Methods for manufacturing architectural constructs

Patent metadata

Field	Value
Publication number	US-2015044378-A1
Application number	US-201414464541-A
Country	US
Kind code	A1
Filing date	Aug 20, 2014
Priority date	Aug 12, 2011
Publication date	Feb 12, 2015
Grant date	—

Abstract

An architectural construct is a synthetic material that includes a matrix characterization of different crystals engineered to exhibit certain properties. An architectural construct can be fabricated by a process involving layer deposition, formation, exfoliation and spacing. In one aspect, purified methane can be dehydrogenated onto a substrate by applying heat through the substrate. Deposited carbon can form a plurality of layers of a matrix characterization of crystallized carbon through self-organization. The layers can be exfoliated and spaced to configure parallel orientation at a desired spacing and thickness using selected precursors and applying heat, pressure, or both. The desired architectural construct can further be stabilized and doped to exhibit desired properties.

First claim

1 . A process comprising:
dehydrogenating hydrocarbon feedstock to deposit carbon onto a substrate, wherein the dehydrogenating comprises applying heat through the substrate; forming a plurality of layers comprising a matrix characterization of carbon derived from a dehydrogenated hydrocarbon, wherein the layers are formed through self-organization of the carbon; and producing an architectural construct of carbon by exfoliating at least one layer from the plurality of layers to form at least one exfoliated layer, wherein the producing the architectural construct of carbon comprises impregnating the at least one exfoliated layer with a fluid to create a pressure, wherein the at least one exfoliated layer is substantially parallel with any other exfoliated layer.

2 . A process of claim 1 , wherein the hydrocarbon feedstock comprises methane.

3 . A process of claim 2 , wherein the methane is substantially purified methane.

4 . A process of claim 1 , wherein the matrix characterization of carbon is graphene.

5 . (canceled)

6 . A process of claim 1 , wherein the fluid comprises a gas such as methane, ethane, propane, or butane.

7 . A process of claim 1 , further comprising adding at least one precursor into the matrix characterization of carbon, between exfoliated layers, or both.

8 . A process of claim 7 , wherein the at least one precursor is selected from a group consisting of titanium, titanium hydride, iron, iron pentacarbonyl, nickel, cobalt, boron, nitrogen, carbon, hydrocarbon, silicon, and carbide gas.

9 . A process of claim 7 , wherein the adding at least one precursor into the matrix characterization of carbon further comprises applying at least one of heat or pressure.

10 . A process of claim 1 , further comprising stabilizing the at least one exfoliated layer with a stabilizer.

11 . A process of claim 10 , wherein the stabilizer comprises at least one of a carbon fiber wrap and dopant atom.

12 - 19 . (canceled)

20 . A process comprising:
dehydrogenating hydrocarbon feedstock to deposit carbon onto a substrate, wherein the dehydrogenating comprises applying heat through the substrate; forming a plurality of layers comprising a matrix characterization of carbon derived from a dehydrogenated hydrocarbon, wherein the layers are formed through self-organization of the carbon; producing an architectural construct of carbon by exfoliating at least one layer from the plurality of layers to form at least one exfoliated layer, wherein the at least one exfoliated layer is substantially parallel with any other exfoliated layer; and adding at least one precursor into the matrix characterization of carbon, between exfoliated layers, or both.

21 . A process of claim 20 , wherein the hydrocarbon feedstock comprises methane.

22 . A process of claim 21 , wherein the methane is substantially purified methane.

23 . A process of claim 20 , wherein the matrix characterization of carbon is graphene.

24 . A process of claim 20 , wherein the producing an architectural construct of carbon by exfoliating at least one layer from the plurality of layers to form at least one exfoliated layer comprises impregnating the at least one exfoliated layer with a fluid to create a pressure.

25 . A process of claim 24 , wherein the fluid comprises a gas such as methane, ethane, propane, or butane.

26 . A process of claim 20 , wherein the at least one precursor includes at least one of titanium, titanium hydride, iron, iron pentacarbonyl, nickel, cobalt, boron, nitrogen, carbon, hydrocarbon, silicon, or carbide gas.

27 . A process of claim 20 , wherein the adding at least one precursor into the matrix characterization of carbon further comprises applying at least one of heat or pressure.

28 . A process of claim 20 , further comprising stabilizing the at least one exfoliated layer with a stabilizer.

29 . A process of claim 28 , wherein the stabilizer comprises at least one of a carbon fiber wrap or dopant atom.

30 . A process comprising:
dehydrogenating hydrocarbon feedstock to deposit carbon onto a substrate, wherein the dehydrogenating comprises applying heat through the substrate; forming a plurality of layers comprising a matrix characterization of carbon derived from a dehydrogenated hydrocarbon, wherein the layers are formed through self-organization of the carbon; producing an architectural construct of carbon by exfoliating at least one layer from the plurality of layers to form at least one exfoliated layer, wherein the at least one exfoliated layer is substantially parallel with any other exfoliated layer; and stabilizing the at least one exfoliated layer with a stabilizer.

31 . A process of claim 30 , wherein the hydrocarbon feedstock comprises methane.

32 . A process of claim 31 , wherein the methane is substantially purified methane.

33 . A process of claim 30 , wherein the matrix characterization of carbon is graphene.

34 . A process of claim 30 , wherein the producing an architectural construct of carbon by exfoliating at least one layer from the plurality of layers to form at least one exfoliated layer comprises impregnating the at least one exfoliated layer with a fluid to create a pressure.

35 . A process of claim 34 , wherein the fluid comprises a gas such as methane, ethane, propane, or butane.

36 . A process of claim 30 , further comprising adding at least one precursor into the matrix characterization of carbon, between exfoliated layers, or both.

37 . A process of claim 36 , wherein the at least one precursor includes at least one of titanium, titanium hydride, iron, iron pentacarbonyl, nickel, cobalt, boron, nitrogen, carbon, hydrocarbon, silicon, or carbide gas.

38 . A process of claim 36 , wherein the adding at least one precursor into the matrix characterization of carbon further comprises applying at least one of heat or pressure.

39 . A process of claim 30 , wherein the stabilizer comprises at least one of a carbon fiber wrap or dopant atom.

Assignees

• Mcalister Technologies Llc

Inventors

• Mcalister Roy Edward

Classifications

• B05D7/50

  Multilayers · CPC title

• B05D5/00 Primary

  Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures · CPC title

• B05D3/0218

  Pretreatment, e.g. heating the substrate · CPC title

• B05D3/107

  Post-treatment of applied coatings · CPC title

• B05D3/12

  by mechanical means · CPC title