Vapor grown carbon fiber reinforced composite materials and methods of making and using same
CAFCFirst Claim
1. A process for producing a carbon reinforced preform of continuous fiber useful in the manufacture of carbon reinforced composite articles, comprising steps of:
- (a) dispersing a catalyst precursor throughout a preform of continuous fiber;
(b) converting said catalyst precursor into catalytic particles, said catalytic particles dispersed throughout the preform; and
(c) contacting the preform of continuous fiber containing the catalytic particles with a hydrocarbon gas whereby vapor grown carbon nanofibers are deposited in situ at the catalytic particles throughout the preform to yield a carbon reinforced preform of continuous fiber.
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Abstract
A process for producing-vapor grown carbon fiber (VGCF) reinforced continuous fiber performs for the manufacture of articles with useful mechanical, electrical, and thermal characteristics is disclosed. Continuous fiber preforms are treated with a catalyst or catalyst precursor and processed to yield VGCF produced in situ resulting in a highly entangled mass of VGCF infused with the continuous fiber preform. The resulting continuous fiber preforms are high in volume fraction of VGCF and exhibit high surface area useful for many applications. Furthermore, this invention provides for a continuous fiber preform infused with VGCF so that the carbon nanofibers are always contained within the fiber preform. This eliminates the processing steps for isolated carbon nanofibers reported in other carbon nanofiber composite approaches and therefore greatly reduces risk of environmental release and exposure to carbon nanofibers.
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Citations
15 Claims
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1. A process for producing a carbon reinforced preform of continuous fiber useful in the manufacture of carbon reinforced composite articles, comprising steps of:
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(a) dispersing a catalyst precursor throughout a preform of continuous fiber; (b) converting said catalyst precursor into catalytic particles, said catalytic particles dispersed throughout the preform; and (c) contacting the preform of continuous fiber containing the catalytic particles with a hydrocarbon gas whereby vapor grown carbon nanofibers are deposited in situ at the catalytic particles throughout the preform to yield a carbon reinforced preform of continuous fiber. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A process for providing a carbon reinforced composite article comprising steps of:
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(a) dispersing a catalyst precursor throughout a preform of continuous fiber; (b) converting said catalyst precursor into catalytic particles, said catalytic particles dispersed throughout the preform of continuous fiber; (c) contacting the preform of continuous fiber containing the catalytic particles with a hydrocarbon gas to yield a carbon nanofiber reinforced preform of continuous fiber; and (d) infusing said carbon reinforced preform of continuous fiber with a thermoplastic or thermoset polymer, thermoplastic or thermoset polymer resin, metal, ceramic, ceramic precursor, or amorphous glass to provide a carbon reinforced composite article.
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Specification