IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
UP-0901227
(2007-09-17)
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등록번호 |
US-7758783
(2010-08-09)
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발명자
/ 주소 |
- Shi, Jinjun
- Zhamu, Aruna
- Jang, Bor Z.
|
출원인 / 주소 |
- Nanotek Instruments, Inc.
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인용정보 |
피인용 횟수 :
11 인용 특허 :
17 |
초록
▼
A process of continuously producing a more isotropic, electrically conductive composite composition is provided. The process comprises: (a) continuously supplying a compressible mixture comprising exfoliated graphite worms and a binder or matrix material, wherein the binder or matrix material is in
A process of continuously producing a more isotropic, electrically conductive composite composition is provided. The process comprises: (a) continuously supplying a compressible mixture comprising exfoliated graphite worms and a binder or matrix material, wherein the binder or matrix material is in an amount of between 3% and 60% by weight based on the total weight of the mixture; (b) continuously compressing the compressible mixture at a pressure within the range of from about 5 psi or 0.035 MPa to about 50,000 psi or 350 MPa in at least a first direction into a cohered graphite composite compact; and (c) continuously compressing the composite compact in a second direction, different from the first direction, to form the composite composition in a sheet or plate form. The process leads to composite plates with exceptionally high thickness-direction electrical conductivity.
대표청구항
▼
The invention claimed is: 1. A process of continuously producing a more isotropic, electrically conductive composite composition, said process comprising: a) continuously supplying a compressible mixture comprising exfoliated graphite worms and a binder or matrix material, wherein said binder or ma
The invention claimed is: 1. A process of continuously producing a more isotropic, electrically conductive composite composition, said process comprising: a) continuously supplying a compressible mixture comprising exfoliated graphite worms and a binder or matrix material, wherein said binder or matrix material is in an amount of between 3% and 60% by weight based on the total weight of the mixture; b) continuously compressing said compressible mixture at a pressure within the range of from about 5 psi or 0.035 MPa to about 50,000 psi or 350 MPa in at least a first direction into a cohered graphite composite compact; and c) continuously compressing said composite compact in a second direction, different from the first direction, to form said composite composition in a sheet or plate form. 2. The process of claim 1 wherein said step (a) comprises: (i) continuously supplying a powder mixture of expandable graphite and a binder or matrix material; and (ii) exposing said powder mixture to a temperature sufficient for exfoliating the expandable graphite to obtain said compressible mixture. 3. The process of claim 1 wherein said step (a) comprises: (i) continuously providing a supply of exfoliated graphite; and (ii) impregnating said exfoliated graphite with a binder or matrix material to obtain said compressible mixture. 4. The process of claim 1, wherein said step (b) comprises an operation selected from (A) compressions in two mutually perpendicular directions; (B) compressions in three mutually perpendicular directions; (C) compression in a cylindrically radial direction; or (D) isostatic compression. 5. The process of claim 1, wherein said step (c) comprises calendering said composite compact into said sheet or plate form. 6. The process of claim 1, further comprising a step of continuously collecting said composite sheet on a winding roll. 7. The process of claim 1, further comprising a step of treating said composite sheet or plate to activate the binder or matrix material thereby promoting adhesion within the composite to produce a consolidated composite composition. 8. The process of claim 7, wherein said step of treating comprises heating, exposing to a high energy radiation, molding, embossing, impressing, or a combination thereof. 9. The process of claim 1, wherein said binder or matrix material comprises a polymer, ceramic, glass, metal, carbon, polymeric carbon, asphalt, tar, coal tar pitch, petroleum pitch, mesophase pitch, or a combination thereof. 10. The process as defined in claim 1, wherein said binder or matrix material comprises a polymer selected from the group consisting of polyethylene, polypropylene, nylon, polyesters, polytetrafluoroethylene, polyvinylidene fluoride, fluoro polymers, polyacrylonitrile, acrylic resins, epoxides, polyimide, bismale imide, phenol formaldehydes, vinyl ester, isocyanate resins, and combinations thereof. 11. The process as defined in claim 1, wherein said compressible mixture further comprises an isotropy-promoting agent selected from the group consisting of non-expandable graphite particles, spheroidal graphite particles, meso-carbon micro-beads, carbon blacks, graphite or carbon fibers, graphite or carbon nano-fibers, nano-tubes, glass fibers, ceramic fibers, polymer fibers, metal fibers, metal particles, polymer particles, organic particles, inorganic particles, and combinations thereof. 12. The process as defined in claim 1, wherein said binder or matrix material comprises a char-yielding material and the process further comprises a step of baking or pyrolizing said composite at a temperature for a period of time sufficient to convert said char-yielding material into carbon or graphite. 13. The process as defined in claim 12, wherein said char-yielding material is selected from the group consisting of asphalt, tar, sugars, phenolic resins, coal tar pitches, petroleum pitches, mesophase pitches, saccharides, organic polymers, and combinations thereof. 14. The process as defined in claim 1 wherein said exfoliated graphite worms are obtained from intercalation and exfoliation of a graphite material selected from natural graphite, synthetical graphite, highly oriented pyrolytic graphite, graphite fiber, graphitic nano-fiber, spheroidal graphite, meso-carbon micro-bead, graphite oxide, graphite fluoride, chemically modified graphite, or a combination thereof. 15. A process of continuously producing a more isotropic, electrically conductive composite composition, said process comprising: a) continuously supplying a compressible mixture of expanded or exfoliated graphite flakes, a non-expandable graphite or carbon powder component, and a binder or matrix material, wherein said non-expandable graphite or carbon powder component is in an amount of between 3% and 60% by weight and said binder or matrix material is in an amount of between 60% and 10% by weight based on the total weight of the compressible mixture; b) continuously compressing said compressible mixture at a pressure within the range of from about 5 psi or 0.035 MPa to about 50,000 psi or 350 MPa in at least a first direction into a cohered graphite composite compact; and c) continuously compressing said composite compact in a second direction, different from the first direction, to form said composite composition in a sheet or plate form. 16. The process of claim 15, wherein step (a) comprises continuously supplying expanded or exfoliated graphite flakes and mixing said exfoliated graphite flakes with non-expandable graphite or carbon particles and a binder or matrix material, in sequence or concurrently. 17. The process of claim 1 wherein said step (a) comprising: (i) continuously supplying a powder mixture of expandable graphite, non-expandable graphite or carbon particles, and a binder or matrix material; and (ii) exposing said powder mixture to a temperature sufficient for exfoliating the expandable graphite to obtain said compressible mixture. 18. The process of claim 15, wherein step (a) comprises (i) continuously supplying a blend of expanded or exfoliated graphite flakes and non-expandable graphite or carbon particles and (ii) impregnating said blend with a binder or matrix material. 19. The process as defined in claim 18, wherein the step of impregnating comprises impregnating the blend with a first component of a two-component or multiple-component thermosetting or polymerizing resin and then impregnating said blend with a second component of said resin. 20. The process as defined in claim 18, wherein the step of impregnating comprises impregnating said blend with a mixture of a volatile diluent and a first component of a two-component or multiple-component thermosetting or polymerizing resin, removing said volatile diluent, and then impregnating said blend with a second component of said resin. 21. The method as defined in claim 20, wherein said resin comprises epoxy resin and said first component comprises a curing agent or hardener. 22. The process of claim 15, wherein said step (b) comprises an operation selected from (A) compressions in two mutually perpendicular directions; (B) compressions in three mutually perpendicular directions; (C) compression in a cylindrically radial direction; or (D) isostatic compression. 23. The process of claim 15, wherein said step (c) comprises calendering said composite compact into said sheet or plate form. 24. The process of claim 15, further comprising a step of continuously collecting said composite sheet on a winding roll. 25. The process of claim 15, further comprising a step of treating said composite sheet or plate to activate the binder or matrix material thereby promoting adhesion within the composite to produce a consolidated composite composition. 26. The process of claim 25, wherein said step of treating comprises heating, exposing to a high energy radiation, molding, embossing, impressing, or a combination thereof. 27. The process of claim 15, wherein said binder or matrix material comprises a polymer, ceramic, glass, metal, carbon, polymeric carbon, asphalt, tar, coal tar pitch, petroleum pitch, mesophase pitch, or a combination thereof. 28. The process as defined in claim 15, wherein said binder or matrix material comprises a polymer selected from the group consisting of polyethylene, polypropylene, nylon, polyesters, polytetrafluoroethylene, polyvinylidene fluoride, fluoro polymers, polyacrylonitrile, acrylic resins, epoxides, polyimide, bismale imide, phenol formaldehydes, vinyl ester, isocyanate resins, and combinations thereof. 29. The process as defined in claim 15, wherein said non-expandable graphite or carbon component is selected from the group consisting of non-expandable natural or synthetic graphite particles, spheroidal graphite particles, meso-carbon micro-beads, carbon blacks, graphite or carbon fibers, graphite or carbon nano-fibers, nano-tubes, and combinations thereof. 30. The process as defined in claim 15, wherein said non-expandable graphite or carbon component further comprises an isotropy-promoting agent selected from the group consisting of glass fibers, ceramic fibers, polymer fibers, metal fibers, metal particles, polymer particles, ceramic particles, glass spheres, organic particles, inorganic particles, and combinations thereof. 31. The process as defined in claim 15, wherein said binder or matrix material comprises a char-yielding material and the process further comprises a step of baking or pyrolizing said composite at a temperature for a period of time sufficient to convert said char-yielding material into carbon or graphite. 32. The process as defined in claim 31, wherein said char-yielding material is selected from the group consisting of asphalt, tar, sugars, phenolic resins, coal tar pitches, petroleum pitches, mesophase pitches, saccharides, organic polymers, and combinations thereof. 33. The process as defined in claim 15 wherein said exfoliated graphite flakes are obtained from intercalation and exfoliation of a graphite material selected from natural graphite, synthetical graphite, highly oriented pyrolytic graphite, graphite fiber, graphitic nano-fiber, spheroidal graphite, meso-carbon micro-bead, graphite oxide, graphite fluoride, chemically modified graphite, or a combination thereof.
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