Back to results
US 5,690,997 AGranted
Catalytic carbon--carbon deposition process
AssigneeSioux Manufacturing Corporation
InventorDana T. Grow
Life of this patent
Estimating the term…
Abstract
A chemical vapor deposition process for production of strong and heat resistant carbon-containing composite materials is disclosed. The process comprises providing a porous substrate, loading the porous substrate with a catalyst, exposing the catalyst-loaded substrate to a heated atmosphere comprising a hydrocarbon and a carrier gas, and rapidly decomposing the hydrocarbon onto the catalyst-loaded substrate.
Claims16
A process for production of a carbon-loaded composite;
- said process comprising steps of:
- (a) loading carbon into a porous substrate;
- (i) the porous substrate having a first void fraction wherein the first void fraction is 0.70 or greater;
- (ii) said step of loading carbon being a loading only by chemical vapor deposition of carbon from methane gas and being conducted at a rate of carbon loading such that:
- 1) at least 25% of the first void fraction is carbon-loaded, and a void fraction, of a resulting carbon-loaded composite, of 0.30 is achieved, within a time period of chemical vapor deposition of not greater than six hours;
- and
- (iii) the porous substrate having a nickel-based or iron-based catalyst thereon in an amount of at least about 22% by weight and not greater than about 27% by weight:
- and
- (b) conducting said step of loading carbon until both:
- (i) at least 25% of the first void fraction of the porous substrate is loaded;
- and
- (ii) a void fraction of no greater than 0.30 is obtained in the resulting carbon-loaded composite.
9 more elements
A process for production of a carbon-loaded composite;
- said process comprising steps of:
- (a) loading carbon into a porous carbon substrate;
- (i) the porous carbon substrate having a first void fraction of at least 0.45 and not greater than 0.55;
- (ii) the porous carbon substrate further including 22-27% by weight magnetite catalyst, comprising magnetite particles having, on average, a largest dimension within the range of 70 Angstroms to 100 Angstroms, distributed thereon;
- and
- (b) conducting said step of loading carbon only by chemical vapor deposition of carbon from a methane gas at least until both:
- (i) at least 25% of the first void fraction of the porous carbon substrate is carbon-loaded;
- and
- (ii) a void fraction of no greater than 0.30 is obtained, within a time period of deposition of not greater than 6 hours, in a resulting carbon-loaded composite;
- and
- (c) said chemical vapor deposition comprising exposing the porous carbon substrate to an environment which is heated to at least 950.degree. C. while passing a gaseous mixture consisting essentially of methane gas and a carrier gas through the porous carbon substrate;
- the gaseous mixture of methane gas and carrier gas having a methane gas to carrier gas ratio, by volume, within the range of 1:1 to 1:2.
9 more elements
A process for production of a carbon-loaded composite;
- said process comprising steps of:
- (a) loading carbon into a porous carbon substrate;
- (i) the porous carbon substrate having a first void fraction, wherein the first void fraction is 0.70 or greater;
- (ii) the porous carbon substrate further including 22-27% by weight magnetite catalyst, comprising magnetite particles having, on average, a largest dimension within the range of 70 Angstroms to 100 Angstroms, distributed thereon;
- and
- (iii) said step of loading carbon being a loading only by chemical vapor deposition of carbon from a methane gas and being conducted at a rate of carbon loading such that:
- 1) at least 25% of the first void fraction is carbon-loaded and
- 2) a void fraction, of a resulting carbon-loaded composite, of 0.30 is achieved, within a time period of deposition of no greater than six hours;
- (b) conducting chemical vapor deposition until both:
- (i) at least 25% of the first void fraction of the porous carbon substrate is loaded;
- and
- (ii) a mass increase of the porous carbon substrate of at least 50% is obtained;
- and
- (c) said chemical vapor deposition comprising exposing the porous carbon substrate to an environment which is heated to at least 950.degree. C. while passing a gaseous mixture consisting essentially of methane gas and a carrier gas through the porous carbon substrate;
- the gaseous mixture of methane gas and carrier gas having a methane gas to carrier gas ratio, by volume, within the range of 1:1 to 1:2.
12 more elements
A process for production of a carbon-loaded composite;
- said process comprising steps of:
- (a) loading carbon into a porous carbon substrate;
- (i) the porous carbon substrate having a first void fraction of at least 0.40 and no greater than 0.70;
- (ii) said step of loading carbon being a loading only by chemical vapor deposition of carbon from a methane gas and being conducted at a rate of carbon loading such that:
- 1) at least 25% of the first void fraction is carbon-loaded and a void fraction, of a resulting carbon-loaded composite, of 0.30 is achieved, within a time period of deposition of no greater than six hours;
- and
- (iii) the porous substrate having a nickel-based or iron-based catalyst thereon in an amount of at least 22% by weight and not greater than about 27% by weight;
- and
- (b) conducting said step of loading carbon until:
- (i) at least 25% of the first void fraction of the porous substrate is loaded;
- and
- (ii) a mass increase of the porous carbon substrate of at least 50% is obtained.
9 more elements
A process for production of a carbon-loaded composite;
- said process comprising steps of:
- (a) loading carbon into a porous carbon substrate;
- (i) the porous carbon substrate having a first void fraction of at least 0.45 and no greater than 0.55;
- (ii) the porous carbon substrate further including 22-27% by weight magnetite catalyst, comprising magnetite particles having, on average, a largest dimension within the range of 70 Angstroms to 100 Angstroms, distributed thereon;
- and
- (b) conducting said step of loading carbon only by chemical vapor deposition of carbon from a methane gas until:
- (i) at least 25% of the first void fraction of the porous carbon substrate is carbon loaded;
- and
- (ii) a mass increase of the porous carbon substrate of at least 50% is obtained;
- and
- (c) said chemical vapor deposition being performed within a time period of deposition of not greater than 6 hours and comprising exposing the porous carbon substrate to an environment which is heated to at least 950.degree. C. while passing a gaseous mixture consisting essentially of methane gas and a carrier gas through the carbon-loaded substrate;
- the gaseous mixture of methane gas and carrier gas having a methane gas to carrier gas ratio, by volume, within the range of 1:1 to 1:2.
9 more elements
Dependencies are inferred from the claim text.