US4234650A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Laminar carbon member and a method of manufacturing it
Assignee: Individual
•
Filing: 1978-05-25
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Granted: 1980-11-18
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Expires: 1998-05-25
Abstract
Abstract A thin, laminar carbon member made of carbon or graphite felt impregnated with a carbonaceous, hardenable, cokable binder is hardened under the action of pressure and temperature and subsequently coked or graphitized in such a way that the carbon or graphite felt is only partially impregnated with the binder, i.e. with a solution of impregnating agent which is at least partially driven out of the cavities in the felt, but so that a thin coating of impregnating agent remains on the felt fibres, whereafter the felt returns to its original shape, is dried and then compressed to the desired thickness, during which the impregnating agent simultaneously condenses, whereafter the carbon member is calcined and graphitized. The such manufactured partially impregnated carbon member has a gross density of 0.1 to 0.8 g/cm 3 and a thickness of 0.1 to 5 mm, the ratio of the area to the thickness of the plate being at least 10 5 .
Inventors
- 👤 Franz Schieber
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-27 17:30
CPC Classifications
C; C04; C04B; C04B41/00; C04B41/009; B; B32; B32B; B32B18/00; C04B35/00; C04B35/622; C04B35/626; C04B35/63; C04B35/632; C04B35/634; C04B35/63448; C04B35/63472; C04B35/63476; C04B35/71; C04B35/78; C04B35/80; C04B35/83; C04B37/00; C04B37/001; C04B37/003; C04B37/005; C04B41/45; C04B41/50; C04B41/5001; C04B41/80; C04B41/81; C04B41/85; H; H01; H01M; H01M4/00; H01M4/86; H01M4/96; C04B2235/00; C04B2235/02; C04B2235/30; C04B2235/48; C04B2235/65; C04B2235/656; C04B2235/6567; C04B2237/00; C04B2237/02; C04B2237/04; C04B2237/08; C04B2237/086; C04B2237/30; C04B2237/32; C04B2237/36; C04B2237/363; C04B2237/38; C04B2237/385; C04B2237/50; C04B2237/58; C04B2237/586; C04B2237/70; C04B2237/704; Y; Y02; Y02E; Y02E60/00; Y02E60/30; Y02E60/50; Y10; Y10T; Y10T428/00; Y10T428/30; Y10T442/00; Y10T442/20; Y10T442/2418; Y10T442/2926; Y10T442/2959
Claims Analysis
Total Claims: 15
Claim 1
Independent Claim
72 words
A thin laminar porous carbon member having a gross density of 0.1 to 0.8 gm/cm, a thickness of 0.1 to 5 mm and a ratio of surface area to thickness of at least 10 5 produced by carbonizing a carbon fiber felt impregnated with a heat and pressure hardened carbonaceous binder coating substantially all the carbon fibers of the felt in such a manner that the porosity of the felt is retained.
Claim 2
Dependent Claim
72 words
A thin laminar porous carbon member having a gross density of 0.1 to 0.8 gm/cm, a thickness of 0.1 to 5 mm and a ratio of surface area to thickness of at least 10 5 produced by carbonizing a carbon fiber felt impregnated with a heat and pressure hardened carbonaceous binder coating substantially all the carbon fibers of the felt in such a manner that the porosity of the felt is retained.
Claim 3
Dependent Claim
26 words
A laminar carbon member as defined in claim 1, wherein said ratio of the surface area to the thickness is not more than 10 8 .
Claim 4
Dependent Claim
23 words
A laminar carbon member as defined in claim 1 wherein said carbon member is built up in individual layers of said carbon felt.
Claim 5
Dependent Claim
17 words
A laminar carbon member as defined in claim 3 wherein said individual layers have different physical properties.
Claim 6
Dependent Claim
16 words
A laminar carbon member as defined in claim 4 wherein said individual layers have different porosities.
Claim 7
Dependent Claim
17 words
A laminar carbon member as defined in claim 3 wherein said individual layers have different pore distributions.
Claim 8
Independent Claim
138 words
A method of forming a thin carbon member from a hardenable binder and porous carbon felt, said carbon felt being formed of carbon fibers, said method comprising the steps of; (a) impregnating said porous felt with a carbonaceous, hardenable and cokable binder such that substantially all of said fibers are coated with said binder; (b) eliminating some of said binder from said porous felt to the extent that said impregnated felt is porous; and (c) hardening said binder with heat and pressure to produce a rigid, partially impregnated, porous carbon member (d) carbonizing said member by heating to produce a rigid, high strength, dimensionally stable and porous carbon member having a gross density of 0.1 to 0.8 g/cm, a thickness of 0.1 to 5 mm, and a surface area to thickness ratio of at least 10 5 .
Claim 9
Independent Claim
138 words
A method of forming a thin carbon member from a hardenable binder and porous carbon felt, said carbon felt being formed of carbon fibers, said method comprising the steps of; (a) impregnating said porous felt with a carbonaceous, hardenable and cokable binder such that substantially all of said fibers are coated with said binder; (b) eliminating some of said binder from said porous felt to the extent that said impregnated felt is porous; and (c) hardening said binder with heat and pressure to produce a rigid, partially impregnated, porous carbon member (d) carbonizing said member by heating to produce a rigid, high strength, dimensionally stable and porous carbon member having a gross density of 0.1 to 0.8 g/cm, a thickness of 0.1 to 5 mm, and a surface area to thickness ratio of at least 10 5 .
Claim 10
Dependent Claim
14 words
A method as claimed by claim 7 wherein said binder is a duroplastic material.
Claim 11
Dependent Claim
16 words
A method as claimed by claim 8 wherein said binder is a methanolic phenolformaldehyde resin solution.
Claim 12
Dependent Claim
14 words
A method as claimed by claim 7 wherein said binder is a thermoplastic material.
Claim 13
Dependent Claim
22 words
A method as claimed by claim 7 further comprising repeated impregnation and coating to increase the gross density and to improve conductivity.
Claim 14
Dependent Claim
20 words
A method as claimed by claim 7 further comprising pressing together a number of said layers of felt before hardening.
Claim 15
Dependent Claim
21 words
A method comprising the step of binding a plurality of thin laminar carbon members produced by the method of claim 7.
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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) | 1983-11-18 | 1984-05-19 | 1984-11-18 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1987-11-18 | 1988-05-19 | 1988-11-18 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1991-11-18 | 1992-05-19 | 1992-11-18 | $7700.00 | Window Closed / Lapsed |