Controlling Varying Temperature Or Plural Heating Steps Patents (Class 264/29.7)
  • Patent number: 10865475
    Abstract: A method for depositing a metal film onto a substrate is disclosed. In particular, the method comprises pulsing a metal halide precursor onto the substrate and pulsing a reducing precursor onto the substrate. A reaction between the metal halide precursor and the reducing precursor forms a metal film. Specifically, the method discloses forming a metal boride or a metal silicide film.
    Type: Grant
    Filed: April 21, 2016
    Date of Patent: December 15, 2020
    Assignee: ASM IP Holding B.V.
    Inventors: Petri Raisanen, Eric Shero, Suvi Haukka, Robert Brennan Milligan, Michael Eugene Givens
  • Patent number: 10774010
    Abstract: Techniques for infiltrating a CMC substrate may include infiltrating the CMC substrate with a first slurry to at least partially fill at least some inner spaces of the CMC substrate, where the first slurry includes first solid particles, drying the first slurry to form an infiltrated CMC including the first solid particles, depositing a second slurry including a carrier material and second solid particles on a surface of the infiltrated CMC, where the second solid particles include a plurality of fine ceramic particles, a plurality of coarse ceramic particles, and a plurality of diamond particles, drying the second slurry to form an article having an outer surface layer including the second solid particles on the infiltrated CMC, and infiltrating the article with a molten infiltrant to form a composite article.
    Type: Grant
    Filed: April 28, 2017
    Date of Patent: September 15, 2020
    Assignee: Rolls-Royce High Temperature Composites, Inc.
    Inventors: Sungbo Shim, Andrew Joseph Lazur, Robert Shinavski
  • Patent number: 10717681
    Abstract: A method of preparing a ceramic matrix composite (CMC) component that includes a protective ceramic layer comprises adhering at least one flexible ceramic tape to a ceramic fiber preform, where the at least one flexible ceramic tape comprises ceramic particles dispersed in an organic binder phase. After the adhering, the at least one flexible ceramic tape is heated to a temperature sufficient to volatilize the organic binder phase, thereby forming a porous ceramic layer on at least a portion of the ceramic fiber preform. After the heating and volatilizing, the ceramic fiber preform and the porous ceramic layer are infiltrated with a molten material, thereby forming a CMC component including, on at least a portion thereof, a protective ceramic layer.
    Type: Grant
    Filed: December 3, 2015
    Date of Patent: July 21, 2020
    Assignee: ROLLS-ROYCE CORPORATION
    Inventors: Sean Erin Landwehr, Benjamin John Bowin Lai, Adam Lee Chamberlain
  • Patent number: 10611697
    Abstract: Example techniques may include depositing a slurry on at least a predetermined surface region of a ceramic matrix composite substrate. The slurry may include a solvent and particles comprising at least one of silicon metal or silicon carbide. The slurry may be dried to form a wicking layer on the predetermined surface region. The ceramic matrix composite substrate and the wicking layer may be heated to a temperature of at least 900° C. to wick at least one wickable species from the ceramic matrix composite substrate into the wicking layer. Substantially all of the wicking layer may be removed from the predetermined surface region. Example articles may include a ceramic matrix composite substrate. A wicking layer may be disposed on at least a predetermined surface region of the ceramic matrix composite substrate. The wicking layer may include at least one wicked species wicked from the ceramic matrix composite substrate.
    Type: Grant
    Filed: October 21, 2016
    Date of Patent: April 7, 2020
    Assignees: Rolls-Royce High Temperature Composites, Inc., Rolls-Royce Corporation
    Inventors: Sungbo Shim, Kang N. Lee
  • Patent number: 9845267
    Abstract: Provided is a long and large-area graphite film having improved thermal diffusivity and flex resistance, and accompanied by ameliorated ruffling. According to a method for producing a graphite film, in which graphitization of a heat-treated film consisting of a carbonized polymer film is carried out in a state being wrapped around an internal core, the method being characterized in that a heat treatment is executed by controlling distance(s) between the internal core and the film, and/or between the layers of the film, a graphite film accompanied by significantly ameliorated ruffling can be obtained.
    Type: Grant
    Filed: January 13, 2016
    Date of Patent: December 19, 2017
    Assignee: KANEKA CORPORATION
    Inventors: Yusuke Ohta, Makoto Mishiro, Takashi Inada, Yasushi Nishikawa
  • Patent number: 9193592
    Abstract: The present invention performs special heat treatment on a polymer film in a temperature range from (i) a lower limit to temperature rise being equal to or higher than a starting temperature of thermal decomposition of the polymer film, i.e., which is a temperature observed at an early stage of the thermal decomposition of the polymer film, to (ii) an upper limit to temperature rise being equal to or lower than an intermediate temperature of thermal decomposition of the polymer film. This reduces foaming in the film during graphitization treatment following the special heat treatment. Thus, even with a higher heating rate for graphitization, it is possible to produce a graphite film having good quality.
    Type: Grant
    Filed: May 4, 2015
    Date of Patent: November 24, 2015
    Assignee: KANEKA CORPORATION
    Inventors: Yusuke Ohta, Takashi Inada, Makoto Mishiro, Yasushi Nishikawa
  • Patent number: 8992807
    Abstract: 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: Grant
    Filed: January 11, 2011
    Date of Patent: March 31, 2015
    Assignees: Samsung Techwin Co., Ltd., Sungkyunkwan University Foundation for Corporate Collaboration
    Inventors: Keun-soo Kim, Jong-hyun Ahn, Byung-hee Hong
  • Patent number: 8956480
    Abstract: The carbon-carbon composite material is obtained by densification with a pyrolytic carbon matrix originating from a precursor in gaseous state at least in a main external phase of the matrix, and, at the end of the densification, final heat treatment is performed at a temperature lying in the range 1400° C. to 1800° C.
    Type: Grant
    Filed: December 15, 2010
    Date of Patent: February 17, 2015
    Assignee: Messier-Bugatti-Dowty
    Inventors: Jean-Marie Jouin, Eric Lherm, Philippe Turgis
  • Patent number: 8932513
    Abstract: A method of synthesizing mechanically resilient titanium carbide (TiC) nanofibrous felts comprising continuous nanofibers or nano-ribbons with TiC crystallites embedded in carbon matrix, comprising: (a) electrospinning a spin dope for making precursor nanofibers with diameters less than 0.5 J.Lm; (b) overlaying the nanofibers to produce a nanofibrous mat (felt); and then (c) heating the nano-felts first at a low temperature, and then at a high temperature for making electrospun continuous nanofibers or nano-ribbons with TiC crystallites embedded in carbon matrix; and (d) chlorinating the above electrospun nano-felts at an elevated temperature to remove titanium for producing carbide derived carbon (CDC) nano-fibrous felt with high specific surface areas.
    Type: Grant
    Filed: May 29, 2012
    Date of Patent: January 13, 2015
    Assignee: South Dakota Board of Regents
    Inventors: Hao Fong, Lifeng Zhang, Yong Zhao, Zhengtao Zhu
  • Patent number: 8920691
    Abstract: Disclosed herein is a production method capable of efficiently producing a carbonized film wound into a roll without the occurrence of fusion bonding between the layers of the film. The method includes a carbonization step in which a polymer film wound around a core is placed in a heating furnace and carbonized by heat treatment to obtain a carbonized film wound around the core. The carbonization step is performed by increasing a temperature of the heat treatment from an initial temperature through a pyrolysis onset temperature to a pyrolysis end temperature. In the carbonization step, the heating furnace is decompressed when the temperature of the heat treatment is lower than the pyrolysis onset temperature, and after the temperature of the heat treatment reaches the pyrolysis onset temperature, the heating furnace is not decompressed or the heating furnace is decompressed so that an absolute pressure in the heating furnace is in a range of 21.3 kPa to 101.29 kPa.
    Type: Grant
    Filed: March 9, 2011
    Date of Patent: December 30, 2014
    Assignee: Kaneka Corporation
    Inventors: Makoto Mishiro, Yasushi Nishikawa, Yusuke Ohta, Takashi Inada
  • Publication number: 20140371385
    Abstract: The present invention relates to a method for recycling scrap rubber comprising the steps of pyrolyzing scrap rubber to obtain a char material and milling the thus obtained char material. The present invention also relates to carbon black powders and carbon black pellets obtained by the method according to the invention. Moreover, the present invention relates to the use of said carbon black powder and to compositions comprising said carbon black powders.
    Type: Application
    Filed: December 21, 2012
    Publication date: December 18, 2014
    Inventors: Arnoldus Henricus Adrianus Verberne, Jan Anne Jonkman, Christopher Michael Twigg
  • Publication number: 20140339718
    Abstract: Silicon carbide composite materials contain CSiC with a density of 2.95 to 3.05 g/cm?3 and a fiber bundle content of 2 to 10 wt. %. The fiber bundles have a length of 6 to 20 mm, a width of 0.2 to 3 mm, and a thickness of 0.1 to 0.8 mm. The fiber bundles are filled with a cured phenolic resin content of up to 45 wt. %, and the protected fiber bundles are integrated into an SiC matrix. A method produces the silicon carbide composite materials.
    Type: Application
    Filed: August 4, 2014
    Publication date: November 20, 2014
    Inventors: TANJA DAMJANOVIC, ANDREAS KIENZLE, INGRID KRAETSCHMER
  • Patent number: 8845950
    Abstract: A method to manufacture a carbon fiber electrode comprises synthesizing polyamic acid (PAA) as a polyimide (PI) precursor from pryomellitic dian hydride (PMDA) and oxydianiline (ODA) as monomers and triethylamine (TEA) as a catalyst, adding dimethylformamide (DMF) to the polyamic acid (PAA) solution to prepare a spinning solution and subjecting the spinning solution to electrostatic spinning at a high voltage to obtain a PAA nanofiber paper, converting the PAA nanofiber paper into a polyimide (PI) nanofiber paper by heating, and converting the polyimide (PI) nanofiber paper into a carbon nanofiber (CNF) paper by heating under an Ar atmosphere. Also, the method to manufacture a polyimide carbon nanofiber electrode and/or a carbon nanotube composite electrode may utilize carbon nanofibers having diameters that are lessened by optimizing electrostatic spinning in order to improve spinnability.
    Type: Grant
    Filed: September 3, 2008
    Date of Patent: September 30, 2014
    Assignee: Samsung Electronics Co., Ltd.
    Inventors: Dae Wook Park, Hyong Soo Noh, Hideo Nojima, Thi Xuyen Nguyen, Chul Ho Song, Young Hee Lee
  • Publication number: 20140248552
    Abstract: A support for a fuel cell includes a substrate including highly crystalline carbon, and a crystalline carbon layer on the substrate.
    Type: Application
    Filed: November 1, 2013
    Publication date: September 4, 2014
    Applicant: SAMSUNG SDI CO., LTD.
    Inventors: Jun-Young KIM, Sung-Chul LEE, Myoung-Ki MIN, Yong-Bum PARK
  • Patent number: 8808609
    Abstract: The present invention has an object of providing the carbon fiber (or the nonwoven fabric configured of the aforementioned carbon fiber) of which the surface area, the graphitization degree, and the fiber diameter are large, high, and small, respectively, and yet of which dispersion is small. The method of producing the carbon fiber nonwoven fabric includes a dispersion liquid preparing step of preparing a dispersion liquid containing resin and pitch, an electrospinning step of producing the nonwoven fabric that is comprised of carbon fiber precursors with electrospinning from the aforementioned dispersion liquid, and a modifying step of modifying the carbon fiber precursors of the nonwoven fabric obtained in the aforementioned electrospinning step into the carbon fiber.
    Type: Grant
    Filed: September 17, 2010
    Date of Patent: August 19, 2014
    Assignees: TEC One Co., Ltd., Shinshu University
    Inventors: Takahiro Kitano, Fujio Okino
  • Patent number: 8758656
    Abstract: In order to obtain a graphite film having an excellent thermal diffusivity, a high density, and excellent flatness without flaws, recesses and wrinkles on the surface, the process for producing a graphite film according to the present invention comprises the graphitization step for a raw material film made of a polymer film and/or a carbonized polymer film and/or the post-planar pressurization step for the film in this order to prepare a graphite film, wherein the graphitization step is a step of thermally treating two or more stacked raw material films at a highest temperature of 2,000° C. and includes a method of electrically heating the raw material films themselves and/or a method of thermally treating the films while applying pressure to the films planarly, and the post-planar pressurization step includes a method of planarly pressurizing the one raw material film or the multiple stacked raw material films after graphitization by single-plate press or vacuum press.
    Type: Grant
    Filed: March 9, 2011
    Date of Patent: June 24, 2014
    Assignee: Kaneka Corporation
    Inventors: Yasushi Nishikawa, Shuhei Wakahara, Mutsuaki Murakami
  • Patent number: 8703027
    Abstract: Methods and compositions relate to manufacturing a carbonaceous article from particles that have pitch coatings. Heating the particles that are formed into a shape of the article carbonizes the pitch coatings. The particles interconnect with one another due to being formed into the shape of the article and are fixed together where the pitch coatings along adjoined ones of the particles contact one another and are carbonized to create the article.
    Type: Grant
    Filed: October 31, 2011
    Date of Patent: April 22, 2014
    Assignee: Phillips 66 Company
    Inventor: Zhenhua Mao
  • Patent number: 8673450
    Abstract: The problem of the present invention is to provide, in high current-low energy type ion implantation apparatuses, a graphite member for a beam line inner member of an ion implantation apparatus, which graphite member can markedly reduce particles incorporated in a wafer surface. This problem can be solved by the graphite member of the present invention, which is a graphite member for a beam line inner member of an ion implantation apparatus, which member having a bulk density of not less than 1.80 Mg/m3 and an electric resistivity of not more than 9.5 ??·m. Preferably, the R value obtained by dividing D band intensity at 1370 cm?1 by G band intensity at 1570 cm?1 in the Raman spectrum of a spontaneous fracture surface of the graphite member is not more than 0.20.
    Type: Grant
    Filed: October 12, 2006
    Date of Patent: March 18, 2014
    Assignee: Toyo Tanso Co., Ltd.
    Inventors: Kiyoshi Saito, Fumiaki Yokoyama, Hitoshi Suzuki, Atsuko Ando, Tetsuro Tojo, Seiji Shinohara
  • Publication number: 20140030601
    Abstract: The carbon material for a negative electrode of a lithium ion secondary battery includes: particles having a structure including a plurality of stacked plates which are prepared from a raw coke materials obtained by a delayed coking method, where the ratio of the total of the generation rate of a hydrogen gas, a hydrocarbon gas having one carbon atom, and a hydrocarbon gas having two carbon atoms and the formation rate of a raw coke materials satisfies the condition: total of generation rate/formation rate=0.30 to 0.60, and where the structure is curved into a bow shape, and where, in each of the plates, an average plate thickness is defined as T, an average bow height including the plate thickness is defined as H, and an average length in the vertical direction is defined as L, L/T is 5.0 or more and H/T is from 1.10 to 1.25.
    Type: Application
    Filed: September 27, 2013
    Publication date: January 30, 2014
    Applicant: JX NIPPON OIL & ENERGY CORPORATION
    Inventors: Tamotsu TANO, Hiroshi OZAWA, Takashi OYAMA, Takashi SUZUKI, Masatoshi NISHIDA
  • Publication number: 20140015153
    Abstract: The present invention performs special heat treatment on a polymer film in a temperature range from (i) a lower limit to temperature rise being equal to or higher than a starting temperature of thermal decomposition of the polymer film, i.e., which is a temperature observed at an early stage of the thermal decomposition of the polymer film, to (ii) an upper limit to temperature rise being equal to or lower than an intermediate temperature of thermal decomposition of the polymer film. This reduces foaming in the film during graphitization treatment following the special heat treatment. Thus, even with a higher heating rate for graphitization, it is possible to produce a graphite film having good quality.
    Type: Application
    Filed: March 26, 2012
    Publication date: January 16, 2014
    Applicant: KANEKA CORPORATION
    Inventors: Yusuke Ohta, Takashi Inada, Makoto Mishiro, Yasushi Nishikawa
  • Patent number: 8628707
    Abstract: A system for making carbon foam anodes including a digestion vessel in communication with a coal feedstock unit for producing a digested coal; a mold having an interior for accepting the digested coal to produce an ungraphitized carbon foam anode having a desired shape; a pressure unit in communication with the mold for producing an increased pressure within the interior of said mold; a heating element in communication with the mold to provide heat to the mold sufficient to convert the digested coal into the ungraphitized carbon foam anode; and a graphitization oven for graphitizing the ungraphitized carbon foam anode to produce the carbon foam anode. The present invention further includes methods for making carbon foam anodes.
    Type: Grant
    Filed: January 8, 2008
    Date of Patent: January 14, 2014
    Assignee: Carbonxt Group Limited
    Inventors: Randall J. Harris, Damian Wales
  • Patent number: 8628705
    Abstract: 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 mesopores.
    Type: Grant
    Filed: January 15, 2013
    Date of Patent: January 14, 2014
    Assignees: UT-Battelle, LLC, University of Tennessee Research Foundation
    Inventors: Sheng Dai, Georges A. Guiochon, Chengdu Liang
  • Patent number: 8608992
    Abstract: A method for producing one or more nanofibers includes providing (a) a solution comprising a polymer and a solvent, (b) a nozzle for ejecting the solution, and (c) a stationary collector disposed a distance d apart from the nozzle. A voltage is applied between the nozzle and the stationary collector, and a jet of the solution is ejected from the nozzle toward the stationary collector. An electric field intensity of between about 0.5 and about 2.0 kV/cm is maintained, where the electric field intensity is defined as a ratio of the voltage to the distance d. At least a portion of the solvent from the stream is evaporated, and one or more polymer nanofibers are deposited on the stationary collector as the stream impinges thereupon. Each polymer nanofiber has an average diameter of about 500 nm or less and may serve as a precursor for carbon fiber production.
    Type: Grant
    Filed: September 23, 2011
    Date of Patent: December 17, 2013
    Assignee: The Board of Trustees of the University of Illinois
    Inventors: Ioannis Chasiotis, Mohammad Naraghi, Salman N. Arshad
  • Patent number: 8603374
    Abstract: A polymer-bonded fiber agglomerate includes short fibers selected from carbon, ceramic materials, glasses, metals and organic polymers, and a polymeric bonding resin selected from synthetic resins and thermoplastics. The fiber agglomerates have an average length, measured in the fiber direction, of from 3 mm to 50 mm and an average thickness, measured perpendicularly to the fiber direction, of from 0.1 mm to 10 mm. At least 75% of all of the contained fibers have a length which is at least 90% and not more than 110% of the fiber agglomerate average length. A fiber-reinforced composite material having the fiber agglomerate and processes for the production thereof are also provided.
    Type: Grant
    Filed: September 7, 2011
    Date of Patent: December 10, 2013
    Assignee: SGL Carbon SE
    Inventors: Peter Domagalski, Alfred Haeusler, Ingrid Kraetschmer, Andreas Kienzle, Dieter Wuestner
  • Patent number: 8366979
    Abstract: 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 mesopores.
    Type: Grant
    Filed: January 21, 2011
    Date of Patent: February 5, 2013
    Assignees: UT-Battelle, LLC, University of Tennessee Research Foundation
    Inventors: Sheng Dai, Georges A. Guiohon, Chengdu Liang
  • Patent number: 8349231
    Abstract: This invention relates to a process for the production of a shaped composite material and the material obtained through that process. In particular it relates to a process for obtaining a disk of composite ceramic material for disc brakes in which the friction coefficient is varied by varying the composition of the surface layer.
    Type: Grant
    Filed: December 30, 2004
    Date of Patent: January 8, 2013
    Assignee: Brembo Ceramic Brake Systems S.p.A.
    Inventors: Ralf Siegfried Goller, Marco Orlandi, Riccardo Piavani
  • Patent number: 8337730
    Abstract: The present invention relates to a continuous, multicellular, hollow carbon fiber wherein the fiber structure includes a substantially hollow fiber and multiple internal walls defining multiple integral internal hollow fibers such that the fiber structure comprises a honeycomb-like cross section.
    Type: Grant
    Filed: January 5, 2009
    Date of Patent: December 25, 2012
    Assignees: The Boeing Company, Hill, Inc.
    Inventors: Thomas K. Tsotsis, Jeff Haggard
  • Publication number: 20120280413
    Abstract: The disclosure relates to a process for producing a refractory, ceramically fired, carbon-bonded magnesia brick whose matrix is more than 70% by weight, in particular from 80 to 98% by weight, of MgO grains and also a carbon framework binder matrix resulting from carbonization, and pores, wherein the MgO grains are fixed by means of carbon bonding of the carbon framework and at least 30%, in particular from 50 to 100%, of the MgO grains have at least one sintering bridge resulting from the ceramic firing.
    Type: Application
    Filed: May 7, 2012
    Publication date: November 8, 2012
    Inventor: Helge Jansen
  • Publication number: 20120208100
    Abstract: In one embodiment, an electrical power storage system using hydrogen includes a power generation unit generating power using hydrogen and oxidant gas and an electrolysis unit electrolyzing steam. The electrical power storage system includes a hydrogen storage unit storing hydrogen generated by the electrolysis and supplying the hydrogen to the power generation unit during power generation, a high-temperature heat storage unit storing high temperature heat generated accompanying the power generation and supplying the heat to the electrolysis unit during the electrolysis, and a low-temperature heat storage unit storing low-temperature heat, which is exchanged in the high-temperature heat storage unit and generating with this heat the steam supplied to the electrolysis unit.
    Type: Application
    Filed: August 11, 2011
    Publication date: August 16, 2012
    Inventors: Shoko SUYAMA, Yoshiyasu Ito, Shigeo Kasai, Yasuo Takagi, Tsuneji Kameda, Kentaro Matsunaga, Masato Yoshino, Daisuke Horikawa, Kazuya Yamada
  • Patent number: 8206624
    Abstract: A method for producing carbon nanotubes uses a polymer as a raw material to undergo in situ thermal decomposition. The method includes steps of mixing the polymer and metallic catalyst through a multiple heating stage process of in-situ thermal decomposition to carbonize the polymer and release carbon elements to produce carbon nanotubes. Advantages of the present invention include easy to prepare, low temperature in manipulation, low production cost, and high safety.
    Type: Grant
    Filed: February 7, 2009
    Date of Patent: June 26, 2012
    Assignee: National Chung Cheng University
    Inventors: Yuan-Yao Li, Chao-Wei Huang
  • Patent number: 8058197
    Abstract: This invention provides carbon composite materials, which comprise metal carbide particles, at least the particle surfaces or the entirety of which are metal carbides, synthesized in situ from a metal source, i.e., at least one member selected from the group comprising metal particles, metal oxide particles, and composite metal oxide particles, and a carbon source, i.e., a thermosetting resin, dispersed in a carbon, carbon fiber, or carbon/carbon fiber matrix, and contain no free metal particles. This invention also provides a method for producing such composite carbon materials, which enables the production of carbon composite materials having a high coefficient of friction, high thermostability, and abrasion resistance.
    Type: Grant
    Filed: July 23, 2010
    Date of Patent: November 15, 2011
    Assignee: Toyota Jidosha Kabushiki Kaisha
    Inventors: Shigeru Ichikawa, Sumio Kamiya, Koji Yamada, Hironori Sasaki
  • Patent number: 8051666
    Abstract: A microporous graphite foam, comprising a matrix of graphite fibers joined by a graphitized graphite-forming precursor, wherein the foam comprises irregular interstitial spaces having an average pore size in the range from about 0.1 to about 10 microns and a void fraction in the range from about 80% to about 95%. A process for producing a microporous graphite foam including a matrix of graphite fibers joined by a graphitized graphite-forming precursor. In its various embodiments, the graphite foam has one or more of pore sizes less than about ten microns, low bulk density, high physical strength and good machinability, while also having the desirable characteristics of graphite, including high thermal conductivity, electrical conductivity and solderability. A cryogenic cooling system including the graphite foam. In one embodiment, the graphite foam is a component of a cooling interface in the cryogenic cooling system.
    Type: Grant
    Filed: April 4, 2011
    Date of Patent: November 8, 2011
    Assignee: Raytheon Company
    Inventor: Philip Christopher Theriault
  • Patent number: 8034266
    Abstract: A process for the production of an open-cell carbon foam from a metallic salt of a lignosulfonate is described. The process includes heating the metallic salt of a lignosulfonate from ambient temperature to a maximum temperature, greater than about 250° C., at a rate sufficiently slow as to provide for essentially uniform heating of the lignin derived material. Heating of the lignin derived material is performed in a non-oxidizing atmosphere having a pressure greater than about 100 psig. The resultant carbon foam can subsequently be optionally subjected to carbonization or graphitization temperatures as desired. The resultant carbon foam has a regular open-cell structure. Densities of the carbon foam products are commonly in the range of about 0.1 g/cm3 to 0.2 g/cm3. The carbon foams may also exhibit compressive strengths of up to about 200 psi. The carbon foam materials potentially have utility as lightweight thermal barriers and in many other of the applications associated with carbon foams.
    Type: Grant
    Filed: August 3, 2004
    Date of Patent: October 11, 2011
    Assignee: Touchstone Research Laboratory, Ltd.
    Inventors: Drew M. Spradling, Doug R. Amie
  • Patent number: 7993549
    Abstract: 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: Grant
    Filed: September 16, 2005
    Date of Patent: August 9, 2011
    Assignee: Audi AG
    Inventors: Joachim Niewöhner, Markus Stettberger, Arno Sommer, Dunja Müller, Jens Rosenlöcher
  • Publication number: 20110189077
    Abstract: A microporous graphite foam, comprising a matrix of graphite fibers joined by a graphitized graphite-forming precursor, wherein the foam comprises irregular interstitial spaces having an average pore size in the range from about 0.1 to about 10 microns and a void fraction in the range from about 80% to about 95%. A process for producing a microporous graphite foam including a matrix of graphite fibers joined by a graphitized graphite-forming precursor. In its various embodiments, the graphite foam has one or more of pore sizes less than about ten microns, low bulk density, high physical strength and good machinability, while also having the desirable characteristics of graphite, including high thermal conductivity, electrical conductivity and solderability. A cryogenic cooling system including the graphite foam. In one embodiment, the graphite foam is a component of a cooling interface in the cryogenic cooling system.
    Type: Application
    Filed: April 4, 2011
    Publication date: August 4, 2011
    Inventor: Philip Christopher Theriault
  • Publication number: 20110171427
    Abstract: 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: Application
    Filed: January 11, 2011
    Publication date: July 14, 2011
    Applicants: SAMSUNG TECHWIN CO., LTD., SUNGKYUNKWAN UNIVERSITY FOUNDATION FOR CORPORATE COLLABORATION
    Inventors: Keun-soo KIM, Jong-hyun AHN, Byung-hee HONG
  • Patent number: 7976745
    Abstract: The present invention relates to a process for the preparation of a composite polymeric material containing nanometric inorganic inclusions comprising the steps of: mixing a polymer with a thermolytic precursor to provide a homogeneous dispersion of said at least one precursor and of said at least one polymer; subjecting said homogeneous dispersion to heating to provide a molten polymer and thermolytic fission of the precursor, generating the inclusions dispersed in the molten polymer.
    Type: Grant
    Filed: November 4, 2005
    Date of Patent: July 12, 2011
    Assignees: STMicroelectronics S.r.l., Universita degli Studi di Napoli Federico II
    Inventors: Raffaele Vecchione, Gianfranco Carotenuto, Valeria Casuscelli, Floriana Esposito, Salvatore Leonardi, Luigi Nicolais, Maria Viviana Volpe
  • Patent number: 7867608
    Abstract: 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: Grant
    Filed: December 25, 2007
    Date of Patent: January 11, 2011
    Assignee: Touchstone Research Laboratory, Ltd.
    Inventors: Jesse M. Blacker, Janusz W. Plucinski
  • Publication number: 20100279177
    Abstract: It discloses a carbon fiber conductive sheet and its manufacturing method. The manufacturing method includes the steps of (1) carding step, (2) hydro-entanglement processing step, (3) resin dipping step, (4) hot pressing step, (5) flattening step, (6) surface refining step, (7) first carbonization processing step, (8) second carbonization processing step, and (9) finishing step. By the special hydro-entanglement process, many horizontally disposed fibers are bent down to entangle with other fibers, so its thickness can be smaller than 250 ?m. About this invention, the hydro-entanglement process makes the fibers evenly and well distributed. The hydro-entanglement process will not destroy the fiber material. It is possible to fabricate a carbon fiber conductive sheet thinner than 15 ?m. In addition, this invention has a great electric conductivity between both sides of this sheet.
    Type: Application
    Filed: January 3, 2008
    Publication date: November 4, 2010
    Inventor: Hsiharng Yang
  • Patent number: 7824645
    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.
    Type: Grant
    Filed: January 20, 2005
    Date of Patent: November 2, 2010
    Assignee: Touchstone Research Laboratory, Ltd.
    Inventors: Dwayne R. Morgan, Rick D. Lucas
  • Patent number: 7824650
    Abstract: A graphitizable carbon foam 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 is then foamed to provide an oriented pitch foam. The pitch foam can be heated to carbonize the pitch thereby forming an oriented carbon foam. The carbon foam can be further heated to provide an oriented graphite foam.
    Type: Grant
    Filed: February 21, 2007
    Date of Patent: November 2, 2010
    Assignee: GrafTech International Holdings Inc.
    Inventors: Peter G. Stansberry, Leonard Singer
  • Patent number: 7799250
    Abstract: 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: Grant
    Filed: February 16, 2006
    Date of Patent: September 21, 2010
    Assignee: Audi AG
    Inventors: Ronald Huener, Moritz Bauer, Peter Winkelmann
  • Patent number: 7767183
    Abstract: Methods for the production of carbon foam from swelling coals that do not require the use of high process pressures, oxidized coal, devolatized coal, or high-strength, foam expansion confining molds are described. In some embodiments, a comminuted swelling bituminous coal is heated to a first elevated temperature sufficient to result in the coal particles softening and melting together to form a substantially homogeneous open cell plastic carbon material. The substantially homogeneous open cell plastic carbon material may then be heated to a second elevated temperature at a slow rate to form carbon foam. In some embodiments, the resulting carbon foam may be heated to a higher third elevated temperature. The resulting carbon foam may be subsequently heated to elevated temperatures as great as 3200° C. or more.
    Type: Grant
    Filed: November 20, 2006
    Date of Patent: August 3, 2010
    Assignee: Touchstone Research Laboratory, Ltd.
    Inventor: Thomas M. Matviya
  • Patent number: 7708810
    Abstract: 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: Grant
    Filed: July 18, 2006
    Date of Patent: May 4, 2010
    Assignee: The Penn State Research Foundation
    Inventors: Henry C. Foley, Ramakrishnan Rajagopalan, Anna R. Merritt
  • Patent number: 7700014
    Abstract: Method of manufacturing dense carbon-carbon composite material by: infiltrating a fibrous preform with pitch to form pitch-infiltrated preform; carbonizing the pitch-infiltrated preform; injecting resin or pitch into the preform in a mold; oxygen stabilizing the filled preform and carbonizing and heat-treating the oxygen-stabilized impregnated preform; and subjecting the preform to a single final cycle of chemical vapor deposition. This process reduces densification time as compared to comparable conventional carbon-carbon composite manufacturing procedures.
    Type: Grant
    Filed: April 13, 2006
    Date of Patent: April 20, 2010
    Assignee: Honeywell International Inc.
    Inventors: Allen H. Simpson, Slawomir T. Fryska, Mark L. La Forest, Barry P. Soos
  • Patent number: 7682534
    Abstract: A method for the production of a carbon or a ceramic component based on carbon, using a cellulose-containing semi-finished molded piece which is pyrolyzed. According to the invention, homogeneous large-size ceramic components may be produced, whereby a cellulose-containing, semi-finished molded piece containing fibers, chips or strands of homogeneous density distribution and homogeneous structure is used as semi-finished molded piece and is pyrolyzed in non-oxidizing gas atmospheres.
    Type: Grant
    Filed: December 12, 2002
    Date of Patent: March 23, 2010
    Assignees: Schunk Kohlenstofftechnik GmbH, Fraunhofer-Gesellschaft zur Forderung der Angewandten Forschung E.V.
    Inventors: Stefan Siegel, Gottfried Boden, Uwe Petasch, Volker Thole, Roland Weiss, Thorsten Scheibel, Martin Henrich, Marco Ebert, Martin Kühn, Andreas Lauer, Gotthard Nauditt
  • Patent number: 7658902
    Abstract: A process for producing a graphite article having a CTE of less than about 2.0 ppm/° C. over the temperature range of from 30° C. to 100° C. and an isotropy ratio of less than about 1.5 also advantageously having a thermal shock resistance parameter of greater than about 150×103 W/m in both the with-grain and against-grain directions, and the graphite so produced.
    Type: Grant
    Filed: September 12, 2006
    Date of Patent: February 9, 2010
    Assignee: GrafTech International Holdings Inc.
    Inventors: Tracy Albers, Douglas J. Miller, Irwin C. Lewis, David R. Ball
  • Publication number: 20090176130
    Abstract: A system for making carbon foam anodes including a digestion vessel in communication with a coal feedstock unit for producing a digested coal; a mold having an interior for accepting the digested coal to produce an ungraphitized carbon foam anode having a desired shape; a pressure unit in communication with the mold for producing an increased pressure within the interior of said mold; a heating element in communication with the mold to provide heat to the mold sufficient to convert the digested coal into the ungraphitized carbon foam anode; and a graphitization oven for graphitizing the ungraphitized carbon foam anode to produce the carbon foam anode. The present invention further includes methods for making carbon foam anodes.
    Type: Application
    Filed: January 8, 2008
    Publication date: July 9, 2009
    Applicant: Carbonxt Group Limited
    Inventors: Randall J. Harris, Damian Wales
  • Patent number: 7544316
    Abstract: 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: Grant
    Filed: June 8, 2005
    Date of Patent: June 9, 2009
    Assignee: GrafTech International Holdings Inc.
    Inventors: James William Kortovich, Richard Liichang Shao, Irwin Charles Lewis, Richard Thomas Lewis, Dai Huang
  • Patent number: 7517832
    Abstract: Disclosed is a fibrous activated carbon wherein fine pores in the surface of the activated carbon have diameters of 0.1-200 nm and the activated carbon is in the form of fiber having a fiber diameter of not more than 1000 nm.
    Type: Grant
    Filed: September 16, 2004
    Date of Patent: April 14, 2009
    Assignee: Teijin Limited
    Inventors: Hiroshi Sakurai, Mai Kitahara, Masumi Hirata, Toru Sawaki