Reticulated anisotropic porous vitreous carbon

Abstract

A reticulated anisotropic porous carbon structure composed of bent or crimped interconnected and continuous strands is described. The structure is isomorphic with the compression bent strands of the flexible reticulated polyurethane structure from which it is derived. The structure compression can be sufficient for interbonding of the bent strands which overlay each other or the bent strands can be essentially free of bonding to adjacent strands. The carbon structure is derived by providing a compressed reticulated anisotropic polyurethane structure composed of the bent strands which is then infused with a liquid thermosetting resin or resin solution or resin precursor, removing any excess liquid resin or resin precursor or resin solution from the surfaces of the strands; and then carbonizing the infused strands at an elevated temperature. The reticulated carbon structures so formed are relatively unreactive, even at very high temperatures, under reducing or neutral conditions and are particularly useful as corrosive and high temperature material filters, battery electrodes, porous catalysts or catalyst supports as well as for making carbide containing articles by infusion of the pores with a carbide forming metal or cladding thereof such as with carbide or nitride coatings by chemical vapor deposition and the like.