Graphite foam material and method of making same
First Claim
1. A method of making a graphite material comprising the steps of:
- a) grinding flexible graphite into a powder having a particle size in a range of 25 to 80 mesh;
b) mixing the graphite powder in an amount ranging between approximately 10% - 90% by weight, with a resin, in an amount ranging between approximately 10% - 90% by weight; and
c) hot pressing said graphite powder mixed with said resin.
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Accused Products
Abstract
Methods of making a graphite material are provided. A flexible graphite is ground into a powder. The graphite powder is mixed with a resin and the mixture is hot pressed. A second method of making a graphite material is provided where the graphite is ground into a powder; the graphite powder is soaked in a cryogenic liquid; the soaked graphite powder is then expanded; the expanded soaked graphite powder is mixed with a graphite powder; and the graphite powder mixed with a resin are hot pressed. According to a third method, the flexible graphite is ground into a powder; the graphite powder is soaked into a cryogenic liquid, the soaked graphite powder is expanded; and the expanded soaked graphic powder is ground into a fine powder. The resulting graphite powder is mixed with a resin. The graphite powder mixed with the resin is hot pressed. According to a fourth method, graphite flakes are soaked into an acid; the soaked graphite flakes are expanded; and the expanded soaked graphite flakes are precompacted. The precompacted soaked graphite flakes are ground into a powder. The ground precompacted expanded soaked graphite powder is then mixed with a resin. The graphite powder with the resin is hot pressed.
32 Citations
74 Claims
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1. A method of making a graphite material comprising the steps of:
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a) grinding flexible graphite into a powder having a particle size in a range of 25 to 80 mesh;
b) mixing the graphite powder in an amount ranging between approximately 10% - 90% by weight, with a resin, in an amount ranging between approximately 10% - 90% by weight; and
c) hot pressing said graphite powder mixed with said resin. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method of making a graphite material, the method comprising:
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a) grinding flexible graphite into a powder having a particle size in a range of approximately 25 to 80 mesh;
b) soaking the graphite powder in a cryogenic liquid;
c) expanding the soaked graphite powder;
d) mixing the graphite powder in an amount ranging between approximately 10% - 90% by weight, with a resin, in an amount ranging between approximately 10% - 90% by weight; and
e) hot pressing said graphite powder mixed with said resin. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16, 17)
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18. A method of making a graphite material, the method comprising:
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a) grinding flexible graphite into a powder having a particle size in a range of approximately 25 to 80 mesh;
b) soaking the graphite powder in a cryogenic liquid;
c) expanding the soaked graphite powder;
d) grinding the expanded soaked graphite powder into a powder having a particle size in a range of approximately 48 to 100 mesh;
e) mixing the graphite powder in an amount ranging between approximately 10% - 90% by weight, with a resin, in an amount ranging between approximately 10% - 90% by weight; and
f) hot pressing said graphite powder mixed with said resin. - View Dependent Claims (19, 20, 21, 22, 23, 24, 25, 26)
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27. A method of making a graphite material, the method comprising:
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a) soaking graphite flakes into an acid;
b) expanding the soaked graphite flakes;
c) precompacting the expanded soaked graphite flakes;
d) grinding the precompacted expanded soaked graphite flakes into a powder having a particle size in a range of approximately 25 to 80 mesh;
e) mixing the ground, precompacted expanded soaked graphite powder in an amount ranging between approximately 10% - 90% by weight, with a resin, in an amount ranging between approximately 10% - 90% by weight; and
f) hot pressing said ground, precompacted expanded graphite powder mixed with said resin. - View Dependent Claims (28, 29, 30, 31, 32, 33, 34, 35, 36)
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37. A graphite material made by a process comprising:
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a) grinding flexible graphite into a powder having a particle size in a range of 25 to 80 mesh;
b) mixing the graphite powder in an amount ranging between approximately 10% - 90% by weight, with a resin, in an amount ranging between approximately 10% - 90% by weight; and
c) hot pressing said graphite powder mixed with said resin. - View Dependent Claims (38, 39, 40, 41, 42, 43, 44)
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45. A graphite material made by a process comprising:
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a) grinding flexible graphite into a powder having a particle size in a range of 25 to 80 mesh;
b) soaking the graphite powder in a cryogenic liquid;
c) expanding the soaked graphite powder;
d) mixing the expanded soaked graphite powder in an amount ranging between approximately 10% - 90% by weight, with a resin, in an amount ranging between approximately 10% - 90% by weight; and
e) hot pressing said expanded soaked graphite powder mixed with said resin. - View Dependent Claims (46, 47, 48, 49, 50, 51, 52, 53)
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54. A graphite material made by a process comprising:
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a) grinding flexible graphite into a powder having a particle size in a range of 25 to 80 mesh;
b) soaking the graphite powder in a cryogenic liquid;
c) expanding the soaked graphite powder;
d) grinding the expanded soaked graphite powder into a powder having a particle size in a range of approximately 48 to 100 mesh;
e) mixing the graphite powder in an amount ranging between approximately 10% - 90% by weight, with a resin, in an amount ranging between approximately 10% - 90% by weight; and
f) hot pressing said graphite powder mixed with said resin. - View Dependent Claims (55, 56, 57, 58, 59)
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60. A graphite material made by a process comprising:
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a) soaking graphite flakes into an acid;
b) expanding the soaked graphite flakes;
c) precompacting the expanded soaked graphite flakes;
d) grinding the precompacted expanded soaked graphite into a powder having a particle size in an approximate range of 25 to 80 mesh;
e) mixing the expanded soaked graphite powder in an amount ranging between approximately 10% - 90% by weight, with a resin, in an amount ranging between approximately 10% - 90% by weight; and
f) hot pressing said graphite powder mixed with said resin. - View Dependent Claims (61, 62, 63, 64, 65)
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66. A graphite material made by a process comprising:
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a) grinding flexible graphite into a powder;
b) mixing the graphite powder with a thermoplastic material; and
c) injecting into a mold the graphite powder mixed with the thermoplastic material. - View Dependent Claims (67, 68, 69, 70)
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71. A graphite material made by a process comprising:
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a) grinding flexible graphite into a graphite powder;
b) soaking said graphite powder into a cryogenic liquid;
c) expanding the soaked braphite powder;
d) mixing the expanded graphite with a thermoset resin, and e) heating the graphite resin mixture under pressure. f) heat treating the product of step e. - View Dependent Claims (72, 73, 74)
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Specification