US4900483A
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Method of producing isotropically reinforced net-shape microcomposites
Assignee: ExxonMobil Technology and Engineering Co
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Filing: 1987-10-29
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Granted: 1990-02-13
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Expires: 2007-10-29
Abstract
Abstract A novel isotropically reinforced microcomposite is described. An entirely fluid-phase method has been devised for producing the net-shape filamentary structures. The process depends for its success on the ability to generate in situ, within a shaped mold, a three-dimensional random weave of carbon filaments by catalytic decomposition of a hydrocarbon feed. Almost any desired filament filler matrix combination can be produced by utilizing chemical vapor deposition to modify the surface and bulk properties of the filamentary structure. Infiltration of filler matrix materials can be achieved by adaptation of existing materials technologies.
Inventors
- 👤 Horst Witzke
- 👤 Bernard H. Kear
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-06 09:00
CPC Classifications
C; C04; C04B; C04B30/00; C04B30/02; B; B82; B82Y; B82Y30/00; C04B35/00; C04B35/622; C04B35/626; C04B35/628; C04B35/62844; C04B35/62857; C04B35/62873; C04B35/62876; C04B35/62884; C04B35/71; C04B35/78; C04B35/80; C04B40/00; C04B40/0028; C22; C22C; C22C43/00; D; D01; D01F; D01F9/00; D01F9/08; D01F9/12; D01F9/127; D01F9/1271; D01F9/1272; D01F9/1273; D01F9/1275; D01F9/1276; D01F9/1278; C04B2235/00; C04B2235/02; C04B2235/50; C04B2235/52; C04B2235/5208; C04B2235/5216; C04B2235/524; C04B2235/5248; C04B2235/5252
Claims Analysis
Total Claims: 12
Claim 1
Independent Claim
85 words
A method for producing an isotropically reinforced net-shape microcomposite structures by contacting one or more hydrocarbons which will catalytically decompose to form a filamentary carbon with a metallic catalyst, consisting of a solid solution of nickel and copper, for growing multidirectional carbon fibers in a mold at a temperature sufficient to form filamentary carbon and insufficient to cause the pyrolytic deposition of carbon, introducing a matrix material to fill the mold, converting the matrix material to a solid and releasing the structure from the mold.
Claim 2
Independent Claim
85 words
A method for producing an isotropically reinforced net-shape microcomposite structures by contacting one or more hydrocarbons which will catalytically decompose to form a filamentary carbon with a metallic catalyst, consisting of a solid solution of nickel and copper, for growing multidirectional carbon fibers in a mold at a temperature sufficient to form filamentary carbon and insufficient to cause the pyrolytic deposition of carbon, introducing a matrix material to fill the mold, converting the matrix material to a solid and releasing the structure from the mold.
Claim 3
Dependent Claim
26 words
A method of claim 1 wherein one or more conformal coatings are deposited on the filamentary carbon before the matrix material is introduced to the mold.
Claim 4
Dependent Claim
19 words
A method of claim 2 wherein the conformal coating is carbon, a metal, a ceramic compound or mixture thereof.
Claim 5
Dependent Claim
19 words
A method of claim 1 wherein the conformal coating is deposited by chemical vapor deposition, electroplating or electroless deposition.
Claim 6
Dependent Claim
18 words
A method of claim 1 wherein the material is a polymer, elastomer, epoxy resin, metal, alloy or ceramic.
Claim 7
Dependent Claim
23 words
A method of claim 1 wherein the net-shape microcomposite structure has at least one section with a thickness of less than one millimeter.
Claim 8
Dependent Claim
15 words
A method of claim 1 wherein the hydrocarbon is ethane, ethylene or a mixture thereof.
Claim 9
Dependent Claim
19 words
A method of claim 1 wherein the net-shape microcomposite structure reinforcement is a three-dimensional random weave of carbon filaments.
Claim 10
Dependent Claim
12 words
A method of claim 1 wherein the metallic catalyst is finely divided.
Claim 11
Independent Claim
73 words
A method for producing a net-shape microcomposite structure isotropically reinforced with a three-dimesional random weave of thin carbon filaments, which method comprises contacting a nickel-copper solid solution catalyst with ethylene in a mold to form a random weave of thin carbon filaments, at a temperature from about 450° C. to about 750° C., introducing a matrix material to the mold, converting the matrix to a solid and releasing the structure from the mold.
Claim 12
Independent Claim
73 words
A method for producing a net-shape microcomposite structure isotropically reinforced with a three-dimesional random weave of thin carbon filaments, which method comprises contacting a nickel-copper solid solution catalyst with ethylene in a mold to form a random weave of thin carbon filaments, at a temperature from about 450° C. to about 750° C., introducing a matrix material to the mold, converting the matrix to a solid and releasing the structure from the mold.
References Cited (Backward Citations)
US4518575A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1993-02-12 | 1993-08-14 | 1994-02-13 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1997-02-12 | 1997-08-14 | 1998-02-13 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2001-02-12 | 2001-08-14 | 2002-02-13 | $7700.00 | Window Closed / Lapsed |