Carbonizing To Form Article Patents (Class 264/29.1)
-
Patent number: 7998376Abstract: Method for producing carbon-carbon composite brake discs by: (a) providing annular nonwoven carbon fiber brake disc preforms; (b) carbonizing the brake disc preforms; (c) densifying the carbonized preforms by CVD/CVI (chemical vapor deposition/chemical vapor infiltration); (d) densifying the products of step (c) with isotropic or mesophase pitch by VPI (vacuum pitch infiltration) or RTM (resin transfer molding) processing; (e) carbonizing the preforms to remove non-carbon volatiles from the pitch and to open porosity in the pitch-infused preforms; (f) densifying the products of step (e) with isotropic or mesophase pitch by VPI or RTM processing; (g) carbonizing the preforms to remove non-carbon volatiles from pitch and to open porosity in the pitch-infused preforms; and (h) heat-treating the resulting pitch-densified carbon-carbon composite brake disc preforms. This manufacturing approach reduces lot-to-lot variability in friction performance of the resulting carbon-carbon composite brake discs.Type: GrantFiled: February 6, 2008Date of Patent: August 16, 2011Assignee: Honeywell International Inc.Inventors: Mark L. La Forest, Neil Murdie, Allen H. Simpson
-
Patent number: 7993549Abstract: Process for producing carbon-ceramic brake discs comprising the following steps: production of a carbonized core body by press-molding a mixture containing reinforcing fibers and a binder, curing the binder by heating, and carbonizing by heating the press-molded body under exclusion of oxidizing substances to a temperature of between 750° C. and 1300° C., press-molding a moldable, reinforcing fiber-containing material onto the prefabricated carbonized core body which after the additional process steps produces the friction layer, curing the material for the friction layer, carbonizing the entire body and then infiltrating the composite body with liquid silicon.Type: GrantFiled: September 16, 2005Date of Patent: August 9, 2011Assignee: Audi AGInventors: Joachim Niewöhner, Markus Stettberger, Arno Sommer, Dunja Müller, Jens Rosenlöcher
-
Publication number: 20110180946Abstract: Methods of making a carbon-carbon composite preforms, particularly suitable as brake discs in aircraft landing systems, by combining titanium carbide particles ranging in size from 0.01 to 10 microns in diameter, resinous binder, and carbon fibers or carbon fiber precursors in a mold, and subsequently subjecting the combined components to pressure and heat to carbonize the resinous binder by methods, thereby providing the carbon-carbon composite preform having particulate titanium carbide uniformly distributed throughout its mass. Prior to combining the titanium carbide and the binder with the fibers in this process, the particulate titanium carbide may be mixed with liquid binder, the resulting TiC/binder mixture may then solidified, and the resulting solid TiC/binder mixture may be ground into a fine powder for use in the process. Also, compositions for preparing a carbon-carbon composite friction materials, and methods of improving wear and dynamic stability in a carbon-carbon composite brake discs.Type: ApplicationFiled: March 25, 2009Publication date: July 28, 2011Inventors: Allen H. Simpson, Slawomir T. Fryska, Mark L. La Forest, Nabil Abu Gharbieh
-
Publication number: 20110177393Abstract: Composite materials and methods of forming composite materials are provided. The composite materials described herein can be utilized as an electrode material for a battery. In certain embodiments, the composite material includes greater than 0% and less than about 90% by weight silicon particles, and greater than 0% and less than about 90% by weight of one or more types of carbon phases. At least one of the one or more types of carbon phases can be a substantially continuous phase. The method of forming a composite material can include providing a mixture that includes a precursor and silicon particles, and pyrolysing the precursor to convert the precursor into one or more types of carbon phases to form the composite material.Type: ApplicationFiled: January 18, 2011Publication date: July 21, 2011Applicant: ENEVATE CORPORATIONInventors: BENJAMIN PARK, ALEXANDER GORKOVENKO, RABIH ZAOUK, WILLIAM SCHANK, GENIS TURON TEIXIDOR, LOTHAR STEFFENS
-
Publication number: 20110169180Abstract: In a method for producing a carbonaceous film in which a polymer film is wrapped around a core and is subjected to a heat treatment, material film surfaces during the carbonization step are prevented from fusion, whereby a long carbonaceous having a large area film is obtained. Fusion can be prevented by subjecting a polymer film to a heat treatment under a reduced pressure, and under a reduced pressure while allowing an inert gas to flow. The range of the pressure reduction is preferably ?0.08 MPa to ?0.01 kPa. It is preferred to carry out carbonization with the pressure reduced in the range of from ?0.08 MPa to ?0.01 kPa while allowing an inert gas to flow.Type: ApplicationFiled: September 11, 2009Publication date: July 14, 2011Inventors: Takashi Inada, Yasushi Nishikawa, Makoto Mishiro
-
Publication number: 20110171427Abstract: A graphene sheet and a method of manufacturing the graphene sheet are provided. The method includes: growing a graphene sheet on a graphene growth support by applying carbon sources and heat to the graphene growth support, the graphene growth support including a carbonization catalyst; and forming at least one ripple on the graphene sheet by cooling at least one of the graphene growth support and the graphene sheet, wherein the graphene growth support and the graphene sheet have different thermal expansion coefficients.Type: ApplicationFiled: January 11, 2011Publication date: July 14, 2011Applicants: SAMSUNG TECHWIN CO., LTD., SUNGKYUNKWAN UNIVERSITY FOUNDATION FOR CORPORATE COLLABORATIONInventors: Keun-soo KIM, Jong-hyun AHN, Byung-hee HONG
-
Publication number: 20110140296Abstract: A carbon monolith includes a robust carbon monolith characterized by a skeleton size of at least 100 nm, and a hierarchical pore structure having macropores and mesoporesType: ApplicationFiled: January 21, 2011Publication date: June 16, 2011Applicants: UT-BATTELLE, LLC, UNIVERSITY OF TENNESSEE RESEARCH FOUNDATIONInventors: Sheng Dai, Georges A. Guiochon, Chengdu Liang
-
Patent number: 7959974Abstract: Methods and articles providing for precise aligning, positioning, shaping, and linking of nanotubes and carbon nanotubes. An article comprising: a solid surface comprising at least two different surface regions including: a first surface region which comprises an outer boundary and which is adapted for carbon nanotube adsorption, and a second surface region which is adapted for preventing carbon nanotube adsorption, the second region forming an interface with the outer boundary of the first region, at least one carbon nanotube which is at least partially selectively adsorbed at the interface. The shape and size of the patterns on the surface and the length of the carbon nanotube can be controlled to provide for selective interfacial adsorption.Type: GrantFiled: December 4, 2006Date of Patent: June 14, 2011Assignee: Northwestern UniversityInventors: Chad A. Mirkin, Yuhuang Wang, Daniel Maspoch
-
Patent number: 7951424Abstract: The present invention provides a method for the selective placement of carbon nanotubes on a particular surface. In particular, the present invention provides a method in which self-assembled monolayers formed on an unpatterned or patterned metal oxide surface are used to attract or repel carbon nanotubes from a dispersion containing the same. In accordance with the present invention, the carbon nanotubes can be attracted to the self-assembled monolayers so as to be attached to the metal oxide surface, or they can be repelled by the self-assembled monolayers bonding to a predetermined surface other than the metal oxide surface containing the self-assembled monolayers.Type: GrantFiled: May 19, 2008Date of Patent: May 31, 2011Assignee: International Business Machines CorporationInventors: Ali Afzali-Ardakani, James Bowler Hannon
-
Publication number: 20110101554Abstract: Processes for preparing or handling graphene sheets wherein low bulk density graphene sheets are compressed. The graphene sheets may be produced by a thermal treatment such as exfoliation of precursor or reduction or annealing of previously existing graphene sheets and conveyed in a closed system to a compression apparatus.Type: ApplicationFiled: April 23, 2010Publication date: May 5, 2011Applicant: VORBECK MATERIALS CORP.Inventors: Gautham Krishnaiah, John Lettow
-
Publication number: 20110085962Abstract: A system for making low volatile carbonaceous material including a digestion vessel in communication with a carbonaceous material feedstock unit for producing a digested carbonaceous material; an extraction vessel in communication with the digestion vessel, the extraction vessel containing supercritical carbon dioxide fluid for extracting hydrocarbons from the digested carbonaceous material to produce an extract solvent and the low volatile carbonaceous material; and at least one separation vessel in communication with the extraction vessel for separating the extract solvent to a carbon dioxide gas and a stream of extracted hydrocarbons.Type: ApplicationFiled: December 14, 2010Publication date: April 14, 2011Inventors: Randall J. Harris, Damian Wales
-
Publication number: 20110071013Abstract: A ceramic matrix composite is formed from a non-oxide ceramic and continuous ceramic fibers. The matrix includes a hafnium donor in the matrix in an amount sufficient to harden the composite at elevated temperatures to prevent ablation of the composite. The matrix also includes a boron donor in the matrix in an amount sufficient to lower the glass transition temperature of the composite to flow over cracks formed in the composite. The method to form the matrix is selected from polymer infiltration pyrolysis, chemical vapor infiltration, and sequential polymer infiltration pyrolysis and chemical vapor infiltration.Type: ApplicationFiled: September 24, 2009Publication date: March 24, 2011Applicant: UNITED TECHNOLOGIES CORPORATIONInventors: Kirk C. Newton, Michael A. Kmetz
-
Patent number: 7897072Abstract: Low cost isotropic and/or mesophase pitch is used to densify carbon fiber preforms by VPI and/or RTM equipment in place of CVI/CVD processing, for reduced manufacturing cycle times and costs and reduced need for expensive densification equipment. The process includes: heat treating a carbon fiber preform; infiltrating the preform with a pitch feedstock by VPI and/or RTM; carbonizing the pitch-infiltrated carbon fiber preform at 1200-2450° C. with a hold time of 4 hrs to ensure the entire furnace reaches the max temperature; repetition of the pitch infiltration and carbonization steps until the density of the preform is about 1.7 g/cc or higher; and a final heat-treatment of the densified composite. Brake discs manufactured in this way have higher densities and better thermal characteristics, which result in improved mechanical properties and friction and wear performance as compared with conventional CVI/CVD-densified brake discs.Type: GrantFiled: March 17, 2008Date of Patent: March 1, 2011Assignee: Honeywell International Inc.Inventors: Mark L. La Forest, Neil Murdie, Allen H. Simpson
-
Patent number: 7875219Abstract: A process for producing meso-porous nanocomposite electrode comprising nano-scaled graphene platelets.Type: GrantFiled: October 4, 2007Date of Patent: January 25, 2011Assignee: Nanotek Instruments, Inc.Inventors: Aruna Zhamu, Bor Z. Jang
-
Patent number: 7871592Abstract: A method for preparing a carbon/carbon (C/C) composite comprising carbonizing a carbon fiber-reinforced polymer matrix composite precursor by heating the precursor in an inert atmosphere with a heating rate greater than 20° C./min up to 1500° C./min.Type: GrantFiled: December 27, 2005Date of Patent: January 18, 2011Inventors: Jiin-Huey Chern Lin, Chien-Ping Ju, Hua-Hsuan Kuo, Shu-Ching Ho, Seng-Meng Chen
-
Patent number: 7867608Abstract: Electrically gradated carbon foam materials that have changing or differing electrical properties through the thickness of the carbon foam material and methods for making these electrically gradated carbon foam materials are described herein. In some embodiments, the electrically gradated carbon foam materials exhibit increasing electrical resistivity through the thickness of the carbon foam material such that the electrical resistivity near a second surface of the carbon foam is at least 2 times greater than the electrical resistivity near a first surface of the carbon foam. These electrically gradated carbon foam materials may be used as radar absorbers, as well as in electromagnetic interference (EMI) shielding schemes.Type: GrantFiled: December 25, 2007Date of Patent: January 11, 2011Assignee: Touchstone Research Laboratory, Ltd.Inventors: Jesse M. Blacker, Janusz W. Plucinski
-
Publication number: 20100324656Abstract: A method for manufacturing a carbon composite is provided. The method includes providing a carbon-containing resin material to which an appropriate concentration of catalyst particles may be added. Thereafter, the catalyzed resin may be subject to a high temperature range, at which point carbon in the resin to begins to couple to the catalyst particles. Continual exposure to high temperature leads to additional attachment of carbon to existing carbon on the particles. Subsequently growth, within the resin material, of an array of carbon nanotubes occurs, as well as the formation of the composite material.Type: ApplicationFiled: July 22, 2010Publication date: December 23, 2010Inventors: David S. Lashmore, Joseph J. Brown
-
Publication number: 20100314790Abstract: A graphite article having enhanced directional thermal conductivity is provided. The mesophase portions of a mesophase pitch are aligned with each other to create an oriented mesophase pitch which may be stabilized. The article may subject to further carbonization and graphitization as needed.Type: ApplicationFiled: June 12, 2009Publication date: December 16, 2010Inventors: Peter G. Stansberry, Richard L. Shao, Douglas J. Miller
-
Patent number: 7850942Abstract: A method of making mesoporous carbon beads comprises steps of providing a nucleophilic component such as phenolic compound or phenol condensation prepolymer, dissolving the nucleophilic component in a pore former, together with at least one electrophilic cross-linking agent such as formaldehyde, paraformaldehyde, furfural and hexamethylene tetramine, dispersing the resulting solution into a mineral oil to form beads, condensing both the component and the agent in the presence of the pore former to form beads of porous resin, removing the beads from the mineral oil and carbonizing the beads to form mesoporous carbon beads.Type: GrantFiled: May 7, 2007Date of Patent: December 14, 2010Assignee: British American Tobacco (Investments) Ltd.Inventors: Stephen Robert Tennison, Oleksundr Prokopovych Kozynchenko, Volodymyr Vasyljovych Strelko, Andrew John Blackburn
-
Patent number: 7842736Abstract: A method is provided for making mesoporous resin. It comprises: (a) providing a nucleophilic component which comprises a phenolic compound or a phenol condensation prepolymer optionally with one or more modifying reagents selected from hydroquinone, resorcinol, urea, aromatic amines and heteroaromatic amines; (b) dissolving the nucleophilic component in a pore former selected from the group consisting of a diol, a diol ether, a cyclic ester, a substituted cyclic ester, a substituted linear amide, a substituted cyclic amide, an amino alcohol and a mixture of any of the above with water, together with at least one electrophilic cross-linking agent selected from the group consisting of formaldehyde, paraformaldehyde, furfural and hexamethylene tetramine; and (c) condensing the nucleophilic component and the electrophilic cross-linking agent in the presence of the pore former to form a porous resin. The resin may be formed in situ by pouring the partially cross-linked resin into hot oil.Type: GrantFiled: April 10, 2007Date of Patent: November 30, 2010Assignee: British American Tobacco (Investments) LimitedInventors: Stephen Robert Tennison, Oleksundr Prokopovych Kozynchenko, Volodymyr Vasyljovych Strelko, Andrew John Blackburn
-
Patent number: 7799250Abstract: Ceramic friction linings comprising a material consisting essentially of metal oxides which are present in the form of a sintered ceramic or in the form of ceramic particles bound by carbon and/or carbides, processes for producing them and their use in combination with ceramic friction bodies, in particular for high-performance brakes.Type: GrantFiled: February 16, 2006Date of Patent: September 21, 2010Assignee: Audi AGInventors: Ronald Huener, Moritz Bauer, Peter Winkelmann
-
Patent number: 7794793Abstract: A method for preparation of carbon nanotubes (CNTs) bundles for use in field emission devices (FEDs) includes forming a plurality of carbon nanotubes on a substrate, contacting the carbon nanotubes with a polymer composition comprising a polymer and a solvent, and removing at least a portion of the solvent so as to form a solid composition from the carbon nanotubes and the polymer to form a carbon nanotube bundle having a base with a periphery, and an elevated central region where, along the periphery of the base, the carbon nanotubes slope toward the central region.Type: GrantFiled: December 3, 2007Date of Patent: September 14, 2010Assignee: Brother International CorporationInventor: Kangning Liang
-
Patent number: 7790135Abstract: The present invention is directed to the production of nanostructures, e.g., single wall carbon nanotubes (“SWNT”) and/or multi-wall carbon nanotubes (“MWNT”), from solutions containing a polymer, such as polyacrylonitrile (PAN). In particular, the invention is directed to the production of nanostructures, for example, SWNT and/or MWNT, from mixtures, e.g., solutions, containing polyacrylonitrile, polyaniline emeraldine base (PANi) or a salt thereof, an iron salt, e.g., iron chloride, and a solvent. In one embodiment, a mixture containing polyacrylonitrile, polyaniline emeraldine base or a salt thereof, an iron salt, e.g., iron chloride, and a solvent is formed and the mixture is electrospun to form nanofibers. In another embodiment, the electrospun nanofibers are then oxidized, e.g., heated in air, and subsequently pyrolyzed to form carbon nanostructures.Type: GrantFiled: July 1, 2004Date of Patent: September 7, 2010Assignee: Physical Sciences, Inc.Inventor: John D. Lennhoff
-
Patent number: 7785447Abstract: Closed apparatus and processes by which carbon feedstock is composed of a mixture of non-coking coal fines and another carbonaceous material, such as waste coke fines, are described. The coal and coke fines are mixed together and may be formed into solid pieces. The mixture alone or as solid pieces is fired through pyrolyzation into solid pieces of coke, with solid and gaseous by-products of pyrolyzation being recycled for use within the coke-producing closed system, thereby reducing or eliminating release of undesirable substances to the environment. A char-forming binder may or may not be added to the carbon mixture prior to pyrolyzation.Type: GrantFiled: December 3, 2007Date of Patent: August 31, 2010Assignee: Combustion Resources, LLCInventors: Craig N. Eatough, Jon S. Heaton, Steven R. Eatough
-
Publication number: 20100187708Abstract: A disposal method for entirely recycling solid refuse includes the following steps: sorting, crushing, drying, pressing with high pressure to shaped articles, producing charcoal from combustible refuse in high temperature and firing incombustible refuse in high temperature, at last cooling high temperature articles to obtain solid fuel with various shapes and bricks or board used for building. The method achieves entirely recycling house refuse, especial solid refuse. The method recycles solid refuse to obtain fuel and building material with economic value. The method is simple and its processing cost is low.Type: ApplicationFiled: July 21, 2008Publication date: July 29, 2010Inventor: Qihui Lian
-
Patent number: 7758779Abstract: A reinforced carbon foam material is formed from carbon fibers incorporated within a carbon foam's structure. First, carbon fiber bundles are combined with a liquid resol resin. The carbon fiber bundles separate into individual carbon fiber filaments and disperse throughout the liquid resol resin. Second, the carbon fiber resin mixture is foamed thus fixing the carbon fibers in a permanent spatial arrangement within the phenolic foam. The foam is then carbonized to create a carbon fiber reinforced foam with improved graphitic characteristics as well as increased strength. Optionally, various additives can be introduced simultaneously with the addition of the carbon fiber bundles into the liquid resol, which can improve the graphitic nature of the final carbon foam material and/or increase the foam's resistance to oxidation.Type: GrantFiled: December 29, 2005Date of Patent: July 20, 2010Assignee: GrafTech International Holdings Inc.Inventors: Douglas J. Miller, Irwin C. Lewis, Richard L. Shao, Mehmet Suha Yazici
-
Patent number: 7758783Abstract: A process of continuously producing a more isotropic, electrically conductive composite composition is provided. The process comprises: (a) continuously supplying a compressible mixture comprising exfoliated graphite worms and a binder or matrix material, wherein the binder or matrix material is in an amount of between 3% and 60% by weight based on the total weight of the mixture; (b) continuously compressing the compressible mixture at a pressure within the range of from about 5 psi or 0.035 MPa to about 50,000 psi or 350 MPa in at least a first direction into a cohered graphite composite compact; and (c) continuously compressing the composite compact in a second direction, different from the first direction, to form the composite composition in a sheet or plate form. The process leads to composite plates with exceptionally high thickness-direction electrical conductivity.Type: GrantFiled: September 17, 2007Date of Patent: July 20, 2010Assignee: Nanotek Instruments, Inc.Inventors: Jinjun Shi, Aruna Zhamu, Bor Z. Jang
-
Patent number: 7749425Abstract: A method of forming a nanoscale ceramic composite generally includes modifying a polymeric ceramic precursor, mixing the modified polymeric ceramic precursor with a block copolymer to form a mixture, forming an ordered structure from the mixture, wherein the modified polymeric ceramic precursor selectively associates with a specific type of block of the block copolymer, and heating the ordered structure for a time and at a temperature effective to form the nanoscale ceramic composite.Type: GrantFiled: December 21, 2005Date of Patent: July 6, 2010Assignee: General Electric CompanyInventors: Patrick Roland Lucien Malenfant, Julin Wan, Mohan Manoharan
-
Patent number: 7736554Abstract: A method of manufacturing a part out of impervious thermostructural composite material, the method comprising forming a porous substrate from at least one fiber reinforcement made of refractory fibers, and densifying the reinforcement by a first phase of carbon and by a second phase of silicon carbide. The method then continues by impregnating the porous substrate with a composition based on molten silicon so as to fill in the pores of the substrate.Type: GrantFiled: April 14, 2005Date of Patent: June 15, 2010Assignee: Snecma Propulsion SolideInventors: Jacques Thebault, Clément Bouquet, Michel Laxague, Hervé Evrard
-
Patent number: 7732037Abstract: A conductive porous material includes a matrix having a sintered compact of an oxide, a communicating opening formed in the matrix, having a small diameter and being permeable to gas and impermeable to substance other than gas, and a conductive layer provided on an internal wall of the communicating opening and receiving a current to generate heat. As conductive material is used, an organic substance adheres on the internal wall of communicating opening. To address this, conductive layer is caused to generate heat to decompose and thus remove the organic substance and thus prevent the communicating opening from clogging.Type: GrantFiled: January 25, 2005Date of Patent: June 8, 2010Assignees: Towa Corporation, Japan Fine Chemicals CenterInventors: Takaki Kuno, Keiji Maeda, Yoshinori Noguchi, Satoshi Kitaoka, Naoki Kawashima
-
Publication number: 20100112322Abstract: The various embodiments of the present invention provide improved carbon fibers and films, as well as methods of making the carbon fibers and films. The carbon fibers and films disclosed herein are generally formed from an acrylonitrile-containing polymer. The carbon fibers and/or films can also be formed from a composite that includes the acrylonitrile-containing polymer as well as carbon nanotubes, graphite sheets, or both. The fibers and films described herein can be tailored to exhibit one or more of high strength, high modulus, high electrical conductivity, high thermal conductivity, or optical transparency, depending on the desired application for the fibers or films.Type: ApplicationFiled: January 30, 2008Publication date: May 6, 2010Applicant: GEORGIA TECH RESEARCH CORPORATIONInventors: Satish Kumar, Han Gi Chae
-
Patent number: 7708050Abstract: A composite material having a high thermal conductivity and a small thermal expansion coefficient, which is obtained by impregnating a porous graphitized extrudate with a metal; the composite material having such anisotropy that the thermal conductivity and the thermal expansion coefficient are 250 W/mK or more and less than 4×10?6/K, respectively, in an extrusion direction; and that the thermal conductivity and the thermal expansion coefficient are 150 W/mK or more and 10×10?6/K or less, respectively, in a direction perpendicular to the extrusion direction.Type: GrantFiled: February 23, 2007Date of Patent: May 4, 2010Assignee: Hitachi Metals, Ltd.Inventor: Hideko Fukushima
-
Patent number: 7708810Abstract: A gas permeable, carbon based, nanocomposite membrane comprises a nanoporous carbon matrix comprising a pyrolyzed polymer, and a plurality of nanoparticles of carbon or an inorganic compound disposed in the matrix. The matrix is prepared by pyrolyzing a polymer, and nanoparticles of the particulate material are disposed in the polymer prior to pyrolysis. The particles may be disposed in a precursor of the polymer, which precursor is subsequently polymerized, or in the polymer itself.Type: GrantFiled: July 18, 2006Date of Patent: May 4, 2010Assignee: The Penn State Research FoundationInventors: Henry C. Foley, Ramakrishnan Rajagopalan, Anna R. Merritt
-
Publication number: 20100092724Abstract: A process for producing a carbon structural body is provided, with which a carbon structural body having any of various nanostructures can be produced inexpensively and efficiently. The method includes forming a carbon-containing material into a pattern, coating the obtained pattern with a proto-shaped mold, and calcining and carbonizing the coated pattern.Type: ApplicationFiled: November 21, 2006Publication date: April 15, 2010Applicants: MITSUBISHI CHEMICAL CORPORATION, NATIONAL UNIVERSITY CORPORATION HOKKAIDO UNIVERSITYInventors: Toshifumi Shiroya, Hiroyuki Aikyou, Masaki Yamamoto, Jun Enda, Masatsugu Shimomura, Sadaaki Yamamoto, Kuniharu Ijiro, Kenji Hijikata, Hiroshi Yabu, Yasutaka Matsuo, Masaru Tanaka
-
Patent number: 7695669Abstract: The present invention provides a method of reutilization and method of shaping of waste plastic which reduces the amount of volatile ingredients and oil cake* to extents preferable as materials for coke ovens, enables the formation of plastic granular materials able to maintain suitable shapes even after charging into a coke oven, and does not require expensive facilities for treating any produced hydrogen chloride gas, that is, a method of reutilization of waste plastic characterized by melting waste plastic at over 160° C. to 250° C. in temperature in part or whole, compression shaping it to thereby obtain a plastic granular material having an apparent density of 0.7 to 1.2 kg/liter, and mixing this plastic granular material with coal for dry distillation in a coke oven.Type: GrantFiled: October 20, 2004Date of Patent: April 13, 2010Assignee: Nippon Steel CorporationInventors: Takayuki Araki, Koichi Fukuda, Kenji Kato
-
Publication number: 20100084075Abstract: This invention relates to an improved carbon-carbon composite material and method of preparation. The carbon-carbon composite material comprises a plurality of carbon fiber substrates that have been joined or consolidated. In the present invention, the carbon fibers are stressed during the preparation of the composite material. The invention comprises adding a low-melting point pitch to the carbon fiber substrates and heat treating the carbon fiber substrates. The fibers tend to shrink more than the pitch during heat-treatment which produces stress in the fibers. This invention enhances the strength of the composite material and improves reliability.Type: ApplicationFiled: October 13, 2006Publication date: April 8, 2010Inventors: Anthony J. Rutten, Slawomir T. Fryska, Mark L. LaForest, Allen H. Simpson, Barry P. Soos
-
Patent number: 7686990Abstract: A method of producing a CMC article having a net shape, and by which the article can be formed to have an exterior surface with desirable characteristics, such as being free of an imprint pattern of a fiber reinforcement material within the article. The method entails providing a body comprising the fiber reinforcement material, and depositing a coating on a surface of the body. The coating contains a carbonaceous binder and a slurry containing a ceramic particulate material. Following its deposition, the carbonaceous binder within the coating is cured to render the coating machinable, and the coating is then machined to approximately produce the net shape of the article.Type: GrantFiled: December 31, 2004Date of Patent: March 30, 2010Assignee: General Electric CompanyInventor: Paul Edward Gray
-
Patent number: 7658903Abstract: A highly isotropic graphite useful for, inter alia, nuclear applications is disclosed, which has a ash content of less than 300 ppm and a boron equivalence of less than about 2 ppm without requiring a post graphitization purification step.Type: GrantFiled: September 12, 2006Date of Patent: February 9, 2010Assignee: GrafTech International Holdings Inc.Inventors: Douglas J. Miller, David R. Ball
-
Patent number: 7632435Abstract: Method of carbonizing pitch-infiltrated fibrous annular preform by: infiltrating the preform with pitch; placing the pitch-infiltrated preform in a constraint fixture having an ejector base plate, an inner wall, an outer wall, and a top press plate; selecting the relative sizes of the preform and the constraint fixture so that a layer of inert friable material may be situated between the preform and walls of the constraint fixture; placing inert friable material (e.g., activated carbon) between the preform and the top, bottom, and walls of the constraint fixture; and subjecting the pitch-infiltrated fibrous preform to carbonization in the constraint fixture. The activated carbon or other inert friable material adsorbs pitch molecules that escape the preform during carbonization, which reduces problems with foaming.Type: GrantFiled: May 18, 2006Date of Patent: December 15, 2009Assignee: Honeywell International Inc.Inventors: Allen H. Simpson, Slawomir T. Fryska, Mark L. La Forest, Barry P. Soos
-
Patent number: 7628942Abstract: A process has been developed for fabricating composite structures using either reaction forming or polymer infiltration and pyrolysis techniques to densify the composite matrix. The matrix and reinforcement materials of choice can include, but are not limited to, silicon carbide (SiC) and zirconium carbide (ZrC). The novel process can be used to fabricate complex, net-shape or near-net shape, high-quality ceramic composites with a crack-free matrix.Type: GrantFiled: August 17, 2006Date of Patent: December 8, 2009Assignee: The United States of America as represented by the United States Department of EnergyInventors: David V. Miller, Rita Baranwal
-
Patent number: 7625543Abstract: Provided is a production process for a carbonized product characterized by comprising the following steps (a) to (b): (a) a step in which metal-made or ceramic-made plural granular matters are charged into a heat treating apparatus which is maintained at a temperature of 400° C. or higher and 700° C. or lower and allowed to move therein and in which a carbonized product precursor is fed into the above apparatus and subjected to heat treatment, whereby the carbonized product is adhered on the surface of the above granular matters and (b) a step in which the carbonized product adhered on the surface of the granular matters is heated at a higher temperature than the heat treating temperature in the step (a) and 900° C. or lower, whereby the carbonized product is separated from the granular matters. The present invention provides a production process for an inexpensive and useful carbonized product by simple apparatus and steps.Type: GrantFiled: February 23, 2005Date of Patent: December 1, 2009Assignee: Mitsubishi Gas Chemical Company, Inc.Inventors: Ryusuke Shigematsu, Koichi Kanno, Takahiro Ojima, Takashi Kojima
-
Patent number: 7611609Abstract: A method for producing non-recovery/heat recovery coke may include the steps of providing a container, disposing a volume of loose coal into the container such that a vertical dimension of the volume of loose coal in the container is smaller than a horizontal dimension of the volume of loose coal, applying a force to the coal in the container to produce a volume of compacted coal having a substantially uniform density which is larger than that of the loose coal, disposing the compacted coal into a non-recovery/heat recovery type oven, and heating the compacted coal to produce coke. The method may also include the steps of providing a container, and moving the non-recovery/heat recovery coke mass from the oven at a substantially constant elevation to the container, quenching the coke mass in the container to produce a quenched coke mass, and removing the quenched coke mass from the container.Type: GrantFiled: May 1, 2001Date of Patent: November 3, 2009Assignee: ArcelorMittal Investigacion y Desarrollo, S. L.Inventors: Hardarshan S Valia, William J Ambry
-
Publication number: 20090236763Abstract: Method of manufacturing composite wheel beam key by: forming entirely from carbon fiber precursors or from carbon fiber precursors and ceramic materials a fibrous preform blank in a shape of a desired wheel beam key, wherein the fiber volume fraction of the preform blank is at least 50%; carbonizing the carbon fiber precursors; rigidifying the carbonized preform blank by subjecting it to at least one cycle of CVD; grinding the surface of the preform blank to open pores on its surface; and subjecting the open-pored preform blank to RTM processing with pitch. Also, carbon-carbon composite or carbon-ceramic composite wheel beam key produced by this process, having a density of from 1.5 g/cc to 2.1 g/cc and a maximum internal porosity of 10% or less.Type: ApplicationFiled: March 27, 2006Publication date: September 24, 2009Applicant: HONEYWELL INTERNATIONAL INC.Inventors: Allen H. Simpson, Mark L. La Forest, Slawomir T. Fryska
-
Publication number: 20090220826Abstract: Disclosed are processes for producing monolithic and metal doped monolithic porous carbon disks from prepolymer organic precursors in the powder form composed of either or both polyimide and polybenzimidazole. The powders are consolidated (compressed) into disks and then pyrolyzed to form the desired porous carbon disk. Porous carbon-carbon composite disks are also prepared by adding carbon to the prepolymer organic precursors.Type: ApplicationFiled: February 23, 2009Publication date: September 3, 2009Inventor: Jing Wang
-
Patent number: 7578860Abstract: According to the present invention there is provided a coal-based carbon foam having a density of between about 0.1 g/cm3 and about 0.8 g/cm3, preferably between about 0.2 g/cm3 and about 0.6 g/cm3 and most preferably between about 0.3 g/cm3 and about 0.4 g/cm3 that is produced by the controlled heating of high volatile bituminous coal particulate in a “mold” and under a non-oxidizing atmosphere. The high volatile bituminous coal starting material preferably exhibits a free swell Index of between about 3.5 and about 5.0 and most preferably between about 3.75 and about 4.5. A number of additional highly desirable characteristics of the high volatile bituminous coal starting material are also described. The carbon foam product thereby produced can be machined, adhered and otherwise fabricated to produce a wide variety of low cost, low density products, or used in its preformed shape as a filter, beat or electrical insulator etc.Type: GrantFiled: March 29, 2004Date of Patent: August 25, 2009Assignee: Touchstone Research Laboratory, Ltd.Inventor: Darren Kenneth Rogers
-
Publication number: 20090173050Abstract: The invention concerns a process for the production of a porous ?-SiC-bearing ceramic molded body that includes an aluminum oxide layer at the surface of the pores and passages of the porous ?-SiC-bearing ceramic molded body. The invention further concerns a porous ?-SiC-bearing ceramic molded body which has pores of a mean pore size in the range of between 0.1 urn and 50 ?m and an aluminum oxide layer at the surface of the open pores and passages.Type: ApplicationFiled: July 5, 2006Publication date: July 9, 2009Applicant: HELSA-AUTOMOTIVE GMBH & CO. KGInventors: Nahum Travitzky, Daniel Galsterer, Peter Greil, Thomas Wolff, Heino Sieber, Lars Weisensel
-
Publication number: 20090176079Abstract: The present invention relates to a process based on phase separation for the production of porous carbon monoliths, to the monoliths produced in accordance with the invention, and to the use thereof.Type: ApplicationFiled: April 28, 2007Publication date: July 9, 2009Inventors: Karin Cabrera-Perez, Phillip Adelhelm, Bernd Smarsly, Markus Antonietti
-
Publication number: 20090169738Abstract: A method of manufacturing a carbon-based tooling for use as the support during melt infiltration processing of a prepreg preform used, for example, to manufacture turbine engine components, comprising forming an admixture of chopped carbon fibers, graphite powder and a high durometer thermosetting organic resin, applying a potion of the admixture at room temperature onto the surface of an aluminum die, initially curing the admixture as applied to the aluminum die for a period of 3-5 hours at a temperature of between about 100 and 200 degrees C., removing the carbon-based tooling from the aluminum die and carbonizing the tooling by heating the initially cured tooling to a temperature of about 750 degrees C for a period of about 40 hours.Type: ApplicationFiled: December 28, 2007Publication date: July 2, 2009Applicant: General Electric CompanyInventors: Paul Edward Gray, Roger Lee Ken Matsumoto
-
Patent number: 7544316Abstract: A process for preparing graphite articles is presented. In particular, the process includes employing a particulate fraction comprising at least about 35 weight percent coke, coal or combinations thereof having a diameter such that a major fraction of it passes through a 0.25 mm to 25 mm mesh screen. The particulate fraction is mixed with a liquid or solid pitch binder, to form a stock blend; the stock blend is extruded to form a green stock; the green stock is baked to form a carbonized stock; and the carbonized stock is graphitized. The stock blend further includes carbon fibers added after mixing of the particulate fraction and pitch has begun.Type: GrantFiled: June 8, 2005Date of Patent: June 9, 2009Assignee: GrafTech International Holdings Inc.Inventors: James William Kortovich, Richard Liichang Shao, Irwin Charles Lewis, Richard Thomas Lewis, Dai Huang
-
Patent number: 7534328Abstract: The present invention provides a method of making a carbon electrode, suitable for use as an anode in an aluminum reduction cell, which comprises mixing an aggregate, comprising a mixture of particulate shot coke, and a particulate carbonaceous material other than shot coke with coal tar pitch or petroleum pitch or a combination of these pitches at an elevated temperature to form a paste wherein said aggregate comprises a combination of butts, coarse, and fine particles and said particulate shot coke may comprise a majority of said coarse particles or fine particles, and said paste comprises from about 80 to about 90%, by weight, of said aggregate and from about 10 to about 20%, by weight, of said pitch; forming said paste into a solid body; and baking said solid body at an elevated temperature to form said carbon electrode.Type: GrantFiled: September 29, 2006Date of Patent: May 19, 2009Assignees: CII Carbon LLC, Century Aluminum CompanyInventors: Leslie C. Edwards, M. Franz Vogt, Richard O. Love, J. Anthony Ross, William Rogers Morgan, Jr.