Continuous glassy carbon composite materials reinforced with carbon nanotubes and methods of manufacturing same
First Claim
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17. A composite material comprising:
- a substantially continuous sheet; and
an array of substantially continuous carbon nanotubes extending within the sheet along its length.
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Abstract
A method for manufacturing a carbon composite is provided. The method includes providing a carbon-containing resin material having an appropriate concentration of catalyst particles. Thereafter, the resin material may be extruded through an aperture while being exposed to a high temperature range to permit polymerization of the extruded resin material. A subsequent exposure of the extruded resin material to another elevated temperature range causes carbon in the resin material to couple to the catalyst particles to promote carbon nanotube growth and transformation of the resin material to a reinforced composite material. Reinforced composite materials are also provided.
28 Citations
43 Claims
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17. A composite material comprising:
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a substantially continuous sheet; and an array of substantially continuous carbon nanotubes extending within the sheet along its length. - View Dependent Claims (1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 39)
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18-1. A composite material as set forth in claim 17, wherein the sheet has a thickness of less than about 10 microns.
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33. A method of manufacturing a composite material, the method comprising:
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extruding a resin material having a glassy carbon precursor and a catalyst through an aperture; exposing the resin material as it is being extruded to a first elevated temperature range, so as to polymerize the resin material; subjecting the polymerized resin material to a second elevated temperature range, so as to promote growth of at least one carbon nanotube from the catalyst and to transform the resin material into a reinforced composite material. - View Dependent Claims (34, 35, 36, 37, 38, 40, 41, 42, 43)
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39-2. A method as set forth in claim 31, wherein the step of exposing includes substantially completing the polymerization of the resin material.
Specification