Carbon composites and methods of manufacture

Patent metadata

Field	Value
Publication number	US-10501323-B2
Application number	US-201916393078-A
Country	US
Kind code	B2
Filing date	Apr 24, 2019
Priority date	Sep 29, 2014
Publication date	Dec 10, 2019
Grant date	Dec 10, 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 SiO2, Si, B, B2O3, 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 for the manufacture of pellets comprising a carbon composite, the method comprising:
extruding a composition comprising a binder and a carbon;
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 SiO2, Si, B, B2O3, and a combination thereof;
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; and
the carbon is selected from the group consisting of expanded graphite, expandable graphite, natural graphite, synthetic graphite, and a combination thereof.

2. The method of claim 1 , further comprising heating the sheet to a temperature greater than the melting point of the binder after hot rolling.

3. The method of claim 1 , wherein the composition is extruded at a temperature of about 350° C. to about 1200° C. or about 800° C. to about 1200° C.

4. The method of claim 1 , wherein the binder has a melting temperature, and the composition is extruded at a temperature that is about ±20° C. to about ±100° C. of the melting point of the binder.

5. The method of claim 4 , wherein the composition is extruded at a temperature that is about 20 to about 50° C. higher than the melting point of the binder.

6. The method of claim 1 , wherein the binder has a melting temperature, and the method further comprises heating the pellets in a furnace above the melting temperature of the binder.

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

8. The method of claim 1 , wherein the carbon is selected from the group consisting of expanded graphite, expandable graphite, natural graphite, synthetic graphite, and a combination thereof.

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

10. 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.

11. The method of claim 1 , further comprising forming a bar, block, sheet, tubular, cylindrical billet, or toroid from the pellets.

12. A method for the manufacture of a sheet comprising a carbon composite, the method comprising:
hot rolling a composition comprising a binder and a carbon;
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;
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; and
the carbon is selected from the group consisting of expanded graphite, expandable graphite, natural graphite, synthetic graphite, and a combination thereof.

13. The method of claim 12 , further comprising heating the sheet to a temperature greater than the melting point of the binder after hot rolling.

14. The method of claim 12 , wherein the composition comprises about 20 to about 95 wt. % of the carbon and about 5 to about 80 wt. % of the binder.

15. The method of claim 12 , wherein the carbon comprises expanded graphite, expandable graphite, natural graphite, synthetic graphite, or a combination comprising at least one of the foregoing.

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

17. The method of claim 12 , 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.

Assignees

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

Inventors

• Xu Zhiyue
• Zhao Lei

Classifications

• C04B35/82

  Asbestos; Glass; Fused silica · CPC title

• C04B2235/5216

  Inorganic · CPC title

• C04B38/0022

  obtained by a chemical conversion or reaction other than those relating to the setting or hardening of cement-like material or to the formation of a sol or a gel, e.g. by carbonising or pyrolysing preformed cellular materials based on polymers, organo-metallic or organo-silicon precursors · CPC title

• C04B38/0054

  the pores being microsized or nanosized · CPC title

• C04B35/6316

  Binders based on silicon compounds · CPC title