Methods of treating a carbon foam precursor to facilitate subsequent foaming of the material at low pressures, which may be on the order of about 0.5 to 1.5 atmospheres, are disclosed. In one embodiment, the carbon foam precursor is subjected to partial devolatilization under controlled conditions w
Methods of treating a carbon foam precursor to facilitate subsequent foaming of the material at low pressures, which may be on the order of about 0.5 to 1.5 atmospheres, are disclosed. In one embodiment, the carbon foam precursor is subjected to partial devolatilization under controlled conditions with subsequent foaming being effected at low pressure. The carbon foam precursor may be one of various forms of coal including raw coal, coal extract mesophase pitch, synthetic mesophase pitch or petroleum based pitch. The prefoaming treatment of the carbon foam precursor may remove a portion of the internal blowing agent and may alter the fluidity of the carbon foam precursor matrix. In another embodiment, the precursor after being converted into a powder is subjected to oxidation prior to foaming.
대표청구항▼
1. A method of making a carbon foam material comprisingproviding a carbon foam precursor,heating said carbon foam precursor to remove a portion of the volatiles therefrom and create a partially devolatilized precursor extract,effecting said heating in an inert gas environment in a sealed vessel,cool
1. A method of making a carbon foam material comprisingproviding a carbon foam precursor,heating said carbon foam precursor to remove a portion of the volatiles therefrom and create a partially devolatilized precursor extract,effecting said heating in an inert gas environment in a sealed vessel,cooling said devolatilized precursor extract,converting said devolatilized extract into powder,introducing said powder into a sealed vessel,foaming said devolatilized precursor extract in said vessel by heating it at a pressure of less than about 20 atmospheres, andcooling said foamed material. 2. The method of claim 1 includingeffecting said foaming in an inert gas environment. 3. The method of claim 1 includingeffecting said partial devolatilization under an inert gas environment. 4. The method of claim 1 includingeffecting said foaming under an inert gas environment. 5. The method of claim 1 includingeffecting said foaming at a pressure of about 0.5 to 1.5 atmospheres. 6. The method of claim 5 includingeffecting said foaming at a temperature of about 330° C. to 600° C. for about 1 minute to 6 hours. 7. The method of claim 6 includingeffecting said heating to devolatilize said carbon foam precursor to a temperature of about 100° C. to 720° C. 8. The method of claim 6 includingcreating said devolatilized carbon foam precursor powder with a size of about 10 to 325 mesh. 9 .The method of claim 1 includingeffecting by said partial devolatilization of said carbon foam precursor alteration of the fluid nature of the matrix of said heated carbon foam precursor. 10. The method of claim 1 includingemploying bituminous coal as said carbon foam precursor. 11. The method of claim 1 includingemploying coal extract as said carbon foam precursor. 12. The method of claim 11 includingemploying a material selected from the group consisting of de-ashed coal extract and un-ashed coal extract as said carbon foam precursor. 13. The method of claim 1 includingemploying mesophase pitch as said carbon foam precursor. 14. The method of claim 1 includingemploying petroleum based pitch as said carbon foam precursor. 15. The method of claim 1 includingeffecting by said partial devolatilization removal of a portion of the internal blowing agent from said carbon foam precursor. 16. The method of claim 1 includingafter said partial devolatilization, but before said foaming, storing said devolatilized powder. 17. The method of claim 1 includingafter said devolatilizing, but before said foaming, oxidizing said power. 18. The method of claim 3 includingemploying stagnant inert gas as said inert gas environment. 19. The method of claim 3 includingemploying flowing inert gas as said inert gas environment. 20. The method of claim 4 includingemploying stagnant inert gas as said inert gas environment. 21. The method of claim 4 includingemploying flowing inert gas as said inert gas environment. 22. A method of making a carbon foam material comprisingproviding a carbon foam precursor,creating a power of said precursor,heating said powdered carbon foam precursor at a pressure of about 0.5 to 1.5 atmospheres at a temperature of about 20° C. to 500° C. for about 1 minute to 72 hours to effect oxidation thereof,cooling said oxidized carbon foam precursor powder to room temperature,shaping said oxidized carbon foam precursor powder by placing said oxidized carbon foam precursor powder in a mold,heating said oxidized carbon foam precursor powder in said mold in an inert gas environment at a pressure less than 20 atmospheres to a temperature of about 330° C. to 600° C. to foam said powdered precursor within said mold, andcooling said foam to room temperature. 23. A method of making a carbon foam material comprisingproviding a carbon foam precursor,creating a powder of said precursor,heating said powdered carbon foam precursor at a pressure of about 0.5 to 1.5 atmospheres at a temperature of about 20° C. to 500° C. for about 1 minute to 72 hours to effect oxidation thereof,heating said oxidized carbon foam precursor in an inert gas environment at a pressure less than 20 atmospheres to a temperature of about 330° C. to 600° C. to foam said powdered precursor,cooling said foam to room temperature, andemploying bituminous coal as said carbon foam precursor. 24. The method of claim 22 includingemploying coal extract as said carbon foam precursor. 25. The method of claim 22 includingemploying a material selected from the group consisting of de-ashed coal extract and un-ashed coal extract as said carbon foam precursor. 26. The method of claim 22 includingemploying hydrogenated coal extract as said carbon foam precursor. 27. The method of claim 22 includingemploying mesophase pitch as said carbon foam precursor. 28. The method of claim 22 includingemploying petroleum based pitch as said carbon foam precursor. 29. The method of claim 22 includingeffecting said carbon foam precursor oxidation in the presence of at least one material selected from the group consisting of water and steam. 30. The method of claim 22 includingdevolatilizing said precursor prior to said oxidation. 31. The method of claim 22 includingcreating said precursor powder in the range of about 10 to 325 mesh. 32. A method of making a carbon foam material comprisingproviding a carbon foam precursor,creating a powder of said precursor,heating said powdered carbon foam precursor at a pressure of about 0.5 to 1.5 atmospheres at a temperature of about 20° C. to 500° C. for about 1 minute to 72 hours to effect oxidation thereof,heating said oxidized carbon foam precursor in an inert gas environment at a pressure less than 20 atmospheres to a temperature of about 330° C. to 600° C. to foam said powdered precursor,cooling said foam to room temperature, andafter said oxidation, but prior to said foaming, storing said oxidized precursor. 33. The method of claim 22 includingeffecting said foaming at a pressure of about 0.5 to 1.5 atmospheres.
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