Abstract: A carbon foam article useful for, inter alia, composite tooling or other high temperature applications, which includes a substrate, wherein the substrate includes at least one material selected from carbon foam, extruded graphite, graphite foam, and isomolded graphite. The tool may also include a skin as a working surface and a filler disposed below the skin. The tool has a surface roughness of no more than about 63 micro-inches. Such a tool may be used to make a composite prototype part.

Abstract: An article for tooling composite materials, including a carbon foam, a sealant attached to the carbon foam so as to form a monolithic fine-grain graphite-like surface; and a skin of facesheet materials. The facesheet materials include: a spray-deposited coating of metal; more preferably, a thermal or plasma spray-deposited metal; and most preferably, a plasma sprayed Invar metal. The facesheet materials may optionally include a flash coating. The facesheet materials alternately include plastics, resinous materials and carbon-carbon composite materials.

Abstract: A carbon foam composite including a carbon foam skeleton having a supplemental material therein, the composite useful for, inter alia, a variety of applications including applications requiring durability and water resistance. Also included is a method for making such carbon foam composite materials.

Abstract: A carbon foam article useful for, inter alia, composite tooling or other high temperature applications, which includes a carbon foam substrate, an intermediate material on a surface of the carbon foam substrate, and a tool facing material on an outer surface of the article such that the intermediate material is positioned between the tool facing material and the carbon foam substrate.

Abstract: A graphite-based heat exchanger, especially for use as a solar energy receptor as part of the thermal process in a solar power system, including an energy collection panel, a heat spreader, and a thermal element, wherein the heat spreader is formed of flexible graphite having a density of at least about 0.6 g/cc and a thickness of less than about 10 mm, and the heat spreader further has a first side and a second side, wherein the heat spreader is in a thermal transfer relationship with the thermal element, and wherein the energy collection panel includes at least one sheet or block of graphite.

Abstract: An article for tooling composite materials, including a carbon foam, a sealant attached to the carbon foam so as to form a monolithic fine-grain graphite-like surface; and a skin of facesheet materials. The facesheet materials include: a spray-deposited coating of metal; more preferably, a thermal or plasma spray-deposited metal; and most preferably, a plasma sprayed Invar metal. The facesheet materials may optionally include a flash coating. The facesheet materials alternately include plastics, resinous materials and carbon-carbon composite materials.

Abstract: A carbon foam composite including a carbon foam skeleton having a supplemental material therein, the composite useful for, inter alia, a variety of applications including applications requiring durability and water resistance. Also included is a method for making such carbon foam composite materials.

Abstract: The invention comprises novel apparatuses and testing methods for evaluating a fluid diffusion component. The apparatus includes a fluid capable of undergoing oxidation or reduction, a half-cell electrode assembly able to receive the fluid, and a change in acidity indicator in communication with the assembly. An inventive method of the invention includes the steps of passing a fluid capable of undergoing oxidation or reduction through a half-cell electrode assembly to form a sample, contacting the sample with an indicator, and detecting a change in acidity in the indicator.

Abstract: An article for tooling composite materials, including a carbon foam, a sealant attached to the carbon foam so as to form a monolithic fine-grain graphite-like surface; and a skin of facesheet materials. The facesheet materials include: a spray-deposited coating of metal; more preferably, a thermal or plasma spray-deposited metal; and most preferably, a plasma sprayed Invar metal. The facesheet materials may optionally include a flash coating. The facesheet materials alternately include plastics, resinous materials and carbon-carbon composite materials.

Abstract: The invention relates to expanded graphite and methods of making the graphite and products that can be made from the graphite made from the inventive process. The invention includes the step of introducing a fluid into at least one of a plurality of interstices of graphite flake, wherein the fluid comprises at least one of a sub-critical point fluid, a near critical point fluid, or a supercritical fluid. The graphite flake is also intercalated with an intercalant and optionally an oxidizing agent. The invention may further include novel techniques of exfoliating the graphite. The invention may be practiced to make nano-sized graphite particles and also graphite composites. Preferred composites which may be made in accordance with the invention include conductive polymeric composites (thermally or electrically), paint composites, battery composites, capacitor composites, and pollution abatement catalyst support composites.

Abstract: The invention may be practiced to make graphite composites. Preferred composites which may be made in accordance with the invention include conductive polymeric composites (thermally or electrically), paint composites, battery composites, capacitor composites, and pollution abatement catalyst support composites. One method of making the graphite aforementioned composites includes introducing an intercalant into at least one interstice of at least one flake of natural graphite. The method also includes introducing a fluid into the at least one interstices of the flake. Preferably, the fluid comprises at least one of a sub-critical fluid, near critical point fluid, or a supercritical fluid. Furthermore the method includes blending the flake with a polymer, thereby forming a graphite-polymeric composite.

Abstract: The invention comprises novel apparatuses and testing methods for evaluating a fluid diffusion component. The apparatus includes a fluid capable of undergoing oxidation or reduction, a half-cell electrode assembly able to receive the fluid, and a change in acidity indicator in communication with the assembly. An inventive method of the invention includes the steps of passing a fluid capable of undergoing oxidation or reduction through a half-cell electrode assembly to form a sample, contacting the sample with an indicator, and detecting a change in acidity in the indicator.

Abstract: The invention comprises novel apparatuses and testing methods for evaluating a fluid diffusion component. The apparatus includes a fluid capable of undergoing oxidation or reduction, a half-cell electrode assembly able to receive the fluid, and a change in acidity indicator in communication with the assembly. An inventive method of the invention includes the steps of passing a fluid capable of undergoing oxidation or reduction through a half-cell electrode assembly to form a sample, contacting the sample with an indicator, and detecting a change in acidity in the indicator.

Abstract: The invention may be practiced to make graphite composites. Preferred composites which may be made in accordance with the invention include conductive polymeric composites (thermally or electrically), paint composites, battery composites, capacitor composites, and pollution abatement catalyst support composites. One method of making the graphite aforementioned composites includes introducing an intercalant into at least one interstice of at least one flake of natural graphite. The method also includes introducing a fluid into the at least one interstices of the flake. Preferably, the fluid comprises at least one of a sub-critical fluid, near critical point fluid, or a supercritical fluid. Furthermore the method includes blending the flake with a polymer, thereby forming a graphite-polymeric composite.

Abstract: The invention relates to expanded graphite and methods of making the graphite and products that can be made from the graphite made from the inventive process. The invention includes the step of introducing a fluid into at least one of a plurality of interstices of graphite flake, wherein the fluid comprises at least one of a sub-critical point fluid, a near critical point fluid, or a supercritical fluid. The graphite flake is also intercalated with an intercalant and optionally an oxidizing agent. The invention may further include novel techniques of exfoliating the graphite. The invention may be practiced to make nano-sized graphite particles and also graphite composites. Preferred composites which may be made in accordance with the invention include conductive polymeric composites (thermally or electrically), paint composites, battery composites, capacitor composites, and pollution abatement catalyst support composites.