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.

1 . A cold storage panel comprising a carbon foam material with a density of from about 0.08 g/cc to about 0.16 g/cc.  
     
     
         2 . The panel of  claim 1  further comprising: 
 a first outer layer bound to a first surface of the carbon foam material; and    a second outer layer bound to a second surface of the carbon foam material.    
     
     
         3 . The panel of  claim 1  wherein the carbon foam material has a ratio of compressive strength to density of at least about 20 MPa/g/cc.  
     
     
         4 . The panel of  claim 1  wherein the carbon foam material has a thermal conductivity of from about 0.06 W/mK to about 0.3 W/mK.  
     
     
         5 . The panel of  claim 1  wherein the carbon foam material includes a coating on the carbon foam's exterior surface.  
     
     
         6 . The panel of  claim 6  wherein the coating improves fire retardancy of the carbon foam material.  
     
     
         7 . The panel of  claim 6  wherein the coating improves oxidation resistance of the carbon foam material.  
     
     
         8 . The panel of  claim 1  further comprising a layer of compressed particles of exfoliated graphite on at least one surface of the carbon foam material.  
     
     
         9 . The panel of  claim 2  wherein the outer layers are selected from the group consisting of paper, reinforced paper composites, oriented strand board, fiberboard, drywall, gypsum, gypsum composites, wood, wood composites, plywood, thermoplastics, plastic composites, resins, metals, metal alloys, metal composites, and combinations thereof.  
     
     
         10 . A cold storage panel comprising a carbon foam material having a ratio of compressive strength to density of at least about 20 MPa/g/cc.  
     
     
         11 . The panel of  claim 10  further comprising: 
 a first outer layer bound to a first surface of the carbon foam material; and    a second outer layer bound to a second surface of the carbon foam material.    
     
     
         12 . The panel of  claim 10  wherein the carbon foam material with a density of from about 0.08 g/cc to about 0.16 g/cc.  
     
     
         13 . The panel of  claim 10  wherein the carbon foam material has a thermal conductivity of from about 0.06 W/mK to about 0.3 W/mK.  
     
     
         14 . The panel of  claim 10  wherein the carbon foam material includes a coating on the carbon foam's exterior surface.  
     
     
         15 . The panel of  claim 14  wherein the coating improves fire retardancy of the carbon foam material.  
     
     
         16 . The panel of  claim 14  wherein the coating improves oxidation resistance of the carbon foam material.  
     
     
         17 . The panel of  claim 10  further comprising a layer of compressed particles of exfoliated graphite on at least one surface of the carbon foam material.  
     
     
         18 . The panel of  claim 11  wherein the outer layers are selected from the group consisting of paper, reinforced paper composites, oriented strand board, fiberboard, drywall, gypsum, gypsum composites, wood, wood composites, plywood, thermoplastics, plastic composites, resins, metals, metal alloys, metal composites, and combinations thereof