THREE DIMENSIONAL CARBON ARTICLES
A method for making a three dimensional carbon and graphite articles using three dimensional printing techniques is provided. The method includes depositing alternating layers of a binder and a filler to form an article. The filler includes at least one of carbon, graphite and combinations thereof. The article is heat treated in a non-oxidizing environment to at least about 2000° C. Another method of forming an article includes depositing alternating layers of a binder and a filler, wherein said filler includes a carbon or graphite powder in combination with a milled pitch. The binder volatizes at a temperature greater than a softening point temperature of the milled pitch, the article is heat treated in a non-oxidizing environment to at least about 800° C.
1 . A method for making a three dimensional article comprising:
depositing alternating layers of a binder and a filler to form an article, wherein said filler includes at least one of carbon, graphite and combinations thereof; and
heat treating said article in a non-oxidizing environment to at least about 2000° C.
2 . The method according to claim 1 wherein said filler further comprises a powder blend including a carbon or graphite powder and a pitch.
3 . The method according to claim 2 wherein said binder volatizes at temperatures less than about 200° C.
4 . The method according to claim 2 wherein said pitch has a softening point from between about 80° C. and about 300° C.
5 . The method according to claim 1 further comprising the step of infusing said article with an impregnating pitch.
6 . The method according to claim 1 wherein said powder further comprises a coated powder having a carbon or graphite base powder and a pitch coating.
7 . The method according to claim 6 wherein said coated powder has an average diameter from between about 2 to about 200 microns
8 . The method according to claim 7 wherein said coating is from between and 1 and about 50 percent by weight of the base powder.
9 . The method according to claim 1 wherein said binder comprises coal tar pitch or petroleum pitch.
10 . The method according to claim 1 wherein said binder comprises a resin having a coking value greater than about 20 percent.
11 . The method according to claim 1 wherein said filler further comprises carbon or graphite powder derived from amorphous carbon, green, calcined or graphitized petroleum, coal tar coke, graphitized powder from synthetic sources, or natural graphite.
12 . A method for making a three dimensional article comprising:
forming an article by depositing alternating layers of a binder and a filler, wherein said filler includes a carbon or graphite powder in combination with a milled pitch, said binder volatizing at a temperature greater than a softening point temperature of said milled pitch; and
heat treating said article in a non-oxidizing environment to at least about 800° C.
13 . The method according to claim 12 wherein said binder volatizes at temperatures greater than 300° C. and said milled pitch has a softening point less than 300° C.
14 . The method according to claim 12 wherein said binder volatizes at temperatures less than about 200° C.
15 . The method according to claim 12 wherein said pitch has a softening point temperature from between about 80° C. and about 300° C.
16 . The method according to claim 12 wherein further comprising the step of infusing said article with an impregnating pitch.
17 . The method according to claim 12 wherein said powder further comprises a coated powder having a carbon or graphite base powder and a pitch coating.
18 . The method according to claim 17 wherein said coated powder has an average diameter from between about 2 to about 200 microns
19 . The method according to claim 17 wherein said pitch coating is from between and 1 and about 50 percent by weight of the base powder.
20 . The method according to claim 12 wherein said binder comprises coal tar pitch or petroleum pitch.
21 . The method according to claim 12 wherein said binder comprises a resin having a coking value greater than about 20 percent.
22 . A method for making a three dimensional article comprising:
depositing a plurality of binder coated filler particles to form a monolithic article, wherein said filler includes carbon or graphite; and
heat treating said article in a non-oxidizing environment to at least about 800° C.
23 . The method of claim 22 wherein a shape of the article prior to the heat treating comprises a shape other than a rectangular billet and a cylindrical billet.