Low-defect fabrication of composite materials

Abstract

Methods and systems for the fabrication of composite materials are generally described. Certain inventive methods and systems can be used to fabricate composite materials with few or no defects. According to certain embodiments, composite materials are fabricated without the use of an autoclave. In some embodiments, composite materials are fabricated in low pressure environments.

1 . A method of forming a composite article, comprising:
 arranging, within an environment, a collection of nanostructures between a first substrate comprising a polymer and a second substrate comprising a polymer; and   heating the first substrate and/or the second substrate such that polymer within the first substrate and/or polymer within the second substrate softens and/or melts and nanostructures within the collection become at least partially embedded in the first substrate and/or the second substrate to form the composite article;   wherein:
 during at least a portion of the arranging step, the collection of nanostructures is separate from the first substrate and the second substrate; and 
 a pressure of the environment does not exceed, during any part of the heating step, 3 bar absolute. 
   
     
     
         2 . A method of forming a composite article, comprising:
 arranging, within an environment, a collection of nanostructures between a first substrate comprising a polymer and a second substrate comprising a polymer; and   heating the first substrate and/or the second substrate such that polymer within the first substrate and/or polymer within the second substrate softens and/or melts and nanostructures within the collection become at least partially embedded in the first substrate and/or the second substrate to form the composite article;   wherein during at least a portion of the arranging step, the collection of nanostructures is separate from the first substrate and the second substrate.   
     
     
         3 . A method of forming a composite article, comprising:
 arranging, within an environment, a collection of nanostructures between a first substrate comprising a polymer and a second substrate comprising a polymer; and   heating the first substrate and/or the second substrate such that polymer within the first substrate and/or polymer within the second substrate softens and/or melts and nanostructures within the collection become at least partially embedded in the first substrate and/or the second substrate to form the composite article;   wherein heating the first substrate and/or the second substrate comprises moving a source of the heat laterally across the first substrate and/or the second substrate.   
     
     
         4 - 5 . (canceled) 
     
     
         6 . The method of  claim 1 , wherein heating the first substrate and/or the second substrate comprises moving a source of the heat laterally across the first substrate and/or the second substrate. 
     
     
         7 . The method of  claim 1 , wherein the collection of nanostructures comprises carbon-based nanostructures. 
     
     
         8 . The method of  claim 1 , wherein the collection of nanostructures comprises carbon nanotubes. 
     
     
         9 . The method of  claim 1 , wherein the first substrate comprises a prepreg. 
     
     
         10 . The method of  claim 1 , wherein the second substrate comprises a prepreg. 
     
     
         11 . The method of  claim 9 , wherein the prepreg is an autoclave prepreg. 
     
     
         12 . The method of  claim 1 , wherein at least a portion of the heating does not take place within an autoclave. 
     
     
         13 . The method of  claim 1 , wherein the nanostructures within the collection become at least partially embedded in the first substrate and the second substrate. 
     
     
         14 . The method of  claim 1 , wherein the nanostructures within the collection become at least partially embedded in the first substrate and/or the second substrate during the heating step. 
     
     
         15 . The method of  claim 1 , wherein the collection of nanostructures comprises elongated nanostructures. 
     
     
         16 . The method of  claim 1 , wherein the collection of nanostructures comprises a forest of elongated nanostructures. 
     
     
         17 . The method of  claim 1 , wherein the collection of nanostructures comprises nanostructures that are substantially aligned. 
     
     
         18 . The method of  claim 1 , wherein the collection of nanostructures has a number average nearest neighbor distance of less than or equal to 100 nm. 
     
     
         19 . The method of  claim 1 , wherein the collection of nanostructures has a number average nearest neighbor distance of greater than or equal to 1 nm. 
     
     
         20 . The method of  claim 1 , wherein the collection of nanostructures has a volume fraction of nanostructures of greater than or equal to 0.001. 
     
     
         21 . The method of  claim 1 , wherein the collection of nanostructures has a volume fraction of nanostructures of less than or equal to 0.8. 
     
     
         22 . The method of  claim 1 , wherein at least a portion of the nanostructures comprise carbon, silicon, indium-gallium-arsenide materials, boron nitride, silicon nitride, silicon carbide, dichalcogenides, oxides, boron-carbon-nitrogen compounds, and/or polymers. 
     
     
         23 - 24 . (canceled)