U.S. patent application number 13/520222 was filed with the patent office on 2013-02-07 for graphite-containing plate and method for producing a graphite-containing plate.
This patent application is currently assigned to SGL CARBON SE. The applicant listed for this patent is Werner Guckert, Christian Kipfelsberger, Robert Michels, Siegfried Rauch. Invention is credited to Werner Guckert, Christian Kipfelsberger, Robert Michels, Siegfried Rauch.
Application Number | 20130032750 13/520222 |
Document ID | / |
Family ID | 47626380 |
Filed Date | 2013-02-07 |
United States Patent
Application |
20130032750 |
Kind Code |
A1 |
Guckert; Werner ; et
al. |
February 7, 2013 |
GRAPHITE-CONTAINING PLATE AND METHOD FOR PRODUCING A
GRAPHITE-CONTAINING PLATE
Abstract
A graphite-containing plate contains a solidified mixture of
substantially evenly distributed graphite particles and plastic
particles. In the method, graphite particles and plastics particles
are mixed to form a mixture of substantially uniform distribution.
The mixture is subsequently solidified.
Inventors: |
Guckert; Werner; (Baar,
DE) ; Kipfelsberger; Christian; (Naila, DE) ;
Rauch; Siegfried; (Gersthofen, DE) ; Michels;
Robert; (Thierhaupten, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Guckert; Werner
Kipfelsberger; Christian
Rauch; Siegfried
Michels; Robert |
Baar
Naila
Gersthofen
Thierhaupten |
|
DE
DE
DE
DE |
|
|
Assignee: |
SGL CARBON SE
WIESBADEN
DE
|
Family ID: |
47626380 |
Appl. No.: |
13/520222 |
Filed: |
December 31, 2010 |
PCT Filed: |
December 31, 2010 |
PCT NO: |
PCT/EP2010/070979 |
371 Date: |
September 27, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12915340 |
Oct 29, 2010 |
|
|
|
13520222 |
|
|
|
|
Current U.S.
Class: |
252/62 |
Current CPC
Class: |
E04C 1/392 20130101;
E04C 2/20 20130101 |
Class at
Publication: |
252/62 |
International
Class: |
E04B 1/90 20060101
E04B001/90 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 31, 2009 |
DE |
10 2009 055 440.8 |
Dec 31, 2009 |
DE |
10 2009 055 441.6 |
Dec 31, 2009 |
DE |
10 2009 055 442.4 |
Dec 31, 2009 |
DE |
10 2009 055 443.2 |
Dec 31, 2009 |
DE |
10 2009 055 444.0 |
Feb 16, 2010 |
DE |
10 2010 002 000.1 |
Feb 26, 2010 |
DE |
10 2010 002 434.1 |
Mar 17, 2010 |
DE |
10 2010 002 989.0 |
Sep 20, 2010 |
DE |
10 2010 041 085.3 |
Sep 30, 2010 |
DE |
10 2010 041 822.6 |
Claims
1-25. (canceled)
26. A graphite-containing plate, comprising: a solidified mixture
of substantially uniformly distributed graphite particles and
plastic particles.
27. The plate according to claim 26, wherein said graphite
particles and said plastic particles are homogeneously distributed
in the mixture.
28. The plate according to claim 26, which further comprises at
least one component embedded in the plate.
29. The plate according to claim 26, consisting exclusively of said
mixture of graphite particles and plastic particles.
30. The plate according to claim 26, wherein said graphite
particles contain expanded graphite.
31. The plate according to claim 26, wherein said mixture contains
5 to 90 weight % of plastic particles.
32. The plate according to claim 26, wherein said mixture contains
15 to 60 weight % of plastic particles.
33. The plate according to claim 26, wherein said mixture contains
20 to 50 weight % of plastic particles.
34. The plate according to claim 26, wherein said plastic particles
contain one or both of thermoplastics and thermosetting
plastics.
35. The plate according to claim 26, wherein said plastic particles
are selected from the group consisting of polyvinylchloride,
polypropylene, polyamides, acrylonitrile butadiene styrene,
polyether ketone, polyvinylidene fluoride, fluoropolymers,
benzoxazines, and polysulphone.
36. The plate according to claim 26, wherein said plastic particles
are selected from the group consisting of epoxy resin, phenol
resin, melamine resin, urea resins, polyester resins, and
unsaturated polyester resins.
37. The plate according to claim 26, wherein said solidified
mixture is formed into a plastically deformable plate.
38. The plate according to claim 26, wherein said solidified
mixture is formed in a predefined contour.
39. A method of producing a graphite-containing plate, the method
comprising: mixing graphite particles and plastic particles to form
a mixture having a largely uniform distribution of graphite
particles and plastic particles; and subsequently solidifying the
mixture of graphite particles and plastic particles.
40. The method according to claim 39, which comprises forming the
mixture with a homogeneous distribution of graphite particles and
plastic particles.
41. The method according to claim 39, wherein the solidifying step
comprises carrying out a compression step.
42. The method according to claim 41, wherein the compression step
comprises pressing the mixture.
43. The method according to claim 39, wherein the solidifying step
comprises a melting and a cooling step.
44. The method according to claim 43, which comprises completely
melting the plastic particles in a melting step.
45. The method according to claim 37, wherein the solidifying step
comprises a process step selected from the group consisting of a
curing step and a sintering step.
46. The method according to claim 37, which comprises initially
pre-solidifying the mixture to maintain a plastically deformable
mixture.
47. The method according to claim 46, which comprises pressing at
least one component into the plastically deformable mixture.
48. The method according to claim 46, which comprises molding the
plastically deformable mixture to a predefined contour.
49. The method according to claim 46, wherein the plastically
deformable mixture is subsequently finally solidified.
50. The method according to claim 37, which comprises, prior to
solidifying the mixture, introducing at least one component into
the mixture and subsequently finally solidifying the mixture.
Description
[0001] The invention relates to a graphite-containing plate
according to the preamble of claim 1 and a method for producing a
graphite-containing plate.
[0002] Known from DE 103 41 255 B4 is a light-weight heat
conduction plate and a method for the manufacture thereof. This
heat conduction plate is produced from expanded graphite known per
se (expanded graphite) by compression. The production of expanded
graphite is sufficiently known from the prior art, inter alia, from
U.S. Pat. No. 3,404,061 A. In order to produce expanded graphite,
graphite intercalation compounds or graphite salts such as, for
example, graphite hydrogen sulphate or graphite nitrate are heated
in a shock-like manner. The volume of the graphite particles is
thereby increased by a factor of about 200-400 and at the same
time, the bulk density decreases to values of 2-20 g/l. The
expanded graphite thus obtained consists of worm- or
concertina-shaped aggregates. In the light-weight heat conduction
plate of DE 103 41 255 B4, such expanded graphite is compacted
under directional action of pressure so that the layer planes of
the graphite are preferably arranged perpendicular to the direction
of action of the pressure and the individual aggregates become
entangled with one another. By this means self-supporting flat
structures such as webs or plates can be produced without adding
binders. Such compacted heat conduction plates without binders are
fundamentally dimensionally stable but have a low strength and
therefore readily break apart under relatively low loads. Thus, for
example, rectangular heat conduction plates having a weight per
unit area of 1000 g/m.sup.2, a thickness of 13 mm and the size
11.times.13 cm only have a bending strength of 0.1 MPa. Therefore,
dimensionally stable plates having relatively small dimensions,
e.g. 50.times.50 cm can only be produced since larger plates can no
longer be handled. In particular the intrinsic weight of larger
plates has the result that the plate only ruptures on one lateral
edge under wear. These plates are therefore not suitable for use in
the construction area without additional stiffening.
[0003] In order to overcome this disadvantage, DE 103 41 255 B4
proposes that after pressing, the heat conduction plates should be
completely or partially impregnated with plastics, for example,
resins or thermoplastics, in order to increase the density and the
resistance to mechanical and other environmental effects. This
subsequent liquid impregnation of the pressed expanded graphite
plates has the disadvantage, however, that the infiltration of the
expanded, compressed graphite with the liquid binders takes place
non-uniformly. It has already been established in films of
compressed expanded graphite that they are only uniformly
infiltrated in the near-surface region. The binder only penetrates
inadequately or not at all into the regions of the films located
further inwards. The same applies to an even greater extent for the
significantly thicker plates of compressed expanded graphite
compared with films. This non-uniform distribution of the binder
results in a non-uniform stiffness and stability of the plates so
that the plates break more easily at places not identifiable from
the outside than at other places.
[0004] FIG. 1 shows a schematic cross-section through such a
light-weight heat conduction plate 1. There pressed, expanded
graphite 2 has been infiltrated subsequently with a liquid binder 3
from the lateral surfaces of the plate 1. However, the binder 3 has
only penetrated non-uniformly into the plate so that in particular
a region 4 identified by the oval dashed boundary is binder-free
and therefore significantly less stiff and stable than adjoining
regions of the plate 1. This region 4 is therefore more liable to
break than the adjoining regions of the plate 1.
[0005] It is therefore the object of the invention to provide a
graphite-containing plate and a method for producing a
graphite-containing plate which overcomes the above-mentioned
disadvantages and provides a uniformly stiff and dimensionally
stable plate.
[0006] This object is solved by a graphite-containing plate having
the features of claim 1 and a method for producing a
graphite-containing plate having the features of claim 10.
Advantageous further developments and preferred embodiments of the
plate and the method are given in the subclaims.
[0007] A graphite-containing plate according to the invention is
characterised in that this contains a solidified mixture of largely
uniformly distributed graphite particles and plastic particles,
where this plate according to the invention can be produced by
firstly mixing graphite particles and plastic particles to form a
mixture having a largely uniform distribution of graphite particles
and plastic particles, and then solidifying the mixture.
[0008] In a preferred embodiment, the graphite particles and
plastic particles can be homogeneously distributed in the mixture,
which can be achieved inter alia by sufficiently long mixing of the
particles.
[0009] In an advantageous embodiment from the production
engineering viewpoint, the plate can consist exclusively of the
mixture of graphite particles and plastic particles without other
additives needing to be added. They are not required to obtain a
dimensionally stable plate.
[0010] Advantageously, the mixture can contain 5 to 90 weight %,
preferably 15 to 60 weight % and particular preferably 20 to 50
weight % of plastic particles in order to obtain a sufficiently
stable plate.
[0011] The graphite particles can advantageously contain expanded
graphite and particularly advantageously expended graphite. The
plastic particles can advantageously contain thermoplastics and/or
thermosetting plastics.
[0012] In a preferred embodiment PVC can be used as plastic since
it can be used at temperatures above 80.degree. C. This is
particularly advantageous in the advantageous use of the plates
according to the invention as a thermally active component for
heating rooms since temperatures of heating media are usually up to
60.degree. C.
[0013] Advantageously polypropylene (PP), polyamides (PA),
acrylonitrile butadiene styrene (ABS), polyether ketone (PEEK),
polyvinylidene fluoride (PVDF), fluoropolymers, benzoxazines and/or
polysulphone (PP) can be used as other suitable thermoplastics for
the plastic particles.
[0014] A suitable thermosetting plastic is preferably epoxy resin,
which is widely used, easy to process, relatively cost-effective
and temperature-resistant. For higher demands, phenol resins can
advantageously be used, likewise also melamine resin, urea resins
and polyester resins, in particular unsaturated polyester resins
(UP resins).
[0015] The solidification of the mixture can preferably be
accomplished by compression, in particular by means of pressing.
The solidification can also comprise a melting and a cooling step
in order, for example, to partially or completely melt
thermoplastics. By this means a good bond can be achieved between
graphite particles and plastic particles. In particular, when using
thermosetting plastics, the solidification can comprise a curing
step. The solidification can also be accomplished by an alternative
or additional sintering of the mixture.
[0016] In an advantageous embodiment, the plate is plastically
deformable so that it can be moulded simply at the installation
site to predefined contours of walls or ceilings of rooms, for
example, edges, curves, corners, friezes etc. The plate can then be
finally solidified at the installation site, for example, by
heating the still plastically deformable plate in the installed
state.
[0017] For the advantageous use of the plate according to the
invention as wall or ceiling cladding and/or as thermally active
component for cooling or heating rooms, the mixture can initially
be pre-solidified so that it remains plastically deformable. Then
at least one component, advantageously pipes or pipelines for
receiving a fluid cooling or heating medium can be pressed into the
plastically deformable mixture.
[0018] Additionally or alternatively, the plastically deformable
mixture or the thus plastic deformable plate can be moulded to a
predefined contour, for example in order to be able to be moulded
to non-flat wall or ceiling profiles. The plastically deformable
mixture or plate can then be finally solidified. Alternatively, it
can advantageously be provided that before solidification of the
mixture, at least one aforesaid component can be introduced into
the mixture and the mixture subsequently finally solidified.
However, fixing elements, anchors etc. can advantageously be
embedded as components.
[0019] Plates according to the invention can be used in the
construction area, for example, as a ceiling or wall element for
fixing to a ceiling or wall. The plates according to the invention
are thus suitable, for example, for use in room temperature control
systems and in acoustic elements for improving sound
absorption.
[0020] Further particular features and advantages of the invention
are obtained from the following description of preferred exemplary
embodiments by reference to the drawings. In the figures:
[0021] FIG. 1 shows a graphite-containing plate known from the
prior art;
[0022] FIG. 2 shows a cross-section through a graphite-containing
plate according to the invention according to a first exemplary
embodiment;
[0023] FIG. 3 shows a cross-section through a graphite-containing
plate according to the invention according to a second exemplary
embodiment;
[0024] FIG. 4 shows a cross-section through a graphite-containing
plate according to the invention according to a third exemplary
embodiment.
[0025] A graphite-containing plate 5 according to the invention,
shown in FIG. 2 consists of graphite particles 6 made of expanded
graphite which are worm- or concertina-shaped in a known manner.
Instead of expanded graphite, natural graphite or synthetic
graphite, preferably in powder form, can also be used. However,
expanded graphite has the advantage that on the one hand it can be
readily pressed to give a dense, dimensionally stable plate to a
small extent and on the other hand, can be readily mixed with solid
plastic particles 7.
[0026] The graphite particles 6 are initially mixed largely
uniformly with the solid plastic particles 7, here PVC. This can be
accomplished in a known manner by mixing devices known per se for
powdery materials. The graphite particles 6 are in this case mixed
largely uniformly, that is advantageously at least 85%, with the
plastic particles 7 in order to obtain a plate 5 which is as
uniformly stable as possible. The particles 6, 7 are preferably
mixed homogeneously with one another.
[0027] After mixing, the mixture is pressed in a known manner by
action of pressure to form the plate 5. In order to increase the
binding between the plastic particles 7 amongst one another and
with the graphite particles 6, the mixture is additionally heated
so that the plastic particles 7 begin to melt or even melt
completely, then fuse with one another and bind with the graphite
particles. In a cooling process that can take place by active
cooling or passive cooling of the mixture, the molten plastic
particles 7 solidify whilst retaining their molten shape so that a
uniformly dimensionally stable plate 5 is obtained.
[0028] The two aforesaid steps--pressing and heating--can also be
carried out successively. Alternatively or additionally, the
solidification or compression can also take place by hardening
and/or sintering. These different types of compression can also be
combined with one another.
[0029] As a result of the mixing according to the invention of the
graphite particles 6 and the plastic particles 7 to form a mixture
having a largely uniform distribution of particles before the
solidification, an advantageous plate 5 which is uniform over its
surface, dimensionally stable, stiff, robust and easy to handle can
be produced compared with the known graphite-containing plates
1.
[0030] FIGS. 3 and 4 show preferred examples of use of the plate
according to the invention and the method of manufacture according
to the invention. The same parts are provided with the same
reference numbers as in FIG. 2.
[0031] FIG. 3 shows the advantageous use according to the invention
of a plate 5 according to the invention as a thermally active
component in the form of a ceiling/wall cladding plate for heating
and/or cooling a room. In this case, after mixing the graphite
particles 6 and the plastic particles 7 but before solidification
of this mixture, two pipes 8 are inserted centrally in the mixture.
Then the mixture was finally solidified subsequently as described
above. By this means simply pre-assembled wall cladding plates
prepared for use as heating and/or cooling elements can be produced
so that the manufacture of these plates and their use in the
construction field can be carried out on an industrial scale. As a
result of the large dimensional stability and stiffness of these
plates, the handling and assembly of the plates in the building
site area is made easier, in particular dimensionally stable plates
having larger dimensions can be manufactured and used without
needing to fear any damage to the plates during transport and
handling.
[0032] Such a plate with embedded pipes 8 can be used, for example,
in a device for temperature control of a room where the device has
at least one component such as, for example, a concrete ceiling or
wall which forms a thermal storage device and has a surface
pointing into the room and where the pipes 8 are coupled to the
thermal storage device and can be acted upon with a heating or
cooling medium.
[0033] Such a device for the temperature control of a room makes it
possible to use the mass of the ceilings or walls as thermal
storage devices without pipes for carrying a heating or cooling
medium for thermal activation of the storage device needing to be
inserted in the ceilings or walls. An energy-efficient temperature
control system having short response times is thereby provided
which can also be installed subsequently when renovating old
buildings.
[0034] FIG. 4 shows the advantageous use according to the invention
of a plate 5 according to the invention as a thermally active
component in the form of a ceiling/wall cladding plate for heating
and/or cooling a room. In this case, unlike the embodiment in FIG.
3, after mixing the graphite particles 6 and plastic particles 7,
the mixture is initially pre-solidified so that it is still
plastically deformable and only then are two pipes 9 pressed into
the plastically deformable plate 5 and the plate 5 or the mixture
is then finally solidified as described above. In the embodiment
according to FIG. 4, the advantages are obtained as in the
embodiment according to FIG. 3.
[0035] In a further development of the plate 5 from FIG. 4, this
can advantageously be pre-solidified in a plastically deformable
manner during manufacture, then transported to the place of use,
for example, a building site, and only there are the pipes 9
pressed into the plate 5 at suitable locations. The final
solidification is then carried out on site, for example, by heating
the still plastically deformable plate 5 when already installed. By
this means the laying of the pipes 9 can be simply adapted to the
special conditions on site.
* * * * *