Composite Layers, Methods for Their Manufacture and Uses Thereof
First Claim
1. A composite layer of carbon nanotubes and metal, the layer having thickness of at least 10 μ
- m, the carbon nanotubes being distributed through the layer and being present in the layer at a volume fraction of at least 0.001 vol % and at most 65 vol %, the volume fraction being based on the total volume of the metal and carbon nanotubes and not including any pore volume.
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Accused Products
Abstract
A composite layer of carbon nanotubes and metal such as copper is formed by electrodeposition. The layer has a thickness of at least 10 μm. The carbon nanotubes are distributed through the layer and are present in the layer at a volume fraction of at least 0.001 vol % and at most 65 vol %. The volume fraction is based on the total volume of the metal and carbon nanotubes and not including any pore volume. The carbon nanotubes are substantially uniformly plated with the metal. The composite layer has a density ratio satisfying PlayerPmetal≤0.35 where player is the bulk density of the composite layer of thickness of at least 10 μm, including any voids that are present in the composite layer and pmetal is the volumetric mass density material property of the metal. The composite layer is of use in evaporation-condensation apparatus, as an active material layer in an electrochemical device or in an electroforming process.
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Citations
16 Claims
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1. A composite layer of carbon nanotubes and metal, the layer having thickness of at least 10 μ
- m, the carbon nanotubes being distributed through the layer and being present in the layer at a volume fraction of at least 0.001 vol % and at most 65 vol %, the volume fraction being based on the total volume of the metal and carbon nanotubes and not including any pore volume.
- View Dependent Claims (2, 3, 4)
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5. A process for manufacturing a composite layer of carbon nanotubes and metal, the process comprising the steps:
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providing carbon nanotubes; dispersing the carbon nanotubes in an electrolyte solution; providing a working electrode and a counter electrode comprising the metal, each in contact with the electrolyte; and electroplating the working electrode with the carbon nanotubes and metal to grow the composite layer at a rate of change of thickness of the composite layer of at least 10 μ
m/min to a thickness of at least 10 μ
m;wherein, for at least a part of the process, the composite layer of thickness of at least 10 μ
m has a density ratio satisfying; - View Dependent Claims (6, 7, 8, 9, 10, 11)
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12. An evaporation-condensation apparatus for the transfer of heat,
the apparatus comprising a closed container having an evaporator region and a condenser region, the container having a wicking layer formed on an internal surface of the container and a working fluid contained in the container, wherein the wicking layer comprises a composite layer of carbon nanotubes and metal, the composite layer having thickness of at least 10 μ - m, the carbon nanotubes being distributed through the composite layer and being present in the composite layer at a volume fraction of at least 0.001 vol % and at most 65 vol %, the volume fraction being based on the total volume of the metal and carbon nanotubes and not including any pore volume,
wherein evaporation of the working fluid at the evaporator region, the mass transport of the evaporated working fluid from the evaporator region to the condenser region and the condensation of the working fluid at the condenser region contribute to the transfer of heat, the condensed working fluid being transported back to the evaporator region along the wicking layer. - View Dependent Claims (13, 14)
- m, the carbon nanotubes being distributed through the composite layer and being present in the composite layer at a volume fraction of at least 0.001 vol % and at most 65 vol %, the volume fraction being based on the total volume of the metal and carbon nanotubes and not including any pore volume,
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15. An electrochemical device comprising an anode, electrolyte and cathode, wherein at least one of the anode and cathode includes an active material layer and a current collecting layer, wherein the current collecting layer is a composite layer of carbon nanotubes and metal, the composite layer having thickness of at least 10 μ
- m, the carbon nanotubes being distributed through the composite layer and being present in the composite layer at a volume fraction of at least 0.001 vol % and at most 65 vol %, the volume fraction being based on the total volume of the metal and carbon nanotubes and not including any pore volume.
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16. An electroforming process comprising the steps:
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(i) providing a composite layer of carbon nanotubes and metal, the composite layer having thickness of at least 10 μ
m, the carbon nanotubes being distributed through the composite layer and being present in the composite layer at a volume fraction of at least 0.001 vol % and at most 65 vol %, the volume fraction being based on the total volume of the metal and carbon nanotubes and not including any pore volume;
orcarrying out a process to manufacture a composite layer of carbon nanotubes and metal, the process comprising the steps; providing carbon nanotubes; dispersing the carbon nanotubes in an electrolyte solution; providing a working electrode and a counter electrode comprising the metal, each in contact with the electrolyte; and electroplating the working electrode with the carbon nanotubes and metal to grow the composite layer at a rate of change of thickness of the composite layer of at least 10 μ
m/min to a thickness of at least 10 μ
m;wherein, for at least a part of the process, the composite layer of thickness of at least 10 μ
m has a density ratio satisfying;
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Specification