Fabrication of Composite Materials from Fibrous Precursors Using Paper Making Procedures

Novel composite materials have been fabricated from fibrous precursors using paper making procedures. Small metal fibers (2 μm in diameter) and carbon fiber bundles (20 μm in diameter) were combined with cellulose (as the binding agent) into an interwoven paper preform. The composite paper preform was then sintered at high temperatures in a controlled atmosphere, subsequently removing the cellulose and forming a sinter-bonded composite structure. The sinter bonding of the metal locked the metal fibers and provided high mechanical flexibility and structural integrity to the resulting composite structure. The composite structures were characterized using scanning electron microscopy, electrochemical and kinetic measurements. The optimization of these structures for high energy density applications was demonstrated through these measurements.