CERAMIC COMPOSITE MATERIALS CONTAINING CARBON NANOTUBE-INFUSED FIBER MATERIALS AND METHODS FOR PRODUCTION THEREOF

• US 20110124483A1
• Filed: 11/23/2010
• Published: 05/26/2011
• Est. Priority Date: 11/23/2009
• Status: Active Grant

• Current Assignee: Applied NanoStructured Solutions, LLC (Cabot Corporation)
• Original Assignee: Applied NanoStructured Solutions, LLC (Cabot Corporation)
• Inventors: Carson, Murray N., SHAH, Tushar K., Malecki, Harry C.
• Granted Patent: US 8,168,291 B2
• Time in Patent Office: Days
• US Class Current: 501/32
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C04B 14/386 Carbon carbon nanotubes C04B14/026
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 14/46 Rock wool ; Ceramic or silicate fibres C04B14/40, C04B14/42 take precedence
• CPC Class Codes: C04B 16/06 fibrous
• CPC Class Codes: C04B 20/1014 Coating or impregnating materials characterised by the shape, e.g. fibrous materials
• CPC Class Codes: C04B 20/1055 with inorganic materials
• CPC Class Codes: C04B 20/1062 Metals
• CPC Class Codes: C04B 20/12 Multiple coating or impregnating
• CPC Class Codes: C04B 2235/5224 Alumina or aluminates
• CPC Class Codes: C04B 2235/524 Non-oxidic, e.g. borides, carbides, silicides or nitrides
• CPC Class Codes: C04B 2235/5244 Silicon carbide
• CPC Class Codes: C04B 2235/5248 Carbon, e.g. graphite
• CPC Class Codes: C04B 2235/5252 having a specific pre-form
• CPC Class Codes: C04B 2235/5256 Two-dimensional, e.g. woven structures
• CPC Class Codes: C04B 2235/526 characterised by the length of the fibers
• CPC Class Codes: C04B 2235/5264 characterised by the diameter of the fibers
• CPC Class Codes: C04B 2235/5268 Orientation of the fibers
• CPC Class Codes: C04B 2235/5272 Fibers of the same material with different length or diameter
• CPC Class Codes: C04B 2235/5288 Carbon nanotubes
• CPC Class Codes: C04B 2235/604 : Pressing at temperatures other than sintering temperatures
• CPC Class Codes: C04B 2235/75 : Products with a concentration gradient
• CPC Class Codes: C04B 28/04 : Portland cements
• CPC Class Codes: C04B 35/117 : Composites
• CPC Class Codes: C04B 35/185 : Mullite 3Al2O3-2SiO2
• CPC Class Codes: C04B 35/4682 : based on BaTiO3 perovskite phase
• CPC Class Codes: C04B 35/5607 : based on refractory metal carbides
• CPC Class Codes: C04B 35/5611 : based on titanium carbides
• CPC Class Codes: C04B 35/5626 : based on tungsten carbides
• CPC Class Codes: C04B 35/565 : based on silicon carbide
• CPC Class Codes: C04B 35/58014 : based on titanium nitrides, e.g. TiAlON
• CPC Class Codes: C04B 35/58042 : based on iron group metals nitrides
• CPC Class Codes: C04B 35/58071 : based on titanium borides
• CPC Class Codes: C04B 35/584 : based on silicon nitride
• CPC Class Codes: C04B 35/6269 : Curing of mixtures
• CPC Class Codes: C04B 35/62849 : Silica or silicates
• CPC Class Codes: C04B 35/62852 : Alumina or aluminates
• CPC Class Codes: C04B 35/62857 : with non-oxide ceramics
• CPC Class Codes: C04B 35/62873 : Carbon
• CPC Class Codes: C04B 35/62876 : with metals
• CPC Class Codes: C04B 35/62889 : with a discontinuous coating layer
• CPC Class Codes: C04B 35/62894 : with more than one coating layer
• CPC Class Codes: C04B 35/62897 : Coatings characterised by their thickness
• CPC Class Codes: C04B 35/76 : Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C04B 35/80 : Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C04B 35/82 : Asbestos; Glass; Fused silica
• CPC Class Codes: Y10S 977/742 : Carbon nanotubes, CNTs
• CPC Class Codes: Y10T 428/249927 : Fiber embedded in a metal matrix
• CPC Class Codes: Y10T 428/249928 : Fiber embedded in a ceramic, glass, or carbon matrix

Abstract

In various embodiments, composite materials containing a ceramic matrix and a carbon nanotube-infused fiber material are described herein. Illustrative ceramic matrices include, for example, binary, ternary and quaternary metal or non-metal borides, oxides, nitrides and carbides. The ceramic matrix can also be a cement. The fiber materials can be continuous or chopped fibers and include, for example, glass fibers, carbon fibers, metal fibers, ceramic fibers, organic fibers, silicon carbide fibers, boron carbide fibers, silicon nitride fibers and aluminum oxide fibers. The composite materials can further include a passivation layer overcoating at least the carbon nanotube-infused fiber material and, optionally, the plurality of carbon nanotubes. The fiber material can be distributed uniformly, non-uniformly or in a gradient manner in the ceramic matrix. Non-uniform distributions may be used to form impart different mechanical, electrical or thermal properties to different regions of the ceramic matrix.

Claims

1. A composite material comprising:

a ceramic matrix; and

a carbon nanotube-infused fiber material.

2. The composite material of claim 1, wherein the ceramic matrix comprises at least one compound selected from the group consisting of silicon carbide, tungsten carbide, chromium carbide, titanium carbide, titanium nitride, titanium boride, aluminum oxide, silicone nitride, Mullite, SiCN, Fe₂N, and BaTiO₃.

3. The composite material of claim 1, wherein the ceramic matrix comprises a cement.

4. The composite material of claim 3, wherein the cement is selected from the group consisting of Portland cement, Pozzolan-lime cement, slag-lime cement, supersulfated cement, calcium aluminate cement, calcium sulfoaluminate cement, carbide-based cements, refractory cements, chromium-alumina cements, and nickel-magnesia iron-zirconium carbide cements and combinations thereof.

5. The composite material of claim 4, wherein the Portland cement is of a type selected from the group consisting Type I Portland cement, Type II Portland Cement, Type III Portland cement, Type IV Portland cement and Type V Portland cement.

6. The composite material of claim 1, wherein the carbon nanotube-infused fiber material comprises at least one fiber type selected from the group consisting of glass fibers, carbon fibers, metal fibers, ceramic fibers, organic fibers, silicon carbide fibers, boron carbide fibers, silicon nitride fibers, aluminum oxide fibers and combinations thereof.

7. The composite material of claim 1, further comprising:

a passivation layer overcoating at least the carbon nanotube-infused fiber material.

8. The composite material of claim 7, wherein the carbon nanotubes are also overcoated with the passivation layer.

9. The composite material of claim 7, wherein the passivation layer comprises nickel, chromium, magnesium, titanium, silver, tin or titanium diboride.

10. The composite material of claim 1, wherein the fiber material is selected from the group consisting of chopped fibers and continuous fibers.

11. The composite material of claim 1, wherein the carbon nanotubes comprise between about 0.1 and about 10% of the composite material by weight.

12. The composite material of claim 1, wherein carbon nanotubes comprise between about 0.5 and about 40% of the carbon nanotube-infused fiber material by weight.

13. The composite material of claim 1, wherein at least one of the fiber material or the carbon nanotubes at least partially react with a ceramic precursor material to form at least a portion of the ceramic matrix.

14. The composite material of claim 1, wherein the fiber material is uniformly distributed in the ceramic matrix.

15. The composite material of claim 1, wherein the fiber material is non-uniformly distributed in the ceramic matrix.

16. The composite material of claim 15, wherein the non-uniform distribution comprises a gradient distribution in the ceramic matrix.

17. The composite material of claim 1, wherein the carbon nanotubes comprising the carbon nanotube-infused fiber material are substantially perpendicular to the longitudinal axis of the fiber material.

18. The composite material of claim 1, wherein the carbon nanotubes comprising the carbon nanotube-infused fiber material are substantially parallel to the longitudinal axis of the fiber material.

19. The composite material of claim 1, wherein the carbon nanotube-infused fiber material comprises silicon carbide fibers and the ceramic matrix is selected from the group consisting of aluminum oxide and silicon nitride.

20. The composite material of claim 1, wherein the carbon nanotube-infused fiber material is selected from the group consisting of carbon fibers and silicon carbide fibers and the ceramic matrix comprises silicon carbide.

21. The composite material of claim 1, wherein a weight percentage of the carbon nanotubes comprising the fiber material is determined by an average length of the carbon nanotubes.

22. The composite material of claim 21, wherein the weight percentage of the carbon nanotubes comprising the fiber material is further determined by a density of coverage of the carbon nanotubes infused to the fiber material.

23. The composite material of claim 22, wherein the density of coverage is up to about 15,000 carbon nanotubes/μ

m².

24. The composite material of claim 1, wherein an average length of the carbon nanotubes is between about 1 μ

m and about 500 μ

m.

25. The composite material of claim 1, wherein an average length of the carbon nanotubes is between about 1 μ

m and about 10 μ

m.

26. The composite material of claim 1, wherein an average length of the carbon nanotubes is between about 10 μ

m and about 100 μ

m.

27. The composite material of claim 1, wherein an average length of the carbon nanotubes is between about 100 μ

m and about 500 μ

m.

28. The composite material of claim 1, wherein an average length of the carbon nanotubes is sufficient to decrease the coefficient of thermal expansion of the composite material by about 4-fold or more relative to a composite material lacking carbon nanotubes.

29. The composite material of claim 1, wherein an average length of the carbon nanotubes is sufficient to improve the stiffness and wear resistance of the composite material by about 3-fold or more relative to a composite material lacking carbon nanotubes.

30. The composite material of claim 1, wherein an average length of the carbon nanotubes is sufficient to establish an electrically conductive pathway in the composite material.

31. A composite material comprising:

a ceramic matrix; and

a first portion of a carbon nanotube-infused fiber material in a first region of the ceramic matrix and a second portion of a carbon nanotube-infused fiber material in a second region of the ceramic matrix;

wherein an average length of the carbon nanotubes infused to the first portion and an average length of the carbon nanotubes infused to the second portion are chosen such that the first region of the ceramic matrix and the second region of the ceramic matrix have different mechanical, electrical or thermal properties.

32. The composite material of claim 31, wherein the first portion of a carbon nanotube-infused fiber material and the second portion of a carbon nanotube-infused fiber material comprise the same fiber material.

33. The composite material of claim 31, wherein the first portion of a carbon nanotube-infused fiber material and the second portion of a carbon nanotube-infused fiber material comprise different fiber materials.

34. The composite material of claim 31, wherein at least one of the first portion of a carbon nanotube-infused fiber material and the second portion of a carbon nanotube-infused fiber material further comprise a passivation layer overcoating at least the carbon nanotube-infused fiber material.

35. A method comprising:

providing a carbon nanotube-infused fiber material;

distributing the carbon nanotube-infused fiber material in a green ceramic precursor; and

curing the green ceramic precursor to form a composite material comprising a ceramic matrix and a carbon nanotube-infused fiber material.

36. The method of claim 35, wherein the ceramic matrix comprises at least one ceramic compound selected from the group consisting of a cement, silicon carbide, tungsten carbide, chromium carbide, titanium carbide, titanium nitride, titanium boride, aluminum oxide, silicone nitride, Mullite, SiCN, Fe₂N, and BaTiO₃.

37. The method of claim 35, wherein the fiber material comprises at least one fiber type selected from the group consisting of glass fibers, carbon fibers, metal fibers, ceramic fibers, organic fibers, silicon carbide fibers, boron carbide fibers, silicon nitride fibers, aluminum oxide fibers and combinations thereof.

38. The method of claim 35, wherein the carbon nanotube-infused fiber material is uniformly distributed in the ceramic matrix.

39. The method of claim 35, wherein the carbon nanotube-infused fiber material is non-uniformly distributed in the ceramic matrix.

40. The method of claim 39, wherein the non-uniform distribution comprises a gradient distribution.

41. The method of claim 35, further comprising:

overcoating at least a portion of the carbon nanotube-infused fiber material with a passivation layer.

42. The method of claim 41, wherein the carbon nanotubes are also overcoated with the passivation layer.

43. The method of claim 41, wherein the passivation layer is deposited by a technique selected from the group consisting of electroplating and chemical vapor deposition.

44. The method of claim 41, wherein the passivation layer comprises nickel or titanium diboride.

45. The method of claim 35, further comprising:

densifying the composite material.

46. A method comprising:

providing a ceramic matrix comprising a cement;

providing a carbon nanotube-infused fiber material;

distributing the carbon nanotube-infused fiber material in the cement; and

curing the cement to form a concrete comprising the carbon nanotube-infused fiber material.

47. The method of claim 46, wherein the fiber material comprises chopped fibers.

48. An article comprising:

a composite material comprising;

a ceramic matrix, and

a carbon nanotube-infused fiber material.