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12 - 4 - Atlantic City - 09-68 - 0103
12 - 4 - Atlantic City - 09-68 - 0103
CARBON FOAM
I.
INTRODUCTION
The pyrolysis of the phenolic foam is accomplished in a nonoxidizing environment which may be provided by the product gases. Heating
r a t e s from l o to 200C/hour have been employed i n t h e pyrolysis of phenolic
foams. The rate depends on sample size, density, and the s t r e n g t h requirem e n t s of the products carbon. F o r example, samples of low density
(0. 05 g / c c ) phenolic foam with dimensions of 16" x 16" x 2'' may be heated
at a r a t e of 10O0C/hour t o 1000C to effect the conversion to carbon.
The p r e f e r r e d pyrolysis schedule f o r any starting foam r e p r e s e n t s
a compromise between product yield and properties. When 0.25 g / c c carbon
f o a m s were prepared from phenolic foam a t a heating r a t e which g a v e a
90 percent yield of c r a c k - f r e e pieces, the c o m p r e s s i v e strength ranged from
500 t o 820 psi. When the heating r a t e was extended over twice t h a t period of
time, the yield of c r a c k - f r e e pieces was i n c r e a s e d only slightly but the
compressive strength was nearly doubled, to 1000
1480 psi. On t h e other
hand, when the original heating rate was doubled, the yield was l e s s than
50 percent acceptable pieces.
'
104.
TABLE I
Heat T r e a t m e n t of 0.25 g / c c Phenolic Foam
Temperature
"C
100
200
300
400
500
600
700
800
900
1000
2000
2200
2400
2600
Weight
Loss, 70
2.7
5.6
14. 1
26. 8
44.2
50. 0
54.9
54.4
56..0
56. I
60
61.
61
61
Density
Change,
70
- 1.4
.6
- 4.7
.t
2.9
-12.8
8.2
4.2
1.2
0.9
0.1
3.0
- 1
t 18
t26
/I
105.
111.
Foam
Precursor
Urethane
Phenolic
'
Density
Cell
Diameter
0.05 g / c c
0.25 g / c c
8-32 m i l s
8-16 m i l s
0.05 g / c c
0.25 g / c c
2-6 m i l s
1-3 m i l s
106.
TABLE I11
P r o p e r t i e s of 0 . 2 7 g / c c Phenolic P r e c u r s o r Carbon Foam
Direction
Perpendicular
Property
Density. lb/ft3
Compressive Strength, p s i
Shear Strength, p s i
. Thermal Conductivity,
BTU/ft-Fa - h r
R T -100C
1400C
1800G
210OOC
Direction
Parallel
0.27 g / c c
1,350
725
0.27 g / c c
2, 150
570
0. 18
0.47
0.45
0.60
0.20
0.'53
0.57
0.75
Precursor
Material
1000.C T r e a t
Density,
glcc
'
Urethane
Urethane
0. 05
0.30
Phenolic
Phenolic
0.30
PC-45
ATL Graphite
1.04
1. 78
0.08
Permeability i n Darcy's
Parallel
Perpendicular
to Foam
to Foam
71. 5
24.3
1.9
0.95
20
0.068
31. 0
22.6
1.1
0.36
20
0.064
,f
107.
Figure 1
CARBON FOAM 1 0 0 0 C HEAT-TREAT
108.
Figure 2
2000 I
I800
1600
1400
I200
IO00
800
600
400
200
0
0.15
0.20
0.25
0.30
0.35
I
0.40
DENSITY GMSKC
/ I
References
(1)
iij
" M e a s u r e m e n t s of T h e r m a l D i f f u s i v i t y and T h e r m a l C o n d u c t i v i t y of
G r a p h i t e with C a r b o n A r c I m a g e F u r n a c e , M. R. N u l l a n d W. W.
L o z i e r , 5th T h e r m a l Conductivity C o n f e r e n c e , Denver, C o l o r a d o ,
O c t o b e r 20, 1965.
U. S. P a t e n t 3 , l Z i , 0 5 0 ; E. S. P a t e n t 3 , 3 0 2 , 999; ii. S. P a t e n t
3 , 3 8 7 , 940.
I,