Carbon Nanotube Composite Parallel Orientation

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Solution Overview

Problem

Existing carbon nanotube composites have limited thermal and electrical conductivity due to CNTs being parallel and non-contacting, restricting conductivity to the length of the CNTs and limiting composite thickness.

Innovation Solution

A method involving carbon nanotubes distributed in parallel strip-shaped areas on a substrate, immersed in a liquid matrix, pressed down, and solidified to create a composite with CNTs parallel to the surface, allowing for enhanced thermal and electrical conductivity by ensuring CNTs are in contact within the matrix.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If CNTs are arranged parallel and perpendicular to surfaces, then manufacturing simplicity is maintained, but thermal and electrical conductivity in directions parallel to surfaces is limited

Engineering Contradiction:
Improvemanufacturing simplicityVSAvoidthermal and electrical conductivity
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The patent transitions from a single-dimensional vertical CNT arrangement (perpendicular to surfaces) to a two-dimensional network structure where CNTs are inclined and extend in multiple directions. This dimensional change enables thermal and electrical conduction paths parallel to surfaces while maintaining manufacturing simplicity through a single CVD process step.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent divides the CNT structure into multiple inclined segments rather than a single vertical orientation. CNTs are arranged at different angles to form a network that spans across the composite thickness, creating multiple conduction pathways that improve thermal and electrical conductivity in parallel directions.

Inventive Principle:
Principle #1Segmentation

2Device complexity

If CNT composite thickness is limited to CNT length, then manufacturing complexity is reduced, but conductivity range is restricted

Engineering Contradiction:
Improvemanufacturing complexityVSAvoidconductivity range
Core Design Contradiction:
Device complexityVSLength of stationary object

Solution Approach 1:

The patent uses inclined CNT arrangements to extend conductivity range beyond the vertical CNT length. By positioning CNTs at angles, the effective conduction path length in the thickness direction increases, allowing conductivity to extend beyond what would be possible with vertically-aligned CNTs of the same length.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent pre-arranges CNTs in inclined orientations during the manufacturing process itself, rather than requiring post-manufacturing assembly or stacking of multiple layers. This preliminary arrangement of CNTs at specific angles inherently provides extended conductivity range without adding manufacturing complexity.

Inventive Principle:
Principle #10Preliminary action

3Ease of manufacture

If CNTs do not contact one another, then manufacturing simplicity is maintained, but thermal and electrical conductivity is limited

Engineering Contradiction:
Improvemanufacturing simplicityVSAvoidthermal and electrical conductivity
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The patent uses the third dimension (inclination angle) to enable CNT-to-CNT contact. By arranging CNTs at inclined angles rather than purely vertical orientations, CNTs from adjacent regions can touch and form continuous conduction networks, improving thermal and electrical conductivity while maintaining manufacturing simplicity.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method enables improved thermal and electrical conductivity in a direction parallel to the surface, maximizing conductivity potential and extending it beyond the length of individual CNTs, while maintaining a thin-film form.

Implementation Method 1

immersing the carbon nanotubes into a liquid matrix in order to introduce the liquid matrix into clearances among the carbon nanotubes

Methodology Applied
Scientific EffectCapillary action: Capillary Action

Implementation Method 2

solidifying the matrix bound to the carbon nanotubes

Methodology Applied
Scientific EffectSolidification: Freezing

Data Source

PatentUS7662467B2Carbon nanotube composite and method for fabricating the same
Publication Date: 2010.02.16 HON HAI PRECISION INDUSTRY CO LTD
  • US7662467B2 patent drawing
  • US7662467B2 patent drawing
  • US7662467B2 patent drawing

AI summary

A CNT composite (10) includes a matrix (14) and a number of CNTs (12) embedded in the matrix. The matrix has a surface (102) and an opposite surface (104). Head portions of the respective CNTs are consistently oriented, parallel to the surfaces of the matrix. A method for manufacturing the composite includes (a) providing a substrate and depositing a catalyst film on the substrate; (b) forming the array of CNTs via the catalyst film on the substrate; (c) immersing the CNTs in a liquid matrix material, infusing the liquid matrix material into the array of CNTs; (d) taking the carbon nanotubes with the infused matrix out of the liquid matrix; (e) pressing the still-soft matrix and the CNTs therein, in order to arrange the CNTs consistently and parallel to the surfaces of the matrix; and (f) solidifying and peeling away the matrix to produce the CNT composite.