Abstract: A defect-free vitreous carbon material having a three-dimensional (x,y,z) size in which each of the x, y and z dimensions exceeds twelve millimeters. A process of making such vitreous carbon material employs a three-dimensional fiber mesh that vaporizes at elevated temperature, in which the mesh is impregnated with a polymerizable resin and thereafter the resin is cured. During the initial stage(s) of pyrolysis, the mesh volatilizes to yield a residual network of passages in the cured resin body that thereafter allows gases to escape during pyrolysis of the cured resin material to form the vitreous carbon product. As a result, it is possible to form defect-free vitreous carbon material of large size, suitable for use in structural composites, and product articles such as sealing members, brake linings, electric motor brushes, and bearing members.

Abstract: A biphasic nanoporous vitreous carbon material with a cementitious morphology characterized by presence of non-round porosity, having superior hardness and tribological properties, as useful for high wear-force applications. The biphasic nanoporous vitreous carbon material is produced by firing, under inert atmosphere, of particulate vitrified carbon in a composition containing (i) a precursor resin that is curable and pyrolyzable to form vitreous carbon and, optionally, (ii) addition of one or more of the following: solid lubricant, such as graphite, boron nitride, or molybdenum disulfide; a heat-resistant fiber reinforcement, such as copper, bronze, iron alloy, graphite, alumina, silica, or silicon carbide; or one or more substances to improve electrical conductivity, such as dendritic copper powder, copper “felt” or graphite flake, to produce a superior vitreous carbon that is useful alone or as a continuous phase in reinforced composites, in relation to conventional glassy carbon materials.