US4225569A
Expired / Lapsed
US
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Carbon-carbon composite material and method for its production
Assignee: Kanebo Ltd
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Filing: 1978-06-08
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Granted: 1980-09-30
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Expires: 1998-06-08
Abstract
Abstract The present invention provides a carbon-carbon composite material consisting of a matrix carbon and a fibrous reinforcing carbon, said matrix carbon and fibrous carbon consisting substantially of amorphous carbon and forming an interface without an intervening third material, wherein said composite material has a fracture surface showing a uniform vitreous light reflection, but when it is used as an anode and electrolytically etched in sulfuric acid-acidified water, a difference in the degree of etching arises between the matrix carbon and the fibrous carbon, 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
- 👤 Takashi Ito
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-27 07:51
CPC Classifications
C; C08; C08J; C08J5/00; C08J5/04; C04; C04B; C04B35/00; C04B35/515; C04B35/52; C04B35/524; C04B35/71; C04B35/78; C04B35/80; C04B35/83; C08J2361/00; C08J2361/04; C08J2361/06
Claims Analysis
Total Claims: 15
Claim 1
Independent Claim
118 words
A method for producing a carbon-carbon composite material consisting of a matrix carbon and a fibrous reinforcing carbon, which comprises shaping a resinous composition consisting of 30 to 90% by weight of cured novolac fibers having a methylol group content of at least 3.5% by weight 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 an 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./hour; and firing the product at the final temperature reached.
Claim 2
Independent Claim
118 words
A method for producing a carbon-carbon composite material consisting of a matrix carbon and a fibrous reinforcing carbon, which comprises shaping a resinous composition consisting of 30 to 90% by weight of cured novolac fibers having a methylol group content of at least 3.5% by weight 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 an 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./hour; and firing the product at the final temperature reached.
Claim 3
Dependent Claim
21 words
The method of claim 1 wherein the cured novolac fibers have a methylol group content of 4 to 8% by weight.
Claim 4
Dependent Claim
25 words
The method of claim 1 or 2 wherein the resinous composition contains the cured novolac resins in an amount of 50 to 80% by weight.
Claim 5
Independent Claim
18 words
The method of any one of claims 1 or 2 wherein the phenolic resin is a resol resin.
Claim 6
Dependent Claim
38 words
The method of claim 1 wherein 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 7
Independent Claim
26 words
The method of any one of claims 1 or 2 wherein the shaping and curing of the resinous composition are carried out under heat and pressure.
Claim 8
Independent Claim
50 words
The method of any one of claims 1 or 2 wherein 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./hour.
Claim 9
Independent Claim
25 words
The method of any one of claims 1 or 2 wherein the firing treatment is carried out at a temperature of at least 1,000° C.
Claim 10
Dependent Claim
88 words
A carbon-carbon composite material consisting of a matrix carbon and a fibrous reinforcing carbon, said matrix carbon and fibrous carbon consisting substantially of amorphous optically isotropic carbon and forming an interface without an intervening third material, wherein said composite material has a fracture surface showing a uniform vitreous light reflection, but when it is used as an anode and electrolytically etched in sulfuric acid-acidified water, a difference in the degree of etching arises between the matrix carbon and the fibrous carbon produced by the method of claim 1.
Claim 11
Dependent Claim
25 words
The composite material of claim 9 which has a broad diffraction profile at a diffraction angle of 26° when measured by an X-ray diffraction method.
Claim 12
Dependent Claim
32 words
The composite material of claim 9 or 10 which has a flexural strength of at least 900 kg/cm 2 and a helium gas permeability of more than 1×10 -6 cm 2 /sec.
Claim 13
Dependent Claim
22 words
The composite material of any one of claims 9 or 10 which has a carbon content of at least 94% by weight.
Claim 14
Dependent Claim
16 words
The composite of claim 12 which has a carbon content of at least 96% by weight.
Claim 15
Dependent Claim
23 words
The composite of any one of claims 9 or 10 wherein the matrix carbon and the fibrous reinforcing carbon have the same density.
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) | 1983-09-30 | 1984-03-31 | 1984-09-30 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1987-09-30 | 1988-03-31 | 1988-09-30 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1991-09-30 | 1992-03-31 | 1992-09-30 | $7700.00 | Window Closed / Lapsed |