Prepreg Nanoscale Fiber Films and Methods

• US 20090280324A1
• Filed: 04/27/2009
• Published: 11/12/2009
• Est. Priority Date: 05/22/2006
• Status: Abandoned Application

• Current Assignee: Florida State University (State University System of Florida)
• Original Assignee: Florida State University (State University System of Florida)
• Inventors: Liang, Zhiyong, Wang, Ben, Zhang, Chun
• Application Number:
  US12/430,494
• Publication Number:
  US 20090280324A1
• Time in Patent Office: Days
• US Class Current: 428/367
• CPC Class Codes: B29B 15/10 Coating or impregnating independently of the moulding or shaping stepapplying liquids in general B05
• CPC Class Codes: B29C 70/086 and with one or more layers of pure plastics material, e.g. foam layers applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86
• CPC Class Codes: B29C 70/12 using fibres of short length, e.g. in the form of a mat non-woven fabrics per se D04H1/00
• CPC Class Codes: B29C 70/443 and impregnating by vacuum or injection
• CPC Class Codes: B29K 2105/162 Nanoparticles
• CPC Class Codes: B29K 2105/243 Partially cured
• CPC Class Codes: B29K 2995/0051 mono-axially
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer
• CPC Class Codes: B32B 2260/044 Water-setting substance, e.g. concrete, plaster
• CPC Class Codes: B32B 2262/0269 Aromatic polyamide fibres
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2307/50 having particular mechanical properties
• CPC Class Codes: B32B 2307/51 Elastic
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/714 Inert, i.e. inert to chemical degradation, corrosion
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2457/00 Electrical equipment
• CPC Class Codes: B32B 2605/00 Vehicles
• CPC Class Codes: B32B 27/065 : of foam
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/18 : characterised by the use of special additives
• CPC Class Codes: B32B 27/28 : comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
• CPC Class Codes: B32B 27/281 : comprising polyimides
• CPC Class Codes: B32B 27/38 : comprising epoxy resins
• CPC Class Codes: B32B 27/42 : comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
• CPC Class Codes: B32B 3/12 : characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 37/146 : whereby one or more of the layers is a honeycomb structure
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/22 : characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: B32B 5/245 : another layer next to it being a foam layer
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: D04H 1/43838 : Ultrafine fibres, e.g. microfibres
• CPC Class Codes: D04H 1/587 : characterised by the bonding agents used
• CPC Class Codes: D04H 1/64 : the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
• CPC Class Codes: D04H 1/732 : by fluid current, e.g. air-lay
• CPC Class Codes: H05K 9/009 : comprising electro-conductive fibres, e.g. metal fibres, carbon fibres, metallised textile fibres, electro-conductive mesh, woven, non-woven mat, fleece, cross-linked
• CPC Class Codes: Y10T 428/2918 : including free carbon or carbide or therewith [not as steel]

Abstract

A method is provided for producing a prepreg nanoscale fiber film. The method includes providing a network of nanoscale fibers, impregnating the network of nanoscale fibers with a resin, and B-stage curing the resin. A method is also provided for producing a composite structure from the prepreg nanoscale fiber film.

Claims

1. A method for producing a prepreg nanoscale fiber film comprising:

providing a network of nanoscale fibers;

impregnating the network of nanoscale fibers with a resin; and

B-stage curing the resin.

2. The method of claim 1, wherein impregnating the network of nanoscale fibers comprises applying the resin in a fluid form onto the network of nanoscale fibers and applying a pressure to the resin to wet the network of nanoscale fibers with the resin.

3. The method of claim 2, wherein the pressure comprises a vacuum pressure.

4. The method of claim 1, wherein impregnating the network of nanoscale fibers comprises applying the resin in a film form onto the network of nanoscale fibers and applying a pressure to the resin to wet the network of nanoscale fibers with the resin.

5. The method of claim 1, wherein impregnating the network of nanoscale fibers comprises infiltrating the network of nanoscale fibers with the resin and compressing the network of nanoscale fibers and the resin.

6. The method of claim 1, wherein impregnating the network of nanoscale fibers comprises immersing the network of nanoscale fibers in a solution which comprises the resin and a solvent for the resin.

7. The method of claim 1, wherein providing the network of nanoscale fibers comprises:

dispersing a plurality of nanoscale fibers in a liquid to form a suspension; and

removing at least a portion of the liquid in a controlled manner to form the network of nanoscale fibers.

8. The method of claim 7, wherein removing the liquid is conducted within a magnetic field effective to align the nanoscale fibers forming the network.

9. The method of claim 7, wherein removing the liquid comprises filtering the suspension.

10. The method of claim 9, wherein the filtering comprises moving a filter membrane through the suspension, into transitory contact with a filter element, such that the nanoscale fibers are deposited directly on the filter membrane as the liquid flows through the filter membrane, thereby forming a continuous network of the nanoscale fibers.

11. The method of claim 10, wherein the steps of impregnating and B-stage curing occur continuously along at least a portion of the continuous network of the nanoscale fibers.

12. The method of claim 1, wherein the network of the nanoscale fibers comprises carbon nanotubes.

13. The method of claim 1, wherein the resin comprises an epoxy, a polyimide, a bismaleimide, a phenolic resin, a cyanate, or a combination thereof.

14. The method claim 1, wherein the resin is present in an amount from about 25 wt % to about 70 wt % based on the weight of the prepreg nanoscale fiber film.

15. A method for producing a composite material comprising:

providing a prepreg nanoscale fiber film which comprises a B-stage cured resin; and

curing the B-stage cured resin.

16. The method of claim 15, further comprising placing the prepreg nanoscale fiber film adjacent to a structural material before curing the B-stage cured resin such that the prepreg nanoscale fiber film becomes attached to the structural material upon curing the B-stage cured resin.

17. The method of claim 16, wherein the structural material comprises a foam, a honeycomb structure, a glass fiber laminate, a carbon fiber laminate, a Kevlar fiber composite, a polymeric article, or a combination thereof.

18. The method of claim 15, wherein the prepreg nanoscale fiber film comprises a network of aligned nanoscale fibers.

19. The method of claim 15, wherein the prepreg nanoscale fiber film comprises a network of carbon nanotubes.

20. The method of claim 15, wherein the resin comprises an epoxy, a polyimide, a bismaleimide, a phenolic resin, a cyanate, or a combination thereof.

21. A prepreg nanoscale fiber film comprising:

a network of nanoscale fibers; and

a B-stage cured resin impregnated into the network of nanoscale fibers.

22. The prepreg nanoscale fiber film of claim 21, wherein the network of nanoscale fibers comprises a network of carbon nanotubes.

23. The prepreg nanoscale fiber film of claim 21, wherein the resin comprises epoxy, polyimide, bismaleimide, phenolic resin, cyanate, or a combination thereof.

24. The prepreg nanoscale fiber film of claim 21, wherein the resin is present in an amount from about 25 wt % to about 70 wt % based on the weight of the prepreg nanoscale fiber film.