Hitco Carbon Composites, Inc.

Sgl Carbon Composites

Raj Mathur

Doug Wilson

Sam S-k Lee

Gary Pruett

Robert Howard Metter

A filter media system, which is capable of operating in the microfiltration regime, offers: low cost, durability, high temperature and chemical resistance, no particulation, mechanical strength, separation efficiency, and biocompatibility. The present invention provides a filter media system comprising a fibrous substrate of at least one of carbon and ceramic fibers, wherein an array of carbon or ceramic fiber whiskers have been grown onto the fibrous substrate, without prior densification of the fibrous substrate. A process for manufacturing a filter media system wherein a carbon fiber is treated with a solution of metal catalyst salt, heated in hydrogen at elevated temperatures to reduce the metal salt to metal, and whisker growth is initiated on the surfaces of the metal deposited carbon fibers by decomposition of low molecular weight hydrocarbon gas at elevated temperature is also provided.

High performance filters comprising inorganic fibers having inorganic fiber whiskers grown thereon

A filter media system, which is capable of operating in the microfiltration regime, offers: low cost, durability, high temperature and chemical resistance, no particulation, mechanical strength, separation efficiency, and biocompatibility. A filter media system is comprised of a carbon or ceramic composite substrate which contains a carbon or ceramic matrix reinforced with carbon or ceramic fibers. The composite has an array of carbon or ceramic fiber whiskers grown onto its surface or in its bulk. A process is provided for manufacturing the filter media system wherein a carbon fiber is disposed in a matrix deposited by a CVI or LPI process, at temperatures of about 900 to about 1200&deg; C. to achieve a weight gain of about 10 to 200% (the ceramic matrix is deposited by a CVI process from an aqueous slurry or by use of a preceramic polymer). This composite is treated with an aqueous solution of metal catalyst salt and is then heated in hydrogen at elevated temperatures to reduce the metal salt to metal. Whiskers are then grown on the surface or in the bulk of the catalyst deposited composite such as by decomposition of methane gas using metal catalyzed chemical vapor deposition (CVD).

High performance filters comprising an inorganic composite substrate and inorganic fiber whiskers

The present invention provides a carbon-carbon (C/C) composite valve structure useful for high temperature internal combustion engines comprising (a) a carbon-carbon (C/C) composite valve stem having a flared end and a non-flared end opposite the flared end; and (b) a carbon-carbon (C/C) composite valve head applied onto the flared end of the valve stem, wherein at least one of the carbon-carbon (C/C) composite valve stem and head is coated with a high temperature resistant coating. A method is further provided to fabricate the carbon-carbon (C/C) composite valve comprising machining a carbon-carbon (C/C) composite valve stem having a flared end and a non-flared end from a cured and densified carbon-carbon (C/C) plate having a sufficient thickness; applying a plurality of circular fabric plies, made from a balanced carbon-carbon (C/C) prepreg and having a slit in the center of said ply, coaxially onto the non-flared end of said carbon-carbon ((C/C)) valve stem and advancing said plurality of plies to intimately contact the flared end of said carbon-carbon (C/C) valve stem; placing said carbon-carbon (C/C) valve stem contacted with said plurality of circular fabric plies into a die; closing said die and cure pressing said circular fabric plies onto the flared end of said carbon-carbon (C/C) valve stem to form a valve head; carbonizing said press cured carbon-carbon (C/C) composite valve; densifing said carbon-carbon (C/C) composite valve structure; and coating at least one of said carbon-carbon (C/C) composite valve stem and valve head with a high temperature resistant coating comprising an inner layer and an outer layer.

Method of making carbon-carbon composite valve for high performance internal combustion engines

The present invention provides a carbon--carbon (C/C) composite valve structure useful for high temperature internal combustion engines comprising (a) a carbon--carbon (C/C) composite valve stem having a flared end and a non-flared end opposite the flared end; and (b) a carbon--carbon (C/C) composite valve head applied onto the flared end of the valve stem, wherein at least one of the carbon--carbon (C/C) composite valve stem and head is coated with a high temperature resistant coating. A method is further provided to fabricate the carbon--carbon (C/C) composite valve comprising machining a carbon--carbon (C/C) composite valve stem having a flared end and a non-flared end from a cured and densified carbon--carbon (C/C) plate having a sufficient thickness; applying a plurality of circular fabric plies, made from a balanced carbon--carbon (C/C) prepreg and having a slit in the center of said ply, coaxially onto the non-flared end of said carbon--carbon (C/C) valve stem and advancing said plurality of plies to intimately contact the flared end of said carbon--carbon (C/C) valve stem; placing said carbon--carbon (C/C) valve stem contacted with said plurality of circular fabric plies into a die; closing said die and cure pressing said circular fabric plies onto the flared end of said carbon--carbon (C/C) valve stem to form a valve head; carbonizing said press cured carbon--carbon (C/C) composite valve; densifying said carbon--carbon (C/C) composite valve structure; and coating at least one of said carbon--carbon (C/C) composite valve stem and valve head with a high temperature resistant coating comprising an inner layer and an outer layer.

Carbon--carbon composite valve for high performance internal combustion

A chemical process apparatus component comprising a high purity, corrosion resistant composite including a continuous carbon fiber reinforced carbon matrix having a level of total metal impurity below about 10 ppm, preferably below about 5 ppm. Most preferably, the composite has a level of metal impurity below the detection limit of inductively coupled plasma spectroscopy for the metals Ag, Al, Ba, Be, Ca, Cd, Co, Cr, Cu, K, Mg, Mn, Mo, Na, Ni, P, Pb, Sr and Zn.

Corrosion resistant composites useful in chemical reactors

A chemical process apparatus component comprising a high purity, corrosion resistant composite including a continuous carbon fiber reinforced carbon matrix having a level of total metal impurity below about 10 ppm, preferably below about 5 ppm. Most preferably, the composite has a level of metal impurity below the detection limit of inductively coupled plasma spectroscopy for the metals Ag, Al, Ba, Be, Ca, Cd, Co, Cr, Cu, K, Mg, Mn, Mo, Na, Ni, P, Pb, Sr and Zn. A process utilizing at least one of the above components for use in a chemical process apparatus, wherein said component is in contact with at least one of i) a high purity material, such as for processing, and ii) a corrosive process media.

Growing community of inventors

Huntington Beach, CA, United States of America

Raj Mathur