Methods for manufacturing architectural constructs

Abstract

An architectural construct is a synthetic material that includes a matrix characterization of different crystals engineered to exhibit certain properties. An architectural construct can be fabricated by a process involving layer deposition, formation, exfoliation and spacing. In one aspect, purified methane can be dehydrogenated onto a substrate by applying heat through the substrate. Deposited carbon can form a plurality of layers of a matrix characterization of crystallized carbon through self-organization. The layers can be exfoliated and spaced to configure parallel orientation at a desired spacing and thickness using selected precursors and applying heat, pressure, or both. The desired architectural construct can further be stabilized and doped to exhibit desired properties.

1 . A process comprising:
 dehydrogenating hydrocarbon feedstock to deposit carbon onto a substrate, wherein the dehydrogenating comprises applying heat through the substrate;   forming a plurality of layers comprising a matrix characterization of carbon derived from a dehydrogenated hydrocarbon, wherein the layers are formed through self-organization of the carbon; and   producing an architectural construct of carbon by exfoliating at least one layer from the plurality of layers to form at least one exfoliated layer, wherein the producing the architectural construct of carbon comprises impregnating the at least one exfoliated layer with a fluid to create a pressure, wherein the at least one exfoliated layer is substantially parallel with any other exfoliated layer.   
     
     
         2 . A process of  claim 1 , wherein the hydrocarbon feedstock comprises methane. 
     
     
         3 . A process of  claim 2 , wherein the methane is substantially purified methane. 
     
     
         4 . A process of  claim 1 , wherein the matrix characterization of carbon is graphene. 
     
     
         5 . (canceled) 
     
     
         6 . A process of  claim 1 , wherein the fluid comprises a gas such as methane, ethane, propane, or butane. 
     
     
         7 . A process of  claim 1 , further comprising adding at least one precursor into the matrix characterization of carbon, between exfoliated layers, or both. 
     
     
         8 . A process of  claim 7 , wherein the at least one precursor is selected from a group consisting of titanium, titanium hydride, iron, iron pentacarbonyl, nickel, cobalt, boron, nitrogen, carbon, hydrocarbon, silicon, and carbide gas. 
     
     
         9 . A process of  claim 7 , wherein the adding at least one precursor into the matrix characterization of carbon further comprises applying at least one of heat or pressure. 
     
     
         10 . A process of  claim 1 , further comprising stabilizing the at least one exfoliated layer with a stabilizer. 
     
     
         11 . A process of  claim 10 , wherein the stabilizer comprises at least one of a carbon fiber wrap and dopant atom. 
     
     
         12 - 19 . (canceled) 
     
     
         20 . A process comprising:
 dehydrogenating hydrocarbon feedstock to deposit carbon onto a substrate, wherein the dehydrogenating comprises applying heat through the substrate;   forming a plurality of layers comprising a matrix characterization of carbon derived from a dehydrogenated hydrocarbon, wherein the layers are formed through self-organization of the carbon;   producing an architectural construct of carbon by exfoliating at least one layer from the plurality of layers to form at least one exfoliated layer, wherein the at least one exfoliated layer is substantially parallel with any other exfoliated layer; and   adding at least one precursor into the matrix characterization of carbon, between exfoliated layers, or both.   
     
     
         21 . A process of  claim 20 , wherein the hydrocarbon feedstock comprises methane. 
     
     
         22 . A process of  claim 21 , wherein the methane is substantially purified methane. 
     
     
         23 . A process of  claim 20 , wherein the matrix characterization of carbon is graphene. 
     
     
         24 . A process of  claim 20 , wherein the producing an architectural construct of carbon by exfoliating at least one layer from the plurality of layers to form at least one exfoliated layer comprises impregnating the at least one exfoliated layer with a fluid to create a pressure. 
     
     
         25 . A process of  claim 24 , wherein the fluid comprises a gas such as methane, ethane, propane, or butane. 
     
     
         26 . A process of  claim 20 , wherein the at least one precursor includes at least one of titanium, titanium hydride, iron, iron pentacarbonyl, nickel, cobalt, boron, nitrogen, carbon, hydrocarbon, silicon, or carbide gas. 
     
     
         27 . A process of  claim 20 , wherein the adding at least one precursor into the matrix characterization of carbon further comprises applying at least one of heat or pressure. 
     
     
         28 . A process of  claim 20 , further comprising stabilizing the at least one exfoliated layer with a stabilizer. 
     
     
         29 . A process of  claim 28 , wherein the stabilizer comprises at least one of a carbon fiber wrap or dopant atom. 
     
     
         30 . A process comprising:
 dehydrogenating hydrocarbon feedstock to deposit carbon onto a substrate, wherein the dehydrogenating comprises applying heat through the substrate;   forming a plurality of layers comprising a matrix characterization of carbon derived from a dehydrogenated hydrocarbon, wherein the layers are formed through self-organization of the carbon;   producing an architectural construct of carbon by exfoliating at least one layer from the plurality of layers to form at least one exfoliated layer, wherein the at least one exfoliated layer is substantially parallel with any other exfoliated layer; and   stabilizing the at least one exfoliated layer with a stabilizer.   
     
     
         31 . A process of  claim 30 , wherein the hydrocarbon feedstock comprises methane. 
     
     
         32 . A process of  claim 31 , wherein the methane is substantially purified methane. 
     
     
         33 . A process of  claim 30 , wherein the matrix characterization of carbon is graphene. 
     
     
         34 . A process of  claim 30 , wherein the producing an architectural construct of carbon by exfoliating at least one layer from the plurality of layers to form at least one exfoliated layer comprises impregnating the at least one exfoliated layer with a fluid to create a pressure. 
     
     
         35 . A process of  claim 34 , wherein the fluid comprises a gas such as methane, ethane, propane, or butane. 
     
     
         36 . A process of  claim 30 , further comprising adding at least one precursor into the matrix characterization of carbon, between exfoliated layers, or both. 
     
     
         37 . A process of  claim 36 , wherein the at least one precursor includes at least one of titanium, titanium hydride, iron, iron pentacarbonyl, nickel, cobalt, boron, nitrogen, carbon, hydrocarbon, silicon, or carbide gas. 
     
     
         38 . A process of  claim 36 , wherein the adding at least one precursor into the matrix characterization of carbon further comprises applying at least one of heat or pressure. 
     
     
         39 . A process of  claim 30 , wherein the stabilizer comprises at least one of a carbon fiber wrap or dopant atom.