Rapid generation of carbon filament structures of controlled geometries at low temperatures

A method for preparing a filament coated article comprising:

• placing a template into a container, wherein the template comprises one or more catalytic metal surfaces that at least partially cover the template;
• introducing a fuel rich gaseous mixture into the container, wherein the fuel rich gaseous mixture comprises one or more hydrocarbons and at least one oxidizer and has a flow rate chosen to produce a turbulent flow over the template;
• and
• heating the template to a temperature chosen to at least partially combust the one or more hydrocarbons, thereby depositing a woven carbon filament film on each of the one or more catalytic metal surfaces of the template, wherein the woven carbon filament film comprises a non-graphitic carbon structure.

A method for preparing a filament coated article comprising:

• forming a patterned metal template and placing the patterned metal template into a container comprising a tube furnace;
• pre-treating the patterned metal template in the container;
• introducing a fuel rich gaseous mixture comprising one or more hydrocarbons and oxygen into the container with a flow rate chosen to produce a turbulent flow;
• heating the patterned metal template to a temperature chosen to at least partially combust the one or more hydrocarbons, whereby a patterned woven carbon filament film is deposited on the patterned metal template, wherein the template comprises a catalytic metal and the woven carbon filament film comprises a non-graphitic carbon structure;
• and
• cooling the container to freeze the deposition of the filament film.