Graphite foams were prepared from a coal tar pitch that was partially converted into mesophase. Expandable graphite was used instead of an inert gas to "foam" the pitch.

Hydrated filler-type flame retardants were coated with approximately a monolayer of stearic acid using a solvent technique. Compared to the uncoated powders, the BET surface area was lower, the powder packing density was improved, and the thickening effect on white oil was significantly reduced. The latter two observations are rationalized in terms of a reduction in the attractive interactions between the powder particles. The viscosity of white oil slurries containing 25 wt % solids showed shear-thinning non-Newtonian behavior. The coated powders showed significantly lower viscosities at low shear rates although the difference diminished at high shear rates. The lower viscosities shown by the coated powders indicate that the surface modification facilitated the break-up of agglomerates and the dispersion of individual particles in the fluid.

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The effect of adding poly(vinyl chloride) (PVC) and coke filler on the rheological behavior and thermal properties of a coal tar pitch was investigated with a view to developing an appropriate viscoelastic binder for the injection molding of graphite components. Dynamic mechanical analysis revealed that the pitch formed compatible blends with PVC featuring a single glass transition temperature (Tg) intermediate to the two parent Tg's. Adding PVC to the pitch increased melt viscosity substantially and resulted in strong shear thinning behavior at high PVC addition levels. Adding coke powder as filler increased the melt viscosity even further and enhanced shear thinning trends. Pyrolysis conducted in a nitrogen atmosphere revealed interactions between the PVC and pitch degradation pathways: the blends underwent significant thermal decomposition at lower temperatures but showed enhanced carbon yields at high temperatures. Pyrolytic carbon yield at 1000°C was further improved by a heat treatment (temperature scanned to 400°C) in air or oxygen. However, carbon yield decreased with addition of PVC. In addition, the degree of ordering attained following a one hour heat treatment at 2400°C also decreased with increasing PVC content.

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