Array of processing drums and method of processing carbon fibers

Abstract

This invention is for a novel method of treating fiber batts. Carbon fiber is a very unique material and its processing requires high temperatures which is provided by heating using forced heated air through the carbon fiber batt from and to rotating drum rollers with porous, perforated or slotted exterior surfaces. Such rollers allow controlled gas flow and controlled handling of the carbon fiber batt through the processing stage while reducing crimping, breakage and friction created fiber loss.

What is claimed is:  
     
         1 . An apparatus for treating fibers which comprises: 
 A first drum roller with a generally cylindrical surface and an interior portion wheresaid generally cylindrical surface is porous,    A non-rotating manifold disposed within said first drum to direct gas through at least a portion of the generally cylindrical surface,    Means for supplying a continues fiber batt to said first drum roller,    Means for removing a continuous fiber batt from said first drum roller.    
     
     
         2 . An apparatus for treating fibers which comprises: 
 A plurality of drum rollers where each roller comprises a rotating drum roller with a generally cylindrical exterior surface where gas may be flowed through said surface;    Non-rotating means for inducing gas flow through said generally cylindrical surface;    Wherein said plurality of drum rollers is arranged to a series of rollers that cooperate to form a serpentine pathway through at least a portion of said plurality of drum rollers.    
     
     
         3 . An apparatus for manufacturing carbon fiber materials which comprises: 
 At least one transport drum roller with a generally cylindrical exterior surface that is gas flow porous and with a non-rotating manifold for creating gas flow over at least a portion of said cylindrical exterior surface to provide transport of a carbon fiber precursor over said transport drum roller;    At least one processing drum roller with a temperature impervious, generally cylindrical, gas flow porous exterior surface and a non-rotating means for transporting a reactive gas flow across through at least a portion of said temperature impervious exterior surface,    Wherein said transport drum roller is disposed relative to said processing drum roller to cooperate in transferring fiber material between said rollers.    Wherein said plurality of drum rollers is arranged to a series of rollers that cooperate to form a serpentine pathway through at least a portion of said plurality of drum rollers.    
     
     
         1 . The apparatus of  claim 11  wherein the cylindrical surface is porous because of slots in the surface that communicate to said interior.  
     
     
         2 . The apparatus of  claim 1  wherein the cylindrical surface is made from a material chosen from carbon-carbon composite material, high strength ceramic or inter-metallic material.  
     
     
         3 . The apparatus of  claim 1  wherein the cylindrical surface is porous because of slots in the surface that communicate to said interior.  
     
     
         4 . The apparatus of  claim 1  wherein said first drum roller has disposed on its exterior a porous, insulation material made from a heat resistant material such that heat is retained in said material in order to more rapidly heat a fiber mat material that is passed over said insulation material.  
     
     
         5 . The apparatus of  claim 1  wherein roller drum cylindrical exterior is capable of having a gas flow in the temperature range of 800° to 2700° Celsius.  
     
     
         6 . The apparatus of  claim 11  wherein said first drum roller has disposed on its exterior a porous, insulation material made from a heat resistant material such that heat is retained in said material in order to more rapidly heat a fiber mat material that is passed over said insulation material.  
     
     
         7 . The apparatus of  claim 2  wherein the cylindrical surface is made from a material chosen from carbon-carbon composite material, high strength ceramic or inter-metallic material.  
     
     
         8 . The apparatus of  claim 2  wherein the cylindrical surface is porous because of slots in the surface that communicate to said interior.  
     
     
         9 . The apparatus of  claim 2  wherein said first drum roller has disposed on its exterior a porous, insulation material made from a heat resistant material such that heat is retained in said material in order to more rapidly heat a fiber mat material that is passed over said insulation material.  
     
     
         10 . The apparatus of  claim 2  wherein roller drum cylindrical exterior is capable of having a gas flow in the temperature range of 800° to 2700° Celsius.  
     
     
         11 . The apparatus of  claim 11  wherein roller drum cylindrical exterior is capable of having a gas flow in the temperature range of 800° to 2700° Celsius.  
     
     
         12 . The apparatus of  claim 11  wherein the cylindrical surface is made from a material chosen from carbon-carbon composite material, high strength ceramic or inter-metallic material.