Tda Research, Inc.

Frontier Carbon Corporation

Michael D Diener

J Michael Alford

John Michael Alford

James Nabity

Michael Karpuk

Robert D Bolskar

Bradley Dean Hitch

James William Raebiger

The present invention relates to a process for making polyolefin matrix composites reinforced with continuous carbon fibers. The polymer-fiber composite material comprises a plurality of continuous fibers; and a polyolefin matrix. The present invention also relates to articles of manufacture made substantially from polyolefin matrix composites reinforced with continuous carbon fibers as well as orthopedic implant devices having a wear surface, or bearing comprising a polyolefin matrix composite reinforced with continuous carbon fibers.

Methods of making continuous fiber-polyolefin composites

The present invention relates to polyolefin matrix composites reinforced with continuous carbon fibers, and a process for making them. The polymer-fiber composite material comprises a plurality of continuous fibers; and a polyolefin matrix, wherein, the polyolefin matrix comprises polyolefin polymer chains with a number average molecular weight of at least 1&#xd7;10amu, and wherein, the polymer-fiber composite has a notched impact strength greater than the notched impact strength of a neat polyolefin, wherein the neat polyolefin has an equivalent chemical composition and number average molecular weight as the polyolefin of the polyolefin matrix in the polymer-fiber composite material. The present invention also relates to articles of manufacture made substantially from polyolefin matrix composites reinforced with continuous carbon fibers as well as orthopedic implant devices having a wear surface, or bearing comprising a polyolefin matrix composite reinforced with continuous carbon fibers.

Continuous fiber-polyolefin composites and methods of making

The invention provides improved burners, combustion apparatus, and methods for carbon nanomaterial production. The burners of the invention provide sooting flames of fuel and oxidizing gases. The condensable products of combustion produced by the burners of this invention produce carbon nanomaterials including without limitation, soot, fullerenic soot, and fullerenes. The burners of the invention do not require premixing of the fuel and oxidizing gases and are suitable for use with low vapor pressure fuels such as those containing substantial amounts of polyaromatic hydrocarbons. The burners of the invention can operate with a hot (e.g., uncooled) burner surface and require little, if any, cooling or other forms of heat sinking. The burners of the invention comprise one or more refractory elements forming the outlet of the burner at which a flame can be established. The burners of the invention provide for improved flame stability, can be employed with a wider range of fuel/oxidizer (e.g., air) ratios and a wider range of gas velocities, and are generally more efficient than burners using water-cooled metal burner plates. The burners of the invention can also be operated to reduce the formation of undesirable soot deposits on the burner and on surfaces downstream of the burner.

Burners and combustion apparatus for carbon nanomaterial production

A method of extracting fullerenes from a carbon matrix in which they are produced. The method is applicable to both fullerenes that exhibit greater than 0.1 mg/ml solubility in toluene and to fullerenes that are essentially insoluble in toluene, i.e., those exhibiting less than or equal to 0.1 mg/ml solubility. The method disclosed herein extracts more of the soluble fullerenes from the carbon matrix than extraction conducted by solely contacting with solvent. A method is also provided for creating salts of the extracted fullerenes.

Methods for fullerene recovery

The present invention provides a combustion apparatus for the production of carbon nanomaterials including fullerenes and fullerenic soot. Most generally the combustion apparatus comprises one or more inlets for introducing an oxygen-containing gas and a hydrocarbon fuel gas in the combustion system such that a flame can be established from the mixed gases, a droplet delivery apparatus for introducing droplets of a liquid hydrocarbon feedstock into the flame, and a collector apparatus for collecting condensable products containing carbon nanomaterials that are generated in the combustion system. The combustion system optionally has a reaction zone downstream of the flame. If this reaction zone is present the hydrocarbon feedstock can be introduced into the flame, the reaction zone or both.

Combustion process for synthesis of carbon nanomaterials from liquid hydrocarbon

This invention provides improved methods for combustion synthesis of carbon nanomaterials, including fullerenes, employing multiple-ring aromatic hydrocarbon fuels selected for high carbon conversion to extractable fullerenes. The multiple-ring aromatic hydrocarbon fuels include those that contain polynuclear aromatic hydrocarbons. More specifically, multiple-ring aromatic hydrocarbon fuels contain a substantial amount of indene, methylnapthalenes or mixtures thereof. Coal tar and petroleum distillate fractions provide low cost hydrocarbon fuels containing polynuclear aromatic hydrocarbons, including without limitation, indene, methylnapthalenes or mixtures thereof.

Polynuclear aromatic hydrocarbons for fullerene synthesis in flames

Filter devices and methods for collection of carbon nanomaterials, including fullerenes, produced in gas phase reactors are provided. The filter devices provide for in situ cleaning of filters to release captured product for collection. Product can be released and removed from the reactor without disrupting continuous synthesis of carbon nanomaterials. The filter devices facilitate increased reactor operation and larger scale production of carbon nanomaterials. The filters are cleaned by application of a motive force and/or a gas flow to the filter. In a specific embodiment filters are cleaned by a reverse flow of gas pulses to the filter provided. The invention also provides reactor systems for gas phase synthesis of carbon nanomaterials that can be operated continuously employing the filter device of this invention. Preferred reactor systems are those which synthesize carbon nanomaterials by combustion. Methods for continuous production of carbon nanomaterials using the filtering devices and methods of this invention are also provided.

Filter devices and methods for carbon nanomaterial collection

A method for recovering small bandgap fullerenes, including metallofullerenes, from soot by passivating individual fullerenes and/or metallofullerenes to an anionic configuration. The addition of extra electrons to a metallofullerene or small bandgap fullerene breaks the interfullerene bonding in the solid material, and the resulting anions are soluble in organic electrochemical solvents. Once dissolved, the small bandgap fullerenes can be plated out or precipitated by returning them to a neutral state.

Isolation of small-bandgap fullerenes and endohedral metallofullerenes

A method for recovering small bandgap fullerenes, including metallofullerenes, from soot by passivating individual fullerenes and/or metallofullerenes to an anionic configuration. Thc addition of extra electrons to a metallofullerene or small bandgap fullerene breaks the interfullerene bonding in the solid material, and the resulting anions are soluble in organic electrochemical solvents. Once dissolved, the small bandgap fullerenes can be plated out or precipitated by returning them to a neutral state.

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Denver, CO, United States of America

Michael D Diener