Abstract: A unit load device constructed from fiber reinforced polymer matrix composite materials is described. Individual panels of the unit load device may be customized with composite materials and patterns. The joints are adapted to receive the ends of the panels of the unit load device and may further be customized with fiber reinforced composite materials to strengthen the joint. Some embodiments provide for construction of a unit load device from a variety of fiber reinforcing materials utilizing a matrix of thermoplastic polymers with similar softening temperatures. Each component part within the container was designed and/or created to address the specific needs of the particular part. The unit load devices described herein provide for all composite containers with a significant weight savings from conventional unit load devices.

Abstract: Tools for the forming of composite parts from composite forming materials, having tool bodies that comprise, at least in part, carbon foam and graphite are described. In some embodiments, a surface of the carbon foam or graphite may comprise at least a portion of a tool face. In other embodiments, the carbon foam or graphite may support another material, referred to as tool face material, wherein a surface of the tool face material, may comprise at least a portion of a tool face. The tools of the present invention may be lighter, more durable, and less costly to produce and/or use than conventional tools used for the production of composite parts, particularly those tools used for the production of carbon composites. Additionally, such tools may be reusable, repairable, and more readily modifiable.

Abstract: Carbon foam enclosures for at least partially shielding an at least partially enclosed volume from electromagnetic interference (EMI) and methods for making the carbon foam enclosures are described. The enclosure may comprise at least two sections of electrically conductive carbon foam interconnected by an electrically conductive carbon char that is substantially electrically continuous and substantially structurally continuous with the carbon foam of the walls.

Abstract: Carbon foam assemblies and a method for the production of such carbon foam assemblies are described where the carbon foam assemblies are characterized in that they are comprised of at least two pieces of carbon foam joined by a carbonaceous region, where carbon of the at least two pieces of carbon foam and carbonaceous region is continuous. A method for producing a carbon foam assembly may comprise bonding at least two pieces of carbonizable polymeric foam together with a carbonizable adhesive to provide a carbonizable polymeric foam assembly, and heating the carbonizable polymeric foam assembly to an elevated temperature to carbonize the carbonizable polymeric foam assembly and provide a carbon foam assembly.

Abstract: A method for producing a one-piece carbon foam article having a complex geometric shape is described. The method may include heating a carbonizable polymeric foam article having a complex geometric shape to temperature sufficient to carbonize the polymer foam and produce carbon foam. The resulting carbon foam article retains substantially the same shape and physical pore structure of the carbonizable polymeric foam article.

Abstract: Carbon foam enclosures for at least partially or mostly shielding an at least partially enclosed volume from electromagnetic inference, and a method for using such enclosures, are described. The enclosure may comprise a continuous, non-planar piece of carbon foam. The continuous, non-planar piece of carbon foam may comprise at least two walls an angle greater than zero degrees and define at least a partially enclosed volume. Alternatively, the enclosure may include at least one curved wall and define at least a partially enclosed volume. The carbon foam of the enclosure is electrically conductive. The invention may also include a method for producing a carbon foam electromagnetic interference shielding enclosure.

Abstract: Radar emission absorbing materials that are moldable or that may be coated on a surface are described. A moldable radar emission absorbing material may include commuted carbon foam particles blended with a moldable matrix. In other embodiments, a radar emission absorbing surface coating material may include comminuted carbon foam particles blended with a solvent-solid system.

Abstract: A selectively reinforced carbon foam body is described. The carbon foam body includes one or more reinforcement regions in predetermined locations within the carbon foam body. The reinforcement regions may be formed by permeating portions of the carbon foam body with a precursor to a reinforcement material in a predetermined pattern to form one or more reinforcement regions. The reinforcement regions may have differing sizes and shapes. The selective reinforcement of a carbon foam body allows for additional strength to be provided in needed areas while still maintaining the low density attributes of carbon foam.

Abstract: High density carbon foams and methods for producing the same are described. A method used to prepare high density carbon foam may involve heating a comminuted agglomerating bituminous coal to an elevated temperature sufficient to result in the coal particles softening and melting together to form a generally homogeneous, continuous, open cell carbon material. The homogeneous open cell carbon material is then maintained at an elevated temperature for a period of time sufficient to substantially reduce or essentially eliminate the plastic property of the bituminous coal. As desired, the resultant high density carbon foam may be cooled to essentially ambient temperatures or immediately or subsequently heated to elevated temperatures as great as about 3200° C., followed by cooling.

Abstract: A high density carbon material produced from coal is described. The carbon material may have a density ranging from about 1.0 g/cc to about 1.6 g/cc and may have a crush strength of up to about 20,000 psi. The high density carbon material is produced by slowly heating comminuted swelling bituminous coal particles under pressures of 400 psi to about 500 psi to a first temperature at about the initial plastic temperature of the coal. The material is held at this temperature for a period of time sufficient to provide for a uniform temperature throughout the coal. The material is then heated to a second temperature for a period of time sufficient to provide for the coal achieving an essentially uniform temperature. The resulting product is a three-dimensional, self-supporting carbon that has a substantially continuous carbon matrix defining grain boundaries within the carbon matrix.

Abstract: Radar emission absorbing materials that are moldable or that may be coated on a surface are described. A moldable radar emission absorbing material may include comminuted carbon foam particles blended with a moldable matrix. In other embodiments, a radar emission absorbing surface coating material may include comminuted carbon foam particles blended with a solvent-solid system.

Abstract: A method for increasing the yield of carbon foam is described. The method includes placing a foaming sheet over the top surface of the material to be foamed. In certain embodiments, the foaming sheet is placed over the top surface of particulate coal prior to and during the foaming process. In some embodiments the foaming sheet is a smooth, continuous sheet, such as aluminum foil or the like. The resulting carbon product includes an increased amount of usable carbon foam.

Abstract: Self-heated tools for the production of composite parts are described. The tools include a tool body which, at least in part, includes carbon foam materials that are electrically conductive or permeable to the passage of fluids. These materials can be both electrically conductive and permeable to the passage of fluids. The electrically conductive or fluid permeable carbon foam materials are an intrinsic part of the construction of these tool bodies and are not add-on devices. Electricity may be used to heat the electrically conductive carbon foam material and transfer heat to the tool face. In other embodiments, heated fluid may be passed through and used to heat the fluid permeable carbon foam material and transfer heat to tool body. The electrically conductive or permeable carbon foam materials may define the tool face of the tool body. The tool bodies may comprise carbon foam, which is both electrically conductive and permeable.

Abstract: Tools for the forming of composite parts from composite forming materials, having tool bodies that comprise, at least in part, carbon foam where a surface of the carbon foam may comprise a tool face or supports tool face materials. The tools of the present invention may be lighter, more durable, and less costly to produce and/or use than conventional tools used for the production of composite parts, particularly those tools used for the production of carbon composites. Additionally, such tools may be reusable, repairable, and more readily modifiable.

Abstract: Tools for the forming of composite parts from composite forming materials, having tool bodies that comprise, at least in part, carbon foam where a surface of the carbon foam may comprise a tool face or supports tool face materials. The tools of the present invention may be lighter, more durable, and less costly to produce and/or use than conventional tools used for the production of composite parts, particularly those tools used for the production of carbon composites. Additionally, such tools may be reusable, repairable, and more readily modifiable.