Fiber adhesive material

Abstract

A fiber velvet comprising nano-size fibers or nanofibrils attached to micro-size fibers is disclosed. Methods of manufacturing the velvet as well as various uses of the velvet are also described. For example, the fiber velvet can be used as a thermal interface or as an adhesive material. The nanofibrils may be attached to a flat base or membrane, or may be attached to the tip portions of the micro-size or larger diameter fibers. Various attributes of the micro-size fibers and of the nano-size fibers, for example, geometry (e.g. size, length, packing density) material type (e.g. carbon, metal, polymer, or ceramic) and properties (e.g. conductivity, modulus, surface energy, dielectric constant, surface roughness) can be selected depending on the desired attributes of the fiber velvet. The nanofibrils have a diameter of less than about 1 micron, and may advantageously be formed from single walled and/or multi-walled carbon nanotubes.

1 . A method of producing a substantial intermolecular (e.g. vdW) force over a selected area comprising placing an plurality of fabricated fibers distributed over said selected area in close proximity to a mating surface, wherein said fabricated fibers are configured and oriented to produce a resulting average intermolecular force per unit area that is greater than or equal to 2.6 psi over said selected area.  
     
     
         2 . The method of  claim 1 , wherein at least some of said fabricated fibers have diameters of less than about 1 micron.  
     
     
         3 . The method of  claim 1 , wherein the plurality of fibers has similar sizes.  
     
     
         4 . The method of  claim 1 , wherein the plurality of fibers has different sizes.  
     
     
         5 . The method of  claim 4 , wherein the plurality of fibers comprise a first size fiber attached to a second size fiber.  
     
     
         6 . The method of  claim 5 , wherein the first size fiber has a cross sectional diameter of less than approximately 15 microns and the second size fiber has a cross sectional diameters of less than about 1 micron.  
     
     
         7 . A method of adhering a first surface to a second surface, the method comprising: 
 contacting a plurality of fabricated fibers that are coupled to said first surface with said second surface; and    producing an average intermolecular force per unit area of greater than or equal to 2.6 psi between the plurality of fabricated fibers and the second surface.    
     
     
         8 . The method of  claim 7 , wherein the plurality of fabricated fibers has similar sizes.  
     
     
         9 . The method of  claim 7 , wherein the plurality of fabricated fibers has different sizes.  
     
     
         10 . The method of  claim 9 , wherein the plurality of fabricated fibers comprise a first size fiber attached to a second size fiber.  
     
     
         11 . The method of  claim 10 , wherein the first size fiber has a cross sectional diameter of less than approximately 15 microns and the second size fiber has a cross sectional diameters of less than about 1 micron.  
     
     
         12 . A method of forming an adherent interface comprising producing an intermolecular force of greater than or equal to 2.6 psi over a selected area by placing a fabricated plurality of fibers in close proximity to a mating surface.  
     
     
         13 . A method of thermally and/or electrically coupling first and second components comprising contacting at least one of said components with a compliant array of a plurality of nanofibrils, wherein said nanofibrils are arranged and configured to transfer heat and/or electrical current from said first component to said second component, and wherein said nanofibrils are also arranged and configured to support an average intermolecular adhesive force per unit area of at least 2.6 psi such that plurality of nanofibrils adhere to the component they are in contact.  
     
     
         14 . The method of  claim 13 , wherein said nanofibrils comprise carbon.