Carbon composites, methods of manufacture, and uses thereof

1. A carbon composite comprising

a plurality of expanded graphite particles; and

a second phase comprising a carbide, a carbonization product of a polymer, or a combination thereof;

wherein the second phase bonds at least two adjacent basal planes of the same expanded graphite particle together.

2. The carbon composite of claim 1 , wherein the second phase comprises a carbide of aluminum, titanium, nickel, tungsten, chromium, iron, an aluminum alloy, a copper alloy, a titanium alloy, a nickel alloy, a tungsten alloy, a chromium alloy, an iron alloy, SiC, B 4 C, or a combination comprising at least one of the foregoing carbides.

3. The carbon composite of claim 1 , wherein an amount of the expanded graphite particles is 50 to 98 wt. %, based on the total weight of the carbon composite.

4. The carbon composite of claim 1 , wherein the second phase further bonds at least one basal plane of a graphite particle with at least one basal plane of a different graphite particle.

5. The carbon composite of claim 4 , wherein the second phase comprises a carbide of aluminum, titanium, nickel, tungsten, chromium, iron, an aluminum alloy, a copper alloy, a titanium alloy, a nickel alloy, a tungsten alloy, a chromium alloy, an iron alloy, SiC, B 4 C, or a combination comprising at least one of the foregoing carbides.

6. The carbon composite of claim 4 , wherein an amount of the expanded graphite particles is 25 to 95 wt. %, based on the total weight of the carbon composite.

7. The carbon composite of claim 1 , further comprising a filler selected from SiO 2 , Si, B, B 2 O 3 , a metal selected from aluminum, copper, titanium, nickel, tungsten, chromium, or iron, an alloy of the metal, or a combination comprising at least one of the foregoing materials.

8. The carbon composite of claim 7 , wherein the second phase comprises a carbonization product of a crosslinked polymer.

9. The carbon composite of claim 8 , wherein the crosslinked polymer is derived from a polyphenol, polyacrylonitrile, an epoxy resin, a rayon, a pitch, or a combination comprising at least one of the foregoing.

10. The carbon composite of claim 8 , wherein the carbon composite comprises 2 wt. % to 50 wt. % of the filler, 2 wt. % to 20 wt. % of the second phase, and 30 wt. % to 96 wt. % of the expanded graphite particles.

11. A method for the manufacture of a carbon composite of claim 1 , the method comprising:

compressing a combination comprising expanded graphite particles and a filler to provide a pre-form; and

heating the pre-form to a temperature which is 20° C. to 100° C. higher than the melting point of the filler to form a second phase bonding at least two adjacent basal planes of the same expanded graphite particle together.

12. The method of claim 11 , wherein the second phase further bonds at least one basal plane of a graphite particle with at least one basal plane of a different graphite particle.

13. The method of claim 11 , wherein the heating is conducted for 30 minutes to 3 hours.

14. The method of claim 11 , wherein the heating is conducted at a pressure of 5,000 psi to 30,000 psi.

15. The method of claim 11 , wherein the filler is selected from SiO 2 , Si, B, B 2 O 3 , a metal selected from aluminum, copper, titanium, nickel, tungsten, chromium, iron, an alloy of the metal, or a combination comprising at least one of the foregoing materials.

16. The method of claim 11 , wherein the combination comprises 5 wt. % to 75 wt. % of the filler and 25 wt. % to 95 wt. % of the expanded graphite particles, based on the total weight of the combination.

17. A method for the manufacture of a carbon composite of claim 1 , the method comprising:

providing a plurality of expanded graphite particles;

depositing a filler on a basal plane of an expanded graphite particle through vapor deposition to provide a filled-expanded graphite;

compressing the filled-expanded graphite to provide a pre-form; and

heating the pre-form to form a second phase bonding at least two adjacent basal planes of the same expanded graphite particle together.

18. The method of claim 17 , wherein the deposition comprises physical vapor deposition, chemical vapor deposition, atomic layer deposition, laser vapor deposition, or plasma-assisted vapor deposition.

19. The method of claim 17 , wherein the heating is conducted at a pressure of 5,000 psi to 30,000 psi.

20. The method of claim 17 , wherein the heating is conducted at a temperature of 600 to 1000° C.

21. The method of claim 17 , wherein the filler is selected from SiO 2 , Si, B, B 2 O 3 , a metal selected from aluminum, copper, titanium, nickel, tungsten, chromium, iron, an alloy of the metal, or a combination comprising at least one of the foregoing materials.

22. A method for the manufacture of a carbon composite of claim 1 , the method comprising:

compressing a combination comprising expanded graphite particles, a filler, a crosslinkable polymer, and a crosslinker to provide a pre-form;

crosslinking the crosslinkable polymer with the crosslinker to provide a composition comprising a crosslinked polymer; and

heating the composition to form a carbonization product derived from the crosslinked polymer;

wherein the carbonization product bonds at least two adjacent basal planes of the same expanded graphite particle together; and the carbonization product further bonds at least one basal plane of a graphite particle with at least one basal plane of a different graphite particle.

23. The method of claim 22 , wherein the crosslinkable polymer is selected from a polyphenol, polyacrylonitrile, an epoxy resin, a rayon, a pitch, or a combination comprising at least one of the foregoing, and wherein the crosslinker is selected from amines, cyclic acid anhydrides, and combinations comprising at least one of the foregoing.

24. The method of claim 22 , wherein the combination comprises 2 wt. % to 50 wt. % of the crosslinkable polymer, 2 wt. % to 20 wt. % of the filler, and 30 wt. % to 96 wt. % of the expanded graphite particles.

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

26. The article of claim 25 , wherein the article comprises seals, components of frac plug, bridge plug, packing elements, expanding packing elements, O-rings, bonded seals, bullet seals, subsurface safety valve dynamic seals, subsurface safety valve flapper seals, V rings, back up rings, drill bit seals, or ESP seals.