CNT-INFUSED CERAMIC FIBER MATERIALS AND PROCESS THEREFOR

• US 20110168083A1
• Filed: 02/26/2010
• Published: 07/14/2011
• Est. Priority Date: 01/03/2007
• Status: Abandoned Application

• Current Assignee: Applied NanoStructured Solutions, LLC (Cabot Corporation)
• Original Assignee: Lockheed Martin Corporation (Martin Marietta Corporation)
• Inventors: GARDNER, Slade H., SHAH, Tushar K., MALECKI, Harry C., ALBERDING, Mark R.
• Application Number:
  US12/714,379
• Publication Number:
  US 20110168083A1
• Time in Patent Office: Days
• US Class Current: 118/33
• 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 2202/08 Aligned nanotubes
• CPC Class Codes: C01B 2202/34 Length
• CPC Class Codes: C01B 32/16 Preparation
• CPC Class Codes: C01B 32/162 characterised by catalysts
• CPC Class Codes: C04B 2235/3203 Lithium oxide or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/5224 Alumina or aluminates
• CPC Class Codes: C04B 2235/5236 Zirconia
• 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 2235/5252 having a specific pre-form
• CPC Class Codes: C04B 2235/526 characterised by the length of the fibers
• CPC Class Codes: C04B 2235/5288 Carbon nanotubes
• CPC Class Codes: C04B 2235/5436 micrometer sized, i.e. from 1 to 100 micron
• CPC Class Codes: C04B 2235/614 Gas infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 2235/616 Liquid infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 35/117 Composites
• CPC Class Codes: C04B 35/185 Mullite 3Al2O3-2SiO2
• CPC Class Codes: C04B 35/19 Alkali metal aluminosilicates, e.g. spodumene
• CPC Class Codes: C04B 35/565 : based on silicon carbide
• CPC Class Codes: C04B 35/584 : based on silicon nitride
• CPC Class Codes: C04B 35/62844 : Coating fibres
• CPC Class Codes: C04B 35/62847 : with oxide ceramics
• CPC Class Codes: C04B 35/62852 : Alumina or aluminates
• CPC Class Codes: C04B 35/62873 : Carbon
• CPC Class Codes: C04B 35/62884 : by gas phase techniques
• CPC Class Codes: C04B 35/62886 : by wet chemical techniques
• CPC Class Codes: C04B 35/62892 : with a coating layer consisting of particles
• CPC Class Codes: C04B 35/62897 : Coatings characterised by their thickness
• CPC Class Codes: C04B 35/632 : Organic additives
• CPC Class Codes: C04B 35/80 : Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C08J 5/0405 : with inorganic fibres
• CPC Class Codes: C08J 5/06 : using pretreated fibrous materials
• CPC Class Codes: C08J 5/248 : using pre-treated fibres
• CPC Class Codes: Y10T 428/292 : In coating or impregnation

Abstract

A composition includes a carbon nanotube (CNT)-infused ceramic fiber material, wherein the CNT-infused ceramic fiber material includes: a ceramic fiber material of spoolable dimensions; and carbon nanotubes (CNTs) bonded to the ceramic fiber material. The CNTs are uniform in length and uniform in distribution. A continuous CNT infusion process includes (a) disposing a carbon-nanotube forming catalyst on a surface of a ceramic fiber material of spoolable dimensions; and (b) synthesizing carbon nanotubes on the ceramic fiber material, thereby forming a carbon nanotube-infused ceramic fiber material.

Claims

1. A system for the continuous production of carbon nanotubes on a ceramic fiber material comprising:

a catalyst application station comprising a colloidal solution of CNT growth catalyst nanoparticles; and

a CNT growth station comprising at least one purge zone and a growth chamber;

said growth station adapted for CNT growth on the ceramic fiber material by continuously feeding the ceramic fiber material through the growth station;

said system being capable of reel to reel growth of CNTs on the ceramic fiber material continuously by providing a payout bobbin and an uptake bobbin;

said ceramic fiber material being provided in spoolable form.

2. The system of claim 1, wherein said CNT growth station is open to, but separated from the outside environment by the use of an inert gas flow.

3. The system of claim 1 further comprising a payout and tensioner station.

4. The system of claim 1 further comprising a fiber spreading station.

5. The system of claim 1 further comprising a plasma station adapted to roughen the surface of the ceramic fiber material.

6. The system of claim 1 further comprising a barrier coating station adapted to conformally deposit a barrier coating on said ceramic fiber material;

said barrier coating having CNT growth catalyst embedded therein.

7. The system of claim 5, wherein the catalyst application station and barrier coating station are combined.

8. The system of claim 5, wherein said barrier coating station comprises at least one of spin-on glass, an alumina, a silane, an alkoxysilane, and a liquid ceramic.

9. The system of claim 1 further comprising a fiber sizing removal station.

10. The system of claim 1 further comprising a resin application station downstream of said CNT growth station.

11. The system of claim 1 which is capable of operating speeds in a range from between about 0.5 ft/min to about 36 ft/min.

12. The system of claim 1 further comprising a controller station;

said controller station capable of controlling at least one of linespeed, an inert gas flow rate, a carbon feedstock flowrate, temperature in the CNT growth chamber, temperature of the inert gas, and temperature of the carbon feedstock gas.

13. The system of claim 1, wherein a material residence time in the growth chamber between about 5 to about 30 seconds produces CNTs having a length between about 1 micron to about 10 microns.

14. The system of claim 1, wherein a material residence time in the growth chamber of about 30 to about 180 seconds produces CNTs having a length between about 10 microns to about 100 microns.

15. The system of claim 1, wherein a material residence time in the growth chamber of about 180 to about 300 seconds produces CNTs having a length between about 100 microns to about 500 microns.