Method for processing at least one carbon fiber, method for fabricating a carbon copper composite, and carbon copper composite

Abstract

A method for processing at least one carbon fiber according to an embodiment may include: electroplating a first metal layer over at least one carbon fiber, wherein the first metal layer includes a metal which can form a common phase with carbon, electroplating a second metal layer over the first metal layer, wherein the second metal layer includes a metal which can form a common phase with the metal of the first metal layer, and annealing the at least one carbon fiber, the first metal layer, and the second metal layer so that the metal of the first metal layer forms a common phase with the carbon of the at least one carbon fiber at an interface between the first metal layer and the at least one carbon fiber and the metal of the first metal layer forms a common phase with the metal of the second metal layer at an interface between the first metal layer and the second metal layer.

What is claimed is: 
     
         1 . A method for processing at least one carbon fiber, comprising:
 electroplating a first metal layer over at least one carbon fiber, wherein the first metal layer comprises a metal which can form a common phase with carbon;   electroplating a second metal layer over the first metal layer, wherein the second metal layer comprises a metal which can form a common phase with the metal of the first metal layer; and   annealing the at least one carbon fiber, the first metal layer, and the second metal layer so that the metal of the first metal layer forms a common phase with the carbon of the at least one carbon fiber at an interface between the first metal layer and the at least one carbon fiber and the metal of the first metal layer forms a common phase with the metal of the second metal layer at an interface between the first metal layer and the second metal layer.   
     
     
         2 . The method of  claim 1 , wherein
 the metal of the first metal layer is chromium or manganese and the metal of the second metal layer is nickel.   
     
     
         3 . The method of  claim 2 , wherein
 the annealing is performed at a temperature in the range from about 400° C. to about 1000° C.   
     
     
         4 . The method of  claim 2 , wherein
 the annealing is performed for a time duration in the range from about 1 hour to about 10 hours.   
     
     
         5 . The method of  claim 1 , wherein
 the annealing of the at least one carbon fiber, the first metal layer, and the second metal layer is performed simultaneously.   
     
     
         6 . The method of  claim 1 , wherein
 at least one of the thickness of the first metal layer and the thickness of the second metal layer is approximately the size of crystallization seeds of the respective metal layer.   
     
     
         7 . The method of  claim 1 , wherein
 the at least one carbon fiber comprises graphite and wherein the diameter of the at least one carbon fiber is in the range from about 1 μm to about 50 μm.   
     
     
         8 . The method of  claim 1 , wherein
 at least one of electroplating the first metal layer and electroplating second metal layer comprises pulsed electroplating.   
     
     
         9 . The method of  claim 1 , further comprising:
 at least one of activating and cleaning a surface of the second metal layer after annealing the second metal layer.   
     
     
         10 . The method of  claim 1 , further comprising:
 electroplating a copper layer over the second metal layer.   
     
     
         11 . The method of  claim 10 , further comprising:
 annealing the copper layer at a temperature in the range from about 110° C. to about 150° C.   
     
     
         12 . A method for fabricating a carbon copper composite, comprising:
 providing a plurality of carbon fibers;   electroplating a first metal layer over the plurality of carbon fibers, wherein the first metal layer comprises a metal which can form a common phase with carbon;   electroplating a second metal layer over the first metal layer, wherein the second metal layer comprises a metal which can form a common phase with the metal of the first metal layer;   annealing the plurality of carbon fibers, the first metal layer, and the second metal layer so that the metal of the first metal layer forms a common phase with the carbon of the plurality of carbon fibers at an interface between the first metal layer and the plurality of carbon fibers and the metal of the first metal layer forms a common phase with the metal of the second metal layer at an interface between the first metal layer and the second metal layer; and   electroplating a copper layer over the second metal layer.   
     
     
         13 . The method of  claim 12 , wherein
 the metal of the first metal layer is chromium or manganese and the metal of the second metal layer is nickel.   
     
     
         14 . The method of  claim 12 , wherein
 wherein at least one of electroplating the first metal layer and electroplating the second metal layer comprises pulsed electroplating.   
     
     
         15 . The method of  claim 12 , further comprising:
 at least one of activating and cleaning a surface of the second metal layer before electroplating the copper layer over the second metal layer.   
     
     
         16 . The method of  claim 12 , wherein
 the plurality of carbon fibers comprises a fabric.   
     
     
         17 . The method of  claim 12 , further comprising:
 filling voids between the plurality of copper coated carbon fibers with copper.   
     
     
         18 . A method for fabricating a carbon copper composite heatsink, the method comprising:
 providing a carbon fiber fabric;   electroplating a first metal layer onto the carbon fiber fabric, the first metal layer comprising chromium or manganese;   electroplating a second metal layer onto the first metal layer, the second metal layer comprising nickel;   annealing the carbon fiber fabric, the first metal layer, and the second metal layer so that the chromium or manganese of the first metal layer forms a common phase with the carbon of the carbon fiber fabric at an interface between the first metal layer and the carbon fiber fabric and the chromium or manganese of the first metal layer forms a common phase with the nickel of the second metal layer at an interface between the first metal layer and the second metal layer; and   electroplating a copper layer onto the second metal layer.   
     
     
         19 . The method of  claim 18 , wherein
 electroplating of at least one of the first and second metal layers comprises pulsed electroplating.   
     
     
         20 . The method of  claim 18 , further comprising:
 pre-cleaning and degreasing the carbon fiber fabric before electroplating the first metal layer onto the carbon fiber fabric; and   at least one of activating and cleaning a surface of the second metal layer before electroplating the copper layer over the second metal layer.