Carbon composites and methods of manufacture

Patent metadata

Field	Value
Publication number	US-10315922-B2
Application number	US-201414499397-A
Country	US
Kind code	B2
Filing date	Sep 29, 2014
Priority date	Sep 29, 2014
Publication date	Jun 11, 2019
Grant date	Jun 11, 2019

Abstract

A method for the manufacture of a carbon composite comprises compressing a combination comprising carbon and a binder at a temperature of about 350° C. to about 1200° C. and a pressure of about 500 psi to about 30,000 psi to form the carbon composite; wherein the binder comprises a nonmetal, metal, alloy of the metal, or a combination thereof; wherein the nonmetal is selected from the group consisting of SiO 2 , Si, B, B 2 O 3 , and a combination thereof; and the metal is selected from the group consisting of aluminum, copper, titanium, nickel, tungsten, chromium, iron, manganese, zirconium, hafnium, vanadium, niobium, molybdenum, tin, bismuth, antimony, lead, cadmium, selenium, and a combination thereof.

First claim

What is claimed is:

1. A method of manufacturing a carbon composite, the method comprising:
pressing a composition comprising expanded graphite and a binder at a temperature of about 350° C. to about 1200° C. and a pressure of about 500 psi to about 30,000 psi to form the carbon composite first pressure lower than a predetermined maximum pressure and at a first temperature lower than a predetermined maximum temperature; and
pressing the composition at the predetermined maximum temperature and the predetermined maximum pressure to form the carbon composite, the predetermined maximum temperature being about ±20° C. to about ±100° C. of the melting point of the binder;
wherein the binder is selected from the group consisting of SiO 2 , Si, B, B 2 O 3 , a metal, an alloy of the metal, and a combination thereof; and
the metal is selected from the group consisting of aluminum, copper, titanium, nickel, tungsten, chromium, iron, manganese, zirconium, hafnium, vanadium, niobium, molybdenum, tin, bismuth, antimony, lead, cadmium, selenium, and a combination thereof.

2. The method of claim 1 , wherein the composition comprises about 20 to about 95 wt. % of the expanded graphite and about 5 to about 80 wt. % of the binder.

3. The method of claim 1 , wherein the binder has a size of about 0.05 to about 10 microns.

4. The method of claim 1 , wherein the composition further comprises carbon fibers, carbon black, mica, clay, glass fiber, ceramic fibers, ceramic hollow structures, or a combination comprising at least one of the foregoing.

5. The method of claim 1 , wherein the composition is pressed at the predetermined maximum temperature and the predetermined maximum pressure for about 5 to about 120 minutes.

6. The method of claim 1 , wherein the composition is heated by direct current heating, induction heating, microwave heating, spark plasma sintering, or a combination comprising at least one of the foregoing.

7. The method of claim 1 , wherein the compressing is conducted in a mold to form a bar, block, sheet, tubular, cylindrical billet, or toroid comprising the carbon composite.

8. The method of claim 1 , further comprising machining or shaping the carbon composite to form a bar, block, sheet, tubular, cylindrical billet, or toroid.

9. The method of claim 1 , further comprising milling the carbon composite to form a powder.

10. A method of manufacturing a carbon composite,
the method comprising:
forming a compact by pressing a composition comprising expanded graphite and a binder; and
heating the compact to form the carbon composite;
wherein the binder is selected from the group consisting of SiO 2 , Si, B, B 2 O 3 , a metal, an alloy of the metal, and a combination thereof; and
the metal is selected from the group consisting of aluminum, copper, titanium, nickel, tungsten, chromium, iron, manganese, zirconium, hafnium, vanadium, niobium, molybdenum, tin, bismuth, antimony, lead, cadmium, selenium, and a combination thereof.

11. The method of claim 10 , wherein the composition comprises about 20 to about 95 wt. % of the expanded graphite and about 5 to about 80 wt. % of the binder.

12. The method of claim 10 , wherein the binder has a size of about 0.05 to about 10 microns.

13. The method of claim 10 , wherein the composition further comprises carbon fibers, carbon black, mica, clay, glass fiber, ceramic fibers, ceramic hollow structures, or a combination comprising at least one of the foregoing.

14. The method of claim 10 , wherein forming the compact comprises pressing the composition at a pressure of about 500 psi to about 10 ksi and a temperature of about 20° C. to about 200° C.

15. The method of claim 14 , wherein forming the compact comprises pressing the composition so that a volume of the compact relative to a volume of the composition is about 40% to about 80%.

16. The method of claim 14 , wherein the heating is conducted at a temperature of about 350° C. to about 1200° C. and a pressure of about 500 psi to about 30,000 psi.

17. The method of claim 16 , wherein heating the compact comprises:
pressing the compact at a first pressure lower than a predetermined maximum pressure and at a first temperature lower than a predetermined maximum temperature; and
pressing the compact at the predetermined maximum temperature and the predetermined maximum pressure.

18. The method of claim 17 , wherein the predetermined maximum temperature is about ±20° C. to about ±100° C. of the melting point of the binder.

19. The method of claim 17 , wherein the compact is pressed at the predetermined maximum temperature and the predetermined maximum pressure for about 5 to about 120 minutes.

20. The method of claim 14 , wherein the compact is heated by direct current heating, induction heating, microwave heating, spark plasma sintering, or a combination comprising at least one of the foregoing.

21. The method of claim 14 , wherein compressing the compact comprises pressing the compact so that a volume of the carbon composite relative to a volume of the compact is about 10% to about 70%.

22. The method of claim 10 , wherein forming the compact is conducted at room temperature and a pressure of about 500 psi to about 30,000 psi.

23. The method of claim 22 , wherein the heating is conducted at atmospheric pressure.

24. The method of claim 10 , wherein the compact is compressed in a mold to form a bar, block, sheet, tubular, cylindrical billet, or toroid comprising the carbon composite.

25. The method of claim 10 , further comprising machining or shaping the carbon composite to form a bar, block, sheet, tubular, cylindrical billet, or toroid.

26. The method of claim 10 , further comprising milling the carbon composite.

27. The method of claim 1 , wherein the binder comprises an alloy of nickel or an alloy of iron.

28. The method of claim 10 , wherein the binder comprises an alloy of nickel or an alloy of iron.

Assignees

• Xu Zhiyue
• Zhao Lei
• Baker Hughes A Ge Co Llc

Inventors

• Xu Zhiyue
• Zhao Lei

Classifications

• C04B2235/604

  Pressing at temperatures other than sintering temperatures · CPC title

• C04B35/536

  based on expanded graphite {or complexed graphite} · CPC title

• C04B2235/94

  Products characterised by their shape · CPC title

• C04B38/0054

  the pores being microsized or nanosized · CPC title

• C04B2235/5436

  micrometer sized, i.e. from 1 to 100 micron · CPC title