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US 5,306,675 AGranted
Method of producing crack-free activated carbon structures
AssigneeCorning Incorporated
InventorsShy-Hsien Wu, Evelyn M. DeLiso
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Abstract
A method of producing crack-free green activated carbon structures using a carbon matrix containing high gel strength binders such as methyl cellulose binders is disclosed. The invention also relates to a method of drying activated carbon structures by first contacting the structure with microwave radiation and then drying the structure in a conventional oven.
Claims17
A method of producing a crack-free, dried activated carbon structure, the method comprising the steps of:
- preparing a mixture comprising (a) carbonaceous particles selected from the group consisting of carbon, graphite and mixtures thereof, (b) 3-10% binder selected from methylcellulose, its derivatives, and mixtures thereof, (c) 0.5-5% polyvinyl alcohol, and (d) 100-200% super addition of water based on the weight of carbon;
- forming the mixture into a shaped carbonaceous article;
- and
- drying the shaped article by first contacting the body with electromagnetic energy for a time sufficient to remove a portion of the water, and then placing the body in a conventional oven at a temperature of 60.degree.-150.degree. C. for a period of time sufficient to reduce the water content to less than about 15% of its original level, to form a crack-free activated carbon structure.
1 more element
A method of producing a cellular activated carbon body comprising the steps of:
- compounding carbon powders to form an activated carbon matrix comprising 75-85% of fine carbon powders having average particle size in the range of 3-10 microns, 15-25% of coarse carbon powders having average particle size in the range of 20-50 microns, 3-10% methylcellulose binder, 0.5-5% polyvinyl alcohol, and 120-170% water based on the weight of carbon;
- shaping the carbon matrix into a honeycomb structure to form a green cellular carbon body comprising about 60% water by weight;
- and
- drying the green body to reduce the water content to less than about 15% of its original level by first contacting the body with electromagnetic energy for a time sufficient to remove a portion of the water, and then placing the body in a conventional oven at a temperature of 60.degree.-150.degree. C. for a period of time sufficient to reduce the water content to less than about 15% of its original level, to form a crack free carbon structure.
1 more element
Dependencies are inferred from the claim text.