Abstract: The mold described herein comprises an upper and a lower portion in which the upper portion comprises an inverted cavity flash land mold section and the lower portion comprises a readily removable steel plate. By having the cavity flash land mold portion inverted and in the upper portion of the mold, the molded product is more easily separable by gravity from this upper mold portion which avoids the necessity to use means for lifting the molded product from the cavity and thereby avoids the distortions and stresses previously caused in the product by such lifting means. To aid in separating the product from the inverted cavity upper portion as the upper portion is separated from the lower flat sheet portion of the mold, releasing means, such as air from poppet valves in the upper area of the cavity mold, may be used to facilitate separation of the product from the upper cavity portion and deposition of this product on the lower flat sheet portion of the mold.

Abstract: The vitreous carbon disclosed herein is prepared from the molded product of a moldable composition produced from co-reacted mixtrues of powder or otherwise blendable form of 20-80% by weight of a phenolic-furfuraldehyde Novolac resin and of 20-80% by weight of a phenolic-aldehyde resol resin dispersed in water, either in solution or suspension, the percentages being based on the combined weight of the Novolac and resol resins, and the aldehyde in said Novolac resin comprising at least 50 molar percent, preferably substantially 100 percent, furfuraldehyde. The composition advantageously contains an amine such as hexamethylenetetramine ("hexa") in an amount equivalent to 1-15%, preferably 2-10% of hexamethylenetetramine based on the total amount of phenolic component. The composition is made by adding the preformed phenol-furfuraldehyde Novolac to the resol resin prior to dehydration of the resol resin to produce a grafted polymerization product of improved properties.

Abstract: The process and product derived therefrom use the moldable composition derived from intimate co-reacted mixtures of powder or otherwise blendable form of 20-80% by weight of a phenolic-furfuraldehyde Novolac resin and of 20-80% by weight of a phenolic-aldehyde resol resin dispersed in water, either in solution or suspension, the percentages being based on the combined weight of the Novolac and resol resins, and the aldehyde in said Novolac resin comprising at least 50 molar percent, preferably substantially 100 percent, furfuraldehyde. The composition advantageously contains an amine such as hexamethylenetetramine ("hexa") in an amount equivalent to 1-15%, preferably 2-10% of hexamethylenetetramine based on the total amount of phenolic component. The composition is made by adding the preformed phenol-furfuraldehyde Novolac to the resol resin prior to dehydration of the resol resin to produce a grafted polymerization product of improved properties.

Abstract: The moldable composition disclosed herein comprises co-reacted mixtures of powder or otherwise blendable form of 20-80% by weight of a phenolic-furfuraldehyde Novolac resin and of 20-80% by weight of a phenolic-aldehyde resol resin in water, either in solution or suspension, the percentages being based on the combined weight of the Novolac and resol resins, and the aldehyde in said Novolac resin comprising at least 50 molar percent, preferably substantially 100 percent, furfuraldehyde. The composition contains an amine such as hexamethylenetetramine ("hexa") in an amount equivalent to 1-15%, preferably 2-10% of hexamethylenetetramine based on the total amount of phenolic component. The composition is made by adding the preformed phenol-furfuraldehyde Novolac to the resol resin prior to dehydration of the resol resin to produce a grafted polymerization product of improved properties.

Abstract: The process for producing a vitreous carbon involves the molded product of a moldable composition produced from co-reacted mixtures of powder or otherwise blendable form of 20-80% by weight of a phenolic-furfuraldehyde Novolac resin and of 20-80% by weight of phenolic-aldehyde resol resin dispersed in water, either in solution or suspension, the percentages being based on the combined weight of the Novolac and resol resins, and the aldehyde in said Novolac resin comprising at least 50 molar percent, preferably substantially 100 percent, furfuraldehyde. The composition advantageously contains an amine such as hexamethylenetetramine ("hexa") in an amount equivalent to 1-15%, preferably 2-10% of hexamethylenetetramine based on the total amount of phenolic component. The composition is made by adding the preformed phenol-furfuraldehyde Novolac to the resol resin prior to dehydration of the resol resin to produce a grafted polymerization product of improved properties.

Abstract: The vitreous carbon disclosed herein is prepared from intimate uniform mixtures of powder or otherwise blendable form of 20-80% by weight of a solid phenolic-aldehyde Novolak resin and of 20-80% by weight of a solid phenolic-aldehyde resol resin, the percentages being based on the combined weight of the Novolak and resol resins, and the aldehyde in said Novolak resin comprising at least 50 molar percent, preferably substantially 100 percent, furfuraldehyde, together with a carbonaceous filler, preferably graphite, in a proportion as high as 76% by weight based on the total composition. Generally the graphite may comprise 30-70%, advantageously 35-65% and preferably 40-60% of the molding composition. The vitreous carbon is improved in electrical properties and in the capability of being shaped into large thin plates which are much more stress-free than otherwise produced.

Abstract: The compositions disclosed herein are suitable for thermosetting and conversion to vitreous carbon. They comprise intimate uniform mixtures of powder or otherwise blendable form of 20-80% by weight of a solid phenolic-aldehyde Novolak resin and of 20-80% by weight of a solid phenolic-aldehyde resol resin, the percentages being based on the combined weight of the Novolak and resol resins, and the aldehyde in said Novolak resin comprising at least 50 molar percent, preferably substantially 100 percent, furfuraldehyde, together with a carbonaceous filler, preferably graphite, in a proportion as high as 76% by weight based on the total composition. Generally the graphite may comprise 30-70%, advantageously 35-65% and preferably 40-60% of the molding composition. The vitreous carbon produced from these compositions have improved properties in electrical properties and in the capability of being suitably molded and carburized into large thin plates which are much more stress-free than otherwise produced.

Abstract: The vitreous carbon disclosed herein is prepared from intimate uniform mixtures of powder or otherwise blendable form of 20-80% by weight of a solid phenolic-aldehyde Novolak resin and of 20-80% by weight of a solid phenolic-aldehyde resol resin, the percentages being based on the combined weight of the Novolak and resol resins, and the aldehyde in said Novolak resin comprising at least 50 molar percent, preferably substantially 100 percent, furfuraldehyde, together with a carbonaceous filler, preferably graphite, in a proportion as high as 76% by weight based on the total composition. Generally the graphite may comprise 30-70%, advantageously 35-65% and preferably 40-60% of the molding condition. The vitreous carbon is improved in electrical properties and in the capability of being shaped into large thin plates which are much more stress-free than otherwise produced.