CNT-tailored composite sea-based structures

• US 8,601,965 B2
• Filed: 11/23/2010
• Issued: 12/10/2013
• 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: Shah, Tushar K., Alberding, Mark R., Malecki, Harry C., Markkula, Samuel J., Hughes, John Anthony, Kline, Shawn C.
• Primary Examiner(s): Olson, Lars A
• Application Number:
  US12/953,427
• Publication Number:
  US 20110132245A1
• Time in Patent Office: 1,113 Days
• Field of Search: 114/90, 252/70, 252/71, 252/182.32, 473/324, 977/742, 428/292.1, 428/293.4, 428/297.4, 324/693
• US Class Current: 114/90
• CPC Class Codes: B64G 1/10 Artificial satellites; Systems of such satellites; Interplanetary vehicles space shuttles B64G1/14
• CPC Class Codes: B64G 1/428 Power distribution and management
• CPC Class Codes: B64G 1/50 for temperature control
• CPC Class Codes: B64G 1/54 Protection against radiation
• CPC Class Codes: B64G 1/546 shielding electronic equipment
• CPC Class Codes: B64G 1/56 Protection against meteoroids or space debris
• 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 32/16 Preparation
• CPC Class Codes: C08J 5/06 using pretreated fibrous materials
• CPC Class Codes: C22C 2026/002 Carbon nanotubes
• CPC Class Codes: C22C 49/14 characterised by the fibres or filaments
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles

Abstract

An apparatus having a composite sea-based structure with a first carbon nanotube infused material and a second carbon nanotube infused material. The first and second carbon nanotube infused materials each having a range of carbon nanotube loading selected to provide different functionalities.

Claims

1. A composite structure comprising:

a matrix material;

a first carbon nanotube infused material disposed within a first portion of the matrix material imparting a first functionality comprising at least one of tensile strength, compressive strength, shear strength, flexural strength, crack resistance, and thermal conductivity; and

a second carbon nanotube infused material disposed within a second portion of the matrix material imparting a second functionality comprising at least one of de-icing, electromagnetic interference shielding, lightning strike protection, bio-fouling prevention, and radar absorption.

2. The composite structure of claim 1, further comprising a third carbon nanotube infused material disposed within a third portion of the matrix material imparting a third functionality comprising at least one of electrical resistance, damage sensing, de-icing, electromagnetic interference shielding, lightning strike protection, bio-fouling prevention, and radar absorption, wherein:

the first carbon nanotube infused material and the first portion of the matrix material form a first layer;

the second carbon nanotube infused material and the second portion of the matrix material form a second layer disposed on one side of the first layer; and

the third carbon nanotube infused material and the third portion of the matrix material form a third layer on the other side of the first layer.

3. The composite structure of claim 1, wherein the second carbon nanotube infused material forms a surface layer over the first carbon nanotube infused material.

4. The composite structure of claim 1, wherein:

a carbon nanotube loading of the second carbon nanotube infused material is approximately 0%;

the second carbon nanotube infused material is located on an exterior surface that may contact an overhead power line; and

the second functionality comprises electrical resistance.

5. The composite structure of claim 1, wherein:

a carbon nanotube loading of the second carbon nanotube infused material is in the range of 0-2%;

the second carbon nanotube infused material is located on the structure on an outer surface of an area where it is desired to detect cracks, and wherein

the second functionality comprises damage sensing.

6. The composite structure of claim 1, wherein:

a carbon nanotube loading of the second carbon nanotube infused material is in the range of 2-5%;

the second carbon nanotube infused material is located on the structure on an outer surface of an area where it is desired to remove ice, and wherein

the second functionality comprises de-icing.

7. The composite structure of claim 1, wherein a carbon nanotube loading of the second carbon nanotube infused material is in the range of 5-40%.

8. The composite structure of claim 7, wherein:

the second carbon nanotube infused material is located on the structure in an area where it is desired to provide protection from electromagnetic interference; and

the second functionality comprises electromagnetic interference shielding.

9. The composite structure of claim 7, wherein:

the second carbon nanotube infused material is located on the structure where it is desired to provide protection from lightning strikes, and

the second functionality comprises lightning strike protection.

10. The composite structure of claim 7, wherein:

the second carbon nanotube infused material is located on the structure where it is desired to resist growth of organisms; and

the second functionality comprises bio-fouling prevention.

11. The composite structure of claim 1, wherein a carbon nanotube loading of the first carbon nanotube infused material is a gradient.

12. The composite structure of claim 1, wherein:

the second carbon nanotube infused material is located on an exterior surface; and

the second functionality comprises absorption of radar waves.

13. The composite structure of claim 1, comprising a sailboat mast that comprises a main spar comprising an inner lining comprising the second carbon nanotube infused material comprising a range of carbon nanotube loading in the range of 5-40%, wherein the second functionality comprises lightning strike protection.

14. The composite structure of claim 1, wherein the structure comprises one of a radar dome, a boat hull, a stringer, and a deck.

15. The composite structure of claim 3, wherein the second carbon nanotube infused material forms an outer layer of the composite structure.

16. The composite structure of claim 3, further comprising a hollow composite structure, wherein the second carbon nanotube infused material forms a lining of the hollow composite structure.

17. The composite structure of claim 1, comprising a sailboat mast that comprises a main spar having an upper portion comprising an outer layer of the second carbon nanotube infused material having a carbon nanotube loading in the range of 0-2%, inclusive, wherein the second functionality comprises electrical resistance.

18. The composite structure of claim 1, comprising a sailboat mast that comprises a skin comprising the second carbon nanotube infused material having a carbon nanotube loading in the range of 0-2%, inclusive, wherein the second functionality comprises damage sensing.

19. The composite structure of claim 1, comprising a hull that comprises an outer layer of the second carbon nanotube infused material having a carbon nanotube loading in the range of 5-40%, inclusive, wherein the second functionality comprises bio-fouling prevention.

20. The composite structure of claim 1, wherein at least one of the first and second carbon nanotube (CNT) infused materials comprises a CNT-infused fiber material.

21. The composite structure of claim 20, wherein the CNT-infused fiber material comprises one or more of continuous fibers, chopped fibers, and woven fibers.

22. A method of forming a composite structure, the method comprising the steps of:

embedding a first carbon nanotube infused material within a first portion of a matrix material so as to provide a first functionality comprising at least one of electrical resistance, tensile strength, compressive strength, shear strength, flexural strength, crack resistance, and thermal conductivity; and

embedding a second carbon nanotube infused material within a second portion of the matrix material so as to provide a second functionality comprising at least one of electrical resistance, damage sensing, de-icing, electromagnetic interference shielding, lightning strike protection, bio-fouling prevention, and radar absorption.

23. The method of claim 22, wherein the second portion of the matrix is formed as a surface layer over the first portion of the matrix.

24. The method of claim 22, further comprising the steps of:

selecting the second functionality; and

selecting a carbon nanotube loading of the second carbon nanotube infused material based on the second functionality.