US4067956A
Expired / Lapsed
US
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Reticulated anisotropic porous vitreous carbon
Assignee: Chemotronics International Inc
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Filing: 1976-10-08
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Granted: 1978-01-10
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Expires: 1996-10-08
Abstract
Abstract A reticulated anisotropic porous carbon structure composed of bent or crimped interconnected and continuous strands is described. The structure is isomorphic with the compression bent strands of the flexible reticulated polyurethane structure from which it is derived. The structure compression can be sufficient for interbonding of the bent strands which overlay each other or the bent strands can be essentially free of bonding to adjacent strands. The carbon structure is derived by providing a compressed reticulated anisotropic polyurethane structure composed of the bent strands which is then infused with a liquid thermosetting resin or resin solution or resin precursor, removing any excess liquid resin or resin precursor or resin solution from the surfaces of the strands; and then carbonizing the infused strands at an elevated temperature. The reticulated carbon structures so formed are relatively unreactive, even at very high temperatures, under reducing or neutral conditions and are particularly useful as corrosive and high temperature material filters, battery electrodes, porous catalysts or catalyst supports as well as for making carbide containing articles by infusion of the pores with a carbide forming metal or cladding thereof such as with carbide or nitride coatings by chemical vapor deposition and the like.
Inventors
- 👤 Charles H. Franklin
- 👤 Clarence S. Vinton
- 👤 Henry C. Geen
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 18:23
CPC Classifications
C; C04; C04B; C04B35/00; C04B35/515; C04B35/52; C04B35/522; B; B01; B01J; B01J21/00; B01J21/18; C01; C01B; C01B32/00; C01B32/30; C01B32/354; C01B32/384; C04B35/524; C04B38/00; C04B38/0022; H; H01; H01M; H01M4/00; H01M4/02; H01M4/64; C04B2111/00; C04B2111/00474; C04B2111/00793; C04B2111/0081; C04B2111/90; C04B2111/94; Y; Y02; Y02E; Y02E60/00; Y02E60/10; Y10; Y10T; Y10T428/00; Y10T428/30
Claims Analysis
Total Claims: 17
Claim 1
Independent Claim
118 words
The carbon structure which comprises: a crack-free, reticulated porous anisotropic carbon structure of interconnected and continuous strands which is derived from and which reproduces upon carbonization the isomorphic form of a compressed reticulated flexible polyurethane structure without cell membranes which has been infused with a liquid thermosetting resin or resin precursor or resin solution which alloys with the polyurethane and wherein the structure is substantially free of a non-alloyed surface coating of the resin or resin precursor or resin solution prior to carbonization and wherein the carbonization has been achieved with the infused polyurethane structure maintained in a compressed condition of at least fifty percent of its original dimension before or after infusion in at least one plane.
Claim 2
Dependent Claim
118 words
The carbon structure which comprises: a crack-free, reticulated porous anisotropic carbon structure of interconnected and continuous strands which is derived from and which reproduces upon carbonization the isomorphic form of a compressed reticulated flexible polyurethane structure without cell membranes which has been infused with a liquid thermosetting resin or resin precursor or resin solution which alloys with the polyurethane and wherein the structure is substantially free of a non-alloyed surface coating of the resin or resin precursor or resin solution prior to carbonization and wherein the carbonization has been achieved with the infused polyurethane structure maintained in a compressed condition of at least fifty percent of its original dimension before or after infusion in at least one plane.
Claim 3
Dependent Claim
25 words
The structure of claim 1 wherein the polyurethane structure has been thermally reticulated and then compressed with heating to interbond the strands prior to carbonization.
Claim 4
Dependent Claim
27 words
The structure of claim 1 wherein the thermosetting resin is selected from a phenolic resin in a solvent or a furan resin or a furan resin precursor.
Claim 5
Dependent Claim
29 words
The structure of claim 1 wherein an uncompressed reticulated polyurethane structure has been infused with the liquid thermosetting resin, compressed and then fired to form the anisotropic carbon product.
Claim 6
Dependent Claim
11 words
The structure of claim 1 in the form of vitreous carbon.
Claim 7
Dependent Claim
19 words
The structure of claim 1 wherein the carbonized structure is derived from a furan resin or furan resin precursor.
Claim 8
Dependent Claim
30 words
The structure of claim 1 wherein the cured thermosetting resin infused polyurethane structure prior to carbonization weights up to about six times the weight of the non-infused polyurethane structure alone.
Claim 9
Dependent Claim
63 words
The anisotropic reticulated carbon structure comprised of interconnected and continuous bent strands of carbon in the isomorphic form of a compressed flexible reticulated polyurethane structure infused with a thermoset or thermosettable resin, from which the carbon structure is derived by carbonization, said polyurethane structure being compressed at least fifty percent of its original dimension before or after infusion in at least one plane.
Claim 10
Dependent Claim
63 words
The anisotropic reticulated carbon structure comprised of interconnected and continuous bent strands of carbon in the isomorphic form of a compressed flexible reticulated polyurethane structure infused with a thermoset or thermosettable resin, from which the carbon structure is derived by carbonization, said polyurethane structure being compressed at least fifty percent of its original dimension before or after infusion in at least one plane.
Claim 11
Dependent Claim
13 words
The structure of claim 8 wherein the compression bent carbon strands are interbonded.
Claim 12
Dependent Claim
126 words
In the method of forming a carbon structure by carbonization of a reticulated polyurethane structure of interconnected and continuous strands which has been infused with a liquid thermosetting resin or resin precursor or resin solution to form an alloy and then excess surface coating of the thermosetting resin or resin precursor or resin solution is removed prior to curing and carbonization, the improvement which comprises: a. providing the infused polyurethane structure in a compressed condition of at least fifty percent of its original dimension before or after infusion in at least one plane; and b. carbonizing the infused polyurethane structure either in conjunction with or after curing of the thermosetting resin, resin precursor or resin solution with the infused polyurethane structure maintained in said compressed condition.
Claim 13
Dependent Claim
126 words
In the method of forming a carbon structure by carbonization of a reticulated polyurethane structure of interconnected and continuous strands which has been infused with a liquid thermosetting resin or resin precursor or resin solution to form an alloy and then excess surface coating of the thermosetting resin or resin precursor or resin solution is removed prior to curing and carbonization, the improvement which comprises: a. providing the infused polyurethane structure in a compressed condition of at least fifty percent of its original dimension before or after infusion in at least one plane; and b. carbonizing the infused polyurethane structure either in conjunction with or after curing of the thermosetting resin, resin precursor or resin solution with the infused polyurethane structure maintained in said compressed condition.
Claim 14
Dependent Claim
30 words
The method of claim 10 wherein the compressed structure is subjected to the carbonization procedure in conjunction with curing of the liquid thermosetting resin or resin precursor or resin solution.
Claim 15
Dependent Claim
25 words
The method of claim 10 wherein the thermosetting resin or resin precursor or resin solution in the infused polyurethane structure is cured prior to carbonization.
Claim 16
Dependent Claim
19 words
The method of claim 10 wherein the carbon strands are interbonded as a result of the compression and carbonization.
Claim 17
Dependent Claim
18 words
The method of claim 10 wherein the reticulated structure is isotropic prior to infusion and then is compressed.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1981-01-09 | 1981-07-11 | 1982-01-10 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1985-01-09 | 1985-07-11 | 1986-01-10 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1989-01-09 | 1989-07-11 | 1990-01-10 | $7700.00 | Window Closed / Lapsed |