Textile Carbon Fiber Packaging and NCF Production
This Technical Collaboration Project focused on packaging large tow (≥ 10 grams/meter) textile carbon fibers, for which currently there is no suitable method. Prior to this project, Oak Ridge National Laboratory (ORNL) used a crude packaging approach to deliver (approximately) 100-meter packages for evaluation by intermediates producers, composites fabricators and other collaborators. That packaging approach was simply a hoop wrap on a standard 75 mm (3 inch) cardboard tube, with paper interleaved between layers and little or no tension control during spooling. While this approach was very effective for initial fiber development and sample fiber and small composite sample evaluation, these packages were inadequate for larger-scale demonstrations and more extensive applications development. The paper-interleaved packages were inconsistent, wasteful, and too small for commercial utilization; they were designed as a quick and simple means to package material for delivery into prototyping operations and were never expected to satisfy industrial requirements for commercial production. This project aimed to develop a commercially relevant approach for packaging large tow textile carbon fibers for robust delivery into downstream commercial intermediates and composites production operations. The development of robust packaging equipment that delivers packages meeting industrial requirements is essential to commercial implementation. In this project, the team identified packaging requirements, created a design, and prototyped a new packaging concept at ORNL’s Carbon Fiber Technology Facility (CFTF) and resulting packages were tested in production of non-crimp fabric (NCF).