Flexible Ceramic Composite via Carbon Nanotube Network Infiltration

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Solution Overview

Problem

Existing ceramic composites have limited flexibility and electrical conductivity due to strong ionic/covalent bonding, which restricts their applications in advanced technologies requiring compliant and conductive materials.

Innovation Solution

The development of composite materials with a high volume fraction of carbon nanoscale fibers, aligned in a network and infiltrated with a ceramic precursor, followed by curing and pyrolysis, to create flexible and electrically conductive ceramic composites with enhanced mechanical and thermal properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If ceramic powders are embedded in a polymer phase, then the composite can be formed, but the flexibility is restricted to mild temperatures

Engineering Contradiction:

Improvemechanical propertiesVSAvoidflexibility temperature range

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent changes the temperature parameter range by replacing the polymer phase with a carbon nanotube network that maintains flexibility at high temperatures, allowing the composite to be used beyond mild temperature restrictions

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a new composite material system combining ceramic matrix with carbon nanotube network, where the carbon nanotubes provide both mechanical strength and high-temperature flexibility that neither component alone could achieve

Inventive Principle:

Principle #40Composite materials

2Strength

If strong ionic/covalent bonding is used in conventional ceramic composites, then mechanical properties are improved, but flexibility is undermined

Engineering Contradiction:

Improvemechanical propertiesVSAvoidflexibility

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent combines ceramic matrix with carbon nanotube network to create a composite where the carbon nanotubes provide flexibility while the ceramic provides strength, overcoming the trade-off between strong bonding and flexibility

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent creates different local properties within the composite: the ceramic matrix provides strong ionic/covalent bonding for mechanical strength, while the carbon nanotube network provides flexibility, allowing both properties to coexist in different regions of the material

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If carbon nanotubes are mixed in ceramic powders or polymeric precursors, then composite can be formed, but the volume fraction of carbon nanotubes is limited

Engineering Contradiction:

Improvecomposite formationVSAvoidvolume fraction of carbon nanotubes

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent performs preliminary alignment of carbon nanotubes into a network structure before infiltrating with ceramic precursor, allowing higher volume fraction of carbon nanotubes to be incorporated while maintaining manufacturability

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent segments the manufacturing process into distinct steps: first forming the carbon nanotube network, then infiltrating with ceramic precursor, which allows independent optimization of carbon nanotube content and ceramic matrix formation

Inventive Principle:

Principle #1Segmentation

4Reliability

If high volume fraction of carbon nanotubes is achieved, then electrical conductivity is improved, but manufacturing difficulty increases

Engineering Contradiction:

Improveelectrical conductivityVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent preliminarily forms the carbon nanotube network with aligned structure before ceramic infiltration, which facilitates higher carbon nanotube volume fractions and improves electrical conductivity while keeping the manufacturing process manageable

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses the carbon nanotube network as an intermediary structure that both provides electrical conductivity and serves as a template for ceramic matrix formation, simplifying the overall manufacturing process

Inventive Principle:

Principle #24Intermediary (Mediator)

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 resulting composite materials exhibit high electrical conductivity, flexibility, and mechanical strength, maintaining properties even after rigorous flexibility tests, making them suitable for diverse applications including thermal protection and electronic components.

Implementation Method 1

infiltrating the carbon nanoscale fiber network with a first amount of a liquid ceramic precursor

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

pyrolyzing the cured ceramic precursor to form the composite material

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis

Data Source

PatentUS10927045B2Ceramic composite materials and methods

Publication Date: 2021.02.23 FLORIDA STATE UNIV RES FOUND INC

AI summary

Provided herein are methods of making composite materials. The methods may include infiltrating a carbon nanoscale fiber network with a ceramic precursor, curing the ceramic precursor, and/or pyrolyzing the ceramic precursor. The infiltrating, curing, and pyrolyzing steps may be repeated one or more times. Composite materials also are provided that include a ceramic material and carbon nanoscale fibers.