Carbon composites, methods of manufacture, and uses thereof

1. A carbon composite comprising:

expanded graphite; and

at least one of a filler or a reinforcement;

wherein the expanded graphite comprises a plurality of randomly oriented basal planes.

2. The carbon composite of claim 1 , wherein the filler comprises metal, carbon, ceramic, or a combination comprising at least one of the foregoing.

3. The carbon composite of claim 2 , wherein the metal comprises copper, aluminum, titanium, tungsten, nickel, silicon, chromium, iron, alloys thereof, or a combination comprising at least one of the foregoing.

4. The carbon composite of claim 2 , wherein the carbon comprises amorphous carbon, natural graphite, carbon fiber, or a combination comprising at least one of the foregoing material.

5. The carbon composite of claim 2 , wherein the ceramic comprises SiC, Si 3 N 4 , SiO 2 , BN, and a combination comprising at least one of the foregoing.

6. The carbon composite of claim 1 , wherein the reinforcement comprises a metallic sheet comprising stainless steel, copper alloy, aluminum alloy, titanium alloy, or a combination comprising at least one of the foregoing.

7. The carbon composite of claim 6 , wherein the metallic sheet comprises an aperture.

8. The carbon composite of claim 1 , wherein the expanded graphite is present in an amount of 25 wt. % to 99 wt. %, based on the total weight of the carbon composite.

9. An article comprising the carbon composite of claim 1 .

10. The article of claim 9 , wherein the article is a downhole element.

11. The article of claim 10 , wherein the article comprises packing elements (premier seal), expanding packing elements (ARC seal), O-rings, bonded seals, bullet seals, SSSV dynamic seals, SSSV flapper seals, V rings, back up rings, drill bit seals, mud motor stators, PCP stators, ESP seals, or ESP space out sub.

12. A method for making a carbon composite, the method

comprising

combining expanded graphite and at least one of a filler or a reinforcement to form a combination; and

compressing the combination under an isostatic pressure thereby making the carbon composite;

wherein the basal planes of the expanded graphite in the carbon composite are randomly oriented.

13. The method of claim 12 , wherein the combining comprises combining expanded graphite and a metallic filler.

14. The method of claim 12 , wherein the combining comprises combining expanded graphite, a metallic filler, and a reinforcement comprising a metallic sheet.

15. A method for making a carbon composite, the

method comprising

compressing a composition comprising expanded graphite to form a pre-form comprising an expanded graphite matrix and a plurality of connecting open pores disposed in the matrix; and

combining the pre-form with a filler thereby making the carbon composite;

wherein the expanded graphite matrix in the carbon composite comprises a plurality of randomly oriented basal planes.

16. The method of claim 15 , further comprising compressing the combination of the pre-form and the filler thereby making the composite.

17. The method of claim 15 , wherein the composition further comprises wax.

18. The method of claim 17 , wherein the compressing is conducted at a temperature greater than the melting temperature of the wax.

19. The method of claim 15 , wherein the combining comprises pouring a molten metallic filler to the pre-form.

20. The method of claim 15 , further comprising forming the composite by

compressing expanded graphite to form compressed expanded graphite; and

milling the compressed expanded graphite to form graphite particles.

21. The method of claim 20 further comprising combining the graphite particle with a reinforcement.

22. The method of claim 15 , wherein the pre-form further comprises a reinforcement.

23. A method of forming a carbon composite, the method comprises:

firstly compressing expanded graphite to form compressed expanded graphite;

milling the compressed expanded graphite to form expanded graphite particles;

combining the expanded graphite particles with at least a filler or a reinforcement to form a combination; and

secondly compressing the combination thereby making the carbon composite;

wherein the expanded graphite in the carbon composite comprises a plurality of randomly orientated basal planes.