Acid-Resistant Carbon Composite Structure for Strength and Conductivity

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Solution Overview

Problem

Graphite materials lack elasticity and mechanical strength, and existing graphite composites do not provide sufficient resistance to strong acids at high pressure and temperature environments.

Innovation Solution

A carbon composite is formed using carbon microstructures with interstitial spaces filled with a micro- or nano-sized acid-resistant binder, such as polytetrafluoroethylene, which provides mechanical interlocking and enhanced acid resistance without penetrating the carbon microstructures, preserving their flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If graphite composites are used to improve mechanical strength and elasticity, then mechanical properties are enhanced, but acid resistance at high pressure and temperature deteriorates

Engineering Contradiction:

Improvemechanical strengthVSAvoidacid resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent uses a composite material system consisting of carbon microstructures (graphite, expanded graphite, or carbon fibers) combined with acid-resistant binder particles (such as PTFE, PVDF, or fluorocarbon rubber). This composite structure allows the carbon component to provide mechanical strength and elasticity while the acid-resistant binder component provides protection against strong acids at high pressure and temperature, thus resolving the contradiction between mechanical properties and acid resistance

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The binder particles are distributed locally within the carbon composite structure, specifically filling voids and creating a binding phase at the interfaces between carbon microstructures. This local distribution of acid-resistant material provides targeted protection where it is most needed, maintaining overall acid resistance while preserving the mechanical integrity provided by the carbon framework

Inventive Principle:

Principle #3Local quality

2Strength

If binder is added to improve mechanical strength, then elasticity and strength increase, but thermal and electrical conductivity deteriorate

Engineering Contradiction:

Improvemechanical strengthVSAvoidthermal and electrical conductivity

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The binder is confined to specific locations (interstitial spaces and voids) rather than uniformly distributed throughout the composite. This localized placement ensures that the binder provides mechanical bonding where needed while minimizing its interference with the thermal and electrical conduction pathways that run through the carbon microstructure framework

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The composite maintains a porous structure with voids and interstitial spaces that are selectively filled with binder. The carbon microstructures retain their inherent porosity and conductive pathways, allowing thermal and electrical energy to flow through the carbon framework while the binder provides mechanical strength at the boundaries and interfaces

Inventive Principle:

Principle #31Porous materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The carbon composite exhibits improved mechanical strength, elasticity, acid resistance, and chemical resistance at high temperatures, maintaining excellent thermal and electrical conductivity properties.

Implementation Method 1

a micro- or nano-sized acid resistant binder such as polytetrafluoroethylene... which provides mechanical interlocking and enhanced acid resistance without penetrating the carbon microstructures

Methodology Applied

Scientific EffectMechanical interlocking:

Implementation Method 2

maintaining excellent thermal and electrical conductivity properties

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

maintaining excellent thermal and electrical conductivity properties

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 4

micro- or nano-sized acid resistant binder such as polytetrafluoroethylene... exposed to a fluid containing sulfuric acid, nitric acid, hydrochloric acid, acetic acid, or a combination comprising at least one of the foregoing at a temperature of greater than 150° F.

Methodology Applied

Scientific EffectChemical resistance:

Data Source

PatentUS10982069B2Acid resistant carbon composites, methods of manufacture, and articles formed thereof

Publication Date: 2021.04.20 BAKER HUGHES CO

AI summary

An article comprising a carbon composite containing carbon microstructures having interstitial spaces among the carbon microstructures; and a binder disposed in at least some of the interstitial spaces; wherein the carbon microstructures comprise unfilled voids within the carbon microstructures; and the binder comprises one or more of the following: polytetrafluoroethylene; polyvinyl fluoride; polyvinylidene fluoride; polychlorotrifluoroethylene; perfluoroalkoxy alkane; fluorinated ethylene propylene; ethylene tetrafluoroethylene; ethylene chlorotrifluoroethylene; a peroxide cured copolymer of tetrafluoroethylene and propylene; a fluorocarbon rubber; perfluorocarbon rubber; or a perfluoropolyether.