Raw composition for carbon articles

Claim 1

A method for preparing a homogeneous and low porosity carbon article of great mechanical strength comprising: (I) shaping into a desired form a composition comprising: a sinterable mother material which is in fibrous, powder or particulate form, and which (i) is a polycyclic aromatic compound obtained from tar or pitch, (ii) has a H/C atomic ratio of from 0.3 to 0.75, (iii) a fixed carbon value of 55 to 96%, (iv) does not flow out of a 1 mm diameter nozzle under an applied load of 10 kg/cm 2 at 300° C., (v) benzene insolubles of more than 90%, and (vi) is capable of being sintered together without deformation while baking; and an additive, in an amount sufficient to improve the workability and carbonization characteristics of said mother material, selected from the group consisting of: (i) a hydrocarbon, (ii) a fatty acid, an ester or metal salt thereof, (iii) an organic compound having a OH functional group in the molecule, and (iv) mixtures thereof, the additive having a maximum fixed carbon value of 20%, a boiling or decomposition point of at least 150° C., and becoming fluid at a temperature of at least 1,000° C., wherein said hydrocarbon (i) is selected from the group consisting of a liquid paraffin, a lubricating oil, a light oil, a coal tar, naphthalene, an alkyl naphthalene, an anthracene oil and a bottom oil by-product in the manufacture of olefins; said fatty acid (ii) is selected from the group consisting of lauric acid, myristic acid, palmitic acid, stearic acid and oleic acid; and said organic compound (iii) is selected from the group consisting of ethylene glycol, propylene glycol, glycerine, cyclohexanol, lauryl alcohol, decyl alcohol, cetyl alcohol, polyethylene glycol, polypropylene glycol and polyvinyl alcohol; and (II) baking the shaped composition at a temperature of at least 1,000° C. to sinter and fuse together said mother material and to carbonize or graphitize the composition in a nonoxidizing atmosphere, thereby providing a homogeneous and low porosity carbon article of great mechanical strength.

Claim 2

A method for preparing a homogeneous and low porosity carbon article of great mechanical strength comprising: (I) shaping into a desired form a composition comprising: a sinterable mother material which is in fibrous, powder or particulate form, and which (i) is a polycyclic aromatic compound obtained from tar or pitch, (ii) has a H/C atomic ratio of from 0.3 to 0.75, (iii) a fixed carbon value of 55 to 96%, (iv) does not flow out of a 1 mm diameter nozzle under an applied load of 10 kg/cm 2 at 300° C., (v) benzene insolubles of more than 90%, and (vi) is capable of being sintered together without deformation while baking; and an additive, in an amount sufficient to improve the workability and carbonization characteristics of said mother material, selected from the group consisting of: (i) a hydrocarbon, (ii) a fatty acid, an ester or metal salt thereof, (iii) an organic compound having a OH functional group in the molecule, and (iv) mixtures thereof, the additive having a maximum fixed carbon value of 20%, a boiling or decomposition point of at least 150° C., and becoming fluid at a temperature of at least 1,000° C., wherein said hydrocarbon (i) is selected from the group consisting of a liquid paraffin, a lubricating oil, a light oil, a coal tar, naphthalene, an alkyl naphthalene, an anthracene oil and a bottom oil by-product in the manufacture of olefins; said fatty acid (ii) is selected from the group consisting of lauric acid, myristic acid, palmitic acid, stearic acid and oleic acid; and said organic compound (iii) is selected from the group consisting of ethylene glycol, propylene glycol, glycerine, cyclohexanol, lauryl alcohol, decyl alcohol, cetyl alcohol, polyethylene glycol, polypropylene glycol and polyvinyl alcohol; and (II) baking the shaped composition at a temperature of at least 1,000° C. to sinter and fuse together said mother material and to carbonize or graphitize the composition in a nonoxidizing atmosphere, thereby providing a homogeneous and low porosity carbon article of great mechanical strength.