Composite tooling

Abstract

Carbonaceous, composite tooling fabricated from pitch-based or coal-based cellular or porous products, “carbonaceous foams” having a density of preferably between about 0.1 g/cm 3 and about 0.8 g/cm 3 that are produced by: 1) conventional pitch foaming processes or; 2) the controlled heating of coal particulate preferably up to ¼ inch in diameter in a “mold” and under a non-oxidizing atmosphere. According to a specifically preferred embodiment, the starting material coal has a free swell index as determined by ASTM test D720 of between about 3.5 and about 5.0.

1 - 9 . (Canceled)  
     
     
         10 . Tooling for the fabrication of composite materials comprising a tool body comprising carbonaceous foam, wherein the carbonaceous foam provides structural support for at least a portion of the composite material, and wherein the tool body is adapted for fabricating members from composite materials.  
     
     
         11 . The tooling of  claim 10 , wherein said carbonaceous foam is pitch-based or coal-based.  
     
     
         12 . The tooling of  claim 11 , wherein said carbonaceous foam is a semi-crystalline, largely isotropic, porous coal-based product produced from particulate coal.  
     
     
         13 . The tooling of  claim 12 , wherein said coal exhibits a free swell index of about 3.50 to about 5.0.  
     
     
         14 . The tooling of  claim 11 , wherein the carbonaceous foam has a compressive strength below about 6000 psi.  
     
     
         15 . The tooling of  claim 11 , wherein said carbonaceous foam has been carbonized.  
     
     
         16 . The tooling of  claim 11 , wherein said carbonaceous foam has been graphitized.  
     
     
         17 . The tooling of  claim 10 , further comprising a facesheet of a dissimilar material coated on the tool body.  
     
     
         18 . The tooling of  claim 10 , wherein the density of said carbonaceous foam varies in density throughout the mass thereof.  
     
     
         19 . The tooling of  claim 10 , wherein the tool body is formed of carbonaceous foam that was controllably cooled to a temperature below about 100° C. at a rate of 10° C./min or more to provide an outer surface of the carbonaceous foam with a density higher than a density of an outer surface of the carbonaceous foam when the carbonaceous foam is cooled at a rate of less than 10° C./min.  
     
     
         20 . The tooling of  claim 10 , wherein the coefficient of thermal expansion of the carbonaceous foam is substantially similar to the coefficient of thermal expansion of the composite material.