Articles and Methods for Manufacture of Nanostructure Reinforced Composites

• US 20160340482A1
• Filed: 02/04/2015
• Published: 11/24/2016
• Est. Priority Date: 02/04/2014
• Status: Abandoned Application

• Current Assignee: N12 Technologies, Inc. (NAWATechnologies SA)
• Original Assignee: N12 Technologies, Inc. (NAWATechnologies SA)
• Inventors: Williams, Ryan, Degtiarov, David, Gouldstone, Christopher, Jarosz, Paul, Kennedy, Thomas J. III
• Application Number:
  US15/116,643
• Publication Number:
  US 20160340482A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29C 70/081 Combinations of fibres of continuous or substantial length and short fibres
• CPC Class Codes: B29C 70/62 the filler being oriented during moulding for short fibres B29C70/14
• CPC Class Codes: B29K 2105/0872 Prepregs
• CPC Class Codes: B29K 2105/124 Nanofibers
• CPC Class Codes: B32B 2260/023 Two or more layers
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/103 Metal fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2307/748 Releasability
• CPC Class Codes: B32B 2307/762 Self-repairing, self-healing
• CPC Class Codes: B32B 2457/00 Electrical equipment
• 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 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/06 permitting easy separation
• 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: C04B 2235/48 Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins
• 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 2235/5288 : Carbon nanotubes
• CPC Class Codes: C04B 35/80 : Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C04B 35/83 : Carbon fibres in a carbon matrix
• CPC Class Codes: C04B 37/00 : Joining burned ceramic articles with other burned ceramic articles or other articles by heating soldering and welding materials B23K35/24; laminated products B32B, E04C
• CPC Class Codes: C08J 2300/00 : Characterised by the use of unspecified polymers
• CPC Class Codes: C08J 5/005 : Reinforced macromolecular compounds with nanosized materials, e.g. nanoparticles, nanofibres, nanotubes, nanowires, nanorods or nanolayered materials
• CPC Class Codes: C08J 5/04 : Reinforcing macromolecular compounds with loose or coherent fibrous material
• CPC Class Codes: C08J 5/24 : Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
• CPC Class Codes: C23C 16/44 : characterised by the method of coating C23C16/04 takes precedence
• CPC Class Codes: Y10S 977/742 : Carbon nanotubes, CNTs
• CPC Class Codes: Y10S 977/842 : for carbon nanotubes or fullerenes

Abstract

An article includes a hybrid nanocomposite product, which includes a nanostructure array and a resin matrix contained among and/or around the nanostructure array. The array/matrix is placed in between layers of dry or resin-infused fiber composite to permit formation of a composite structure. The nanostructure array and/or the resin matrix may be disposed in an abutting relationship with other layers of a composite. The array/matrix can provide reinforcement of the composite in the z-direction. Transfer of resin into dry fiber forms may be provided when the array/matrix acts as a resin transfer medium. Nanostructure arrays with a resin matrix can be prepared to form a resin film product. Methods are presented for infusing composites via resin-transfer molding (RTM), vacuum-assisted resin transfer molding (VARTM), resin film infusion (RFI), or injection molding wherein a resin matrix film substantially maintains alignment and position of the nanostructure array during the infusion process.

Claims

1. An article, comprising:

a nanostructure array with a long axes of the nanostructures being substantially aligned relative to each other from top to bottom; and

a resin matrix contained among, interior to the nanostructures themselves and/or around the nanostructure array, the resin matrix being configured to maintain the position and alignment of the nanostructures relative to each other.

2. The article according to claim 1, wherein at least some of the nanostructure array includes one or more of a length of at least 1 micron, a diameter less than 100 nm, or a density of at least 10⁸/cm².

4. The article according to claim 1, wherein the resin matrix includes one or more of a nano-particle that enhances the conductivity of resin matrix, a conducting polymer, an insulating polymer, a self-healing agent, a ceramic precursor, a ceramic material or a precursor to a graphite as in a carbon-carbon composite.

11. The article according to claim 1, wherein the resin matrix comprises a polythiophene, a polypyrrole, a polyacetylene, a polyphenylene, polypyrrole, poly(3,4-ethylenedioxythiophene) (PEDOT), poly(thiophene-3-acetic acid) (PTAA), or copolymers thereof.

12. The article according to claim 1, wherein the resin matrix comprises at least one of TEFLON®

, poly(glycidyl methacrylate), poly(maleic anhydride-alt-styrene), poly[ maleic anhydride-co-dimethyl acrylamide-co-di( ethylene glycol) divinyl ether], poly(furfuryl methacrylate), poly(vinyl pyrrolidone), poly(para-xylylene), poly(dimethylaminomethyl styrene), poly(propargyl methacrylate), poly(methacrylic acid-co-ethyl acrylate), poly(perfluoroalkyl ethyl methacrylate), poly(perfluorodecyl acrylate), poly(trivinyltrimethoxycyclotrisiloxane), poly(furfuryl methacrylate), poly(cyclohexyl methacryateco-ethylene glycol dimethacrylate), poly(pentafluorophenyl methacrylate), poly(pentafluorophenyl methacrylate co-ethylene glycol diacrylate), poly(methacrylic acid-co-ethylene glycol dimethacrylate), poly(methyl methacrylate), poly(3,4-ethylenedioxythiophene), epoxides, phenolics, polyesters, polyurethanes, bis-maleimides, polyimides and silicones.

13. The article according to claim 1, wherein the resin matrix comprises one or more of a B-stage resin or partially cured resin, a hardener, cross-linking agent, coefficient of thermal expansion matching agent, erosion resistance agent, toughener, accelerator, or flame retardant.

15. The article according to claim 1, wherein the resin matrix comprises a material that chemically reacts to form liquid or gaseous species that dissolves in or is removed from the final cured composite.

16. The article according to claim 1, further comprising at least one removable backing or release material associated with the nanostructure array that could be used for shipping and then removed for supporting the nanostructure array.

21. The article according to claim 1, wherein the nanostructures include one or more of a volume fraction of the nanostructures within the article is at least between 0.1% and 78%, an average diameter between 1 nm and 100 nm, or an average distance between the nanostructures is less than between 5 nm and 100 nm.

28. The article according to claim 1, further comprising a power supply connection to permit the nanostructures to be connected to a power supply and used as electrical resistance heaters to assist the resin curing reaction.

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31. A method of producing a material, comprising:

providing a nanostructure array, with the long axes of the nanostructures being substantially aligned relative to each other; and

providing the nanostructure array with a resin matrix comprising a polymeric material; and

maintaining the position and alignment of the nanostructures relative to each other with the resin matrix.

41. The method according to claim 31, further comprising maintaining the alignment of the nanostructure array during provision of the resin matrix.

44. The method according to claim 31, further comprising providing a resin matrix with a thickness that deviates from a height of the nanostructure array between 1% and 1000%.

45. The method according to claim 31, wherein the resin matrix is one or more of heated, placed under vacuum or applied pressure to assist in adhesion between the resin matrix and nanostructure array.

49. The method according to claim 31, wherein the resin matrix is infused into the nanostructure array through capillary action.

51. The method according to claim 31, wherein the resin matrix is introduced to the nanostructure array via one or more of an aerosol spray or resin Chemical Vapor Deposition (CVD).

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52. (canceled)

53. A method of producing a material, comprising:

fabricating a composite with a nanostructure array in a resin matrix, where the nanostructures are aligned and maintained in position and alignment relative to each other with the resin matrix, by placing the nanostructure array with the resin matrix in alternating layers with a sequence of fiber layers.

59. The method according to claim 53, wherein the nanostructure array substantially penetrates one or more of the abutting fiber layers above or below, so as to fix or anchor the position and alignment of the nanostructures.

71. The method according to claim 53 wherein the composite assembly is one or more of heated at high temperature to form a ceramic material or heated in a reducing atmosphere to form a graphitic structure in a carbon-carbon composite.

73. The method according to claim 53, further comprising detecting a status of the material using the nanostructures.

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