Lightweight, high strength carbon aerogel composites and method of fabrication
AssigneeThe Regents of the University of California
InventorLawrence W. Hrubesh
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Abstract
A lightweight, high strength carbon aerogel composite and method of producing such a composite. An organic gel precursor is infiltrated into a pre-formed organic polymer foam or fiber-mat where it gels. The gel composite is then dried by any method that limits the shrinkage of the composite material. The dried gel is then heated in a furnace to pyrolyze the composite, reducing it to a glassy carbon form. The structure of the final carbon product consists of a matrix of porous carbon aerogel, reinforced by solid carbon struts, or fibers all in intimate contact, so that the strength of the composite is maximized.
Claims17
A method for producing lightweight, high strength carbon aerogel composites, comprising:
- infiltrating a polymer liquid into a pre-formed polymer foam, or fiber-mat,
- allowing the liquid to gel such that it encapsulates at least part of the pre-formed polymer foam or fiber-mat,
- drying the gelled composite such that the surface tensile forces are reduced, and pyrolyzing the dried composite wherein both of the polymers decompose simultaneously such that the polymers remain essentially in contact at their interfaces.
A lightweight aerogel composite material composed of an organic gel precursor infiltrated into a pre-formed organic polymer foam, which is gelled, dried, and pyrolyzed to form a glassy carbon material composed of the two organic materials.
A method for producing lightweight, strong carbon aerogel composites, comprising:
- providing an organic gel precursor,
- providing a pre-formed organic polymer foam or fiber-mat,
- infiltrating the organic gel precursor into the pre-formed organic foam to form a composite material,
- providing for gelation of the thus formed composite material,
- drying the thus gelled composite material, and
- pyrolyzing the dried composite material, whereby a carbon aerogel composite is produced which consists of a matrix of porous carbon aerogel, reinforced by solid carbon struts, all in intimate contact so that the strength of the composite is maximized.
Dependencies are inferred from the claim text.