CNT-INFUSED GLASS FIBER MATERIALS AND PROCESS THEREFOR

• US 20100192851A1
• Filed: 02/26/2010
• Published: 08/05/2010
• Est. Priority Date: 01/03/2007
• Status: Abandoned Application

• Current Assignee: Applied NanoStructured Solutions, LLC (Cabot Corporation)
• Original Assignee: Lockheed Martin Corporation (Martin Marietta Corporation)
• Inventors: SHAH, Tushar K., MALECKI, Harry C., ALBERDING, Mark R., GARDNER, Slade H.
• Application Number:
  US12/714,375
• Publication Number:
  US 20100192851A1
• Time in Patent Office: Days
• US Class Current: 118/620
• 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 32/15 Nano-sized carbon materials
• CPC Class Codes: C01B 32/164 involving continuous processes
• CPC Class Codes: C03C 25/12 General methods of coating; Devices therefor
• CPC Class Codes: C03C 25/465 Coatings containing composite materials
• CPC Class Codes: C22C 49/06 Aluminium
• CPC Class Codes: C22C 49/14 characterised by the fibres or filaments
• CPC Class Codes: Y10T 442/2992 Coated or impregnated glass fiber fabric

Abstract

A composition includes a carbon nanotube (CNT)-infused glass fiber material, which includes a glass fiber material of spoolable dimensions and carbon nanotubes (CNTs) bonded to it. The CNTs are uniform in length and distribution. A continuous CNT infusion process includes: (a) disposing a carbon-nanotube forming catalyst on a surface of a glass fiber material of spoolable dimensions; and (b) synthesizing carbon nanotubes on the glass fiber material, thereby forming a carbon nanotube-infused glass fiber material. The continuous CNT infusion process optionally includes extruding a glass fiber material from a glass melt or removing sizing material from a pre-fabricated glass fiber material.

Claims

1. A system for the continuous production of carbon nanotubes on a glass fiber material comprising:

a catalyst application station comprising a colloidal solution of CNT growth catalyst nanoparticles; and

a CNT growth station comprising at least one purge zone and a growth chamber;

said growth station adapted for CNT growth on the glass fiber material by continuously feeding the glass fiber material through the growth station;

said system being capable of reel to reel growth of CNTs on the glass fiber material continuously by providing a payout bobbin and an uptake bobbin;

said glass fiber material being provided in spoolable form.

2. The system of claim 1, wherein said CNT growth station is open to, but separated from the outside environment by the use of an inert gas flow.

3. The system of claim 1 further comprising a payout and tensioner station.

4. The system of claim 1 further comprising a fiber spreading station.

5. The system of claim 1 further comprising a plasma station adapted to roughen the surface of the glass fiber material.

6. The system of claim 1 further comprising a barrier coating station adapted to conformally deposit a barrier coating on said glass fiber material;

said barrier coating having CNT growth catalyst embedded therein.

7. The system of claim 5, wherein the catalyst application station and barrier coating station are combined.

8. The system of claim 5, wherein said barrier coating station comprises at least one of spin-on glass, an alumina, a silane, an alkoxysilane, and a liquid ceramic.

9. The system of claim 1 further comprising a fiber sizing removal station.

10. The system of claim 1 further comprising a resin application station downstream of said CNT growth station.

11. The system of claim 1 which is capable of operating speeds in a range from between about 0.5 ft/min to about 36 ft/min.

12. The system of claim 1 further comprising a controller station;

said controller station capable of controlling at least one of linespeed, an inert gas flow rate, a carbon feedstock flowrate, temperature in the CNT growth chamber, temperature of the inert gas, and temperature of the carbon feedstock gas.

13. The system of claim 1, wherein a material residence time in the growth chamber between about 5 to about 30 seconds produces CNTs having a length between about 1 micron to about 10 microns.

14. The system of claim 1, wherein a material residence time in the growth chamber of about 30 to about 180 seconds produces CNTs having a length between about 10 microns to about 100 microns.

15. The system of claim 1, wherein a material residence time in the growth chamber of about 180 to about 300 seconds produces CNTs having a length between about 100 microns to about 500 microns.

16. A system for the continuous production of carbon nanotubes on a fiber material comprising:

a catalyst application station comprising a colloidal solution of CNT growth catalyst nanoparticles; and

a CNT growth station comprising at least one purge zone and a growth chamber;

said growth station adapted for CNT growth on the fiber material by continuously feeding the fiber material through the growth station;

said system being capable of reel to reel growth of CNTs on the fiber material continuously by providing a payout bobbin and an uptake bobbin;

said fiber material being provided in spoolable form.