Method for producing a composite carbon article and articles produced thereby

Claim 1

A PROCESS FOR PRODUCING A COMPOSITE CARBON ARTICLE WITH DISCRETE ISOLATED AREAS OF PREDETERMINED DENSITY WITH AN IMPERMEABLE OUTER SHELL COPRISING FORMING A FIRST CHARGE OF DENSELY PACKED INTERMINGLED ORGANIC FIBERS, COMPLETELY SURROUNDING SAID FIRST CHARGE WITH A SECOND CHARGE OF INTERMINGLED ORGANIC FIBERS TO FORM A UNIT, SAID SECOND CHARGE HAVING ALOW BULK DENSITY RELATIVE TO SAID FIRST CHARGE, HOLDING THE UNIT UNDER COMPRESSION, PROVIDING AND MAINTAINING A NON-OXIDIZING ENVIRONMENT FOR THE UNIT, APPLYING HEAT TO CARBONIZE THE FIBERS WHILE APPLYING PRESSURE TO SAID UNIT, MAINTAINING SAID PRESSURE DURING AT LEAST PART OF THE CARBONIZING STEP, AND DEPOSITING PYROLYTIC CARBON IN THE PORES OF SAID SECOND CHARE WHEREBY THE FIRST CHARGE IS SEALED BY AN RELATIVELY NON-POROUS CARBON SECOND CHARGE.