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concepts for the future

The design flexibility that PocoFoam materials allow may radically change future shapes, sizes and locations of some very familiar thermal management systems. PocoFoam is a revolutionary advancement in thermal management. This unique material is a lightweight, porous graphite foam with exceptionally high thermal conductivity and very efficient thermal energy transfer characteristics. PocoFoam is produced through a patented foaming process that creates a structure of highly graphitic aligned ligaments within the foams cell walls. These ligaments are the key to the materials high thermal conductivity. They perform like high performance graphite fibers, wicking heat away from its source. PocoFoam has proven to be 3 to 9 times more thermally conductive than typical lightweight carbon foams. PocoFoam also demonstrates thermal conductivity up to 10 times higher than metallic foam materials, such as aluminum foam. Since this exciting new material is an advanced open cell foam, weight savings are significant when compared to conventional thermal management materials like aluminum or copper. When compared to aluminum, samples of graphite foam are five times lighter yet demonstrate equal or greater thermal conductivity. In addition, with an active surface area of more than 4 m2/g, PocoFoams heat transfer efficiencies have been shown in laboratory testing to be significantly greater than aluminum or copper. Unlike traditional materials, PocoFoam is resistant to attack by most acids. This graphite foam can be purified when contamination is a concern. As the demand for smaller, lighter and more efficient thermal management systems increases, the need for advanced material solutions follows. PocoFoams unexpected combination of thermal management properties and physical characteristics provide exciting design opportunities for new and existing applications. With PocoFoam, radical changes in the design of heat sinks, thermal spreaders and heat exchangers are on the horizon.

q Industrial heat exchangers may be reduced as much as 10 times the existing size using PocoFoam materials as the thermal transfer vehicle. q Redesigned heat sinks for electronics are in development that offer reduced weight and may eliminate the need for refrigerated or forced air cooling. q Changes in the design and position of automobile radiators may lead to next generation automobile designs.

variation by design
Variations to the base PocoFoam material will include post processes that further enhance the properties of this unique material for use in other applications.

q Extremely low levels of impurity (less than 10ppm) are possible using POCOs proprietary and proven purification process. q Rigidized graphite foam to increase resistance to shock and vibration is being accomplished using proprietary technology.

Pressure Drop Testing*

19.5 cm Diameter by 25.4 mm Long PocoFoam

properties and characteristics

*Density 0.57 g/cc

10.0 9.0 8.0 Pressure Drop (kPa) 7.0 6.0 5.0 4.0 3.0 2.0 1.0 0.0 0.0 0.1 0.2 0.3 0.4 0.5 0.6 Gas Velocity (m/second) 0.7

q Thermal Conductivity 100 to 150+ W/m-K 58-87 BTUft/ft2hrF q Electrical Resistivity 300 to 1000 -ohm-in q CTE 2 to 3 m/m K 1.1 to 1.6 in/in-F q Oxidation Resistance > 400C in oxygen atmosphere q Heat capacity 0.7 J/g-K 0.17 BTU/lbF qCompressive strength 2.07 MPa (density at 0.5 gm/cc) 300 psi (density at 31lb/ft3)

Pressure Drop Testing*

0.75" Diameter by 1" Long PocoFoam

*Density 0.57 g/cc

1.4 Pressure Drop (psi) 1.2 1.0 0.8 0.6 0.4 0.2 0.0 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 Gas Velocity (ft./sec)

q Bulk < 100 ppm impurities q Purified < 9ppm impurities

q Pore diameter (average) 350 microns 0.0138 inches q Specific surface area > 4m2/g > 19500 ft2/lb q Open Porosity > 96% q Total Porosity 73-82% q Density 0.2-0.6 g/cc 12-37 lb/ft3
PocoFoam is 5.4 times lighter per unit volume compared to Pure Aluminum. PocoFoam is 17.9 times lighter per unit volume compared to Pure Copper. PocoFoam has a 3.7 times higher TD compared to Pure Aluminum. PocoFoam has a 3.2 times higher TD compared to Pure Copper.

Thermal Properties
Material AXM-5Q Diamond Pure Al 6061-T0 6061-T4 6061-T6 Pure Cu C23000 C60800 C65100 C70600 Silver PocoFoam 1.74 85 Cp TD
(g/cm3) (W/mK) (J/gK) (cm2/s)

0.70 0.70

3.51 900 0.51 5.03 2.70 2.70 2.70 2.70 247 180 154 167 0.90 0.90 0.90 0.90 1.02 0.74 0.63 0.69

8.93 398 0.38 1.17 8.75 159 0.38 0.48 8.17 80 0.38 0.26 8.75 57 0.38 0.17 8.94 40 0.38 0.12 10.49 428 0.23 1.77 0.50 130 0.70 3.71


Visit POCOs web site for the latest information on graphite foam. If you would like to receive regular email updates, please send an e-mail request to Poco Graphite, Inc. 1601 South State Street, Decatur, Texas 76234, USA Phone: 1-940-393-4462 Fax: 1-940-393-8435 6/5/00