CA2584711A1 - High strength monolithic carbon foam - Google Patents

High strength monolithic carbon foam Download PDF

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Publication number
CA2584711A1
CA2584711A1 CA002584711A CA2584711A CA2584711A1 CA 2584711 A1 CA2584711 A1 CA 2584711A1 CA 002584711 A CA002584711 A CA 002584711A CA 2584711 A CA2584711 A CA 2584711A CA 2584711 A1 CA2584711 A1 CA 2584711A1
Authority
CA
Canada
Prior art keywords
article
carbon foam
pores
microns
diameter
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002584711A
Other languages
French (fr)
Other versions
CA2584711C (en
Inventor
Douglas J. Miller
Irwin C. Lewis
Robert A. Mercuri
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Gt Acquisition Holdings LLC
Original Assignee
Ucar Carbon Company Inc.
Douglas J. Miller
Irwin C. Lewis
Robert A. Mercuri
Graftech International Holdings Inc.
Gt Acquisition Holdings, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ucar Carbon Company Inc., Douglas J. Miller, Irwin C. Lewis, Robert A. Mercuri, Graftech International Holdings Inc., Gt Acquisition Holdings, Llc filed Critical Ucar Carbon Company Inc.
Publication of CA2584711A1 publication Critical patent/CA2584711A1/en
Application granted granted Critical
Publication of CA2584711C publication Critical patent/CA2584711C/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/0022—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof obtained by a chemical conversion or reaction other than those relating to the setting or hardening of cement-like material or to the formation of a sol or a gel, e.g. by carbonising or pyrolysing preformed cellular materials based on polymers, organo-metallic or organo-silicon precursors
    • C04B38/0032—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof obtained by a chemical conversion or reaction other than those relating to the setting or hardening of cement-like material or to the formation of a sol or a gel, e.g. by carbonising or pyrolysing preformed cellular materials based on polymers, organo-metallic or organo-silicon precursors one of the precursor materials being a monolithic element having approximately the same dimensions as the final article, e.g. a paper sheet which after carbonisation will react with silicon to form a porous silicon carbide porous body
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/52—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite
    • C04B35/524—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite obtained from polymer precursors, e.g. glass-like carbon material
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/0051—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore size, pore shape or kind of porosity
    • C04B38/0054—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore size, pore shape or kind of porosity the pores being microsized or nanosized
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/0067—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the density of the end product
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/007—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore distribution, e.g. inhomogeneous distribution of pores
    • C04B38/0074—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof characterised by the pore distribution, e.g. inhomogeneous distribution of pores expressed as porosity percentage
    • 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
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • 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
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249961—With gradual property change within a component
    • 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
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249976—Voids specified as closed
    • Y10T428/249977—Specified thickness of void-containing component [absolute or relative], numerical cell dimension or density
    • 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

Abstract

A carbon foam article useful for, inter alia, composite tooling or other high temperature applications, which includes a carbon foam having a ratio of compressive strength to density of at least about 7000 psi/g/cc.

Claims (22)

1. A carbon foam article comprising a carbon foam having a ratio of compressive strength to density of at least about 7000 psi/g/cc.
2. The article of claim 1 wherein the carbon foam has a ratio of compressive strength to density of at least about 8000 psi/g/cc.
3. The article of claim 2 wherein the carbon foam has a density of from about 0.05 to about 0.4 and a compressive strength of at least about 2000 psi.
4. The article of claim 3 wherein the carbon foam has a porosity of between about 65% and about 95%.
5. The article of claim 4 wherein the pores of the carbon foam have, on average, an aspect ratio of between about 1.0 and about 1.5.
6. The article of claim 1 wherein at least about 90% of the pore volume of the pores have a diameter of between about 10 and about 150 microns.
7. The article of claim 6 wherein at least about 95% of the pore volume of the pores have a diameter of between about 25 and about 95 microns.
8. The article of claim 6 wherein at least about 1% of the pore volume of the pores have a diameter of between about 0.8 and about 3.5 microns.
9. The article of claim 8 wherein from about 2% to about 10% of the pore volume of the pores have a diameter of about 1 to about 2 microns.
10. The article of claim 1 which has a permeability of no greater than about 3.0 darcys.
11. A carbon foam article comprising a carbon foam having a pore distribution such that at least about 90% of the pore volume of the pores have a diameter of between about 10 and about 150 microns and at least about 1% of the pore volume of the pores have a diameter of between about 0.8 and about 3.5 microns.
12. The article of claim 11 wherein at least about 95% of the pore volume of the pores have a diameter of between about 25 and about 95 microns.
13. The article of claim 12 wherein from about 2% to about 10% of the pore volume of the pores have a diameter of about 1 to about 2 microns.
14. The article of claim 11 wherein the carbon foam has a ratio of compressive strength to density of at least about 7000 psi/g/cc.
15. The article of claim 14 wherein the carbon foam has a ratio of compressive strength to density of at least about 8000 psi/g/cc.
16. The article of claim 15 wherein the carbon foam has a density of from about 0.05 to about 0.4 and a compressive strength of at least about 2000 psi.
17. The article of claim 16 wherein the carbon foam has a porosity of between about 65% and about 95%.
18. The article of claim 17 wherein the pores of the carbon foam have, on average, an aspect ratio of between about 1.0 and about 1.5.
19. The article of claim 11 which has a permeability of no greater than about 3.0 darcys.
20. A process for producing a carbon foam article, comprising carbonizing a polymer foam article in an inert or air-excluded atmosphere.
21. The process of claim 20 wherein the polymer foam article comprises a phenolic foam.
22. The process of claim 21 wherein the phenolic foam has a compressive strength of at least about 100 psi.
CA2584711A 2004-10-21 2005-09-26 High strength monolithic carbon foam Expired - Fee Related CA2584711C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US10/970,352 2004-10-21
US10/970,352 US7527855B2 (en) 2004-10-21 2004-10-21 High strength monolithic carbon foam
PCT/US2005/034475 WO2006047033A2 (en) 2004-10-21 2005-09-26 High strength monolithic carbon foam

Publications (2)

Publication Number Publication Date
CA2584711A1 true CA2584711A1 (en) 2006-05-04
CA2584711C CA2584711C (en) 2011-07-05

Family

ID=36204881

Family Applications (1)

Application Number Title Priority Date Filing Date
CA2584711A Expired - Fee Related CA2584711C (en) 2004-10-21 2005-09-26 High strength monolithic carbon foam

Country Status (10)

Country Link
US (3) US7527855B2 (en)
EP (1) EP1805005B1 (en)
JP (1) JP4970741B2 (en)
KR (2) KR100934821B1 (en)
CN (1) CN1778673B (en)
BR (1) BRPI0516101A (en)
CA (1) CA2584711C (en)
ES (1) ES2398527T3 (en)
TW (1) TW200613217A (en)
WO (1) WO2006047033A2 (en)

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US8372510B2 (en) 2004-10-21 2013-02-12 Graftech International Holdings Inc. High strength monolithic carbon foam

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US8372510B2 (en) 2004-10-21 2013-02-12 Graftech International Holdings Inc. High strength monolithic carbon foam

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