System and method for surface treatment and barrier coating of fibers for in situ CNT growth

• US 10,138,128 B2
• Filed: 02/06/2014
• Issued: 11/27/2018
• Est. Priority Date: 03/03/2009
• Status: Active Grant

• Current Assignee: Applied Nanostructured Solutions
• Original Assignee: Applied NanoStructured Solutions, LLC (Cabot Corporation)
• Inventors: Malecki, Harry C., Alberding, Mark R., Malet, Brandon K., Shah, Tushar K.
• Primary Examiner(s): Wieczorek, Michael P
• Application Number:
  US14/174,715
• Publication Number:
  US 20140154412A1
• Time in Patent Office: 1,755 Days
• CPC Class Codes: B01J 21/185 Carbon nanotubes carbon nanotubes per se C01B32/15
• CPC Class Codes: B01J 23/745 Iron
• CPC Class Codes: B01J 35/23 in a colloidal state
• CPC Class Codes: B01J 37/0219 the coating containing organic compounds
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: B82Y 40/00 Manufacture or treatment of nanostructures
• CPC Class Codes: C01B 32/16 Preparation
• CPC Class Codes: C01B 32/162 characterised by catalysts
• CPC Class Codes: D06B 1/02 by spraying or projecting D06B1/08 takes precedence
• CPC Class Codes: D06B 19/00 Treatment of textile materials by liquids, gases or vapours, not provided for in groups D06B1/00 - D06B17/00
• CPC Class Codes: D06B 3/10 of fabrics D06B3/24, D06B3/28, D06B3/32 take precedence; jiggers D06B3/32
• CPC Class Codes: D06M 11/74 with carbon or graphite; with carbides; with graphitic acids or their salts
• CPC Class Codes: Y10S 977/842 for carbon nanotubes or fullerenes
• CPC Class Codes: Y10T 428/2495 Thickness [relative or absolute]
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles

Abstract

A system for synthesizing carbon nanotubes (CNT) on a fiber material includes a surface treatment system adapted to modify the surface of the fiber material to receive a barrier coating upon which carbon nanotubes are to be grown, a barrier coating application system downstream of the surface treatment system adapted to apply the barrier coating to the treated fiber material surface, and a barrier coating curing system downstream of the barrier coating application systems for partially curing the applied barrier coating to enhance reception of CNT growth catalyst nanoparticles.

Claims

1. A method comprising:

depositing a barrier coating on a substrate comprising a plurality of fibers, the barrier coating being deposited in a liquid form that is uncured;

wherein the barrier coating is a thermal insulator, wherein the barrier coating comprises a substance selected from the group consisting of an alumoxane, spin on glass, and glass nanoparticles;

partially curing the barrier coating;

applying a plurality of catalyst nanoparticles to the partially cured barrier coating;

anchoring the plurality of catalyst nanoparticles to the barrier coating;

further curing the barrier coating; and

growing a plurality of carbon nanotubes on the substrate, the carbon nanotubes extending from the further cured barrier coating.

2. The method of claim 1, further comprising:

treating the substrate with a plasma before depositing the barrier coating thereon.

3. The method of claim 1, wherein the substrate is provided from a payout system and is rewound following growth of the plurality of carbon nanotubes thereon.

4. The method of claim 1, wherein the barrier coating has a thickness ranging between about 10 nm to about 100 nm.

5. The method of claim 1, wherein the barrier coating is further cured while growing the plurality of carbon nanotubes on the substrate.

6. The method of claim 1, further comprising:

spreading the plurality of fibers before depositing the barrier coating thereon.

7. The method of claim 1, wherein the barrier coating is deposited by spray coating or dip coating.

8. The method of claim 1, wherein the carbon nanotubes are oriented perpendicular to the substrate.