Carbon Nanotube Reinforced Porous Carbon Having Three-Dimensionally Ordered Porosity and Method of Fabricating the Same

Abstract

A solid carbon has CNTs dispersed therein and is formed about three-dimensionally ordered spherical voids arranged in an opal-like lattice.

1 . A method of fabricating a three-dimensional structure, comprising the steps of:
 providing a template made from spheres arranged and coupled together to form an opal-like lattice having volumetric spaces formed between said spheres;   filling said volumetric spaces with a cured form of a carbon yield material having carbon nanotubes (CNTs) dispersed therein;   carbonizing said carbon yield material; and   eradicating said spheres wherein said spheres are replaced by spherical voids.   
     
     
         2 . A method according to  claim 1 , wherein each of said spheres is made from silicon dioxide. 
     
     
         3 . A method according to  claim 1 , wherein each of said spheres is approximately the same size. 
     
     
         4 . A method according to  claim 1 , wherein said step of filling comprises the steps of:
 forming a liquefied solution of a solvent and said carbon yield material having said CNTs dispersed therein;   infiltrating said opal-like lattice with said liquefied solution;   converting said liquefied solution so-infiltrated in said opal-like lattice to said cured form of said carbon yield material having said CNTs dispersed therein.   
     
     
         5 . A method according to  claim 4 , wherein said step of forming comprises the steps of:
 forming a first solution of said solvent and said carbon yield material;   forming a second solution of said solvent and said CNTs; and   mixing said first solution with said second solution to produce said liquefied solution.   
     
     
         6 . A method according to  claim 5 , further comprising the steps of:
 heating said first solution during formation thereof; and   heating said second solution during formation thereof.   
     
     
         7 . A method according to  claim 4 , wherein said step of infiltrating comprises the step of immersing said opal-like lattice in a dynamic bath of said liquefied solution wherein said CNTs remain dispersed in said liquefied solution. 
     
     
         8 . A method according to  claim 4 , wherein said step of converting comprises the steps of:
 removing said solvent from said liquefied solution wherein said carbon yield material having said CNTs dispersed therein assumes a solid state; and   curing said carbon yield material having said CNTs dispersed therein in said solid state to form said cured form of said carbon yield material having said CNTs dispersed therein.   
     
     
         9 . A method according to  claim 1 , wherein said step of eradicating comprises the step of chemically dissolving said spheres. 
     
     
         10 . A method according to  claim 4 , wherein said carbon yield material in said liquefied solution comprises a polymer. 
     
     
         11 . A method of fabricating a three-dimensional structure, comprising the steps of:
 providing a template made from spheres arranged and coupled together to form an opal-like lattice having volumetric spaces formed between said spheres;   forming a liquefied solution that includes a solvent, a carbon yield polymer, and carbon nanotubes (CNTs);   immersing said opal-like lattice in a dynamic bath of said liquefied solution wherein said CNTs are dispersed in said liquefied solution;   removing said solvent from said liquefied solution wherein said carbon yield polymer having said CNTs dispersed therein assumes a solid state;   curing said carbon yield polymer having said CNTs dispersed therein in said solid state to form a cured form of said carbon yield polymer having said CNTs dispersed therein;   carbonizing said carbon yield material to form a solid carbon with said CNTs dispersed therein; and   eradicating said spheres wherein said spheres are replaced by spherical voids in said solid carbon with said CNTs dispersed therein.   
     
     
         12 . A method according to  claim 11 , wherein each of said spheres is made from silicon dioxide. 
     
     
         13 . A method according to  claim 11 , wherein each of said spheres is approximately the same size. 
     
     
         14 . A method according to  claim 11 , wherein said step of eradicating comprises the step of chemically dissolving said spheres. 
     
     
         15 . A method according to  claim 11 , wherein said step of forming comprises the steps of:
 forming a first solution of said solvent and said carbon yield polymer;   forming a second solution of said solvent and said CNTs; and   mixing said first solution with said second solution to produce said liquefied solution.   
     
     
         16 . A method according to  claim 15 , further comprising the steps of:
 heating said first solution during formation thereof; and   heating said second solution during formation thereof.