Abstract: A method and apparatus of supplying humid air to a fuel cell is disclosed. The extremely high thermal conductivity of some graphite foams lends itself to enhance significantly the ability to humidify supply air for a fuel cell. By utilizing a high conductivity pitch-derived graphite foam, thermal conductivity being as high as 187 W/m·K, the heat from the heat source is more efficiently transferred to the water for evaporation, thus the system does not cool significantly due to the evaporation of the water and, consequently, the air reaches a higher humidity ratio.

Abstract: A thermally conductive carbon foam is provided, normally having a thermal conductivity of at least 40 W/m·K. The carbon foam usually has a specific thermal conductivity, defined as the thermal conductivity divided by the density, of at least about 75 W·cm3/m·° K·gm. The foam also has a high specific surface area, typically at least about 6,000 m2/m3. The foam is characterized by an x-ray diffraction pattern having “doublet” 100 and 101 peaks characterized by a relative peak split factor no greater than about 0.470. The foam is graphitic and exhibits substantially isotropic thermal conductivity. The foam comprises substantially ellipsoidal pores and the mean pore diameter of such pores is preferably no greater than about 340 microns. Other materials, such as phase change materials, can be impregnated in the pores in order to impart beneficial thermal properties to the foam. Heat exchange devices and evaporatively cooled heat sinks utilizing the foams are also disclosed.

Abstract: A process for producing a carbon foam heat sink is disclosed which 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. The foam is encased and filled with a phase change material to provide a very efficient heat sink device.

Abstract: The present invention discloses a method for molding complex and intricately shaped high density monolithic carbon, carbon-carbon, graphite, and thermoplastic composites using gelcasting technology. The method comprising a polymeric carbon precursor, a solvent, a dispersant, an anti-foaming agent, a monomer system, and an initiator system. The components are combined to form a suspension which is poured into a mold and heat-treated to form a thermoplastic part. The thermoplastic part can then be further densified and heat-treated to produce a high density carbon or graphite composite. The present invention also discloses the products derived from this method.

Abstract: An article and method of producing an article for converting energy from one form to another having a pitch-derived graphitic foam carbon foam substrate and a single layer coating applied to all exposed surfaces wherein the coating is either silicon carbide or carbides formed from a Group IVA metal. The article is used as fully coated carbon foam susceptors that more effectively absorb radio frequency (RF) band energy and more effectively convert the RF energy into thermal band energy or sensible heat. The essentially non-permeable coatings also serve as corrosion or oxidation resistant barriers.

Abstract: An article and method of producing an article for converting energy from one form to another having a pitch-derived graphitic foam carbon foam substrate and a single layer coating applied to all exposed surfaces wherein the coating is either silicon carbide or carbides formed from a Group IVA metal. The article is used as fully coated carbon foam susceptors that more effectively absorb radio frequency (RF) band energy and more effectively convert the RF energy into thermal band energy or sensible heat. The essentially non-permeable coatings also serve as corrosion or oxidation resistant barriers.

Abstract: A process for producing a carbon foam heat sink is disclosed which 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. The foam is encased and filled with a phase change material to provide a very efficient heat sink device.

Abstract: A closed-cycle apparatus for cooling a living body includes a heat pickup body or garment which permits evaporation of an evaporating fluid, transmission of the vapor to a condenser, and return of the condensate to the heat pickup body. A thermal battery cooling source is provided for removing heat from the condenser. The apparatus requires no external power and provides a cooling system for soldiers, race car drivers, police officers, firefighters, bomb squad technicians, and other personnel who may utilize protective clothing to work in hostile environments. An additional shield layer may simultaneously provide protection from discomfort, illness or injury due to harmful atmospheres, projectiles, edged weapons, impacts, explosions, heat, poisons, microbes, corrosive agents, or radiation, while simultaneously removing body heat from the wearer.

Abstract: The present invention discloses a method for molding complex and intricately shaped high density monolithic carbon, carbon-carbon, graphite, and thermoplastic composites using gelcasting technology. The method comprising a polymeric carbon precursor, a solvent, a dispersant, an anti-foaming agent, a monomer system, and an initiator system. The components are combined to form a suspension which is poured into a mold and heat-treated to form a thermoplastic part. The thermoplastic part can then be further densified and heat-treated to produce a high density carbon or graphite composite.

Abstract: A thermally conductive carbon foam is provided, normally having a thermal conductivity of at least 40 W/m·K. The carbon foam usually has a specific thermal conductivity, defined as the thermal conductivity divided by the density, of at least about 75 W·cm3/m·°K·gm. The foam also has a high specific surface area, typically at least about 6,000 m2/m3. The foam is characterized by an x-ray diffraction pattern having “doublet” 100 and 101 peaks characterized by a relative peak split factor no greater than about 0.470. The foam is graphitic and exhibits substantially isotropic thermal conductivity. The foam comprises substantially ellipsoidal pores and the mean pore diameter of such pores is preferably no greater than about 340 microns. Other materials, such as phase change materials, can be impregnated in the pores in order to impart beneficial thermal properties to the foam.

Abstract: A process for producing carbon foam or a composite is disclosed which 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.

Abstract: A process for producing carbon foam or a composite is disclosed which 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.

Abstract: A method and apparatus of supplying humid air to a fuel cell is disclosed. The extremely high thermal conductivity of some graphite foams lends itself to enhance significantly the ability to humidify supply air for a fuel cell. By utilizing a high conductivity pitch-derived graphite foam, thermal conductivity being as high as 187 W/m·K, the heat from the heat source is more efficiently transferred to the water for evaporation, thus the system does not cool significantly due to the evaporation of the water and, consequently, the air reaches a higher humidity ratio.

Abstract: A graded composite energy converting article having a working surface of carbon-bonded carbon-fiber (CBCF) material that can absorb light, RF, microwaves, or other forms of energy and convert this energy to sensible heat. Conversely, CBCF can take sensible heat and convert it to radiative emissions of IR energy. Energy is conducted through the article by carbon foam to a secondary surface. The graded composite is made by first heating pitch under pressure to create the foam, which is then pyrolyzed and graphitized to create graphitic, open-cell foam. A slurry of chopped carbon fibers and organic binder in water or solvent is prepared and deposited on a working surface of the foam, preferably infiltrating the foam to some depth. The green body is dried, cured, and carbonized, creating a graded body of carbon foam in conductive thermal contact with a working surface of CBCF. Secondary surfaces of the foam may optionally be metal-infiltrated for added strength, brazability, or other purposes.

Abstract: A process for producing carbon foam or a composite is disclosed which 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.

Abstract: A process for producing a carbon foam heat sink is disclosed which 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. The foam is encased and filled with a phase change material to provide a very efficient heat sink device.

Abstract: A process for producing a carbon foam heat sink is disclosed which 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. The foam is encased and filled with a phase change material to provide a very efficient heat sink device.

Abstract: A process for producing a carbon foam heat sink is disclosed which 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. The foam is encased and filled with a phase change material to provide a very efficient heat sink device.

Abstract: A process for producing a carbon foam heat sink is disclosed which 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. The foam is encased and filled with a phase change material to provide a very efficient heat sink device.

Abstract: The present invention discloses a method for molding complex and intricately shaped high density monolithic carbon, carbon-carbon, graphite, and thermoplastic composites using gelcasting technology. The method comprising a polymeric carbon precursor, a solvent, a dispersant, an anti-foaming agent, a monomer system, and an initiator system. The components are combined to form a suspension which is poured into a mold and heat-treated to form a thermoplastic part. The thermoplastic part can then be further densified and heat-treated to produce a high density carbon or graphite composite. The present invention also discloses the products derived from this method.