Method for the preparation of carbon filaments

Claim 1

A method for the preparation of carbon filaments, comprising the steps of exposing a thermostable support having substantially completely reduced monocrystalline ferro-magnetic metal particles to a carbon containing gas at a temperature of from about 250° C. up to about 700° C. to 800° C. for a period of time sufficient to promote epitaxial growth of graphite layers at the interface of the metal particle and the support, substantially each of said metal particle having a particle size of at least about 5 nanometers, forming carbon filaments on the support, the upper temperature limit of from 700° C. to 800° C. being contingent upon the stability of a metal carbide which is formed preceding the nucleation of filamentous carbon, said filaments being characterized by a crystalline graphitic structure and a morphology defined by a fishbone-like arrangement of the graphite layers along an axis of the filaments, adjusting loading of the support surface with the metal particles prior to the step of exposing the support and metal particles to the carbon containing gas to control the desired number of the carbon filaments per unit area of support surface, and thereafter separating the carbon filaments from the support.

Claim 2

A method for the preparation of carbon filaments, comprising the steps of exposing a thermostable support having substantially completely reduced monocrystalline ferro-magnetic metal particles to a carbon containing gas at a temperature of from about 250° C. up to about 700° C. to 800° C. for a period of time sufficient to promote epitaxial growth of graphite layers at the interface of the metal particle and the support, substantially each of said metal particle having a particle size of at least about 5 nanometers, forming carbon filaments on the support, the upper temperature limit of from 700° C. to 800° C. being contingent upon the stability of a metal carbide which is formed preceding the nucleation of filamentous carbon, said filaments being characterized by a crystalline graphitic structure and a morphology defined by a fishbone-like arrangement of the graphite layers along an axis of the filaments, adjusting loading of the support surface with the metal particles prior to the step of exposing the support and metal particles to the carbon containing gas to control the desired number of the carbon filaments per unit area of support surface, and thereafter separating the carbon filaments from the support.

Claim 12

A method for the preparation of reinforced polymers comprising the steps of exposing a thermostable support having substantially completely reduced monocrystalline ferro-magnetic metal particles to a carbon containing gas at a temperature of from about 250° C. up to about 700° C. to 800° C. for a period of time sufficient to promote epitaxial growth of graphite layers at the interface of the metal particle and the support, substantially each of said metal particle having a particle size of at least about 5 nanometers, forming carbon filaments on the support, the upper temperature limit of from 700° C. to 800° C. being contingent upon the stability of a metal carbide which is formed preceding the nucleation of filamentous carbon, said filaments being characterized by a crystalline graphitic structure and a morphology defined by a fishbone-like arrangement of the graphite layers along an axis of the filaments, adjusting loading of the support surface with the metal particles prior to the step of exposing the support and metal particles to the carbon containing gas to control the desired number of the carbon filaments per unit area of support surface, separating the carbon filaments from the support, and impregnating the carbon filaments with a molten polymer, a monomer, or a mixture thereof, that is subsequently polymerized.

Claim 13

A method for the preparation of reinforced polymers comprising the steps of exposing a thermostable support having substantially completely reduced monocrystalline ferro-magnetic metal particles to a carbon containing gas at a temperature of from about 250° C. up to about 700° C. to 800° C. for a period of time sufficient to promote epitaxial growth of graphite layers at the interface of the metal particle and the support, substantially each of said metal particle having a particle size of at least about 5 nanometers, forming carbon filaments on the support, the upper temperature limit of from 700° C. to 800° C. being contingent upon the stability of a metal carbide which is formed preceding the nucleation of filamentous carbon, said filaments being characterized by a crystalline graphitic structure and a morphology defined by a fishbone-like arrangement of the graphite layers along an axis of the filaments, adjusting loading of the support surface with the metal particles prior to the step of exposing the support and metal particles to the carbon containing gas to control the desired number of the carbon filaments per unit area of support surface, separating the carbon filaments from the support, and impregnating the carbon filaments with a molten polymer, a monomer, or a mixture thereof, that is subsequently polymerized.

Claim 14

A method for the preparation of a reinforced polymer, comprising the steps of exposing a thermostable support having substantially completely reduced monocrystalline ferro-magnetic metal particles to a carbon containing gas at a temperature of from about 250° C. up to about 700° C. to 800° C. for a period of time sufficient to promote epitaxial growth of graphite layers at the interface of the metal particle and the support, substantially each of said metal particle having a particle size of at least about 5 nanometers, forming carbon filaments on the support, the upper temperature limit of from 700° C. to 800° C. being contingent upon the stability of a metal carbide which is formed preceding the nucleation of filamentous carbon, said filaments being characterized by a crystalline graphitic structure and a morphology defined by a fishbone-like arrangement of the graphite layers along an axis of the filaments, adjusting loading of the support surface with the metal particles prior to the step of exposing the support and metal particles to the carbon containing gas to control the desired number of the carbon filaments per unit area of support surface, separating the carbon filaments from the support, dispersing the carbon filaments in a molten polymer, a monomer, or mixture thereof, subjecting the suspension thus obtained to a shear force, and polymerizing the molten polymer, monomer, or mixture thereof.

Claim 15

A method for the preparation of a reinforced polymer, comprising the steps of exposing a thermostable support having substantially completely reduced monocrystalline ferro-magnetic metal particles to a carbon containing gas at a temperature of from about 250° C. up to about 700° C. to 800° C. for a period of time sufficient to promote epitaxial growth of graphite layers at the interface of the metal particle and the support, substantially each of said metal particle having a particle size of at least about 5 nanometers, forming carbon filaments on the support, the upper temperature limit of from 700° C. to 800° C. being contingent upon the stability of a metal carbide which is formed preceding the nucleation of filamentous carbon, said filaments being characterized by a crystalline graphitic structure and a morphology defined by a fishbone-like arrangement of the graphite layers along an axis of the filaments, adjusting loading of the support surface with the metal particles prior to the step of exposing the support and metal particles to the carbon containing gas to control the desired number of the carbon filaments per unit area of support surface, separating the carbon filaments from the support, dispersing the carbon filaments in a molten polymer, a monomer, or mixture thereof, subjecting the suspension thus obtained to a shear force, and polymerizing the molten polymer, monomer, or mixture thereof.

Claim 16

A method for the preparation of a reinforced polymer, comprising the steps of exposing a thermostable support having substantially completely reduced monocrystalline ferro-magnetic metal particles to a carbon containing gas at a temperature of from about 250° C. up to about 700° C. to 800° C. for a period of time sufficient to promote epitaxial growth of graphite layers at the interface of the metal particle and the support, substantially each of said metal particle having a particle size of at least about 5 nanometers, forming carbon filaments on the support, the upper temperature limit of from 700° C. to 800° C. being contingent upon the stability of a metal carbide which is formed preceding the nucleation of filamentous carbon, said filaments being characterized by a crystalline graphitic structure and a morphology defined by a fishbone-like arrangement of the graphite layers along an axis of the filaments, adjusting loading of the support surface with the metal particles prior to the step of exposing the support and metal particles to the carbon containing gas to control the desired number of the carbon filaments per unit area of support surface, separating the carbon filaments from the support with the metal particles attached to the ends of the filaments, dispersing the carbon filaments in a molten polymer, monomer, or mixture thereof, and subjecting the suspension to an applied external electric and magnetic field or a combination of an electric and magnetic field during solidification.

Claim 17

A method for the preparation of a reinforced polymer, comprising the steps of exposing a thermostable support having substantially completely reduced monocrystalline ferro-magnetic metal particles to a carbon containing gas at a temperature of from about 250° C. up to about 700° C. to 800° C. for a period of time sufficient to promote epitaxial growth of graphite layers at the interface of the metal particle and the support, substantially each of said metal particle having a particle size of at least about 5 nanometers, forming carbon filaments on the support, the upper temperature limit of from 700° C. to 800° C. being contingent upon the stability of a metal carbide which is formed preceding the nucleation of filamentous carbon, said filaments being characterized by a crystalline graphitic structure and a morphology defined by a fishbone-like arrangement of the graphite layers along an axis of the filaments, adjusting loading of the support surface with the metal particles prior to the step of exposing the support and metal particles to the carbon containing gas to control the desired number of the carbon filaments per unit area of support surface, separating the carbon filaments from the support with the metal particles attached to the ends of the filaments, dispersing the carbon filaments in a molten polymer, monomer, or mixture thereof, and subjecting the suspension to an applied external electric and magnetic field or a combination of an electric and magnetic field during solidification.

Claim 18

A method for the production of an electrode, comprising the steps of exposing a thermostable support having substantially completely reduced monocrystalline ferro-magnetic metal particles to a carbon containing gas at a temperature of from about 250° C. up to about 700° C. to 800° C. for a period of time sufficient to promote epitaxial growth of graphite layers at the interface of the metal particle and the support, substantially each of said metal particle having a particle size of at least about 5 nanometers, forming carbon filaments on the support, the upper temperature limit of from 700° C. to 800° C. being contingent upon the stability of a metal carbide which is formed preceding the nucleation of filamentous carbon, said filaments being characterized by a crystalline graphitic structure and a morphology defined by a fishbone-like arrangement of the graphite layers along an axis of the filaments, adjusting loading of the support surface with the metal particles prior to the step of exposing the support and metal particles to the carbon containing gas to control the desired number of the carbon filaments per unit area of support surface, raising the temperature to above about 900° C. while maintaining the atmosphere of the carbon-containing gas mixture to enhance the growth of carbon deposits on the filaments to form a dense and homogeneous block of carbon, and separating the carbon block from the support.

Claim 19

A method for the production of an electrode, comprising the steps of exposing a thermostable support having substantially completely reduced monocrystalline ferro-magnetic metal particles to a carbon containing gas at a temperature of from about 250° C. up to about 700° C. to 800° C. for a period of time sufficient to promote epitaxial growth of graphite layers at the interface of the metal particle and the support, substantially each of said metal particle having a particle size of at least about 5 nanometers, forming carbon filaments on the support, the upper temperature limit of from 700° C. to 800° C. being contingent upon the stability of a metal carbide which is formed preceding the nucleation of filamentous carbon, said filaments being characterized by a crystalline graphitic structure and a morphology defined by a fishbone-like arrangement of the graphite layers along an axis of the filaments, adjusting loading of the support surface with the metal particles prior to the step of exposing the support and metal particles to the carbon containing gas to control the desired number of the carbon filaments per unit area of support surface, raising the temperature to above about 900° C. while maintaining the atmosphere of the carbon-containing gas mixture to enhance the growth of carbon deposits on the filaments to form a dense and homogeneous block of carbon, and separating the carbon block from the support.