Patterned Carbon Nanotube Composite via Selective Laser Bonding
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Solution Overview
Problem
Existing methods for forming carbon nanotube composite structures fail to create a patterned composite, as they do not effectively bond the carbon nanotubes with the substrate, limiting their mechanical and electrical properties.
Innovation Solution
A method involving a polymer substrate with a carbon nanotube layer is used, where the substrate is selectively heated using a laser to bond the carbon nanotubes, creating a patterned composite structure by melting the substrate and encapsulating the nanotubes, while leaving the second layer unattached.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the substrate is melted and permeated into the micro gaps using electromagnetic waves, then the carbon nanotubes are bonded with the substrate, but a patterned carbon nanotube composite structure cannot be formed
Solution Approach 1:
The patent applies local quality by using photomask alignment to selectively expose only specific regions of the carbon nanotube layer to the electromagnetic waves. This creates localized bonding zones where the substrate melts and penetrates into micro gaps, forming a patterned composite structure with distinct bonded and unbonded regions, thereby achieving both strong bonding and precise pattern formation.
Solution Approach 2:
The patent employs preliminary action by placing a photomask on the carbon nanotube layer before applying electromagnetic waves. This pre-positioned mask defines the desired pattern in advance, controlling where the substrate will melt and bond to the carbon nanotubes, thus enabling precise pattern formation while maintaining effective bonding in the exposed regions.
2Reliability
If the substrate is melted and permeated into the micro gaps, then the carbon nanotubes are bonded with the substrate, but the process lacks selectivity for patterned bonding
Solution Approach 1:
The photomask creates local quality differences by allowing electromagnetic waves to reach only specific areas of the carbon nanotube layer. This enables selective bonding in defined patterns while leaving other areas unbonded, providing both reliable bonding where needed and the versatility to create different patterns by changing the mask design.
Solution Approach 2:
The photomask acts as an intermediary element between the electromagnetic waves and the carbon nanotube layer. It mediates the bonding process by selectively blocking or permitting wave transmission to specific regions, thereby enabling patterned bonding with both reliability and adaptability to different design requirements.
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
This approach enables the formation of a patterned carbon nanotube composite structure with enhanced mechanical strength and electrical properties, as the substrate is selectively bonded with the carbon nanotubes, improving the structural integrity and performance.
Implementation Method 1
the substrate is selectively heated using a laser to bond the carbon nanotubes
Implementation Method 2
irradiating only the first layer part in the first part by a laser, wherein the plurality of first carbon nanotubes converts the light energy from the laser to heat energy, to heat the first substrate part
Implementation Method 3
so that the surface of the substrate is melted and is permeated into the micro gaps
Data Source
AI summary
A method for making a carbon nanotube composite structure includes providing a polymer substrate having a first surface and a second surface opposite to the first surface. A first carbon nanotube layer including a plurality of carbon nanotubes is placed on the first surface to form a preformed structure, wherein the carbon nanotube layer and the polymer substrate are stacked with each other. The preformed structure is scanned with a laser according to a predetermined pattern. The treated preformed structure includes a first part and a second part. The first part is scanned by the laser, and the second part is not scanned by the laser. The first part includes a plurality of first carbon nanotubes, and the second part includes a plurality of second carbon nanotubes. The plurality of second carbon nanotubes is removed.