Method and apparatus for moldable material for terrestrial, marine, aeronautical and space applications which includes an ability to reflect radio frequency energy and which may be moldable into a parabolic or radio frequency reflector to obviate the need for reflector construction techniques which produce layers susceptible to layer separation and susceptible to fracture under extreme circumstances

Abstract

The present invention is a unique process of manufacturing rigid members with precise “shape keeping” properties and with reflective properties pertaining to radio frequency energy, so that air, land, sea and space devices or vehicles may be constructed including parabolic reflectors formed without discrete permanent layering. Rather, such parabolic reflectors or similarly, vehicles, may be formed by homogeneous construction where discrete layering is absent, and where energy reflectivity or scattering characteristics are embedded within the homogeneous mixture of carbon nanotubes and associated graphite powders and epoxy, resins and hardeners. The mixture of carbon graphite nanofiber and carbon nanotubes generates higher electrode conductivity and magnetized attraction through molecular polarization. In effect, the rigid members may be tuned based on the application. The combination of these materials creates a unique matrix that is then set in a memory form at a specific temperature, and then applied to various materials through a series of multiple layers, resulting in unparalleled strength and durability.

What is claimed is: 
     
         1 . A manufacturing process for forming an electromagnetic energy absorber having a monolithic structure of uniform energy absorption characteristics without encapsulation of a forming surface wherein forming said electromagnetic energy absorber includes the following steps:
 a. blending together carbon nanotubes, carbon nanofiber, and a resin hardener under suitable conditions to form a cured conductive slurry;   b. applying said curing conductive slurry to a shaped forming surface wherein said shaped forming surface is of a shape corresponding to an electromagnetic energy absorbing surface;   c. allowing said curing conductive slurry to harden; and   d. separating said absorbing surface from said shaped forming surface without encapsulating a support structure for operation as an energy absorber having uniform energy absorption characteristics without encapsulation of said forming surface and wherein said energy absorber is formed to be substantially rigid and fixed into place as a mirror image of said shaped forming surface, and wherein said conductive slurry is tuned to be used in the electromagnetic spectrum to absorb energy.   
     
     
         2 . The manufacturing process for forming an electromagnetic energy absorber according to  claim 1  wherein said energy absorber is formed by a brush application of said slurry onto said shaped forming surface. 
     
     
         3 . The manufacturing process for forming an electromagnetic energy absorber according to  claim 1  wherein said energy absorber is formed by a pour application of said slurry onto said shaped forming surface. 
     
     
         4 . The manufacturing process for forming an electromagnetic energy absorber according to  claim 1  wherein said energy absorber is formed by a spray application of said slurry onto said shaped forming surface. 
     
     
         5 . The manufacturing process of  claim 1  wherein said carbon nanofibers become oriented with said carbon nanotubes to form an organized matrix and are tuned to absorb electromagnetic energy of specific frequencies. 
     
     
         6 . The manufacturing process of  claim 1  wherein said monolithic structure is comprised of several concentrically interlinked carbon nanotubes. 
     
     
         7 . The manufacturing process of  claim 1  wherein said carbon nanotubes are formed as armchair carbon nanotubes. 
     
     
         8 . The manufacturing process of  claim 1  wherein said carbon nanotubes are formed as zigzag carbon nanotubes. 
     
     
         9 . The manufacturing process of  claim 1  wherein said carbon nanotubes are single-walled. 
     
     
         10 . The manufacturing process of  claim 1  wherein said carbon nanotubes are multi-walled. 
     
     
         11 . The manufacturing process according to  claim 1  wherein said energy absorber is formed by application of said slurry onto said shaped forming surface, cured and then released from said forming surface. 
     
     
         12 . The manufacturing process according to  claim 1  wherein an energy reflector is formed by application of said slurry onto said shaped forming surface, cured and then released from said forming surface. 
     
     
         13 . The manufacturing process according to  claim 1  wherein an energy discharger is formed by application of said slurry onto said shaped forming surface, cured and then released from said forming surface. 
     
     
         14 . The manufacturing process for forming a rigid material according to  claim 1  wherein an underwater vehicle is formed from said rigid material. 
     
     
         15 . The manufacturing process for forming a rigid material according to  claim 1  wherein a maritime vehicle is formed from said rigid material. 
     
     
         16 . The manufacturing process for forming a rigid material according to  claim 1  wherein a terrestrial structure is formed from said rigid material. 
     
     
         17 . The manufacturing process for forming a rigid material according to  claim 1  wherein an aeronautical vehicle is formed from said rigid material. 
     
     
         18 . A manufacturing process for forming an electromagnetic energy discharger having a monolithic structure of uniform energy absorption characteristics without encapsulation of a forming surface wherein forming said electromagnetic energy discharger includes the following steps:
 a. blending together carbon nanotubes, carbon nanofiber, and a resin hardener under suitable conditions to form a cured conductive slurry;   b. applying said curing conductive slurry to a shaped forming surface wherein said shaped forming surface is of a shape corresponding to an electromagnetic energy discharging surface;   c. allowing said curing conductive slurry to harden; and   d. separating said absorbing surface from said shaped forming surface without encapsulating a support structure for operation as an energy discharger having uniform energy discharging characteristics without encapsulation of said forming surface and wherein said energy discharger is formed to be substantially rigid and fixed into place as a mirror image of said shaped forming surface, and wherein said conductive slurry is tuned to be used in the electromagnetic spectrum to discharge energy.   
     
     
         19 . The manufacturing process for forming an electromagnetic energy discharger according to  claim 18  wherein said energy discharger is formed by application of said slurry onto said shaped forming surface. 
     
     
         20 . The manufacturing process of  claim 18  wherein said cured conductive slurry possesses uniform levels of energy discharging characteristics through its cross-section and entire volume. 
     
     
         21 . The manufacturing process of  claim 18  wherein said carbon nanofibers become oriented with said carbon nanotubes to form an organized matrix and are tuned to discharge electromagnetic energy of specific frequencies. 
     
     
         22 . A manufacturing process for forming an electromagnetic energy diffuser having a monolithic structure of uniform discharging characteristics without encapsulation of a forming surface wherein forming said absorber includes the following steps:
 a. blending together carbon nanotubes, carbon nanofiber and a resin hardener under suitable conditions to form a cured conductive slurry;   b. applying said curing conductive slurry to a shaped forming surface wherein said shaped forming surface is of a shape corresponding to an energy discharge surface;   c. allowing said curing conductive slurry to harden; and   d. separating said energy discharger from said shaped forming surface without encapsulating a support structure for operation as an electromagnetic energy discharger with uniform energy discharging characteristics without encapsulation of said forming surface, wherein said carbon nanofibers became oriented with said carbon nanotubes to form an organized matrix, wherein said monolithic structure is comprised of several concentrically interlinked carbon nanotubes, and wherein said discharger is formed to be substantially rigid and fixed into place as a mirror image of said shaped forming surface, and wherein said conductive slurry hardens to form said monolithic structure with uniform energy discharging characteristics.   
     
     
         23 . The manufacturing process according to  claim 22  wherein said energy diffuser is formed by application of said slurry onto said shaped forming surface, cured and then released from said forming surface. 
     
     
         24 . The manufacturing process according to  claim 22  wherein an energy diffuser is formed by application of said slurry onto said shaped forming surface, cured and then released from said forming surface. 
     
     
         25 . A manufacturing process for forming a rigid material having a monolithic structure of uniform diffuser characteristics without encapsulation of a forming surface wherein forming said structure includes the following steps:
 a. blending together carbon nanotubes, carbon nanofiber and a resin hardener under suitable conditions to form a cured conductive slurry;   b. applying said curing conductive slurry to a forming surface wherein said forming surface is of a shape or pitch corresponding to a desired discharge surface;   c. allowing said curing conductive slurry to harden; and   d. separating an absorptive surface from said shaped forming surface without encapsulation of said forming surface and without encapsulating a support structure for operation as desired, and wherein said discharge surface is formed to be substantially rigid and fixed into place as a mirror image of said shaped forming surface, and wherein said conductive slurry hardens to form said monolithic structure with uniform discharging characteristics.   
     
     
         26 . The manufacturing process for forming a rigid material according to  claim 25  wherein an underwater vehicle is formed from said rigid material. 
     
     
         27 . The manufacturing process for forming a rigid material according to  claim 25  wherein a maritime vehicle is formed from said rigid material. 
     
     
         28 . The manufacturing process for forming a rigid material according to  claim 25  wherein a terrestrial structure is formed from said rigid material. 
     
     
         29 . The manufacturing process for forming a rigid material according to  claim 25  wherein an aerospace vehicle is formed from said rigid material. 
     
     
         30 . The manufacturing process according to  claim 25  wherein an energy diffuser is formed by application of said slurry onto said shaped forming surface, cured and then released from said forming surface.