METHOD AND APPARATUS FOR MOLDABLE MATERIAL FOR TERRESTRIAL, MARINE, AERONAUTICAL AND SPACE APPLICATIONS WHICH INCLUDES AN ABILITY TO REFLECT RADIO FREQUENCY ENERGY AND WHICH MAY BE MOLDABLE INTO A PARABOLIC OR RADIO FREQUENCY REFLECTOR TO OBVIATE THE NEED FOR REFLECTOR CONSTRUCTION TECHNIQUES WHICH PRODUCE LAYERS SUSCEPTIBLE TO LAYER SEPARATION AND SUSCEPTIBLE TO FRACTURE UNDER EXTREME CIRCUMSTANCES

Abstract

The present invention is a unique process of manufacturing rigid members with precise “shape keeping” properties and with reflective properties pertaining to radio frequency energy, so that air, land, sea and space devices or vehicles may be constructed including parabolic reflectors formed without discrete permanent layering. Rather, such parabolic reflectors or similarly, vehicles, may be formed by homogeneous construction where discrete layering is absent, and where energy reflectivity or scattering characteristics are embedded within the homogeneous mixture of carbon nanotubes and associated graphite powders and epoxy, resins and hardeners. The mixture of carbon graphite nanofiber and carbon nanotubes generates higher electrode conductivity and magnetized attraction through molecular polarization. In effect, the rigid members may be tuned based on the application. The combination of these materials creates a unique matrix that is then set in a memory form at a specific temperature, and then applied to various materials through a series of multiple layers, resulting in unparalleled strength and durability.

Claims

1. A manufacturing process for forming an electromagnetic energy absorber having a monolithic structure of uniform energy absorption characteristics without encapsulation of a forming surface wherein forming said electromagnetic energy absorber includes the following steps: a. blending together carbon nanotubes, carbon nanofiber, and a resin hardener under suitable conditions to form a cured conductive slurry; b. applying said curing conductive slurry to a shaped forming surface wherein said shaped forming surface is of a shape corresponding to an electromagnetic energy absorbing surface; c. allowing said curing conductive slurry to harden; and d. separating said absorbing surface from said shaped forming surface without encapsulating a support structure for operation as an energy absorber having uniform energy absorption characteristics without encapsulation of said forming surface and wherein said energy absorber is formed to be substantially rigid and fixed into place as a mirror image of said shaped forming surface, and wherein said conductive slurry is tuned to be used in the electromagnetic spectrum to absorb energy.

2. The manufacturing process for forming an electromagnetic energy absorber according to claim 1 wherein said energy absorber is formed by a brush application of said slurry onto said shaped forming surface.

3. The manufacturing process for forming an electromagnetic energy absorber according to claim 1 wherein said energy absorber is formed by a pour application of said slurry onto said shaped forming surface.

4. The manufacturing process for forming an electromagnetic energy absorber according to claim 1 wherein said energy absorber is formed by a spray application of said slurry onto said shaped forming surface.

5. The manufacturing process of claim 1 wherein said carbon nanofibers become oriented with said carbon nanotubes to form an organized matrix and are tuned to absorb electromagnetic energy of specific frequencies.

6. The manufacturing process of claim 1 wherein said monolithic structure is comprised of several concentrically interlinked carbon nanotubes.

7. The manufacturing process of claim 1 wherein said carbon nanotubes are formed as armchair carbon nanotubes.

8. The manufacturing process of claim 1 wherein said carbon nanotubes are formed as zigzag carbon nanotubes.

9. The manufacturing process of claim 1 wherein said carbon nanotubes are single-walled.

10. The manufacturing process of claim 1 wherein said carbon nanotubes are multi-walled.

11. The manufacturing process according to claim 1 wherein said energy absorber is formed by application of said slurry onto said shaped forming surface, cured and then released from said forming surface.

12. The manufacturing process according to claim 1 wherein an energy reflector is formed by application of said slurry onto said shaped forming surface, cured and then released from said forming surface.

13. The manufacturing process according to claim 1 wherein an energy discharger is formed by application of said slurry onto said shaped forming surface, cured and then released from said forming surface.

14. The manufacturing process for forming a rigid material according to claim 1 wherein an underwater vehicle is formed from said rigid material.

15. The manufacturing process for forming a rigid material according to claim 1 wherein a maritime vehicle is formed from said rigid material.

16. The manufacturing process for forming a rigid material according to claim 1 wherein a terrestrial structure is formed from said rigid material.

17. The manufacturing process for forming a rigid material according to claim 1 wherein an aeronautical vehicle is formed from said rigid material.

18. A manufacturing process for forming an electromagnetic energy discharger having a monolithic structure of uniform energy absorption characteristics without encapsulation of a forming surface wherein forming said electromagnetic energy discharger includes the following steps: a. blending together carbon nanotubes, carbon nanofiber, and a resin hardener under suitable conditions to form a cured conductive slurry; b. applying said curing conductive slurry to a shaped forming surface wherein said shaped forming surface is of a shape corresponding to an electromagnetic energy discharging surface; c. allowing said curing conductive slurry to harden; and d. separating said absorbing surface from said shaped forming surface without encapsulating a support structure for operation as an energy discharger having uniform energy discharging characteristics without encapsulation of said forming surface and wherein said energy discharger is formed to be substantially rigid and fixed into place as a mirror image of said shaped forming surface, and wherein said conductive slurry is tuned to be used in the electromagnetic spectrum to discharge energy.

19. The manufacturing process for forming an electromagnetic energy discharger according to claim 18 wherein said energy discharger is formed by application of said slurry onto said shaped forming surface.

20. The manufacturing process of claim 18 wherein said cured conductive slurry possesses uniform levels of energy discharging characteristics through its cross-section and entire volume.

21. The manufacturing process of claim 18 wherein said carbon nanofibers become oriented with said carbon nanotubes to form an organized matrix and are tuned to discharge electromagnetic energy of specific frequencies.

22. A manufacturing process for forming an electromagnetic energy diffuser having a monolithic structure of uniform discharging characteristics without encapsulation of a forming surface wherein forming said absorber includes the following steps: a. blending together carbon nanotubes, carbon nanofiber and a resin hardener under suitable conditions to form a cured conductive slurry; b. applying said curing conductive slurry to a shaped forming surface wherein said shaped forming surface is of a shape corresponding to an energy discharge surface; c. allowing said curing conductive slurry to harden; and d. separating said energy discharger from said shaped forming surface without encapsulating a support structure for operation as an electromagnetic energy discharger with uniform energy discharging characteristics without encapsulation of said forming surface, wherein said carbon nanofibers became oriented with said carbon nanotubes to form an organized matrix, wherein said monolithic structure is comprised of several concentrically interlinked carbon nanotubes, and wherein said discharger is formed to be substantially rigid and fixed into place as a mirror image of said shaped forming surface, and wherein said conductive slurry hardens to form said monolithic structure with uniform energy discharging characteristics.

23. The manufacturing process according to claim 22 wherein said energy diffuser is formed by application of said slurry onto said shaped forming surface, cured and then released from said forming surface.

24. The manufacturing process according to claim 22 wherein an energy diffuser is formed by application of said slurry onto said shaped forming surface, cured and then released from said forming surface.

25. A manufacturing process for forming a rigid material having a monolithic structure of uniform diffuser characteristics without encapsulation of a forming surface wherein forming said structure includes the following steps: a. blending together carbon nanotubes, carbon nanofiber and a resin hardener under suitable conditions to form a cured conductive slurry; b. applying said curing conductive slurry to a forming surface wherein said forming surface is of a shape or pitch corresponding to a desired discharge surface; c. allowing said curing conductive slurry to harden; and d. separating an absorptive surface from said shaped forming surface without encapsulation of said forming surface and without encapsulating a support structure for operation as desired, and wherein said discharge surface is formed to be substantially rigid and fixed into place as a mirror image of said shaped forming surface, and wherein said conductive slurry hardens to form said monolithic structure with uniform discharging characteristics.

26. The manufacturing process for forming a rigid material according to claim 25 wherein an underwater vehicle is formed from said rigid material.

27. The manufacturing process for forming a rigid material according to claim 25 wherein a maritime vehicle is formed from said rigid material.

28. The manufacturing process for forming a rigid material according to claim 25 wherein a terrestrial structure is formed from said rigid material.

29. The manufacturing process for forming a rigid material according to claim 25 wherein an aerospace vehicle is formed from said rigid material.

30. The manufacturing process according to claim 25 wherein an energy diffuser is formed by application of said slurry onto said shaped forming surface, cured and then released from said forming surface.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] FIG. 1A is a three-dimensional view of a typical multilayer parabolic reflector.

[0031] FIG. 1B is a lateral view of the parabolic reflector in FIG. 1A.

[0032] FIG. 2A is a rendering of a carbon fiber nanotube arrangement.

[0033] FIG. 2B is a rendering of a graphite or graphene powder arrangement.

[0034] FIG. 3 is an image of one step in connection with the present invention.

[0035] FIG. 4 is an image of another manufacturing step in connection with the present invention.

[0036] FIG. 5 is an image of the epoxy matrix and carbon nanotubes and graphite/graphene powered material formed by the present invention.

[0037] FIGS. 6A & 6B show a parabolic reflector as being assembled, 6A with two quadrants connected together and 6B at three of four quadrants joined together.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0038] In accordance with traditional methods for manufacturing parabolic reflectors, FIG. 1A depicts a parabolic assembly surface 102 made by quasi-parabolic reflector surfaces made of concentric strip rings in a multilayer substrate 104 (p represents the axes in the plane of the substrate which can be x or y 110) where T represents the total thickness of the substrate 106. FIG. 1A shows a three-dimensional view 100 of a parabolic reflector. FIG. 1B shows a lateral view 108 of the parabolic reflector in FIG. 1A.

[0039] In accordance with alternatives to the processes depicted in FIG. 1, other corresponding techniques have been used in the parabolic reflector manufacturing process, wherein various techniques have been used to achieve the integration of layered or sandwiched dissimilar materials, such as metallic inserts, adjacent various dielectric layers. In no case do prior art methods achieve the result of the present invention which enables the overall parabolic reflector to be formed from a single mixture of slurry, to form a homogeneous reflector, which possesses uniform levels of reflective throughout its cross-section and entire volume. Consequently, efficiency, signal to noise ratio and durability, strength and light weight design are all maximized in a streamlined simple manufacturing process.

[0040] FIGS. 2A-B are renderings of carbon fiber materials used in connection with the present invention. In accordance with the preferred embodiment of the present invention, the epoxy matrix of the present invention requires materials such as conductive carbon black nanofibers and/or carbon nanotubes 200, as shown in the rendering of FIG. 2A, and graphite or graphene powder 202, as shown in the rendering of FIG. 2B. To clarify this process, in order to practice the present invention, a manufacturer would start with a parabolic shaped forming surface 300 as shown in FIG. 3. That shaping surface is simply the shape of the article you wish to create: a parabolic reflector or a parabolic reflector broken up into four petals or quadrants that may be bolted together, a maritime vessel, a spacecraft, an aviation asset, building supplies particularly which are earthquake resistant, and so forth. The parabolic forming surface 300 may be made of any material desired such as wood, plaster, stainless steel, aluminum, or any other material suitable for accepting a coating containing the desired elements. The forming surface 300 may be sprayed or otherwise coated prior to application of the reflective resin material (slurry) according to the present invention, again, much like a griddle may be coated prior to cooking a pancake. Such a coating acts as a “release material” so that the formed member or parabolic reflector portion or unit may easily be separated from the forming surface 300. Upon that forming surface is applied a low viscosity resin (or epoxy), carbon nanotubes and/or carbon nanofibers 200, graphite powder (or a graphene powder) 202, and then finally, while heated, a hardener is added to allow the hardening or curing process to lock into place the desired shape of the article desired to be manufactured. Alternatively, a heat box may be used to cure the slurry into the finished product. The hardener is selected to correspond with the resin chosen, such that the resin and hardener act in concert with the carbon nanotubes, carbon nanofibers, and graphite powder to form a homogeneous parabolic reflector unit or portion thereof.

[0041] FIG. 3 is an image of a shaping surface used in connection with shaping a parabolic reflector surface according to the present invention. In accordance with the preferred embodiment, the epoxy mixture or slurry is applied upon the shaping surface 300 so that upon hardening, a parabolic reflector may be formed of before unheard-of characteristics. The parabolic reflector slurry is applied to a mold or forming surface 300 as displayed in FIG. 3 and as it dries and cures, the hardener contained within it produces the desired result, much the way pancake batter is formed on a cooking skillet. The ingredients all disperse themselves throughout the finished article.

[0042] FIG. 4 is an image of a step according to the present invention. In accordance with the preferred embodiment of the present invention, the slurry possessing the required or desired reflective characteristics are applied to the forming surface. One important ingredient in the slurry is an epoxy resin, which mix with the carbon nanotubes, carbon nanofiber and graphite powders to create the finished parabolic reflector 400 as shown in the image of FIG. 4. Importantly, the carbon nanotubes align themselves naturally within the article being formed as they are polarized. The carbon nanofiber is similarly conductive, so it adheres to the carbon nanotubes and in turn, the graphite powder or graphene powder fills in the matrix so that the overall slurry has uniformly dispersed reflective properties distributed uniformly throughout the mixture of resin and hardener.

[0043] According to the present invention. In accordance with the preferred embodiment of the present invention, the epoxy matrix 500 of the parabolic reflector consists of a carbon fiber nanotube 502 and nanofiber structure and graphite powder 504, mixed together with resin and a hardener, as shown in the detailed image in FIG. 5.

[0044] FIGS. 6A & 6B show a parabolic reflector as being assembled, 6A with two quadrants connected together 600 and 6B at three of four quadrants joined together 602, perhaps with bolts to secure the petals to one another. Of course, the parabolic reflector may be formed in one piece or in several pieces for assembly upon usage requirement. In the present embodiment, the parabolic reflector is shown made up of quadrants, so that it may be stored and transported in a portable fashion, easily brought onto an airplane, for example.

[0045] While various embodiments of the disclosed technology have been described above, it should be understood that they have been presented by way of example only, and not of limitation. Likewise, the various diagrams may depict an example architectural or other configuration for the disclosed technology, which is done to aid in understanding the features and functionality that may be included in the disclosed technology. The disclosed technology is not restricted to the illustrated example architectures or configurations, but the desired features may be implemented using a variety of alternative architectures and configurations. Indeed, it will be apparent to one of skill in the art how alternative functional, logical or physical partitioning and configurations may be implemented to implement the desired features of the technology disclosed herein. Also, a multitude of different constituent module names other than those depicted herein may be applied to the various partitions. Additionally, with regard to flow diagrams, operational descriptions and method claims, the order in which the steps are presented herein shall not mandate that various embodiments be implemented to perform the recited functionality in the same order unless the context dictates otherwise.

[0046] Although the disclosed technology is described above in terms of various exemplary embodiments and implementations, it should be understood that the various features, aspects and functionality described in one or more of the individual embodiments are not limited in their applicability to the particular embodiment with which they are described, but instead may be applied, alone or in various combinations, to one or more of the other embodiments of the disclosed technology, whether or not such embodiments are described and whether or not such features are presented as being a part of a described embodiment. Thus, the breadth and scope of the technology disclosed herein should not be limited by any of the above-described exemplary embodiments.

[0047] Terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing: the term “including” should be read as meaning “including, without limitation” or the like; the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; the terms “a” or “an” should be read as meaning “at least one,” “one or more” or the like; and adjectives such as “conventional,” “traditional,” “normal,” “standard,” “known” and terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future. Likewise, where this document refers to technologies that would be apparent or known to one of ordinary skill in the art, such technologies encompass those apparent or known to the skilled artisan now or at any time in the future.

[0048] The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent. The use of the term “module” does not imply that the components or functionality described or claimed as part of the module are all configured in a common package. Indeed, any or all of the various components of a module, whether control logic or other components, may be combined in a single package or separately maintained and can further be distributed in multiple groupings or packages or across multiple locations.

[0049] Additionally, the various embodiments set forth herein are described in terms of exemplary block diagrams, flow charts and other illustrations. As will become apparent to one of ordinary skill in the art after reading this document, the illustrated embodiments and their various alternatives may be implemented without confinement to the illustrated examples. For example, block diagrams and their accompanying description should not be construed as mandating a particular architecture or configuration.