Abstract: A flexible, ignition resistant, non-electrically conductive biregional fiber is disclosed. The biregional fiber comprising an inner core region of a partially oxidized thermoplastic polymeric composition and a surrounding outer sheath region of a thermoset carbonaceous material.

Abstract: A bi-regional fiber with a cellulosic core and a wax outer sheath is disclosed. The sheath can comprise high melting temperature wax. The fiber may be produced by processing the natural fiber at temperatures less than 70° C. The fiber can be processed in a standard manner such as, for example, a Keir process which may include bleach at approximately 100° C. with a wax subsequently added at a temperature sufficient to disperse the wax over the fiber surface. The fibers are ignition resistant as measured by industry standard tests. The wax may comprise from about 0.4 to 25 percent or greater of the fiber by weight. The wax may be natural wax, synthetic or emulsified wax or blends thereof. The bi-regional fibers can be blended with other fibers including BRCF fibers to create fire resistant fabrics including clothing, blankets and household materials.

Abstract: A bi-regional fiber with a cellulosic core and a wax outer sheath is disclosed. The sheath can comprise high melting temperature wax. The fiber may be produced by processing the natural fiber at temperatures less than 70° C. The fiber can be processed in a standard manner such as, for example, a Keir process which may include bleach at approximately 100° C. with a wax subsequently added at a temperature sufficient to disperse the wax over the fiber surface. The fibers are ignition resistant as measured by industry standard tests. The wax may comprise from about 0.4 to 25 percent or greater of the fiber by weight. The wax may be natural wax, synthetic or emulsified wax or blends thereof. The bi-regional fibers can be blended with other fibers including BRCF fibers to create fire resistant fabrics including clothing, blankets and household materials.

Abstract: A flexible, ignition resistant, biregional fiber is disclosed, wherein the fiber is preferably derived from a single homogeneous polymeric precursor composition, said biregional fiber comprising an inner core region of a thermoplastic polymeric composition and a surrounding outer sheath region of a thermoset carbonaceous material. The biregional fiber is particularly characterized by having a ratio of the radius of the core region with respect to the total radius of the fiber (r:R) of from about 1:4 to about 1:1.05, an LOI value of greater than 40, a breaking twist angle of from 4 to 13 degrees, and a bending strain value of from greater than 0.01 to less than 50%.

Abstract: A process for preparing an ignition resistant carbonaceous material by exposing a meltblown or spunbonded acrylic precursor material in the form of at least one ply of a generally planar fibrous web, matt or batt to ionizing radiation to crosslink said acrylic material which is then heat treated in an inert atmosphere to increase the carbon content of said irradiated material to form said carbonaceous material. The invention also resides in a continuous self bonded fibrous carbonaceous material having a carbon content of from about 65% to less than about 92%, an oxygen content of less than about 2%, and a specific resistivity of from about 10.sup.-1 to about 10.sup.10 ohm-cm. Preferably said carbonaceous material has an oxygen content of less than about 1% and a nitrogen content of from about 5% to about 30%.

Abstract: The present invention resides in ignition resistant non-linear carbonaceous fiber or fiber tow having a reversible deflection ratio of greater than 1:1 but equal to or less than 1.2:1. The fibers have a multiplicity of crimps along their length with a crimp frequency on the order of from 6 to 15 crimps per inch. Fibers of the invention have an elongatability of from about 2 to about 9%, a pseudo-elongatability of from about 0.2 to about 18%, and a tenacity without a loss of elongation on the order of at least 6 g/d. The carbonaceous fibers can be used, for example, as thermal insulation and/or fire resistant insulation in vehicles, building structures or clothing in furniture coverings, carpets, and the like, and can be used alone or blended with other fibers to form fine yarns.

Abstract: A novel flexible carbon article for an electrode is disclosed for use in an electrical storage device in which the flexible carbon article, such as a planar sheet of a plurality of substantially parallel fibers or ribbons, and in which the fibers or ribbons have a Young's modulus of less than 1 MM psi (6.89 Gpa). The invention also resides in an electrical energy storage device, such as a secondary battery, comprising a water impermeable housing having at least one and preferably more than two cells in series, wherein a battery containing at least two cells also contains at least one shared bipolar electrode made of the flexible carbon article. Each cell has a foraminous separator between each pair of electrodes and contains an electrolyte comprising an ionizable salt in a non-aqueous fluid. Also disclosed are methods of making the electrode from an unfiltered precursor polymer and from a sub-acrylic polymer.

Abstract: A novel flexible carbon fiber is disclosed which has a generally non-circular or tubular cross-sectional shape, a Young's modulus of from greater than 1 MM psi (6.9 GPa) to 55 MM psi (380 GPa), and a bending strain value of from greater than 0.01 to less than 50%. The invention also resides in an electrode for a secondary energy storage device utilizing the carbon fibers of the invention and containing a non-aqueous electrolyte. The invention further resides in a secondary energy storage device comprising a water impermeable housing having at least two cells containing at least one shared bipolar electrode made of the flexible carbon fibers of the invention. Also disclosed is a pseudo bipolar electrode and terminal electrode for use in a lithium ion battery in which the fibers or a portion of the carbon fibers are coated with an ion active lithium salt of a metal oxide. Also disclosed is a novel battery stack and a method of manufacture of the secondary energy storage device.

Abstract: A process for preparing an ignition resistant carbonaceous material by exposing a meltblown or spunbonded acrylic precursor material in the form of at least one ply of a generally planar fibrous web, matt or batt to ionizing radiation to crosslink said acrylic material which is then heat treated in an inert atmosphere to increase the carbon content of said irradiated material to form said carbonaceous material. The invention also resides in a continuous self bonded fibrous carbonaceous material having a carbon content of from about 65% to less than about 92%, an oxygen content of less than about 2%, and a specific resistivity of from about 10.sup.-1 to about 10.sup.-10 ohm-cm. Preferably said carbonaceous material has an oxygen content of less than about 1% and a nitrogen content of from about 5% to about 30%.

Abstract: A process for preparing a non-flammable linear non-graphitic carbonaceous polymeric fiber, yarn or tow having improved elongability containing the step of heat treating a linear stabilized polymeric fiber, yarn or tow having an LOI greater than 40 without any substantial tension or stress in an inert non-oxidizing atmosphere at a temperature so as to irreversibly heat set said fiber yarn or tow.

Abstract: An ignition resistant fibrous material for use as insulation. The material comprises a multiplicity of meltblown or spunbonded thermoplastic filaments in combination with a multiplicity of nonlinear, nongraphitic carbonaceous fibers. The carbonaceous fibers have a Young's modulus of greater than 300,000 psi and reversible deflection ratio of greater than 1.2:1.

Abstract: An ignition resistant fibrous material for use as insulation. The material comprises a multiplicity of meltblown or spunbonded thermoplastic filaments in combination with a multiplicity of nonlinear, nongraphitic carbonaceous fibers. The carbonaceous fibers have a Young's modulus of greater than 300,000 psi and reversible deflection ratio that is equal to or less than 1.2:1.

Abstract: There is provided a non-flammable expanded fiber comprising carbonaceous polymeric substantially irreversibly heat set fiber having an LOI value of greater than 40, and the fibrous structures thereof. Also, provided are stabilized expanded polymeric fibers.

Abstract: The present invention resides in ignition resistant non-linear carbonaceous fiber or fiber tow having a reversible deflection ratio equal to or less than 1.2:1. The fibers have a multiplicity of crimps along their length with a crimp frequency on the order of from 6 to 15 crimps per inch. Fibers of the invention have improved elongatability of from about 2 to about 9%, a pseudo-elongatability of from about 0.2 to about 18%, and a tenacity without a loss of elongation on the order of at least 6 g/d. The carbonaceous fibers can be used, for example, as thermal insulation and/or fire resistant insulation in vehicles, building structures or clothing in furniture coverings, carpets, and the like, and can be blended with other fibers to form fine yarns.

Abstract: A process for preparing a non-flammable linear non-graphitic carbonaceous polymeric fiber, yarn or tow having improved elongability which comprises the step of heat treating a linear stabilized polymeric fiber, yarn or tow having an LOI greater than 40 without any substantial tension or stress in an inert non-oxidizing atmosphere at a temperature so as to irreversibly heat set said fiber yarn or tow.

Abstract: A structure is provided comprising carbonaceous materials for absorbing and/or reflecting radiated energy or electromagnetic energy. The structure is useful for camouflage or for shielding electromagnetic radiation, especially microwaves.

Abstract: A fibrous thermal insulation comprising an intimate blend of A) an effective amount of non-graphitic carbonaceous fibers having an LOI value greater than 40, a percent char value greater than 65, and a thermal conductivity less than 1 BTU hr ft.sup.2 /.degree.F. for providing a synergistic improvement in fire resistance, and B) hollow thermoplastic fibers.

Abstract: An improvement in an apparatus for separating fluids or non-biotechnological products in solution, wherein said apparatus has a fibrous element which permits flow of fluids therethrough and is composed of irreversibly set non-graphitic carbonaceous fibers having an LOI greater than 40.

Abstract: A flame retardant polymeric foam having a flame retarding amount of non-graphitic carbonaceous materials having an LOI value greater than 40.

Abstract: There is provided a non-flammable expanded fiber comprising carbonaceous polymeric substantially irreversibly heat set fiber having an LOI value of greater than 40, and the fibrous structures thereof. Also, provided are stabilized expanded polymeric fibers.