Patent GB-991581-A (GB)
Title: Expanded pyrolytic graphite and process for producing the same
IPC: D04H1/04
Filed: 1962-10-17
Abstract: The invention comprises pyrolytic graphite which has been expanded in the "C" direction in an amount of from 2 to 125 times the original dimension.  Pyrolytic graphite, which may be obtained by decomposition of hydrocarbon gases at 1500-3000 DEG  C., may be expanded by introducing water or an organic or inorganic blowing agent between the layers of parallel carbon networks and activating the expanding agent by heating and/or initiating a chemical reaction to generate an expanding gas in situ. The pyrolytic graphite, which may be heat-treated at 2500-3600 DEG  C. for 1 to 5 hours prior to expansion, may then be subjected to an oxidizing treatment to partially delaminate the layers thereof by contacting with a solution of sulphuric acid, nitric acid, potassium chlorate, chromic acid, potassium permanganate, potassium chromate, potassium dichromate, ferric chloride or perchloric acid, or of a mixture of nitric acid and potassium chlorate, chromic acid and phosphoric acid, or of a mixture of sulphuric acid with nitric acid, perchloric acid, chromic acid, potassium permanganate, iodic or periodic acid, or ferric chloride.  Temperature and time of treatment range from room temperature to 125 DEG  C. and from 1 to 120 minutes.  The treated pyrolytic graphite may be leached with water, or aqueous acid or alkaline solution, and heated to above 100 DEG  C. and up to 2000 DEG C. to effect expansion of its layers.  The pyrolytic graphite may alternatively be subjected to an electrolytic treatment to effect interlayer attack by utilizing it as an anode in an electrolyte bath comprising, for example, sulphuric acid, chromic acid, phosphoric acid, trifluoroacetic acid, a mixture of sulphuric and nitric acids, or aqueous ferric chloride solution.  A halogen or metal halide may also be used to open up the layers by intercalation between the layers of carbon networks prior to introduction of the expanding agent.  Specified blowing agents include urea oxalate, alkali metal carbonate or bicarbonate, azo and nitroso compounds, and sulphonyl hydrazide.  A polymeric synthetic resinous material may be incorporated between the layers of expanded pyrolytic graphite. Expansion of the layers may also be effected by incorporating sodium borohydride there-between and reacting with water to produce hydrogen, which acts as the expanding agent.ALSO:Sheets of pyrolytic graphite, which have been expanded in the "c" direction in an amount of from 2-125 times the original dimension, are encapsulated with polymeric material to impart strength thereto.  Specified polymeric materials are thermoplastic resins, e.g. acrylics, acrylonitrile-butadiene-styrene resin; cellulosic polymers, e.g. cellulose acetate; fluorocarbon polymers, e.g. tetrafluoroethylene; polyamides; polyalkylenes, e.g. polyethylene, polypropylene; styrene resins, e.g. polystyrene foam; urethanes, e.g. polyurethane foam; vinyls, e.g. polyvinyl chloride; thermosetting resins, e.g. alkyds; allylics; aminoplasts, e.g. urea-formaldehyde; epoxy resins; phenolics, e.g. phenol-formaldehyde; or polyesters, e.g. polyethylene terephthalate.  The polymeric material may include therein pyrolitic graphite powder, fibreglass or metal powder.