Low density microcellular carbon or catalytically impregnated carbon forms and process for their preparation

• Main Authors: HOPPER; ROBERT W, PEKALA; RICHARD W
• Format: Patent
• Language: English
• Published: 21.02.1989
• Edition: 4
• Subjects: ARTIFICIAL STONE; CEMENTS; CERAMICS; CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOIDCHEMISTRY; CHEMISTRY; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDINGMATERIALS; CONCRETE; LIME, MAGNESIA; METALLURGY; PERFORMING OPERATIONS; PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL; REFRACTORIES; SLAG; THEIR RELEVANT APPARATUS; TRANSPORTING; TREATMENT OF NATURAL STONE

Machinable and structurally stable, low density microcellular carbon, and catalytically impregnated carbon, foams, and process for their preparation, are provided. Pulverized sodium chloride is classified to improve particle size uniformity, and the classified particles may be further mixed with a catalyst material. The particles are cold pressed into a compact having internal pores, and then sintered. The sintered compact is immersed and then submerged in a phenolic polymer solution to uniformly fill the pores of the compact with phenolic polymer. The compact is then heated to pyrolyze the phenolic polymer into carbon in the form of a foam. Then the sodium chloride of the compact is leached away with water, and the remaining product is freeze dried to provide the carbon, or catalytically impregnated carbon, foam.