Low density open cell organic foams, low density open cell carbon foams, and methods for preparing same
First Claim
1. A method for preparing an organic gel, said method comprising the steps of:
- (a) forming a reaction mixture comprising one or more hydroxylated benzene compounds, one or more aldehydes, one or more catalysts, and water;
wherein the molar ratio of said hydroxylated benzene compounds to said catalysts in said reaction mixture, R/C, is greater than about 2000; and
,(b) heating said reaction mixture to form said organic gel.
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Accused Products
Abstract
This pertains to the general field of gels, foams, and aerogels, particularly, to low density open cell organic foams and low density open cell carbon foams, and methods for preparing them. These low density open cell organic foams are derived from organic gels which may be prepared from hydroxylated benzenes (such as phenol, catechol, resorcinol, hydroquinone, and phloroglucinol) and aldehydes (such as formaldehyde and furfural) using lower than conventional catalyst concentrations (e.g, an R/C value of greater than about 1000, yielding an initial room temperature pH typically lower than about 6.0). These organic foams are characterized by relatively large particle and pore sizes, high porosity, and high surface area. Low density open cell carbon foams derived from such organic foams are also shown, as are methods for preparing same. These carbon foams are also characterized by relatively large particle and pore sizes, high porosity, high surface area, and high electrical capacitance. Low density open cell carbon foam/carbon substrate composites and methods for preparing them are also shown.
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Citations
68 Claims
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1. A method for preparing an organic gel, said method comprising the steps of:
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(a) forming a reaction mixture comprising one or more hydroxylated benzene compounds, one or more aldehydes, one or more catalysts, and water;
wherein the molar ratio of said hydroxylated benzene compounds to said catalysts in said reaction mixture, R/C, is greater than about 2000; and
,(b) heating said reaction mixture to form said organic gel. - View Dependent Claims (2, 3, 4, 5)
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6. A method for preparing a cured organic gel, said method comprising the steps of:
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(a) forming a reaction mixture comprising one or more hydroxylated benzene compounds, one or more aldehydes, one or more catalysts, and water;
wherein the molar ratio of said hydroxylated benzene compounds to said catalysts in said reaction mixture, R/C, is greater than about 2000; and
,(b) heating said reaction mixture at a gelation temperature for a gelation time to form an organic gel; and
,(c) heating said organic gel at a curing temperature for a curing time to form said cured organic gel. - View Dependent Claims (7, 8, 9, 10)
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11. A method for preparing a low density open cell organic foam, said method comprising the steps of:
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(a) forming a reaction mixture comprising one or more hydroxylated benzene compounds, one or more aldehydes, one or more catalysts, and water;
wherein the molar ratio of said hydroxylated benzene compounds to said catalysts in said reaction mixture, R/C, is greater than about 2000; and
,(b) heating said reaction mixture to form an organic gel; and
,(c) removing at least a portion of the water from said organic gel to form said low density open cell organic foam. - View Dependent Claims (12, 13, 14, 15, 16, 23, 24, 25, 26, 27)
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17. A method for preparing a low density open cell organic foam, said method comprising the steps of:
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(a) forming a reaction mixture comprising one or more hydroxylated benzene compounds, one or more aldehydes, one or more catalysts, and water;
wherein the molar ratio of said hydroxylated benzene compounds to said catalysts in said reaction mixture, R/C, is greater than about 2000; and
,(b) heating said reaction mixture at a gelation temperature for a gelation time to form an organic gel; (c) heating said organic gel at a curing temperature for a curing time to form a cured organic gel; and
,(d) removing at least a portion of the water from said cured organic gel to form said low density open cell organic foam. - View Dependent Claims (18, 19, 20, 21, 22)
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28. A method for preparing a low density open cell carbon foam, said method comprising the steps of:
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(a) forming a reaction mixture comprising one or more hydroxylated benzene compounds, one or more aldehydes, one or more catalysts, and water;
wherein the molar ratio of said hydroxylated benzene compounds to said catalysts in said reaction mixture, R/C, is greater than about 2000; and
,(b) heating said reaction mixture to form an organic gel; (c) drying said organic gel to form a low density open cell organic foam; and
,(d) pyrolyzing said low density open cell organic foam at a high temperature to form said low density open cell carbon foam. - View Dependent Claims (34, 35, 36, 37, 38)
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29. A method for preparing a low density open cell carbon foam, said method comprising the steps of:
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(a) forming a reaction mixture comprising one or more hydroxylated benzene compounds, one or more aldehydes, one or more catalysts, and water;
wherein the molar ratio of said hydroxylated benzene compounds to said catalysts in said reaction mixture, R/C, is greater than about 2000; and
,(b) heating said reaction mixture at a gelation temperature for a gelation time to form an organic gel; (c) heating said organic gel at a curing temperature for a curing time to form a cured organic gel; (d) removing at least a portion of the water from said cured organic gel to form a low density open cell organic foam; and
,(e) pyrolyzing said low density open cell organic foam at a pyrolysis temperature to form said low density open cell carbon foam. - View Dependent Claims (30)
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31. A method for preparing a low density open cell carbon foam/carbon substrate composite, said method comprising the steps of:
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(a) forming a reaction mixture comprising one or more hydroxylated benzene compounds, one or more aldehydes, one or more catalysts, and water;
wherein the molar ratio of said hydroxylated benzene compounds to said catalysts in said reaction mixture, R/C, is greater than about 2000; and
,(b) infusing a porous carbon substrate or a porous organic substrate with said reaction mixture to form an infused porous substrate; (c) heating said infused porous substrate to a gelation temperature for a gelation time to form an organic gel/porous substrate composite; (d) heating said organic gel/porous substrate composite to a curing temperature for a curing time to form a cured organic gel/porous substrate composite; (e) removing at least a portion of the water from said cured organic gel/porous substrate composite to form a low density open cell organic foam/porous substrate composite; and
,(f) pyrolyzing said low density open cell organic foam/porous substrate composite at a pyrolysis temperature to form said low density open cell carbon foam/carbon substrate composite. - View Dependent Claims (32, 33)
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39. A method for preparing a low density open cell organic foam, said method comprising the steps of:
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(a) forming a reaction mixture comprising one or more hydroxylated benzene compounds, one or more aldehydes, one or more catalysts, and water;
wherein the molar ratio of said hydroxylated benzene compounds to said catalysts in said reaction mixture, R/C, is greater than about 1000; and
,(b) heating said reaction mixture to form an organic gel; and
,(c) removing at least a portion of the water from said organic gel by simple evaporative drying of water, to form said low density open cell organic foam. - View Dependent Claims (40, 41, 42)
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43. A method for preparing a low density open cell organic foam, said method comprising the steps of:
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(a) forming a reaction mixture comprising one or more hydroxylated benzene compounds, one or more aldehydes, one or more catalysts, and water;
wherein the molar ratio of said hydroxylated benzene compounds to said catalysts in said reaction mixture, R/C, is greater than about 1000; and
,(b) heating said reaction mixture at a gelation temperature for a gelation time to form an organic gel; (c) heating said organic gel at a curing temperature for a curing time to form a cured organic gel; and
,(d) removing at least a portion of the water from said cured organic gel by simple evaporative drying of water, to form said low density open cell organic foam. - View Dependent Claims (44, 45, 46)
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47. A method for preparing a low density open cell carbon foam, said method comprising the steps of:
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(a) forming a reaction mixture comprising one or more hydroxylated benzene compounds, one or more aldehydes, one or more catalysts, and water;
wherein the molar ratio of said hydroxylated benzene compounds to said catalysts in said reaction mixture, R/C, is greater than about 1000; and
,(b) heating said reaction mixture to form an organic gel; (c) drying said organic gel by simple evaporative drying of water, to form a low density open cell organic foam; and
,(d) pyrolyzing said low density open cell organic foam at a high temperature to form said low density open cell carbon foam. - View Dependent Claims (48, 49, 50)
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51. A method for preparing a low density open cell carbon foam, said method comprising the steps of:
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(a) forming a reaction mixture comprising one or more hydroxylated benzene compounds, one or more aldehydes, one or more catalysts, and water;
wherein the molar ratio of said hydroxylated benzene compounds to said catalysts in said reaction mixture, R/C, is greater than about 1000; and
,(b) heating said reaction mixture at a gelation temperature for a gelation time to form an organic gel; (c) heating said organic gel at a curing temperature for a curing time to form a cured organic gel; (d) removing at least a portion of the water from said cured organic gel by simple evaporative drying of water, to form a low density open cell organic foam; and
,(e) pyrolyzing said low density open cell organic foam at a pyrolysis temperature to form said low density open cell carbon foam. - View Dependent Claims (52, 53, 54)
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55. A method for preparing a low density open cell carbon foam/carbon substrate composite, said method comprising the steps of:
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(a) forming a reaction mixture comprising one or more hydroxylated benzene compounds, one or more aldehydes, one or more catalysts, and water;
wherein the molar ratio of said hydroxylated benzene compounds to said catalysts in said reaction mixture, R/C, is greater than about 1000; and
,(b) infusing a porous carbon substrate or a porous organic substrate with said reaction mixture to form an infused porous substrate; (c) heating said infused porous substrate to a gelation temperature for a gelation time to form an organic gel/porous substrate composite; (d) heating said organic gel/porous substrate composite to a curing temperature for a curing time to form a cured organic gel/porous substrate composite; (e) removing at least a portion of the water from said cured organic gel/porous substrate composite by simple evaporative drying of water, to form a low density open cell organic foam/porous substrate composite; and
,(f) pyrolyzing said low density open cell organic foam/porous substrate composite at a pyrolysis temperature to form said low density open cell carbon foam/carbon substrate composite. - View Dependent Claims (56, 57, 58, 59)
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- 60. A low density open cell organic foam characterized by a density of 300 to 900 mg/cm3, a surface area of 200 to 1000 m2 /g, and a meso-pore size distribution of 5 to 50 nm.
- 65. A low density open cell carbon foam characterized by a density of 300 to 900 mg/cm3, a surface area of 200 to 800 m2 /g, a meso-pore size distribution of 5 to 50 nm, and an electrical capacitance of 10 to 80 F/g.
Specification