FLAME-RESISTANT COMPOSITE MATERIALS AND ARTICLES CONTAINING CARBON NANOTUBE-INFUSED FIBER MATERIALS

• US 20110143087A1
• Filed: 12/14/2010
• Published: 06/16/2011
• Est. Priority Date: 12/14/2009
• Status: Active Grant

• Current Assignee: Applied NanoStructured Solutions, LLC (Cabot Corporation)
• Original Assignee: Applied NanoStructured Solutions, LLC (Cabot Corporation)
• Inventors: Shah, Tushar K., Adcock, Daniel J., Malecki, Harry C., ALBERDING, Mark R.
• Granted Patent: US 8,545,963 B2
• Time in Patent Office: Days
• US Class Current: 428/114
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/105 Ceramic fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 5/12 characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
• CPC Class Codes: B32B 5/16 characterised by features of a layer formed of particles, e.g. chips, powder or granules layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: Y10T 428/24 Structurally defined web or sheet [e.g., overall dimension, etc.]
• CPC Class Codes: Y10T 428/24058 including grain, strips, or filamentary elements in respective layers or components in angular relation
• CPC Class Codes: Y10T 428/24132 including grain, strips, or filamentary elements in different layers or components parallel
• CPC Class Codes: Y10T 428/249921 Web or sheet containing structurally defined element or component
• CPC Class Codes: Y10T 428/249942 Fibers are aligned substantially parallel
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/269 including synthetic resin or polymer layer or component

Abstract

Flame-resistant composite materials containing carbon nanotubes are described herein. The flame-resistant composite materials contain an outer layer and at least one inner layer, containing a first polymer matrix and a second polymer matrix, respectively. The outer layer has an exterior surface and a first carbon nanotube-infused fiber material that contains a first fiber material and a first plurality of carbon nanotubes greater than about 50 μm in length. In some embodiments, the at least one inner layer also contains a second fiber material and/or a second carbon nanotube-infused fiber material containing a second fiber material and a second plurality of carbon nanotubes. When present, the second plurality of carbon nanotubes are generally shorter in length than the first plurality of carbon nanotubes. Alignment of the carbon nanotubes in the outer layer can transfer heat away from the composite material'"'"'s inner layer(s). Flame-resistant articles containing carbon nanotube-infused fiber materials are also described.

Claims

1. A flame-resistant composite material comprising:

an outer layer comprising a first polymer matrix and a first carbon nanotube-infused fiber material;

wherein the outer layer has an exterior surface; and

wherein the first carbon nanotube-infused fiber material comprises a first plurality of carbon nanotubes and a first fiber material;

wherein the first plurality of carbon nanotubes are greater than about 50 μ

m in length; and

at least one inner layer comprising a second polymer matrix.

2. The flame-resistant composite material of claim 1, wherein the at least one inner layer further comprises at least one component selected from the group consisting of a second fiber material, a second carbon nanotube-infused fiber material comprising a second plurality of carbon nanotubes and a second fiber material, and combinations thereof.

3. The flame-resistant composite material of claim 2, wherein a thickness of the outer layer ranges between about 0.005″

and about 0.1″

.

4. The flame-resistant composite material of claim 2, wherein the first fiber material and the second fiber material are the same.

5. The flame-resistant composite material of claim 2, wherein the first fiber material and the second fiber material are different.

6. The flame-resistant composite material of claim 1, wherein the first polymer matrix and the second polymer matrix are the same.

7. The flame-resistant composite material of claim 1, wherein the first polymer matrix and the second polymer matrix are different.

8. The flame-resistant composite material of claim 1, wherein a thickness of the outer layer ranges between about 0.005″

and about 0.1″

.

9. The flame-resistant composite material of claim 1, wherein the at least one inner layer further comprises a second carbon nanotube-infused fiber material;

wherein the second carbon nanotube-infused fiber material comprises a second plurality of carbon nanotubes and a second fiber material;

wherein the second plurality of carbon nanotubes are less than about 50 μ

m in length.

10. The flame-resistant composite material of claim 9, further comprising a transition layer between the outer layer and the at least one inner layer;

wherein the transition layer comprises at least one of the first polymer matrix or the second polymer matrix.

11. The flame-resistant composite material of claim 10, wherein the transition layer further comprises a third fiber material that lacks carbon nanotubes.

12. The flame-resistant composite material of claim 9, wherein the first polymer matrix and the second polymer matrix comprise an epoxy.

13. The flame-resistant composite material of claim 9, wherein at least one of the first carbon nanotube-infused fiber material or the second carbon nanotube-infused fiber material comprises continuous fibers.

14. The flame-resistant composite material of claim 9, wherein at least one of the first carbon nanotube-infused fiber material or the second carbon nanotube-infused fiber material comprises chopped fibers.

15. The flame-resistant composite material of claim 9, wherein the first carbon nanotube-infused fiber material is aligned substantially parallel to the exterior surface.

16. The flame-resistant composite material of claim 15, wherein the first plurality of carbon nanotubes are aligned substantially parallel to the longitudinal axis of the first fiber material.

17. The flame-resistant composite material of claim 15, wherein each fiber of the first carbon nanotube-infused fiber material is aligned substantially parallel in the outer layer.

18. The flame-resistant composite material of claim 9, wherein the first plurality of carbon nanotubes comprise between about 0.1% and about 20% of the outer layer by weight.

19. The flame-resistant composite material of claim 9, wherein the second plurality of carbon nanotubes comprise between about 0.1% and about 10% of the at least one inner layer by weight.

20. The flame-resistant composite material of claim 9, wherein the first fiber material and the second fiber material are independently selected from the group consisting of carbon fibers, ceramic fibers, glass fibers, organic fibers, and combinations thereof.

21. The flame-resistant composite material of claim 9, wherein the at least one inner layer comprises a plurality of inner layers, each comprising second carbon nanotube-infused fiber materials that are aligned substantially parallel to one another in each inner layer;

wherein the substantially parallel aligned second carbon nanotube-infused fiber materials in each inner layer are aligned substantially perpendicular to the substantially parallel aligned second carbon nanotube-infused fiber materials in alternating inner layers.

22. The flame-resistant composite material of claim 1, wherein the first carbon nanotube-infused fiber material comprises chopped fibers.

23. The flame-resistant composite material of claim 1, wherein the first carbon nanotube-infused fiber material comprises continuous fibers.

24. The flame-resistant composite material of claim 1, wherein the first carbon nanotube-infused fiber material is aligned substantially parallel to the exterior surface.

25. The flame-resistant composite material of claim 24, wherein the first plurality of carbon nanotubes are aligned substantially parallel to the longitudinal axis of the first fiber material.

26. The flame-resistant composite material of claim 24, wherein each fiber of the first carbon nanotube-infused fiber material is aligned substantially parallel in the outer layer.

27. The flame-resistant composite material of claim 1, wherein the first fiber material is selected from the group consisting of carbon fibers, ceramic fibers, glass fibers, organic fibers, and combinations thereof.

28. A flame-resistant composite material comprising:

an epoxy matrix comprising an outer layer and at least one inner layer;

wherein the outer layer has an exterior surface and a thickness that ranges between about 0.005″ and

about 0.1″

;

a first carbon nanotube-infused fiber material in the outer layer;

wherein the first carbon nanotube-infused fiber material comprises a first plurality of carbon nanotubes and a first fiber material;

wherein the first plurality of carbon nanotubes are greater than about 50 μ

m in length; and

a second carbon nanotube-infused fiber material in the at least one inner layer;

wherein the second carbon nanotube-infused fiber material comprises a second plurality of carbon nanotubes and a second fiber material.

29. The flame-resistant composite material of claim 28, wherein the second plurality of carbon nanotubes are less than about 50 μ

m in length.

30. The flame-resistant composite material of claim 28, wherein the first carbon nanotube-infused fiber material comprises continuous fibers.

31. The flame-resistant composite material of claim 30, wherein the second carbon nanotube-infused fiber material comprises a form selected from the group consisting of continuous fibers, chopped fibers, and combinations thereof.

32. The flame-resistant composite material of claim 28, wherein the first carbon nanotube-infused fiber material comprises chopped fibers.

33. The flame-resistant composite material of claim 32, wherein the second carbon nanotube-infused fiber material comprises a form selected from the group consisting of continuous fibers, chopped fibers, and combinations thereof.

34. The flame-resistant composite material of claim 28, wherein the first fiber material and the second fiber material are independently selected from the group consisting of carbon fibers, ceramic fibers, glass fibers, organic fibers, and combinations thereof.

35. The flame-resistant composite material of claim 28, further comprising a transition layer comprising the epoxy matrix that is located between the outer layer and the at least one inner layer.

36. The flame-resistant composite material of claim 35, wherein the transition layer further comprises a third fiber material that lacks carbon nanotubes.

37. The flame-resistant composite material of claim 28, wherein the first carbon nanotube-infused fiber material comprises between about 1% and about 30% carbon nanotubes by weight.

38. The flame-resistant composite material of claim 28, wherein the first plurality of carbon nanotubes and the second plurality of carbon nanotubes collectively comprise less than about 10% of the flame-resistant composite material by weight.

39. The flame-resistant composite material of claim 28, wherein the first plurality of carbon nanotubes comprise between about 0.1% and about 20% of the outer layer by weight.

40. The flame-resistant composite material of claim 28, wherein the second plurality of carbon nanotubes comprise between about 0.1% and about 10% of the at least one inner layer by weight.

41. The flame-resistant composite material of claim 28, wherein the second plurality of carbon nanotubes comprise a lower weight percentage of the flame-resistant composite material than does the first plurality of carbon nanotubes.

42. The flame-resistant composite material of claim 28, wherein the first carbon nanotube-infused fiber material is aligned substantially parallel to the exterior surface.

43. The flame-resistant composite material of claim 42, wherein the first plurality of carbon nanotubes are aligned substantially parallel to the longitudinal axis of the first fiber material.

44. The flame-resistant composite material of claim 42, wherein each fiber of the first carbon nanotube-infused fiber material is aligned substantially parallel in the outer layer.

45. A flame-resistant article comprising:

an outer layer having an exterior surface and comprising a carbon nanotube-infused fiber material;

wherein the carbon nanotube-infused fiber material comprises a plurality of carbon nanotubes and a fiber material; and

an interior layer integral to the outer layer and comprising a textile that lacks carbon nanotubes.

46. The flame-resistant article of claim 45, wherein the outer layer further comprises a plurality of textile fibers lacking carbon nanotubes that are woven with the carbon nanotube-infused fiber material.

47. The flame-resistant article of claim 46, wherein the plurality of textile fibers comprise elastomeric fibers.

48. The flame-resistant article of claim 45, wherein the outer layer further comprises an elastomeric matrix.

49. The flame-resistant article of claim 45, wherein the plurality of carbon nanotubes are greater than about 50 μ

m in length.

50. The flame-resistant article of claim 45, wherein the outer layer has a thickness ranging between about 0.005″

and about 0.1″

.

51. The flame-resistant article of claim 45, wherein the carbon nanotube-infused fiber material is aligned substantially parallel to the exterior surface.

52. The flame-resistant article of claim 51, wherein the plurality of carbon nanotubes are aligned substantially parallel to the longitudinal axis of the fiber material.

53. The flame-resistant article of claim 51, wherein each fiber of the carbon nanotube-infused fiber material is aligned substantially parallel in the outer layer.

54. The flame-resistant article of claim 45, wherein the fiber material is selected from the group consisting of carbon fibers, ceramic fibers, glass fibers, organic fibers, and combinations thereof.