Carbon foam thermal core

Abstract

A cold storage panel, which includes a carbon foam core having a high ratio of compressive strength to density, desirable fire retardant properties, and resistance to environmental stress. The carbon foam insulated panel also includes a first layer and a second layer bound to a first surface and second surface of the carbon foam core. Applications of the carbon foam structural insulated panel include structural and fire retardant elements of residential and commercial refrigerators and freezers, food lockers, coolers, and the like.

Description

RELATED APPLICATION [0001] This application is a continuation-in-part of copending and commonly assigned U.S. Patent Application having Ser. No. 11 / 314,975, entitled “Carbon Foam Structural Insulated Panel” filed on Dec. 21, 2005 in the names of Miller, Griffin and Segger, the disclosure of which is incorporated herein by reference.BACKGROUND OF THE INVENTION [0002] 1. Technical Field [0003] The present invention relates to the use of a carbon foam material as the core for structural panels for cold storage applications, such as commercial and residential refrigerators and freezers, food lockers, coolers, refrigerated rooms and holds, and the like. More particularly, the present invention relates to the use of carbon foam in insulated panels which provide insulation while also being non-flammable and which do not release noxious gases when exposed to flame. [0004] 2. Background Art [0005] Many cold storage panels are formed using a core material of an expanded polymeric foam like ex...

AI Technical Summary

Benefits of technology

[0015] The present invention provides a cold storage panel having a carbon foam core, which is uniquely capable of being used in applications requiring good insulative value, is non-flammable and resistant to chemical degradation and which does not emit noxious gases when exposed to flame. Moreover, since the carbon foam core material can provide adequate insulative value in thinner sheets than conventional foams, the inventive panels can be made thinner than conventional panels, thus providing significant space and cost savings.

[0016] The inventive carbon foam panel exhibits a density, compressive strength and compressive strength to density ratio to provide a combination of strength and relatively light weight characteristics not heretofore seen. In addition, the carbon lattice work of the carbon foam resists both charring and combustion while maintaining structural integrity in environmental conditions from high humidity to severely low temperatures. Furthermore, the carbon foam can be produced in a desired size and configuration and can be readily machined for a specific size for a cold storage panel.

[0018] The inventive carbon foam panel should have the carbon foam core of a relatively uniform density both longitudinally and latitudinally for consistent thermal insulation and strength characteristics throughout the panel. Specifically, the carbon foam should have a relatively uniform distribution of pores in order to provide the required high compressive strength, the pores being relatively isotropic. In addition, the carbon foam core should have a total porosity of about 65% to about 95%, more preferably about 70% to about 95% to create the optimal strength to density ratio of the carbon foam structural insulated panel.

[0020] Prior to the addition of outerlayers, the carbon foam core can be treated with a variety of coatings to improve the overall performance of the carbon foam cold storage panel. For example, an anti-oxidation coating can be applied to the carbon foam to increase the longevity of the panel in highly oxidative conditions. Additionally, a fire retardant coating could also be applied to the carbon foam core to further increase the integrity of the carbon foam core and thus the panel, when exposed to extreme temperatures.

Problems solved by technology

While this type of panel is well understood and possesses adequate insulative value, EPS and other polymeric materials are flammable when exposed to heat, are subject to chemical degradation and emit noxious gases when burned.

Images