Vitreous carbon composition

Patent metadata

Field	Value
Publication number	US-9428389-B2
Application number	US-201314391734-A
Country	US
Kind code	B2
Filing date	May 17, 2013
Priority date	Jun 15, 2012
Publication date	Aug 30, 2016
Grant date	Aug 30, 2016

Abstract

A process for preparing a vitreous carbon including the steps of: (I) providing a curable low viscosity liquid carbon precursor formulation comprising (a) at least one aromatic epoxy resin; and (b)(i) at least one aromatic co-reactive curing agent, (b) (ii) at least one catalytic curing agent, or (b)(iii) a mixture thereof; wherein the liquid precursor composition has a neat viscosity of less than 10,000 mPa·s at 25° C. prior to adding optional components, prior to curing, and prior to carbonizing; and wherein the liquid precursor composition being cured has a carbon yield of at least 35 weight percent as measured in the absence of optional components; (II) curing the liquid formulation from step (I) to form a cured product wherein the cured product has a carbon yield of at least 35 weight percent as measured in the absence of optional components; (III) carbonizing the cured product from step (II) to form a carbonized composition; and (IV) purifying the carbonized product from step (III) to form a vitreous carbon composition; and a vitreous carbon prepared by the above process.

First claim

The invention claimed is:

1. A process for preparing a vitreous carbon comprising the steps of:
(I) providing a curable low viscosity liquid carbon precursor formulation comprising (a) at least one aromatic epoxy resin; and (b)(i) at least one aromatic co-reactive curing agent, (b)(ii) at least one catalytic curing agent, or (b)(iii) a mixture thereof; wherein the liquid precursor composition has a neat viscosity of less than 10,000 mPa·s at 25° C. prior to adding optional components, prior to curing, and prior to carbonizing; and wherein the liquid precursor composition being cured has a carbon yield of at least 35 weight percent as measured in the absence of optional components;
(II) curing the liquid formulation from step (I) to form a cured product; wherein the cured product has a carbon yield of at least 35 weight percent as measured in the absence of optional components;
(III) carbonizing the cured product from step (II) to form a carbonized composition; and
(IV) treating the carbonized product from step (III) to reduce the ash content present in the carbonized product to less than 200 ppm to form a vitreous carbon composition.

2. The process of claim 1 , wherein the treating step (IV) comprises passing a gas through at least a portion of the carbonized product.

3. The process of claim 2 , wherein the gas comprises a halogen gas.

4. The process of claim 3 , wherein the halogen gas is chlorine.

5. The process of claim 1 , wherein the treating step (IV) is carried out at a temperature of from 800° C. to 3,000° C.

6. The process of claim 1 , wherein the treating step (IV) removes at least a portion of ash present in the carbonized product.

7. The process of claim 6 , wherein the carbonized product after the treating step (IV) has an ash content of less than 200 ppm.

8. The process of claim 1 , wherein the treating step (IV) removes a portion of hydrogen present in the carbonized product.

9. The process of claim 1 , wherein the treating step (IV) reduces a portion of the porosity in the carbonized product.

10. The process of claim 1 , including a step of shaping the cured product of step (II) prior to carbonizing.

11. The process of claim 1 , including a step of molding the liquid carbon precursor formulation prior to curing and carbonizing.

12. The process of claim 11 , wherein the molding step comprises injecting, casting, coating, extruding, pouring, spraying and mixtures thereof prior to curing and carbonizing.

Assignees

• Blue Cube Ip Llc

Inventors

• Lakrout Hamed
• Marks Maurice J
• Valette Ludovic

Classifications

• C04B2235/602

  Making the green bodies or pre-forms by moulding · CPC title

• C04B2235/6562

  Heating rate · CPC title

• C04B2235/6025

  Tape casting, e.g. with a doctor blade · CPC title

• C04B35/63452

  Polyepoxides · CPC title

• C04B35/6269

  Curing of mixtures · CPC title