Continuous manufacturing of carbon foam structures at atmospheric pressure
AssigneeCONSOL Innovations, LLC
InventorsRudolph Andrew Olson, III, Douglas R. Amie, Bruce M. Hines, Brian H. Nichols, Tatianna Englebert
Life of this patent
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Abstract
A method of manufacturing essentially crack-free carbon foam structures and carbon foam structures made in single-piece flow through a continuous kiln under inert atmosphere at atmospheric pressure. This process greatly reduces the cost to manufacture by reducing manufacturing time and increasing the ability to integrate automation equipment.
Claims10
A continuous method for producing essentially crack-free carbon foam structures, comprising the steps of:
- pulverizing a carbonaceous starting material consisting of bituminous coal. subbituminous coal, anthracitic coal, lignitic coal, and combinations thereof into a powder;
- blending the powder and at least one of a chemical or particulate additive to form a coal mixture;
- placing the coal mixture into a carbon foam structure mold configured for continuous processing in a kiln under inert gas at atmospheric pressure;
- heating the mold and coal mixture at a rate of about 6° F. per minute in a kiln temperature of about 700° F. under an inert gas;
- maintaining the kiln temperature at about 700° F. for a period of time for thermally processing the coal mixture;
- further heating the mold and coal mixture in a kiln temperature of about 900° F. until a carbon foam structure is formed;
- and
- cooling the carbon foam structure at atmospheric conditions;
- wherein the carbon foam structure has a compressive strength of less than 2000 psi or 13.8 MPa, a density of less than 50 pounds per cubic foot or 0.8 grams per cubic centimeter and is essentially crack-free.
An essentially crack-free carbon foam structure made by a continuous method, comprising the steps of:
- pulverizing a carbonaceous starting material consisting of bituminous coal. subbituminous coal, anthracitic coal, lignitic coal, and combinations thereof into a powder;
- blending the powder and at least one of a chemical or particulate additive to form a coal mixture;
- placing the coal mixture into a carbon foam structure mold configured for continuous processing in a kiln under inert atmosphere at atmospheric pressure;
- heating the mold and coal mixture at a rate of about 6° F. per minute in a kiln temperature of about 700° F. under an inert gas;
- maintaining the kiln temperature at about 700° F. for a period of time for thermally processing the coal mixture;
- further heating mold and coal mixture in a kiln temperature of about 900° F. until a carbon foam structure is formed;
- and
- cooling the carbon foam structure at atmospheric conditions;
- wherein the carbon foam structure has a compressive strength of less than 2000 psi or 13.8 MPa, a density of less than 50 pounds per cubic foot or 0.8 grams per cubic centimeter and is essentially crack-free.
Dependencies are inferred from the claim text.