METHOD AND APPARATUS FOR USING A VERTICAL FURNACE TO INFUSE CARBON NANOTUBES TO FIBER

• US 20100260931A1
• Filed: 04/09/2010
• Published: 10/14/2010
• Est. Priority Date: 04/10/2009
• Status: Abandoned Application

• Current Assignee: Applied NanoStructured Solutions, LLC (Cabot Corporation)
• Original Assignee: Lockheed Martin Corporation (Martin Marietta Corporation)
• Inventors: MALECKI, Harry C., Shah, Tushar K., Alberding, Mark R.
• Application Number:
  US12/757,907
• Publication Number:
  US 20100260931A1
• Time in Patent Office: Days
• US Class Current: 427/180
• 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 32/164 involving continuous processes
• CPC Class Codes: D06M 11/74 with carbon or graphite; with carbides; with graphitic acids or their salts

Abstract

A method for forming a CNT infused substrate comprises exposing a catalyst nanoparticle, a carbon feedstock gas, and a carrier gas to a CNT synthesis temperature, allowing a CNT to form on the catalyst nanoparticle, cooling the CNT, and exposing the cooled CNT to a surface of a substrate to form a CNT infused substrate.

Claims

1. A method comprising:

exposing a catalyst nanoparticle, a carbon feedstock gas, and a carrier gas to a CNT synthesis temperature;

allowing a CNT to form on the catalyst nanoparticle;

cooling the CNT; and

exposing the cooled CNT to a surface of a substrate to form a CNT infused substrate.

2. The method of claim 1 further comprising functionalizing the substrate prior to exposing the substrate to the CNT.

3. The method of claim 1 further comprising functionalizing the CNT infused substrate.

4. The method of claim 2 wherein the substrate is functionalized by adding a functional group selected from the group consisting of an amine group, a carbonyl group, a carboxyl group, a fluorine-containing group, a silane group, a siloxane group, and any combination thereof.

5. The method of claim 1 wherein the substrate comprises at least one material selected from the group consisting of:

a carbon fiber, a graphite fiber, a cellulosic fiber, a glass fiber, a metal fiber, a ceramic fiber, a metallic-ceramic fiber, cellulosic fiber, an aramid fiber, and any combination thereof.

6. The method of claim 1 wherein the CNT synthesis temperature is a temperature in the range of from about 450°

C. to about 1000°

C.

7. The method of claim 1 wherein the CNT is cooled to a temperature in the range of from about 25°

C. to about 450°

C.

8. The method of claim 1 further comprising:

providing a catalyst solution comprising a catalyst and a solvent; and

atomizing the catalyst solution and allowing the solvent to evaporate leaving the catalyst nanoparticle.

9. The method of claim 1 wherein the catalyst nanoparticle comprises a d-block transition metal.

10. A system comprising;

a carrier gas source that provides a carrier gas;

a catalyst source that provides a catalyst nanoparticle;

a carbon feedstock source that provides a carbon feedstock;

a substrate source that provides a substrate; and

a CNT growth reactor comprising;

an inlet device that receives the carrier gas, the catalyst nanoparticle, and the carbon feedstock and introduces the carrier gas, the catalyst nanoparticle, and the carbon feedstock into a CNT growth zone;

a heating element that heats the carrier gas, the catalyst nanoparticle, and the carbon feedstock to a CNT synthesis temperature within the CNT growth zone to allow a CNT to synthesize on the catalyst and form a synthesized CNT;

a dispersion hood that receives the synthesized CNT and cools the synthesized CNT; and

a CNT infusion chamber that receives the synthesized CNT and the substrate and exposes the substrate to the cooled synthesized CNT to produce a CNT infused substrate.

11. The system of claim 10 wherein the substrate is functionalized.

12. The system of claim 10 wherein the substrate comprises at least one material selected from the group consisting of:

a carbon fiber, a graphite fiber, a cellulosic fiber, a glass fiber, a metal fiber, a ceramic fiber, a metallic-ceramic fiber, cellulosic fiber, an aramid fiber, and any combination thereof.

13. The system of claim 10 wherein the CNT synthesis temperature is a temperature in the range of from about 450°

C. to about 1000°

C.

14. The system of claim 10 wherein the dispersion hood cools the synthesized CNT to a temperature in the range of from about 25°

C. to about 450°

C.

15. The system of claim 10 wherein the carbon feedstock comprises at least one compound selected from the group consisting of:

acetylene, ethylene, methanol, methane, propane, benzene, natural gas, and any combination thereof.

16. A method comprising:

providing a catalyst nanoparticle, a carbon feedstock gas, and a carrier gas;

heating the catalyst nanoparticle, the carbon feedstock gas, and the carrier gas to a CNT synthesis temperature;

allowing a CNT to form on the catalyst nanoparticle;

cooling the CNT;

providing a substrate;

exposing the substrate to the cooled CNT to form a CNT infused substrate; and

forming a composite material, wherein the composite material comprises the CNT infused substrate.

17. The method of claim 16 wherein the substrate is functionalized.

18. The method of claim 16 further comprising functionalizing the CNT infused substrate prior to forming a composite material.

19. The method of claim 16 wherein the substrate is provided on a dynamic basis.

20. The method of claim 16 wherein the composite material further comprises a matrix material, and wherein the matrix material comprises at least one material selected from the group consisting of:

a thermosetting resin, a thermoplastic resin, a metal, a ceramic, a cement, and any combination thereof.