Methods of making nanoreinforced carbon fiber and components comprising nanoreinforced carbon fiber

• US 20110001086A1
• Filed: 03/25/2009
• Published: 01/06/2011
• Est. Priority Date: 05/02/2006
• Status: Abandoned Application

• Current Assignee: Goodrich Corporation (Rtx Corporation), ROHR Incorporated (Rtx Corporation)
• Original Assignee: Goodrich Corporation (Rtx Corporation), ROHR Incorporated (Rtx Corporation)
• Inventors: Hill, Valerie A., Kruckenberg, Teresa M.
• Application Number:
  US12/410,996
• Publication Number:
  US 20110001086A1
• Time in Patent Office: Days
• US Class Current: 252/182.32
• CPC Class Codes: B29C 70/081 Combinations of fibres of continuous or substantial length and short fibres
• CPC Class Codes: B29K 2105/124 Nanofibers
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C04B 2235/407 Copper
• CPC Class Codes: C04B 2235/425 Graphite
• CPC Class Codes: C04B 2235/483 Si-containing organic compounds, e.g. silicone resins, (poly)silanes, (poly)siloxanes or (poly)silazanes
• CPC Class Codes: C04B 2235/524 Non-oxidic, e.g. borides, carbides, silicides or nitrides
• CPC Class Codes: C04B 2235/5256 Two-dimensional, e.g. woven structures
• CPC Class Codes: C04B 2235/5268 Orientation of the fibers
• CPC Class Codes: C04B 2235/5288 Carbon nanotubes
• CPC Class Codes: C04B 35/62842 Metals
• CPC Class Codes: C04B 35/62876 with metals
• CPC Class Codes: C04B 35/76 Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C04B 35/83 Carbon fibres in a carbon matrix
• CPC Class Codes: D06M 11/74 with carbon or graphite; with carbides; with graphitic acids or their salts
• CPC Class Codes: D06M 2101/40 Fibres of carbon
• CPC Class Codes: D06M 2200/00 Functionality of the treatment composition and/or properties imparted to the textile material
• CPC Class Codes: D06M 23/06 Processes in which the treating agent is dispersed in a gas, e.g. aerosols aerosol compositions C09K3/30
• CPC Class Codes: D06M 23/08 Processes in which the treating agent is applied in powder or granular form adhesives for multi-layer textile fabrics D06M17/00
• CPC Class Codes: Y10S 977/75 Single-walled
• CPC Class Codes: Y10T 428/249928 : Fiber embedded in a ceramic, glass, or carbon matrix
• CPC Class Codes: Y10T 428/31678 : Of metal

Abstract

Methods for enhancing the strength and stiffness of fibers, including nanoreinforced fibers and fiber tows, composite materials including the nanoreinforced fibers and tows, and articles of manufacture including the composite materials, are disclosed. The methods involve adhering random or aligned nanoreinforcement materials, such as carbon nanotubes, nanofibers, graphene plates, nanowires, nanoparticles, into or onto a spread carbon tow or yarn to form modified fibers wherein nanoreinforcement is adhered or trapped within the carbon tow. The carbon nanotubes or nanofibers can be aligned. Carbon fiber tows including the modified carbon fibers can be processed or woven for impregnation with a thermoset resin or thermoplastic to form a composite structure. The performance increase of the modified fibers relative to the unmodified fibers can be greater than the weight increase caused by the modification. Increased fiber stiffness and strength can result in a significant weight saving.

Claims

1-67. -67. (canceled)

68. A method of making a nanoreinforced carbon fiber comprising:

coating a nanoreinforcement material with a powder coat to form a powder coated nanoreinforcement material, wherein the powder coat is a thermoplastic or adhesive; and

contacting at least one carbon fiber with the powder coated nanoreinforcement material to form a coated carbon fiber.

69. The method of claim 68, wherein the at least one carbon fiber is contacted with the powder coated nanoreinforcement material so that the carbon fiber contains from 0.1 to 20 percent by weight of nanoreinforcement material.

70. The method of claim 69, wherein theft at least one carbon fiber is contacted with the powder coated nanoreinforcement material so that the carbon fiber contains from 2 to 8 percent by weight of nanoreinforcement material.

71. The method of claim 69, wherein the carbon fiber is comprised of carbon, glass, aramid or boron.

72. The method of claim 69, wherein the nanoreinforcement material comprises carbon nanotubes, carbon nanofibers, graphene sheets, fullerenes, nanoparticles, nanowires, or a combination thereof.

73. The method of claim 69, further comprising bundling a plurality of the coated carbon fiber to form a tow or yarn.

74. The method of claim 69, wherein the coated carbon fiber is sized.

75. The method of claim 73, further comprising the step of aligning the nanoreinforcement material within the tow or yarn.

76. The method of claim 68, further comprising a step of heating or pressing the coated carbon fiber, or a combination thereof.

77. Aircraft and aircraft components, comprising composite material containing carbon fiber, wherein the carbon fiber comprises from 0.1 to 20 percent by weight nanoreinforcement material.

78. The aircraft components of claim 77, wherein the aircraft components are nacelles or nacelle components for use in aircraft.

79. The aircraft and aircraft components of claim 77, wherein the carbon fiber comprises from 2 to 8 percent by weight nanoreinforcement materials.

80. The aircraft and aircraft components of claim 77, in which the nanoreinforcement material is selected from the group consisting of carbon nanotubes, carbon nanofibers, graphene sheets, nanowires, nanoparticles of elements, nanoparticles of binary compounds, nanoparticles of complex compounds, and combinations thereof.

81. The aircraft and aircraft components of claim 77, wherein the nanoreinforcement material is sized or metallic coated or thermoplastic coated to assist in dispersion, application, or multifunctionality.

82. The aircraft and aircraft components of claim 80, wherein the nanoreinforcement material is comprised of carbon nanotubes.

83. The aircraft and aircraft components of claim 77, wherein the fiber comprises carbon, glass, aramid, or polymer fibers, alone or in combination.

84. The aircraft and aircraft components of claim 83, wherein a plurality of fibers are bundled to form a tow or yarn.

85. The aircraft and aircraft components of claim 84, wherein the fibers are sized.

86. The aircraft and aircraft components of claim 84, wherein the nanoreinforcement material is aligned within the tow or yarn.

87. The aircraft and aircraft components of claim 84, wherein the fiber tow comprises one or more carbon, glass, aramid and polymer fibers, alone or in combination.