Process for making carbon foam

Title: Process for making carbon foam

Abstract

The process obviates the need for conventional oxidative stabilization. The process employs mesophase or isotropic pitch and a simplified process using a single mold. The foam has a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts. The foam material can be made into a composite which is useful in high temperature sandwich panels for both thermal and structural applications.

Inventors:

Klett, James W ^[1]

Knoxville, TN

Issue Date:: 2000-01-01

Research Org.:: Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

OSTI Identifier:: 872887

Patent Number(s):: 6033506

Assignee:: Lockheed Martin Engery Research Corporation (Oak Ridge, TN)

Patent Classifications (CPCs):: Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y10 - TECHNICAL SUBJECTS COVERED BY FORMER USPC Y10T - TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02E - REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

Show more

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y10 - TECHNICAL SUBJECTS COVERED BY FORMER USPC Y10T - TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
Y10T428/2982 - Particulate matter [e.g., sphere, flake, etc.]

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02E - REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
Y02E60/14 - Thermal storage

F - MECHANICAL ENGINEERING F28 - HEAT EXCHANGE IN GENERAL F28D - HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
F28D20/023 - {the latent heat storage material being enclosed in granular particles or dispersed in a porous, fibrous or cellular structure}

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA
C04B38/00 - Porous mortars, concrete, artificial stone or ceramic ware

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y10 - TECHNICAL SUBJECTS COVERED BY FORMER USPC Y10T - TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
Y10T428/30 - Self-sustaining carbon mass or layer with impregnant or other layer

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA
C04B35/52 - based on carbon, e.g. graphite

Show less

DOE Contract Number:: AC05-96OR22464

Resource Type:: Patent

Country of Publication:: United States

Language:: English

Subject:: process; carbon; foam; obviates; conventional; oxidative; stabilization; employs; mesophase; isotropic; pitch; simplified; single; mold; relatively; uniform; distribution; pore; sizes; highly; aligned; graphic; structure; struts; material; composite; useful; temperature; sandwich; panels; thermal; structural; applications; foam material; carbon foam; pore size; pore sizes; relatively uniform; process employs; uniform distribution; structural applications; single mold; sandwich panels; temperature sandwich; simplified process; oxidative stabilization; aligned graphic; graphic structure; employs mesophase; conventional oxidative; isotropic pitch; highly aligned; /156/264/

Citation Formats


                    Klett, James W. Process for making carbon foam.  United States: N. p., 2000. 
        Web.

Copy to clipboard


                    Klett, James W. Process for making carbon foam.  United States.

Copy to clipboard


                    Klett, James W. Sat .  
        "Process for making carbon foam".  United States.  https://www.osti.gov/servlets/purl/872887.

Copy to clipboard


                    
@article{osti_872887,

  title        = {Process for making carbon foam},

  author       = {Klett, James W},

  abstractNote = {The process obviates the need for conventional oxidative stabilization. The process employs mesophase or isotropic pitch and a simplified process using a single mold. The foam has a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts. The foam material can be made into a composite which is useful in high temperature sandwich panels for both thermal and structural applications.},

  doi          = {},

  journal      = {},
number       = ,

  volume       = ,

  place        = {United States},

  year         = {2000},

  month        = {1}

}

Copy to clipboard

Patent:

View Patent

Save / Share:

Export Metadata

Save to My Library

Works referenced in this record:

Formulation of a Mathematical Process Model for the Foaming of a Mesophase Carbon Precursor
journal, January 1992

Sandhu, S. S.; Hager, J. W.
MRS Proceedings, Vol. 270
https://doi.org/10.1557/PROC-270-35

Glass-like carbons
journal, June 1969

Noda, Tokiti; Inagaki, Michio; Yamada, Shigehiko
Journal of Non-Crystalline Solids, Vol. 1, Issue 4
https://doi.org/10.1016/0022-3093(69)90026-X

Novel Hybrid Composites Based on Carbon Foams
journal, January 1992

Hager, Joseph W.; Lake, Max L.
MRS Proceedings, Vol. 270
https://doi.org/10.1557/PROC-270-29

Simple Process Produces High Modulus Carbon Fibers at Much Lower Cost
journal, January 1996

Lake, Max
Materials Technology, Vol. 11, Issue 4
https://doi.org/10.1080/10667857.1996.11752682

Pitch-based processing of carbon-carbon composites
journal, January 1989

White, J. L.; Sheaffer, P. M.
Carbon, Vol. 27, Issue 5
https://doi.org/10.1016/0008-6223(89)90203-0

Vitreous carbon — A new form of carbon
journal, November 1967

Cowlard, F. C.; Lewis, J. C.
Journal of Materials Science, Vol. 2, Issue 6
https://doi.org/10.1007/BF00752216

Widealized Strut Geometries for Open-Celled Foams
journal, January 1992

Hager, Joseph W.
MRS Proceedings, Vol. 270
https://doi.org/10.1557/PROC-270-41

Modelling the mechanical behavior of cellular materials
journal, March 1989

Gibson, L. J.
Materials Science and Engineering: A, Vol. 110
https://doi.org/10.1016/0921-5093(89)90154-8

Pulse Method of Measuring Thermal Diffusivity at High Temperatures
journal, April 1963

Cowan, Robert D.
Journal of Applied Physics, Vol. 34, Issue 4
https://doi.org/10.1063/1.1729564

Application of laser flash method to penetrative materials for measurement of thermal diffusivity
journal, February 1990

Inoue, Katsunori
High Temperature Technology, Vol. 8, Issue 1
https://doi.org/10.1080/02619180.1990.11753453

Microcellular Foams Prepared From Demixed Polymer Solutions
journal, January 1990

Aubert, J. H.
MRS Proceedings, Vol. 207
https://doi.org/10.1557/PROC-207-117

Metallic foams: their production, properties and applications
journal, July 1983

Davies, G. J.; Zhen, Shu
Journal of Materials Science, Vol. 18, Issue 7
https://doi.org/10.1007/BF00554981

Structural development in mesophase pitch based carbon fibers produced from naphthalene
journal, January 1997

Jones, S. P.; Fain, C. C.; Edie, D. D.
Carbon, Vol. 35, Issue 10-11
https://doi.org/10.1016/S0008-6223(97)00106-1

Similar Records in DOE Patents and OSTI.GOV collections:

Pyrophoric metal-carbon foam composites and methods of making the same

Patent Gash, Alexander E [Brentwood, CA]; Satcher, Jr., Joe H. (Patterson, CA); Simpson, Randall L [Livermore, CA]; ...

A method for creating a pyrophoric material according to one embodiment includes thermally activating a carbon foam for creating micropores therein; contacting the activated carbon foam with a liquid solution comprising a metal salt for depositing metal ions in the carbon foam; and reducing the metal ions in the foam to metal particles. A pyrophoric material in yet another embodiment includes a pyrophoric metal-carbon foam composite comprising a carbon foam having micropores and mesopores and a surface area of greater than or equal to about 2000 m.sup.2/g, and metal particles in the pores of the carbon foam. Additional methods andmore » materials are also disclosed.« less
Full Text Available
Method for making thin carbon foam electrodes

Patent Pekala, Richard W [Pleasant Hill, CA]; Mayer, Steven T [San Leandro, CA]; Kaschmitter, James L [Pleasanton, CA]; ...

A method for fabricating thin, flat carbon electrodes by infiltrating highly porous carbon papers, membranes, felts, metal fibers/powders, or fabrics with an appropriate carbon foam precursor material. The infiltrated carbon paper, for example, is then cured to form a gel-saturated carbon paper, which is subsequently dried and pyrolyzed to form a thin sheet of porous carbon. The material readily stays flat and flexible during curing and pyrolyzing to form thin sheets. Precursor materials include polyacrylonitrile (PAN), polymethylacrylonitrile (PMAN), resorcinol/formaldehyde, catechol/formaldehyde, phenol/formaldehyde, etc., or mixtures thereof. These thin films are ideal for use as high power and energy electrodes in batteries,more »« less
Full Text Available
Nanocellular thermoplastic foam and process for making the same

Patent Zhu, Lingbo; Costeux, Stephane; Patankar, Kshitish A.; ...

Prepare a thermoplastic polymer foam having a porosity of 70% or more and at least one of: (i) an average cell size of 200 nanometers or less; and (ii) a nucleation density of at least 1.times.1015 effective nucleation sites per cubic centimeter of foamable polymer composition not including blowing agent using a foamable polymer composition containing a thermoplastic polymer selected from styrenic polymer and (meth)acrylic polymers, a blowing agent comprising at least 20 mole-percent carbon dioxide based on moles of blowing agent and an additive having a Total Hansen Solubility Parameter that differs from that of carbon dioxide by lessmore »« less
Full Text Available
Low density microcellular carbon or catalytically impregnated carbon foams and process for their prepartion

Patent Hopper, Robert W [Danville, CA]; Pekala, Richard W [Pleasant Hill, CA]

Machinable and structurally stable, low density microcellular carbon, and catalytically impregnated carbon, foams, and process for their preparation, are provided. Pulverized sodium chloride is classified to improve particle size uniformity, and the classified particles may be further mixed with a catalyst material. The particles are cold pressed into a compact having internal pores, and then sintered. The sintered compact is immersed and then submerged in a phenolic polymer solution to uniformly fill the pores of the compact with phenolic polymer. The compact is then heated to pyrolyze the phenolic polymer into carbon in the form of a foam. Then themore »« less
Full Text Available
Process for producing carbon foams for energy storage devices

Patent Kaschmitter, James L [Pleasanton, CA]; Mayer, Steven T [San Leandro, CA]; Pekala, Richard W [Pleasant Hill, CA]

A high energy density capacitor incorporating a variety of carbon foam electrodes is described. The foams, derived from the pyrolysis of resorcinol-formaldehyde and related polymers, are high density (0.1 g/cc-1.0 g/cc) electrically conductive and have high surface areas (400 m.sup.2 /g-1000 m.sup.2 /g). Capacitances on the order of several tens of farad per gram of electrode are achieved.
Full Text Available

Similar Records

Title: Process for making carbon foam

Abstract

Citation Formats

Formulation of a Mathematical Process Model for the Foaming of a Mesophase Carbon Precursor journal, January 1992

Glass-like carbons journal, June 1969

Novel Hybrid Composites Based on Carbon Foams journal, January 1992

Simple Process Produces High Modulus Carbon Fibers at Much Lower Cost journal, January 1996

Pitch-based processing of carbon-carbon composites journal, January 1989

Vitreous carbon — A new form of carbon journal, November 1967

Widealized Strut Geometries for Open-Celled Foams journal, January 1992

Modelling the mechanical behavior of cellular materials journal, March 1989

Pulse Method of Measuring Thermal Diffusivity at High Temperatures journal, April 1963

Application of laser flash method to penetrative materials for measurement of thermal diffusivity journal, February 1990

Microcellular Foams Prepared From Demixed Polymer Solutions journal, January 1990

Metallic foams: their production, properties and applications journal, July 1983

Structural development in mesophase pitch based carbon fibers produced from naphthalene journal, January 1997

Formulation of a Mathematical Process Model for the Foaming of a Mesophase Carbon Precursor
journal, January 1992

Glass-like carbons
journal, June 1969

Novel Hybrid Composites Based on Carbon Foams
journal, January 1992

Simple Process Produces High Modulus Carbon Fibers at Much Lower Cost
journal, January 1996

Pitch-based processing of carbon-carbon composites
journal, January 1989

Vitreous carbon — A new form of carbon
journal, November 1967

Widealized Strut Geometries for Open-Celled Foams
journal, January 1992

Modelling the mechanical behavior of cellular materials
journal, March 1989

Pulse Method of Measuring Thermal Diffusivity at High Temperatures
journal, April 1963

Application of laser flash method to penetrative materials for measurement of thermal diffusivity
journal, February 1990

Microcellular Foams Prepared From Demixed Polymer Solutions
journal, January 1990

Metallic foams: their production, properties and applications
journal, July 1983

Structural development in mesophase pitch based carbon fibers produced from naphthalene
journal, January 1997