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  Carbon foam thermal coreThe Patent Description & Claims data below is from USPTO Patent Application 20070193158. Brief Patent Description - Full Patent Description - Patent Application Claims
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 expanded polystyrene (EPS). The EPS or other foam is conventionally sandwiched between outer panels depending on the specific application. For instance, when the panel is used to form a relatively large structure such as a food locker or refrigerated room, the foam can be sandwiched between layers of oriented strand board, fiber board, plywood, or other like materials. Alternatively, the outer layers can be formed of a metal sheet, such as a thin layer of steel. When the panel is used to form a smaller structure, such as a cooler or a refrigerator or freezer, the core is sandwiched between a plastic material such as a high density polyethylene (HDPE). 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. [0006] What is desired, therefore, is a core material for a panel for cold storage applications which possesses at least adequate insulative value (preferably a thermal R value of at least about 2, and as high as about 4 or higher), while being relatively non-flammable, resistant to chemical degradation and which does not emit noxious gases when exposed to flame. The desired core material should also be light weight, have a high strength to density ratio, can be recycled, can be used in thinner sections, is inert and non-corrosive and resists deterioration over time. Certain carbon foams provide just such a material. [0007] In Hardcastle et al. (U.S. Pat. No. 4,425,396) an insulating panel is disclosed with a synthetic organic polymeric foam with protective weathering layers comprised of multiple thermoplastic sheets. [0008] Cahill (U.S. Pat. No. 6,656,858) describes a lightweight laminate wall comprised of a low density layer of from about 0.5 to 3 pounds per cubic foot and a second, reinforcing layer of a polymeric fabric. These structures are lightweight, have a low moisture resistance and meet building code requirements regarding transverse wind loading. [0009] Porter (U.S. Pat. No. 6,599,621) describes a structural insulated panel (SIP) with high strength and resistance to fire and particularly to water and changes in humidity. The disclosed structures are comprised of an inner insulating core with a gypsum fiberboard on one face of the insulating core and an oriented strand board on the second face of the insulating core. Preferably, the insulating core is comprised of a plastic foam such as expanded polystyrene or urethane which is bonded to both the gypsum fiberboard and the oriented strand board. [0010] Porter (U.S. Pat. No. 6,588,172) describes the incorporation of a laminated layer of plastic impregnated paper into a SIP to increase the panel's tensile strength while rendering it impervious to moisture. This layer is typically situated between the gypsum board and plastic foam core, adhered through a conventional bonding agent. [0011] Parker (U.S. Pat. No. 4,628,650) describes a SIP with a foam core with a layer having an overhang projecting from the foam core edges. The overhang is situated to facilitate an effective seal between adjacent SIPs, providing better thermal insulation. Additionally, the core of the panels has channels through the structure for the placement of joists, studs or rafters. [0012] Clear (U.S. Pat. No. 6,079,175) describes a SIP of cementitious material for building structures. A lightweight fill material such as bottom ash, cement and water is poured between spaces of two outermost ribs, which is claimed to provide insulation, strength and also rigidity to the panel and therefore the structure the panel comprises. This SIP has the advantage of being constructed in remote or more barren areas as it is fairly inexpensive to create. [0013] Pease (U.S. Pat. No. 6,725,616) prepares an insulated concrete wall either cast or built with blocks which is attached to reinforced insulated strips. The patentee indicates that users will require less time and labor in making insulated using the patentee's method of fixing reinforced rigid foam to the surface of a concrete wall. [0014] Pease (U.S. Pat. No. 6,892,507) describes a method and apparatus for making an SIP with a rigid foam sheet. The rigid foam sheets have multiple grooves in which reinforcing strips are situated. The strips and rigid foam are then covered and bonded with a reinforcing sheet, the sheet providing both structural support and moisture retention. SUMMARY OF THE INVENTION [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. [0017] More particularly, the inventive carbon foam cold storage panel has a carbon foam core with a density of from about 0.08 to about 0.16 grams per cubic centimeter (g/cc) and a compressive strength of at least about 5 megaPascals (MPa), more preferably at least about 6 MPa (measured by, for instance, ASTM C695). An important characteristic for the carbon foam core when intended for use in larger scale applications such as walk-in refrigerators and freezers, food lockers, etc. is a strength to density ratio of at least about 20 MPa/g/cc, more preferably at least about 33 MPa/g/cc, most preferably at least about 37.5 MPa/g/cc, and higher. [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. [0019] Advantageously, to produce the carbon foam core, a polymeric foam block, particularly a phenolic foam block, is carbonized in an inert or air-excluded atmosphere, at temperatures which can range from about 500.degree. C., more preferably at least about 800.degree. C., up to about 3200.degree. C. to prepare the carbon foams for use in the structural carbon foam panels. [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. [0021] Most commonly, the carbon foam core's first and second outerfaces are each covered with a layer to form the inventive cold storage panel. Optionally, the outer layers may be comprised of oriented strand board (OSB) or a variety of gypsum board, or combinations thereof. Other outerlayers exist including, but not limited to, a variety of thermoplastics, metals, organic sheets, fiber impregnations, and composite boards. Continue reading... Full patent description for Carbon foam thermal core Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Carbon foam thermal core patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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