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Abstract

A new class of composites results from a matrix of fibers, such as fibers of carbon, alumina, ceramics, and aluminosilicates, interwined in a network of fused metal fibers. The composites can be fabricated to have varying surface area, void volume, and pore size while maintaining high electrical conductivity. Composites are readily prepared from a preform of a dispersion of the metal fibers, other fibers, and an organic binder such as cellulose, by heating the preform at a temperature sufficient to fuse the metal fibers and to volatilize at least 90% of the binder. Where a carbon fiber is used, the metal fibers are fused at a temperature causing a loss of less than about 25%, and usually under 15%, by weight of carbon fiber.

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First Claim