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US3632385A Expired / Lapsed US ⏱️ 0.0 years remaining

Carbon composite structures and method for making same

Assignee: United States Atomic Energy Commission
•
Filing: 1970-03-17
•
Granted: 1972-01-04
•
Expires: 1990-03-17
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Abstract

Abstract Porous carbon structures such as honeycomb and reticulated carbon foam contain cavities or interstices which are filled with cellular carbon foam to provide thermal insulating products having relatively high strength-to-weight ratios and structural integrity at high temperatures. A tenacious bond between the carbon foam and the porous carbon structure is attained by impregnating the porous structure with partially polymerized furfuryl alcohol, curing the latter, and then filling the cavities with a carbon foam formulation which includes a binder of partially polymerized furfuryl alcohol. After the foam producing reaction and the curing of the binder the filled structures are heated to a temperature sufficient to carbonize the furfuryl alcohol. The partially polymerized furfuryl alcohol employed as the impregnant and the binder provides the bond between the porous structure and the carbon foam filler.

Inventors

  • 👤 Charles R Schmitt
  • 👤 James M Schreyer

Bibliographic Details

Application Number —
Jurisdiction US
Data Source google_patents
Last Synchronized 2026-10-30 08:54
CPC Classifications
G; G21; G21C; G21C11/00; G21C11/08; C; C01; C01B; C01B32/00; C04; C04B; C04B35/00; C04B35/515; C04B35/52; C04B35/521; C04B35/524; E; E04; E04C; E04C2/00; E04C2/02; E04C2/10; E04C2/20; E04C2/205; E04C2/30; E04C2/34; E04C2/36; E04C2/365; Y; Y02; Y02E; Y02E30/00; Y02E30/30; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24149; Y10T428/30

Claims Analysis

Total Claims: 8
Claim 1
Independent Claim 38 words
The method of fabricating a carbon composite as claimed in claim 1, including the additional steps of successively impregnating the framework and curing the resin after each impregnation prior to filling the interstices with the foam producing admixture.
Claim 2
Dependent Claim 21 words
The method of fabricating a carbon composite as claimed in claim 1, wherein the thermosetting resin is partially polymerized furfuryl alcohol.
Claim 3
Dependent Claim 27 words
The method of fabricating a carbon composite as claimed in claim 3, wherein the carbonaceous framework and the foam in the framework interstices comprise rigid polyurethane foam.
Claim 4
Dependent Claim 28 words
The method of fabricating a carbon composite as claimed in claim 4, wherein the foam producing admixture comprises a two-component urethane system interactable to produce a cellular foam.
Claim 5
Dependent Claim 30 words
The method of fabricating a carbon composite as claimed in claim 1, wherein the configuration of the carbonaceous framework is selected from the group consisting of honeycomb and reticulated foam.
Claim 6
Dependent Claim 27 words
The method of fabricating a carbon composite as claimed in claim 1, wherein the framework is in a carbonized state prior to impregnating with said thermosetting resin.
Claim 7
Dependent Claim 29 words
The method of fabricating a carbon composite as claimed in claim 6, wherein the foam producing admixture consists essentially of said resin and hollow microspheres formed of said resin.
Claim 8
Dependent Claim 49 words
The method of fabricating a carbon composite as claimed in claim 6, wherein the framework is formed of at least two layers of reticulated foam having a different number of interstices per unit area, and wherein the layers are bonded together by the resin impregnant upon the curing thereof.

References Cited (Backward Citations)

US3089195A Cited
US3102047A Cited
US3342555A Cited
US3302999A Cited
US3387940A Cited
US3353994A Cited
US3416944A Cited
US3510323A Cited

USPTO Annuity & Maintenance Windows

Annuity Stage Window Opens Payment Deadline Surcharge Period Until Estimated Fee Status
3.5 Years (Year 4) 1975-01-03 1975-07-05 1976-01-04 $2000.00 Window Closed / Lapsed
7.5 Years (Year 8) 1979-01-03 1979-07-05 1980-01-04 $3760.00 Window Closed / Lapsed
11.5 Years (Year 12) 1983-01-03 1983-07-05 1984-01-04 $7700.00 Window Closed / Lapsed

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