US3922334A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Foam carbonization and resulting foam structures
Assignee: Airco Inc
•
Filing: 1973-01-31
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Granted: 1975-11-25
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Expires: 1993-01-31
Abstract
Abstract A fully reticulated polyurethane foam is treated with a solution of a phenolic resin and coal-tar pitch in a tetrahydrofuran solvent. The resin and pitch are absorbed into the polyurethane strands, thereby becoming an integral part of such strands. The structure is subsequently heat-treated through a rigidizing cure cycle and through a carbonizing cycle, to obtain a fully reticulated, low-density carbon foam. This resulting structure may be activated to high surface area values by selective oxidation of the carbon article; or activation can be effected by carbonizing the cured article in the presence of metal chlorides.
Inventors
- 👤 Ronald W Marek
- 👤 William T Yudichak
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 20:26
CPC Classifications
C; C08; C08J; C08J9/00; C08J9/36; C08J9/40; C08J9/42; C01; C01B; C01B32/00; C01B32/30; C01B32/354; C01B32/382; C04; C04B; C04B35/00; C04B35/515; C04B35/52; C04B35/524; C04B38/00; C04B38/0022; C04B41/00; C04B41/53; C08J2375/00; C08J2375/04; C08J2461/00
Claims Analysis
Total Claims: 10
Claim 1
Independent Claim
82 words
A METHOD FOR PREPARING A FULLY RETICULATED CARBONIZED FOAM WHEREIN THE WEBS DEFINING THE WALLS OF INDIVIDUAL PORES ARE SUBSTANTIALLY SOLIDS, COMPRISING IN SEQUENCE THE STEPS OF: IMPREGNATING A FULLY RETICULATED POLYURETHANE FOAM WITH A SOLUTION COMPRISING A THERMOSETTING PHENOLIC RESIN IN A TETRAHYDROFURAN SOLUTION, SAID SOLUTION BEING ABSORBED INTO AND BECOMING AN INTEGRAL PART OF THE STRUCTURE OF SAD FOAM; HEATCURING THE IMPREGNATED FOAM TO RIGIDIZE FOAM; AND BAKING SAID CURED FOAM TO EVAPORATE THE POLYURETHANE AND CARBONIZE THE RESIDUAL IMPREGNANT.
Claim 2
Independent Claim
82 words
A METHOD FOR PREPARING A FULLY RETICULATED CARBONIZED FOAM WHEREIN THE WEBS DEFINING THE WALLS OF INDIVIDUAL PORES ARE SUBSTANTIALLY SOLIDS, COMPRISING IN SEQUENCE THE STEPS OF: IMPREGNATING A FULLY RETICULATED POLYURETHANE FOAM WITH A SOLUTION COMPRISING A THERMOSETTING PHENOLIC RESIN IN A TETRAHYDROFURAN SOLUTION, SAID SOLUTION BEING ABSORBED INTO AND BECOMING AN INTEGRAL PART OF THE STRUCTURE OF SAD FOAM; HEATCURING THE IMPREGNATED FOAM TO RIGIDIZE FOAM; AND BAKING SAID CURED FOAM TO EVAPORATE THE POLYURETHANE AND CARBONIZE THE RESIDUAL IMPREGNANT.
Claim 3
Dependent Claim
13 words
A method according to claim 1, further including in said solution, coal-tar pitch.
Claim 4
Dependent Claim
27 words
A method according to claim 2, wherein said resin and coal-tar pitch components are in a weight ratio to said solvent component of between 2:8 and 8:2.
Claim 5
Dependent Claim
45 words
A method in accordance with claim 2, wherein said phenolic resin is present in the weight range of from about 7 to 29 p.p.h. by weight, said coal-tar pitch as about 4 to 29 p.p.h. by weight and the balance of said solution is tetrahydrofuran.
Claim 6
Dependent Claim
13 words
A method according to claim 2, further including activating said carbon foam structure.
Claim 7
Dependent Claim
25 words
A method according to claim 5, wherein said foam is activated by selective oxidation of the carbonaceous material subsequent to said carbonization of said foam.
Claim 8
Dependent Claim
22 words
A method according to claim 5, wherein said foam is activated by conducting said carbonization step in the presence of metal chlorides.
Claim 9
Dependent Claim
10 words
The carbonized foam product prepared by the process of claim
Claim 10
Dependent Claim
11 words
The carbonized foam product prepared by the process of claim 2.
References Cited (Backward Citations)
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-11-24 | 1979-05-26 | 1979-11-25 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-11-24 | 1983-05-26 | 1983-11-25 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-11-24 | 1987-05-26 | 1987-11-25 | $7700.00 | Window Closed / Lapsed |