Scalable multiple-inverse diffusion flame burner for synthesis and processing of carbon-based and other nanostructured materials and films and fuels

Patent metadata

Field	Value
Publication number	US-9388042-B2
Application number	US-201213984397-A
Country	US
Kind code	B2
Filing date	Feb 24, 2012
Priority date	Feb 25, 2011
Publication date	Jul 12, 2016
Grant date	Jul 12, 2016

Abstract

Apparatus and methods of use thereof for the production of carbon-based and other nanostructures, as well as fuels and reformed products, are provided.

First claim

What is claimed is:

1. A multiple inverse-diffusion flame (IDF) method to fabricate strengthened composites, comprising the steps of:
a) depositing Fe or other catalyst on a substrate by thermal decomposition of a metalorganic precursor;
b) depositing a thin coat of a hard material on the Fe or catalyst-coated substrate by low-temperature thermal decomposition of a hydrocarbon precursor; and
c) depositing a thicker coat of the hard material on the thin-coated substrate by high-temperature thermal decomposition of a hydrocarbon precursor.

2. The method of claim 1 , wherein the thin coating of step b) and thicker coating of step c) are of a hard material selected from the group consisting of diamond, SiC, TiC, B 4 C, and cubic-BN.

3. The method of claim 1 , wherein the metalorganic precursor is a volatile Fe-rich compound.

4. The method of claim 3 , wherein said Fe-rich compound is iron pentcarbonyl or ferrocene.

5. The method of claim 1 , where thermal decomposition of the metalorganic precursor yields a deposit of nanocrystalline Fe or other catalyst on the substrate.

6. The method of claim 1 , wherein the hydrocarbon precursor is a volatile C-rich compound.

7. The method of claim 6 , wherein the C-rich compound is methane or ethylene.

8. The method of claim 1 , wherein low-temperature thermal decomposition of the hydrocarbon precursor yields a thin deposit of nanocrystalline diamond on the Fe-coated substrate.

9. The method of claim 8 , where the nanocrystalline diamond serves as a substrate for high-temperature thermal decomposition of the hydrocarbon precursor to develop an overlay coating of textured microcrystalline diamond.

10. The method of claim 1 , where the substrate is a fiber material.

11. The method of claim 10 , wherein the fiber material is C or SiC.

12. The method of claim 1 , wherein the substrate is a film/sheet material.

13. The method of claim 12 , wherein the film/sheet material comprises a polymer, metal, or ceramic.

14. The method of claim 13 , wherein said fabricate strengthened composite is a fiber-reinforced polymer-matrix composites (PMCs), metal-matrix composites (MMCs), or ceramic-matrix composites (CMCs) with diamond-coated fibers.

15. The method of claim 12 , wherein the polymer-, metal-, or ceramic-matrix composites are laminated with diamond/graphene-coated film/sheet materials.

16. The method of claim 10 , wherein the fiber materials are woven-fiber materials and wherein the resultant composites contain residual porosity.

17. The method of claim 16 , wherein the residual porosity is filled by pressure-infiltration of a compatible liquid phase.

18. The method of claim 10 , wherein the fiber materials are woven-fiber materials and wherein the woven-fiber materials are infiltrated with a hard material selected from the group consisting of diamond, SiC, TiC, B 4 C, and cubic-BN by varying the gas flow rate to obtain uniform through-thickness deposition.

19. The method of claim 18 , wherein the substrate is carbon nanotubes (CNTs) or silicon-carbide nanotubes (SiCNTs).

20. The method of claim 19 , further comprising fabricating D/CNT-reinforced PMCs or D/SiCNT-reinforced CMCs from the diamond-coated CNTs or SiCNTs.

21. The method of claim 19 , further comprising removing the CNT component of the diamond-coated CNT by selective gasification in a hydrogen-rich gas stream, thereby forming diamond nanotubes (DNTs).

22. The method of claim 21 , wherein the DNTs reinforce PMCs or CMCs.

Assignees

• Tse Stephen D
• Memon Nasir K
• Kear Bernard H
• Univ Rutgers

Inventors

• Tse Stephen D
• Memon Nasir K
• Kear Bernard H

Classifications

• C01B32/963

  Preparation from compounds containing silicon · CPC title

• B22F9/30

  with decomposition of metal compounds, e.g. by pyrolysis · CPC title

• F23D14/58

  characterised by the shape or arrangement of the outlet or outlets from the nozzle, e.g. of annular configuration · CPC title

• F23D2900/00001

  local catalytic coatings applied to burner surfaces · CPC title

• C01B21/0605

  Binary compounds of nitrogen with carbon · CPC title