrestment and Retention of Bromhidrosis
US9352267B2 (en) 2012-06-20 2016-05-31 Hollingsworth & Vose Company Absorbent and/or adsorptive filter media

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Cited By (63)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3966887A (en) * 1971-11-08 1976-06-29 Charbonnages De France Process for production of carbon fibers and the resultant fibers
US4234326A (en) * 1972-07-05 1980-11-18 The Secretary Of State For Defence In Her Britannic Majesty's Government Of The United Kingdom Of Great Britain And Northern Ireland Filter assemblies with layers of activated carbon fibrous cloth
US3903220A (en) * 1972-12-04 1975-09-02 Carborundum Co Method for producing carbon fibers
US4032607A (en) * 1974-09-27 1977-06-28 Union Carbide Corporation Process for producing self-bonded webs of non-woven carbon fibers
US4014725A (en) * 1975-03-27 1977-03-29 Union Carbide Corporation Method of making carbon cloth from pitch based fiber
US4217386A (en) * 1979-06-07 1980-08-12 The United States Of America As Represented By The Secretary Of The Army Laminated, highly sorbent, active carbon fabric
US4500581A (en) * 1981-03-20 1985-02-19 Boseki Kabushiki Kaisha Material for protecting human bodies from harmful or poisonous chemical substance
US4520623A (en) * 1982-07-17 1985-06-04 Toho Beslon Co., Ltd. Activated carbon fiber spun yarn
US4433024A (en) * 1982-07-23 1984-02-21 Minnesota Mining And Manufacturing Company Reduced-stress vapor-sorptive garments
US4538303A (en) * 1982-09-16 1985-09-03 Romer Gmbh Protective helmet
US4539249A (en) * 1983-09-06 1985-09-03 Textile Products, Incorporated Method and apparatus for producing blends of resinous, thermoplastic fiber, and laminated structures produced therefrom
EP0144553A1 (en) * 1983-09-12 1985-06-19 American Cyanamid Company Non-woven activated carbon fabric
US4565727A (en) * 1983-09-12 1986-01-21 American Cyanamid Co. Non-woven activated carbon fabric
EP0150124A2 (en) * 1984-01-23 1985-07-31 Burlington Industries, Inc. Sorbent internally ribbed carbon-containing materials and protective garment fabricated therefrom
EP0150124A3 (en) * 1984-01-23 1987-08-26 Burlington Industries, Inc. Sorbent internally ribbed carbon-containing materials and protective garment fabricated therefrom
US4513047A (en) * 1984-01-23 1985-04-23 Burlington Industries, Inc. Sorbent internally ribbed carbon-containing material and protective garment fabricated therefrom
EP0199150A1 (en) * 1985-04-23 1986-10-29 American Cyanamid Company Non-woven activated carbon fabric
US4772508A (en) * 1986-01-24 1988-09-20 Brassell Gilbert W Activated carbon-carbon composite of high surface area and high compressive strength
US5024594A (en) * 1986-07-23 1991-06-18 Membrane Technology & Research, Inc. Protective clothing material
US4943475A (en) * 1986-07-23 1990-07-24 Membrane Technology & Research, Inc. Multilayer composite protective fabric material and use in protective clothing
US4868032A (en) * 1986-08-22 1989-09-19 Minnesota Mining And Manufacturing Company Durable melt-blown particle-loaded sheet material
US4681801A (en) * 1986-08-22 1987-07-21 Minnesota Mining And Manufacturing Company Durable melt-blown fibrous sheet material
EP0264131A3 (en) * 1986-10-17 1989-02-08 Akira Hayashi Diaphragm for producing sound
EP0264131A2 (en) * 1986-10-17 1988-04-20 Akira Hayashi Diaphragm for producing sound
WO1988010134A1 (en) * 1987-06-22 1988-12-29 Charcoal Cloth Limited Protective clothing against chemical and biological agents
US5112666A (en) * 1987-06-22 1992-05-12 Charcoal Cloth Limited Cbw protective clothing
US5082701A (en) * 1987-12-09 1992-01-21 Quadrax Corporation Multi-directional, light-weight, high-strength interlaced material and method of making the material
US5229177A (en) * 1987-12-09 1993-07-20 Quadrax Corporation Multi-directional, light-weight, high-strength interlaced material
EP0374426A3 (en) * 1988-12-21 1991-07-24 E.I. Du Pont De Nemours And Company Laminated fabric for protective clothing
EP0374426A2 (en) * 1988-12-21 1990-06-27 E.I. Du Pont De Nemours And Company Laminated fabric for protective clothing
US4869947A (en) * 1988-12-21 1989-09-26 E. I. Du Pont De Nemours And Company Laminated fabric for protective clothing
EP0439184A2 (en) * 1990-01-26 1991-07-31 PETOCA Ltd. Carbon fiber structure and process for producing the same
EP0439184A3 (en) * 1990-01-26 1992-01-08 Petoca Ltd. Carbon fiber structure and process for producing the same
US5254396A (en) * 1990-01-26 1993-10-19 Petoca Ltd. Carbon fiber structure and process for producing the same
US5265981A (en) * 1992-06-05 1993-11-30 Mcneil Ronald A System and method for rehabilitating a manhole, and manhole rehabilitated thereby
US5490744A (en) * 1993-12-08 1996-02-13 Mcneil; Ronald A. Method and apparatus for inflating and curing a resin impregnated manhole liner
US6237160B1 (en) * 1998-04-01 2001-05-29 Thierry Bouville Trousers belt for a cook
US6521200B1 (en) * 1998-05-14 2003-02-18 University Of Waterloo Catalyst and process for oxidation of sulphur dioxide
US6966918B1 (en) * 1999-08-31 2005-11-22 Ethicon G.M.B.H. Reinforced areal implant
US6959855B2 (en) 2000-07-25 2005-11-01 Tex Tech Industries Inc. Carbon-based weld blanket, methods of making and methods of use
US20040128808A1 (en) * 2000-07-25 2004-07-08 Bridgeman William M. Carbon-based weld blanket, methods of making and methods of use
US6696374B2 (en) 2000-07-25 2004-02-24 William M. Bridgeman Carbon-based weld blanket
US6503856B1 (en) 2000-12-05 2003-01-07 Hexcel Corporation Carbon fiber sheet materials and methods of making and using the same
US20040092188A1 (en) * 2002-11-08 2004-05-13 Shih-Ju Hsieh Clothing material structure of fiber cloth containing PAN series activated carbon
US20050113771A1 (en) * 2003-11-26 2005-05-26 Kimberly-Clark Worldwide, Inc. Odor control in personal care products
US20100125262A1 (en) * 2003-11-26 2010-05-20 Kimberly-Clark Worldwide, Inc. Odor Control in Personal Care Products
US20050142966A1 (en) * 2003-12-31 2005-06-30 Kimberly-Clark Worldwide, Inc. Odor control materials and face masks including odor control materials
US20050183727A1 (en) * 2004-02-23 2005-08-25 Chou Su J. Mask having anti-virus and anti-germ effect
US20070202259A1 (en) * 2004-05-26 2007-08-30 Shulong Li Process for making treated activated carbon
US20050262620A1 (en) * 2004-05-26 2005-12-01 Shulong Li Protective garment system having activated carbon composite with improved adsorbency
US20050266750A1 (en) * 2004-05-26 2005-12-01 Shulong Li Treated activated carbon and process for making same
US20110016618A1 (en) * 2004-05-26 2011-01-27 Shulong Li Protective garment system having activated carbon composite with improved absorbency
US7589034B2 (en) * 2004-05-26 2009-09-15 Milliken & Company Treated activated carbon and process for making same
WO2006078270A3 (en) * 2004-05-26 2006-09-08 Milliken & Co Protective garment system having activated carbon composite with improved adsorbency
US7655829B2 (en) 2005-07-29 2010-02-02 Kimberly-Clark Worldwide, Inc. Absorbent pad with activated carbon ink for odor control
GB2452471B (en) * 2007-09-07 2010-12-22 Ztek Tekstil Terbiye Tesisleri Sanayi Ve Ticaret Anonim Sirketi Biological and Chemical Clothings
GB2452471A (en) * 2007-09-07 2009-03-11 Oeztek Tekstil Terbiye Tesisle Three layer fabric for nuclear, biological and chemical protective clothing
EP2147781A1 (en) * 2008-07-24 2010-01-27 Nat Style Limited Layered product with high thermal insulation and self-extinguishing capacity
US20100021723A1 (en) * 2008-07-24 2010-01-28 Nat Style Limited "Layered product with high thermal insulation and self-extinguishing capacity"
ITMI20081354A1 (en) * 2008-07-24 2010-01-25 Roberto Fantino LAYERED PRODUCT WITH HIGH CAPACITY OF THERMAL INSULATION AND AUTOESTINGUENCE.
WO2010016085A1 (en) 2008-08-05 2010-02-11 Maria Cristina Tommasino New methods and apparatus for the measurements of radon concentrations indoors, in soil, in water, and/or aqueous media
US20130045252A1 (en) * 2010-05-06 2013-02-21 Thomas Douglas Rawlings Apparatus for the Arrestment and Retention of Bromhidrosis
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