Patent ID: 9023175
Filing Date: 2015-05-05
Classification: C08K,C09J,Y10S,Y10T

Abstract:
1. A method of manufacturing a composite assembly comprising a first carbon composite structure, a second carbon composite structure, and a carbonized fiber adhesive film located therebetween to connect adjacent surfaces thereof, the method comprising: providing a film material comprising carbon fibers; growing carbon nanotubes on the fibers of the film material; infiltrating the film material with heat stabilized nano-material filler particulates selected from the group consisting of: carbon black, graphite particulates, graphene, carbonized phenolic micro-balloons, meta-stable high density carbon particulates, near-diamond coatings, and ground phenolic char; after growing the carbon nanotubes on the fibers, infiltrating the film material with a matrix resin to provide the adhesive film, the matrix resin being selected from the group consisting of a phenolic resin, a napthelene resin, a high char yielding resin of either condensation or addition reaction mechanism, resin formulations which produce foam microstructures by pyrolysis of low char yield discontinuous phases, and poly butyral vinyl rubber; positioning the adhesive film between and in contact with the first and second carbon composite structures to provide the composite assembly, the positioning causing the particulates to flow into any non uniformities in opposing outer surfaces of the structures; and heating the composite assembly to cure the composite assembly.