Xiamen Zopin New Material Limited Established in 2011, it is a new material industry with capabilities of independent research & development, production and sales as one. Our ISO9001:2012 factory covers an area of 6 hectares and a building area of 28,000 square meters, with annual production of high-performance metal foams of 250,000 square meters. Our R&D team is composed of academicians and experts from Tsinghua University, Polytechnic University of Hong Kong, Nanyang Technological University, and other domestic and foreign metal foam professionals. After many years’ endeavor, we now own our proprietary intellectual property rights in manufacturing high purity and high porosity metal foams.
Ultramet Carbon Foam: A HighPerformance Material for Advanced Applications
Ultramet carbon foam, developed by Ultramet Corporation, is a specialized type of reticulated carbon foam known for its exceptional thermal, electrical, and mechanical properties. This material is widely used in advanced applications such as aerospace, defense, energy storage, and thermal management systems. Below is a detailed overview of Ultramet carbon foam, including its structure, properties, manufacturing process, applications, and advantages.
●1. What Is Ultramet Carbon Foam?
Ultramet carbon foam is a lightweight, porous material with an interconnected, opencell structure. It is engineered to provide high surface area, excellent thermal conductivity, and superior mechanical strength. The material is composed of pure carbon or graphite, making it highly resistant to corrosion and capable of operating in extreme environments.
Key features of Ultramet carbon foam include:
High Porosity: Typically ranges from 70% to 98%, depending on the application.
Interconnected Pores: Facilitates efficient fluid flow and heat transfer.
Customizable Properties: Tailored pore sizes, densities, and wall thicknesses can be achieved during manufacturing.
●2. Structure of Ultramet Carbon Foam
The structure of Ultramet carbon foam consists of:
Carbon Struts/Ligaments: Form the framework of the foam, providing mechanical strength and conductivity.
Open Cells: Allow for the free movement of fluids (liquids or gases) through the material.
Pore Density: Measured in pores per inch (PPI), typically ranging from 5 PPI (large pores) to 100 PPI (fine pores).
This unique structure enables Ultramet carbon foam to excel in applications requiring efficient mass transfer, heat exchange, or catalytic reactions.
●3. Manufacturing Process
Ultramet carbon foam is produced using a proprietary replication method:
1. Template Creation: A sacrificial template (e.g., polymer foam or metal foam) is created with the desired pore structure.
2. Infiltration: The template is infiltrated with a carbon precursor, such as phenolic resin or pitch.
3. Carbonization: The infiltrated template is subjected to high temperatures in an inert atmosphere to convert the precursor into carbon.
4. Template Removal: The sacrificial template is removed, leaving behind a reticulated carbon foam structure.
This process ensures precise control over the foam's morphology and properties.
●4. Properties of Ultramet Carbon Foam
| Property | Description |
|||
| Density | Ranges from 0.1 to 0.5 g/cm³, depending on porosity. |
| Surface Area | Can exceed 500 m²/g, providing ample active sites for reactions. |
| Thermal Conductivity | High thermal conductivity, enabling efficient heat dissipation. |
| Electrical Conductivity | Excellent electrical conductivity, ideal for energy storage applications. |
| Mechanical Strength | High compressive strength and flexibility, resisting deformation under load. |
| Chemical Stability | Resistant to acids, bases, and organic solvents. |
| Temperature Resistance | Stable up to 3,000°C in inert atmospheres, making it suitable for extreme conditions. |
●5. Applications of Ultramet Carbon Foam
A. Thermal Management
Heat Exchangers: Efficiently transfers heat due to its high thermal conductivity and opencell structure.
Cooling Systems: Dissipates heat in electronic devices, power systems, and industrial equipment.
B. Energy Storage
Batteries: Used as electrodes in lithiumion, sodiumion, and other advanced battery systems.
Supercapacitors: Provides high surface area for rapid charge/discharge cycles.
Fuel Cells: Acts as a catalyst support and gas diffusion layer.
C. Aerospace and Defense
Lightweight Structures: Reduces weight in aircraft and spacecraft components.
Radiation Shielding: Protects against ionizing radiation in space missions.
Thermal Protection Systems: Absorbs and dissipates heat during reentry.
D. Environmental Remediation
Water Treatment: Adsorbs pollutants and contaminants due to its high surface area.
Air Filtration: Captures particulate matter and harmful gases.
E. Industrial Applications
Catalyst Supports: Enhances reaction rates in chemical processes.
Electrodes: Used in electrochemical systems for water splitting, electrolysis, and more.
Carbon Foam Batteries
●6. Advantages of Ultramet Carbon Foam
| Advantage | Description |
|||
| High Surface Area | Increases active sites for chemical reactions and energy storage. |
| Excellent Conductivity | Ensures efficient electron and heat transfer. |
| Mechanical Stability | Resists deformation during operation and cycling. |
| Chemical Resistance | Maintains integrity in corrosive environments. |
| Fluid Permeability | Allows efficient flow of liquids or gases through the material. |
| Customizability | Tailored pore sizes, densities, and properties for specific applications. |
●7. Challenges and Limitations
A. Cost
Advanced manufacturing techniques and highquality materials increase production costs.
Solution: Develop scalable and costeffective processes, such as recycling or optimizing precursors.
B. Durability
Repeated use or exposure to harsh environments may degrade the foam structure over time.
Solution: Optimize material composition and design to enhance durability.
C. Integration
Integrating Ultramet carbon foam into existing systems may require significant modifications.
Solution: Collaborate with manufacturers to standardize designs and ensure compatibility.
●8. Future Trends and Innovations
A. Hybrid Materials
Combining Ultramet carbon foam with other advanced materials (e.g., graphene, metal oxides) to enhance performance.
B. Sustainable Production
Developing ecofriendly methods to produce Ultramet carbon foam from renewable or wastederived precursors.
C. Emerging Applications
Exploring Ultramet carbon foam in fields like quantum computing, wearable electronics, and biomedical devices.
●9. Suppliers and Research Institutions
If you're interested in Ultramet carbon foam, here are some key players:
Ultramet Corporation: The original developer of Ultramet carbon foam, specializing in advanced porous materials for aerospace, defense, and industrial applications.
Graphene Solutions: Offers hybrid carbon materials for energy storage and thermal management.
Porvair Advanced Materials: Provides reticulated carbon foam solutions for various industries.
Universities and Research Labs: Institutions like MIT, Stanford, and Tsinghua University are actively researching carbon foam technologies.
●10. Conclusion
Ultramet carbon foam is a versatile and highperformance material with applications spanning thermal management, energy storage, aerospace, and environmental remediation. Its unique combination of high surface area, excellent conductivity, and lightweight structure positions it as a key player in nextgeneration technologies. While challenges remain, ongoing research and development continue to unlock new possibilities and address limitations.
If you're exploring Ultramet carbon foam for your project, carefully evaluate factors such as application requirements, budget, and desired performance metrics. For further details or assistance, feel free to ask!
Daisy@foam-material.com
