RESIN COMPLEX CONTAINING CARBON NANOTUBE AND METHOD FOR PRODUCTION THEREOF

• US 20100203316A1
• Filed: 04/24/2008
• Published: 08/12/2010
• Est. Priority Date: 04/24/2007
• Status: Active Grant

• Current Assignee: National Institute of Advanced Industrial Science and Technology (Government of Japan)
• Original Assignee: National Institute of Advanced Industrial Science and Technology (Government of Japan)
• Inventors: Nishino, Hidekazu, Hata, Kenji
• Granted Patent: US 8,231,965 B2
• Time in Patent Office: Days
• US Class Current: 428/299.100
• CPC Class Codes: B29B 15/10 Coating or impregnating independently of the moulding or shaping stepapplying liquids in general B05
• CPC Class Codes: B29C 45/0013 using fillers dispersed in the moulding material, e.g. metal particles
• CPC Class Codes: B29C 70/14 oriented
• CPC Class Codes: B29C 70/504 using rollers or pressure bands for corrugating B29C53/22
• CPC Class Codes: B29K 2105/162 Nanoparticles
• CPC Class Codes: B29K 2105/167 Nanotubes
• CPC Class Codes: B29K 2707/04 Carbon
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C08J 5/005 Reinforced macromolecular compounds with nanosized materials, e.g. nanoparticles, nanofibres, nanotubes, nanowires, nanorods or nanolayered materials
• CPC Class Codes: C08K 7/24 inorganic
• CPC Class Codes: C08K 9/08 Ingredients agglomerated by treatment with a binding agent
• CPC Class Codes: Y10S 977/753 with polymeric or organic binder
• CPC Class Codes: Y10T 156/1043 Subsequent to assembly
• CPC Class Codes: Y10T 428/24994 Fiber embedded in or on the surface of a polymeric matrix
• CPC Class Codes: Y10T 428/249945 Carbon or carbonaceous fiber

Abstract

A carbon nanotubes (CNTs)-containing resin composite comprised of a synthetic resin-impregnated aligned CNTs aggregate to have a specific surface area of at least 600 m²/g. Its production method comprises a step of laying down an aligned CNTs aggregate having grown perpendicularly from a substrate, a step of impregnating the laid-down aligned CNTs aggregate with a resin, and a step of shaping the resin-impregnated aligned CNTs aggregate into a sheet. Accordingly, there are provided a CNTs-containing resin composite having a high CNT content and a high degree of alignment and having a desired shape capable of fully taking the advantages of anisotropy intrinsic to CNTs, and a production method capable of producing it with ease.

Claims

1. A carbon nanotubes-containing resin composite comprised of a resin-impregnated aligned carbon nanotube aggregate,

wherein the aligned carbon nanotube aggregate have a specific surface area of at least 600 m²/g.

2. The carbon nanotubes-containing resin composite as claimed in claim 1, wherein the carbon nanotube content is from 5 to 50 mass %.

3. A method for producing a carbon nanotubes-containing resin composite comprised of a resin-impregnated aligned carbon nanotube aggregate,

comprising a step of laying down an aligned carbon nanotube aggregate having grown perpendicularly from a substrate carrying a catalyst thereon,

a step of impregnating the laid-down aligned carbon nanotube aggregate with a resin, and

a step of shaping the resin-impregnated aligned carbon nanotube aggregate into a sheet.

6. The method for producing a carbon nanotubes-containing resin composite as claimed in claim 3, wherein a catalyst is patterned in a predetermined shape on the substrate and the carbon nanotubes-containing resin composite is formed to have the patterned shape.

7. The method for producing a carbon nanotubes-containing resin composite as claimed in claim 3, wherein the alignment direction of the laid-down aligned carbon nanotube aggregate is the in-plane direction of the substrate.

8. The method for producing a carbon nanotubes-containing resin composite as claimed in claim 3, wherein the weight density of the laid-down aligned carbon nanotube aggregate is at least 0.05 g/cm³.

9. The method for producing a carbon nanotubes-containing resin composite as claimed in claim 3, wherein the substrate is a flexible substrate.

10. The method for producing a carbon nanotubes-containing resin composite as claimed in claim 3, wherein the height of the aligned carbon nanotubes aggregate having grown perpendicularly from the substrate is at least 10 μ

m.

4. A method for producing a carbon nanotubes-containing resin composite comprised of a resin-impregnated aligned carbon nanotube aggregate,

comprising a step of applying a unidirectional pressure force onto an aligned carbon nanotube aggregate having grown perpendicularly from a substrate via a sheet-like transfer material therebetween to thereby lay down the carbon nanotubes,

a step of impregnating the aligned carbon nanotube aggregate as laid down and stuck to the sheet-like transfer material with a resin, and

a step of shaping the resin-impregnated aligned carbon nanotube aggregate into a sheet.

5. The method for producing a carbon nanotubes-containing resin composite as claimed in claim 4, wherein the sheet-like transfer material is a fluororesin.

11. The method for producing a carbon nanotubes-containing resin composite as claimed in claim 4, wherein a catalyst is patterned in a predetermined shape on the substrate and the carbon nanotubes-containing resin composite is formed to have the patterned shape.

12. The method for producing a carbon nanotubes-containing resin composite as claimed in claim 4, wherein the alignment direction of the laid-down aligned carbon nanotube aggregate is the in-plane direction of the substrate.

13. The method for producing a carbon nanotubes-containing resin composite as claimed in claim 4, wherein the weight density of the laid-down aligned carbon nanotube aggregate is at least 0.05 g/cm³.

14. The method for producing a carbon nanotubes-containing resin composite as claimed in claim 4, wherein the substrate is a flexible substrate.

15. The method for producing a carbon nanotubes-containing resin composite as claimed in claim 4, wherein the height of the aligned carbon nanotubes aggregate having grown perpendicularly from the substrate is at least 10 μ

m.