RFHIC, a global leader in providing radio frequency (RF) & microwave solutions utilizing Gallium Nitride (GaN) for various applications in wireless infrastructure, commercial and military radar, and industrial/scientific/medical (ISM) industries, is using GaN solid-state technology to provide significant benefits and cost savings in carbon fiber manufacturing.
Carbon fiber is becoming an increasingly popular composite material due to its high strength and high elastic modulus and low-density characteristics. Carbon fiber is stronger and stiffer than steel, however, it is also lighter making it an ideal manufacturing material for aerospace, athletics, automotive, construction, defense, marine, and wind energy sectors among others.
RFHIC’s GaN solid-state technology for carbon fiber manufacturing provides instantaneous microwave energy without warming up – which shortens the over-processing time, thus, saving production costs. The microwave power generation solution allows digital controllability of signal power, frequency and phase which leads to the development of more uniform and higher quality carbon fibers.
The Carbon Fiber Manufacturing Process
The current method for manufacturing carbon fiber is normally achieved in five continuous stages:
Stage 1: Polymerization of Polyacrylonitrile (PAN)
Stage 2: Oxidation followed by stabilization of the polymer
Stage 3: Carbonization to convert fibers to nearly 100% carbon
Stage 4: Surface Treatment to provide better adhesion to the resin
Stage 5: Sizing to protect the fibers for further processing
Carbonization is the conversion of organic matter into carbon through destructive distillation. It is a pyrolytic reaction, therefore, is considered a complex process in which many reactions take place concurrently such as dehydrogenation, condensation, hydrogen transfer and isomerization. For the final pyrolysis temperature, the amount of heat applied controls the degree of carbonization and the residual content of foreign elements.
As the fibers stabilize, manufacturers heat the fiber to about 1000-1500°C. Carbonization further expels non-carbon atoms from the fibers, along with a few carbon atoms. As these atoms leave the fibers, the remaining atoms form tightly bonded carbon crystals. The process of heating up the fibers make the overall process slow and energy-intensive which results in high OPEX costs. With the goal of reducing carbon fiber production costs, researchers and companies are utilizing microwave-assisted plasma (MAP) technologies to carbonize and graphitize the PAN precursor.
Click here to learn more about how RFHIC can provide significant cost savings in Carbon Fiber Manufacturing.
Here are Microwave Generator Products from RFHIC that can be used for Carbon Fiber Manufacturing
1.6 kW GaN SSPA Based Microwave Generator from 2.4 to 2.5 GHz
The RIM251K6-20G from RFHIC is a GaN SSPA-based Microwave Generator that operates from 2400 to 2500 MHz. It delivers an adjustable output power from 100 to 1600 W with an efficiency of up to 55%. The generator uses GaN-on-SiC HEMT transistors that provide excellent thermal stability and efficiency for high-power applications. It consists of a high-grade phase-locked-loop (PLL) synthesizer that generates the desired frequency in a precise and stable manner. The generator allows sweeping of frequency, power, and signal source and is ideally designed for ISM (Industrial, Scientific, and Medical) and plasma generation applications.
Click here to learn more about the RIM251K6-20G Microwave Generator.
3 kW GaN Solid-State Microwave Generator from 2.4 to 2.5 GHz
The RIU243K0-40TG from RFHIC is a Solid-State Microwave Generator that operates from 2400 to 2500 MHz. It delivers an output power of 3 KW and has a peak efficiency of 55%. This Microwave Generator has a unique configuration where the GaN SSPA head is separate from the control module and PSU allowing for greater flexibility. It is based on RFHIC’s IP-protected internal waveguide architecture which simplifies system integration and lowers cost. This generator is ideal for microwave heating, food processing, plasma generation, and for sterilization & pasteurization.
Click here to learn more about the RIU243K0-40TG Microwave Generator.
6 kW GaN Solid-State Microwave Generator from 2.4 to 2.5 GHz
The RIU256K0-40TG from RFHIC is a Solid-State Microwave Generator that operates from 2.4 to 2.5 GHz. It delivers a CW output power of up to 6 kW with an efficiency of 55% and has an optional Pulsed operating mode. The generator is built using RFHIC’s cutting-edge gallium-nitride (GaN) on SiC HEMTs providing excellent thermal stability and power. It has a modular architecture where the SSPA head is separated from the power supply unit by a cable assembly.
Click here to learn more about the RIU256K0-40TG Microwave Generator.
12 kW GaN Microwave Generator from 2.4 to 2.5 GHz
The RIK2512K-40TG from RFHIC is a GaN Microwave Generator that operates from 2400 to 2500 MHz. It has optional CW or pulsed operating mode and delivers a CW peak output power of 12 kW with an efficiency of 54%. The generator uses GaN-on-SiC HEMT transistors and has high frequency stability with PLL technology. It is targeted to replace industrial magnetrons and other vacuum tubes which are currently used in high power industrial applications, artificial diamond manufacturing, semiconductor equipment, and plasma systems. The microwave generator requires a DC supply of 50 V for the SSPA head.
Click here to learn more about the RIK2512K-40TG Microwave Generator.
Click here to see more Microwave Generator products from RFHIC.
