Magnetic carbon nanotube cluster systems and methods

• US 10,457,410 B2
• Filed: 04/27/2016
• Issued: 10/29/2019
• Est. Priority Date: 04/27/2016
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Humfeld, Keith Daniel, Safai, Morteza
• Primary Examiner(s): Benedik, Justin M
• Application Number:
  US15/140,386
• Publication Number:
  US 20170313437A1
• Time in Patent Office: 1,280 Days
• CPC Class Codes: B64D 27/10 of gas-turbine type jet aircraft B64D27/16
• CPC Class Codes: B64D 37/16 Filling systems ground installations for fuelling aircraft B64F
• CPC Class Codes: B64D 37/32 Safety measures not otherwise provided for, e.g. preventing explosive conditions extinguishing or preventing fires in aircraft A62C
• CPC Class Codes: B64D 45/02 Lightning protectors; Static dischargers in general H01T
• CPC Class Codes: C01B 32/16 Preparation
• CPC Class Codes: C23C 16/4417 Methods specially adapted for coating powder
• CPC Class Codes: Y02T 50/40 Weight reduction

Abstract

Techniques are disclosed for systems and methods to provide magnetic carbon nanotube clusters configured to form electrically conductive coatings. A magnetic carbon nanotube cluster is formed by receiving a magnetic particle, forming a plurality of carbon nanotube catalyst nanoparticles on an outer surface of the magnetic particle, and forming a plurality of carbon nanotubes extending from the catalyst nanoparticles while the magnetic particle is levitated within a nanotube growth chamber to form the magnetic carbon nanotube cluster. A plurality of magnetic carbon nanotube clusters are suspended in a carrier fluid, the carrier fluid is flowed over a surface of an object, and a magnetic field is applied to the carrier fluid while it is flowing over the surface to cause the plurality of magnetic carbon nanotube clusters to form a coating on the surface of the object.

Claims

1. A method comprising:

receiving a magnetic particle;

forming a plurality of carbon nanotube catalyst nanoparticles on an outer surface of the magnetic particle; and

forming a plurality of carbon nanotubes extending from the catalyst nanoparticles while the magnetic particle is levitated within a nanotube growth chamber to form a magnetic carbon nanotube cluster, wherein the forming the plurality of carbon nanotubes extending from the catalyst nanoparticles comprises controlling a magnetic field generator to levitate the magnetic particles in a growth region of the nanotube growth chamber, and wherein the growth region comprises a carrier gas configured to supply carbon atoms to form the plurality of carbon nanotubes.

2. The method of claim 1, wherein:

the magnetic particle comprises an intermediate layer formed on a magnetic core; and

the intermediate layer comprises a material selected to couple to the plurality of catalyst nanoparticles via a Van der Waals force.

3. The method of claim 1, wherein the magnetic particle comprises a hard magnetic material or a soft magnetic material.

4. The method of claim 1, wherein the outer surface of the magnetic particle is substantially ellipsoidal or spherical.

5. The method of claim 1, wherein the plurality of catalyst nanoparticles comprises titanium, cobalt, iron, molybdenum, nickel, and/or yttrium.

6. The method of claim 1, wherein:

each one of the plurality of carbon nanotubes are covalently bonded to one or more of the plurality of catalyst nanoparticles on the outer surface of the magnetic particle; and

the forming of the plurality of carbon nanotubes extending from the catalyst nanoparticles comprises controlling the magnetic field generator to remove the magnetic particle from the growth region of the nanotube growth chamber after a predetermined period of time corresponding to an average desired length of the plurality of carbon nanotubes.

7. The method of claim 6, further comprising controlling the magnetic field generator to:

rotate the magnetic particle in the growth region by applying a rotating magnetic field to the magnetic particle to cause at least a portion of the plurality of carbon nanotubes to grow preferentially as curved carbon nanotubes.

8. The method of claim 6, further comprising:

controlling a density of the carrier gas, a flow rate of the carrier gas, a flow direction of the carrier gas, and/or a rotation rate of the magnetic particle to select a shape of at least a portion the plurality carbon nanotubes.

9. A plurality of magnetic carbon nanotube clusters each formed according to the method of claim 1.

10. A method of forming a coating of magnetic carbon nanotube clusters (MCNCs) formed according to the method of claim 1, comprising:

receiving a plurality of MCNCs suspended in a carrier fluid;

flowing the carrier fluid over a surface of an object; and

applying a magnetic field to the carrier fluid while it is flowing over the surface to cause the plurality of MCNCs to form a coating on the surface of the object.

11. The method of claim 10, wherein the surface comprises a feature causing a disturbance in the flow of the carrier fluid over a portion of the surface, and wherein the applying the magnetic field to the carrier fluid comprises:

controlling the magnetic field to guide the plurality of MCNCs towards the feature and/or the portion of the surface to form the MCNC coating on the feature and/or the portion of the surface.

12. The method of claim 10, wherein the MCNC coating is sufficiently electrically conductive to substantially block formation of a localized electrostatic charge in or on the surface of the object.

13. The method of claim 10, wherein:

the object comprises a tube; and

the surface comprises an internal surface of the tube.

14. The method of claim 10, further comprising:

measuring a resistance across the surface of the object; and

determining a presence of the MCNC coating sufficient to substantially block formation of a localized electrostatic charge in or on the surface of the object based, at least in part, on the measured resistance.

15. A device comprising:

an object comprising a surface; and

a coating of magnetic carbon nanotube clusters (MCNCs) formed on the surface, wherein each MCNC of the coating of MCNCs comprises a plurality of carbon nanotube catalyst nanoparticles formed on an outer surface of a magnetic particle and a plurality of carbon nanotubes extending from the catalyst nanoparticles and formed while the magnetic particle is levitated within a nanotube growth chamber, wherein the plurality of carbon nanotubes extending from the catalyst nanoparticles are formed by controlling a magnetic field generator to levitate the magnetic particles in a growth region of the nanotube growth chamber, and wherein the growth region comprises a carrier gas configured to supply carbon atoms to form the plurality of carbon nanotubes.

16. The device of claim 15, wherein:

the outer surface of the magnetic particle is substantially ellipsoidal or spherical;

the magnetic particle comprises an intermediate layer formed on a hard magnetic material or a soft magnetic material; and

the intermediate layer comprises a material selected to couple to the plurality of catalyst nanoparticles via a Van der Waals force.

17. The device of claim 15, wherein:

each one of the plurality of carbon nanotubes are covalently bonded to one or more of the plurality of catalyst nanoparticles on the outer surface of the magnetic particle; and

the plurality of carbon nanotubes extending from the catalyst nanoparticles are formed by controlling the magnetic field generator to remove the plurality of carbon nanotubes from the growth region of the nanotube growth chamber after a predetermined period of time corresponding to an average desired length of the plurality of carbon nanotubes.

18. The device of claim 15, wherein:

the object comprises a polymeric fuel line;

the surface comprises an internal surface of the polymeric fuel line;

the internal surface of the polymeric fuel line comprises a feature causing a disturbance in flow of a fluid over a portion of the internal surface of the polymeric fuel line; and

the coating of MCNCs is formed on the internal surface of the polymeric fuel line by;

receiving a plurality of MCNCs suspended in the fluid; and

controlling a magnetic field applied to the fluid to guide the plurality of MCNCs towards the feature and/or the portion of the surface to form the coating of MCNCs on the feature and/or the portion of the internal surface of the polymeric fuel line.

19. A method of using the device of claim 15, wherein the object comprises a polymeric fuel line for an aircraft and the surface comprises an internal surface of the polymeric fuel line, the method comprising:

attaching the polymeric fuel line to an aircraft fuel tank through a corresponding refueling port; and

pumping fuel from a fuel reservoir to the aircraft fuel tank through the polymeric fuel line, wherein the coating of MCNCs is sufficiently electrically conductive to substantially block formation of a localized electrostatic charge in or on the internal surface of the polymeric fuel line.

20. The device of claim 15, wherein the coating of MCNCs is configured to attract and/or bond to particulates and/or solids in a fluid flowing over the surface substantially adjacent to the coating of MCNCs.