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US4198382A
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Novel carbon-carbon composite material and method for its production
Assignee: Kanebo Ltd
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Filing: 1978-09-01
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Granted: 1980-04-15
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Expires: 1998-09-01
Abstract
Abstract The present invention provides a carbon-carbon composite material consisting of a matrix carbon and a fibrous reinforcing carbon, said matrix carbon consisting substantially of optically anisotropic carbon and said fibrous reinforcing carbon consisting substantially of optically isotropic carbon, and said matrix carbon and fibrous reinforcing carbon forming an interface without an intervening third material, wherein said composite material has a fracture surface showing a uniform vitreous light reflection, and a method for the preparation thereof. The composite material has a high flexural strength and a very low gas permeability and is useful as a molding material in the fields of high temperature chemistry, the atomic energy industry and medicine.
Inventors
- 👤 Hironori Matsui
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 15:57
CPC Classifications
A; A61; A61L; A61L27/00; A61L27/02; A61L27/08; C; C04; C04B; C04B35/00; C04B35/71; C04B35/78; C04B35/80; C04B35/83; A61F; A61F2310/00; A61F2310/00005; A61F2310/00161
Claims Analysis
Total Claims: 20
Claim 1
Independent Claim
71 words
A carbon-carbon composite material consisting of a matrix carbon and a fibrous reinforcing carbon, said matrix carbon consisting substantially of optically anisotropic carbon and said fibrous reinforcing carbon consisting substantially of optically isotropic carbon, and said matrix carbon and fibrous reinforcing carbon forming an interface without an intervening third material, wherein said composite material has a fracture surface showing a uniform vitreous light reflection produced by the method of claim 9.
Claim 2
Dependent Claim
20 words
The composite material of claim 1 in which said matrix carbon and fibrous reinforcing carbon consist substantially of amorphous carbon.
Claim 3
Dependent Claim
27 words
The composite material of claim 1 or 2 which has a broad diffraction profile at a diffraction angle of 26° when measured by an X-ray diffraction method.
Claim 4
Dependent Claim
36 words
The composite material of any one of claims 1 or 2 which has a flexural strength of at least 9 kg/mm 2 and a helium gas permeability of not more than 1×10 -6 cm 2 /sec.
Claim 5
Dependent Claim
22 words
The composite material of any one of claims 1 or 2 which has a carbon content of at least 94% by weight.
Claim 6
Dependent Claim
17 words
The composite material of claim 5 which has a carbon content of at least 96% by weight.
Claim 7
Dependent Claim
25 words
The composite material of any one of claims 1 or 2 in which the matrix carbon and the fibrous reinforcing carbon have the same density.
Claim 8
Dependent Claim
41 words
The composite material of any one of claims 1 or 2 which when used as an anode and electrolytically etched in sulfuric acid-acidified water, develops a difference in the degree of etching between the matrix carbon and the fibrous reinforcing carbon.
Claim 9
Independent Claim
131 words
A method for producing a carbon-carbon composite material consisting of a matrix carbon and a fibrous reinforcing carbon, which comprises heat-treating cured novolac fibers at a temperature of from 250° C. to less than 500° C. in a non-oxidizing atmosphere; shaping a resinous composition consisting of 30 to 90% by weight of the resulting heat-treated novolac fibers and 10 to 70% by weight, as the solids content after curing, of a phenolic resin; curing the shaped product; heating the cured product in a non-oxidizing atmosphere to at least 800° C. in such a manner that at least within a temperature range of 200° to 500° C., the heating is carried out at a rate of not more than 60° C. per hour; and firing the product at the final temperature reached.
Claim 10
Independent Claim
131 words
A method for producing a carbon-carbon composite material consisting of a matrix carbon and a fibrous reinforcing carbon, which comprises heat-treating cured novolac fibers at a temperature of from 250° C. to less than 500° C. in a non-oxidizing atmosphere; shaping a resinous composition consisting of 30 to 90% by weight of the resulting heat-treated novolac fibers and 10 to 70% by weight, as the solids content after curing, of a phenolic resin; curing the shaped product; heating the cured product in a non-oxidizing atmosphere to at least 800° C. in such a manner that at least within a temperature range of 200° to 500° C., the heating is carried out at a rate of not more than 60° C. per hour; and firing the product at the final temperature reached.
Claim 11
Dependent Claim
22 words
The method of claim 9 in which the cured novolac fibers have a methylol group content of at least 3.5% by weight.
Claim 12
Dependent Claim
22 words
The method of claim 10 in which the cured novolac fibers have a methylol group content of 4 to 12% by weight.
Claim 13
Independent Claim
28 words
The method of any one of claims 9, 10 or 11 in which the heat-treatment is carried out at a temperature of from 270° C. to 440° C.
Claim 14
Independent Claim
89 words
The method of any one of claims 9, 10 or 11 in which the heat-treatment is carried out until in the infrared absorption spectrum of the resulting heat-treated novolac fibers, the ratio (D 770 /D 1600 ) of the absorption wavelength intensity (D 770 ) of an absorption peak near 740 to 770 cm -1 ascribable to adjacent hydrogen atoms on the benzene ring to the absorption wavelength intensity (D 1600 ) of an absorption peak near 1600 cm -1 ascribable to the benzene ring becomes 0.05 to 0.40.
Claim 15
Independent Claim
31 words
The method of any one of claims 9, 10 or 11 in which the resinous composition contains the resulting heat-treated novolac fibers in an amount of 50 to 80% by weight.
Claim 16
Independent Claim
20 words
The method of any one of claims 9, 10 or 11 in which the phenolic resin is a resol resin.
Claim 17
Dependent Claim
39 words
The method of claim 9 in which the phenolic resin is a novolac resin, and the curing of the shaped resinous composition is carried out by using formaldehyde or a compound capable of liberating formaldehyde under the curing conditions.
Claim 18
Independent Claim
28 words
The method of any one of claims 9, 10 or 11 in which the shaping and curing of the resinous composition are carried out under heat and pressure.
Claim 19
Independent Claim
54 words
The method of any one of claims 9, 10 or 11 in which the heating of the cured product is carried out in such a manner that at least within a temperature range of 200° to 500° C., the heating is carried out at a rate of not more than 40° C. per hour.
Claim 20
Independent Claim
27 words
The method of any one of claims 9, 10 or 11 in which the firing treatment is carried out at a temperature of at least 1,000° C.
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) | 1983-04-15 | 1983-10-15 | 1984-04-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1987-04-15 | 1987-10-15 | 1988-04-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1991-04-15 | 1991-10-15 | 1992-04-15 | $7700.00 | Window Closed / Lapsed |