High strength monolithic carbon foam
A carbon foam article useful for, inter alfa, EMI shielding, sound attenuation, composite tooling or other high temperature applications, which includes a carbon foam having a ratio of compressive strength to density of at least about 7000 psi/g/cc.
1 . A carbon foam article useful for shielding electromagnetic interference comprising a carbon foam having a ratio of compressive strength to density of at least about 7000 psi/g/cc and characteristics desirable for shielding electromagnetic interference.
2 . The article of claim 1 wherein the carbon foam has a density of from about 0.05 to about 0.4 and a compressive strength of at least about 2000 psi.
3 . The article of claim 1 wherein the carbon foam has a porosity of between about 65% and about 95%.
4 . The article of claim 1 wherein at least about 90% of the pore volume of the pores have a diameter of between about 10 and about 150 microns.
5 . The article of claim 4 wherein from about 2% to about 10% of the pore volume of the pores have a diameter of about 1 to about 2 microns.
6 . The article of claim 1 which has a permeability of no greater than about 3.0 darcys.
7 . A carbon foam article useful for shielding electromagnetic interference, comprising a carbon foam having a pore distribution such that at least about 90% of the pore volume of the pores have a diameter of between about 10 and about 150 microns and at least about 1% of the pore volume of the pores have a diameter of between about 0.8 and about 3.5 microns and characteristics desirable for shielding electromagnetic interference.
8 . The article of claim 7 wherein the carbon foam has a ratio of compressive strength to density of at least about 7000 psi/g/cc.
9 . The article of claim 7 which has a permeability of no greater than about 3.0 darcys.
10 . A carbon foam article useful for sound attenuation comprising a carbon foam having a ratio of compressive strength to density of at least about 7000 psi/g/cc and characteristics desirable for sound attenuation.
11 . The article of claim 10 wherein the carbon foam has a density of from about 0.05 to about 0.4 and a compressive strength of at least about 2000 psi.
12 . The article of claim 10 wherein the carbon foam has a porosity of between about 65% and about 95%.
13 . The article of claim 10 wherein at least about 90% of the pore volume of the pores have a diameter of between about 10 and about 150 microns.
14 . The article of claim 13 wherein from about 2% to about 10% of the pore volume of the pores have a diameter of about 1 to about 2 microns.
15 . The article of claim 10 which has a permeability of no greater than about 3.0 darcys.
16 . A carbon foam article useful for sound attenuation, comprising a carbon foam having a pore distribution such that at least about 90% of the pore volume of the pores have a diameter of between about 10 and about 150 microns and at least about 1% of the pore volume of the pores have a diameter of between about 0.8 and about 3.5 microns and characteristics desirable for sound attenuation.
17 . The article of claim 16 wherein the carbon foam has a ratio of compressive strength to density of at least about 7000 psi/g/cc.
18 . The article of claim 16 which has a permeability of no greater than about 3.0 darcys.