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US4970123A
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Isotropically reinforced net-shape microcomposites
Assignee: ExxonMobil Technology and Engineering Co
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Filing: 1990-02-09
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Granted: 1990-11-13
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Expires: 2010-02-09
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
2026-11-08 23:07
CPC Classifications
C; C04; C04B; C04B30/00; C04B30/02; B; B82; B82Y; B82Y30/00; C04B35/00; C04B35/515; C04B35/58; C04B35/584; C04B35/589; C04B35/622; C04B35/626; C04B35/628; C04B35/62844; C04B35/62847; C04B35/62849; C04B35/62857; C04B35/6286; C04B35/62863; C04B35/62865; C04B35/62871; C04B35/62873; C04B35/62876; C04B35/62884; C04B35/71; C04B35/78; C04B35/80; C04B40/00; C04B40/0028; C08; C08K; C08K7/00; C08K7/02; C08K7/04; C08K7/06; C22; C22C; C22C47/00; C22C47/02; C22C47/04; C22C47/06; C22C47/08; C22C47/12; C22C49/00; C22C49/02; C22C49/04; C22C49/06; C22C49/14; 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; C04B2235/30; C04B2235/40; C04B2235/405; C04B2235/407; C04B2235/408; C04B2235/50; C04B2235/52; C04B2235/5208; C04B2235/5216; C04B2235/524; C04B2235/5248; C04B2235/5268; C04B2235/60; C04B2235/614; C08K3/00; C08K3/02; C08K3/04; Y; Y10; Y10T; Y10T428/00; Y10T428/12; Y10T428/12007; Y10T428/12014; Y10T428/12028; Y10T428/12035; Y10T428/30; Y10T428/31504; Y10T428/31511; Y10T428/31529; Y10T442/00; Y10T442/10; Y10T442/102; Y10T442/133; Y10T442/134
Claims Analysis
Total Claims: 18
Claim 1
Independent Claim
73 words
An isotropically reinforced net-shape microcomposite structure produced by contacting one or more hydrocarbons which will catalytically decompose to form a filamentary carbon with a metallic catalyst for growing multi-directional 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
Dependent Claim
73 words
An isotropically reinforced net-shape microcomposite structure produced by contacting one or more hydrocarbons which will catalytically decompose to form a filamentary carbon with a metallic catalyst for growing multi-directional 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
15 words
The structure of claim 1 wherein the catalyst is a solid solution of two metals.
Claim 4
Dependent Claim
23 words
The structure of claim 2 wherein the catalyst is a Group VIII metal in solution with a Group VIII or Group I(B) metal.
Claim 5
Dependent Claim
22 words
The structure of claim 3 wherein the catalyst is nickel in solution with a metal selected from copper, gold, silver, and palladium.
Claim 6
Dependent Claim
22 words
The structure of claim 1 wherein the catalyst is selected from the group consisting of nickel-copper, nickel-palladium, nickel-gold, palladium-gold, cobalt-gold and cobalt-palladium.
Claim 7
Dependent Claim
16 words
The structure of claim 1 wherein the catalyst is a solid solution of nickel and copper.
Claim 8
Dependent Claim
16 words
The structure of claim 1 wherein the catalyst is a solid solution of nickel and palladium.
Claim 9
Dependent Claim
26 words
The structure 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 10
Dependent Claim
19 words
The structure of claim 8 wherein the conformal coating is carbon, a metal, a ceramic compound or mixture thereof.
Claim 11
Dependent Claim
21 words
The structure of claim 8 or 9 wherein the conformal coating is deposited by chemical vapor deposition, electroplating or electroless deposition.
Claim 12
Dependent Claim
19 words
The structure of claim 1 wherein the matrix material is a polymer, elastomer, epoxy resin, metal, alloy or ceramic.
Claim 13
Dependent Claim
23 words
The structure of claim 1 wherein the net-shape microcomposite structure has at least one section with a thickness of less than one millimeter.
Claim 14
Dependent Claim
15 words
The structure of claim 1 wherein the hydrocarbon is ethane, ethylene or a mixture thereof.
Claim 15
Dependent Claim
19 words
The structure of claim 1 wherein the net-shape microcomposite structure reinforcement is a three-dimensional random weave of carbon filaments.
Claim 16
Dependent Claim
12 words
The structure of claim 1 wherein the metallic catalyst is finely divided.
Claim 17
Dependent Claim
72 words
A net-shape microcomposite structure isotropically reinforced with a three-dimensional random weave of thin carbon filaments, produced by the method which 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 18
Dependent Claim
72 words
A net-shape microcomposite structure isotropically reinforced with a three-dimensional random weave of thin carbon filaments, produced by the method which 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)
US4900483A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1993-11-12 | 1994-05-14 | 1994-11-13 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1997-11-12 | 1998-05-14 | 1998-11-13 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2001-11-12 | 2002-05-14 | 2002-11-13 | $7700.00 | Window Closed / Lapsed |