CNT-tailored composite air-based structures

• US 8,662,449 B2
• Filed: 11/23/2010
• Issued: 03/04/2014
• 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): Dinh, Tien
• Assistant Examiner(s): BENEDIK, JUSTIN M
• Application Number:
  US12/953,425
• Publication Number:
  US 20110133031A1
• Time in Patent Office: 1,197 Days
• Field of Search: 244/1.A, 244/133, 244/123.1, 244/119
• US Class Current: 244/121
• 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 air-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. An apparatus comprising:

a structure configured to carry a load on an aircraft, the structure comprising;

a first material comprising a plurality of carbon nanotubes (CNTs) that are bonded to substrate fibers thereby forming CNT-infused fibers that are distributed within a matrix material thereby imparting a first functionality to the structure, the first functionality selected from tensile strength, compressive strength, shear strength, and flexural strength; and

a second material, different from the first material, the second material comprising CNT-infused fibers imparting a second functionality to the structure, the second functionality selected from damage sensing, de-icing, crack resistance, electromagnetic interference shielding, lightning strike protection, and radar absorption.

2. The apparatus of claim 1, wherein the CNT-infused fibers comprise CNTs grown on the fibers.

3. The apparatus of claim 1, wherein a CNT loading of the second material is between 0% and 2%.

4. The apparatus of claim 3, wherein the second functionality is damage sensing.

5. The apparatus of claim 1, wherein a CNT loading of the second material is between 2% and 5%.

6. The apparatus of claim 5, wherein the second functionality is de-icing.

7. The apparatus of claim 5, wherein the second functionality is crack resistance.

8. The apparatus of claim 1, wherein a CNT loading of the first material is between 5% and 40%.

9. The apparatus of claim 8, wherein the second functionality is electromagnetic interference shielding.

10. The apparatus of claim 8, wherein the second functionality is lightning strike protection.

11. The apparatus of claim 1, wherein a CNT loading of the second material is a gradient.

12. The apparatus of claim 11, wherein the second functionality is radar absorption.

13. The apparatus of claim 1, wherein the structure is a fuselage.

14. The apparatus of claim 13, wherein the fuselage comprises:

one or more panels comprising the first material wherein the first functionality comprises tensile strength;

an outer layer over the one or more panels and comprising the second material wherein the second functionality comprises electromagnetic interference shielding and lightning strike protection;

a skin over the outer layer and comprising a third material comprising CNT-infused fibers with a CNT loading between 0% and 2%, imparting a functionality of damage sensing; and

a middle layer disposed between the skin and the one or more panels and comprising a fourth material comprising CNT-infused fibers with a CNT loading, imparting a functionality of de-icing.

15. The apparatus of claim 1, wherein the structure is a nose cone.

16. The apparatus of claim 1, wherein the structure is an aircraft wing.

17. The apparatus of claim 1, wherein the structure is a propeller.

18. The apparatus of claim 1, wherein the structure is a helicopter rotor blade.

19. The apparatus of claim 1, wherein the structure is a portion of an aircraft engine.

20. The apparatus of claim 1, wherein the structure is a portion of a weather balloon instrument.

21. A method comprising:

providing a load-carrying structure for use with an aircraft, the structure comprising;

a first material comprising a plurality of carbon nanotubes (CNTs) that are bonded to substrate fibers thereby forming CNT-infused fibers that are distributed within a matrix material thereby imparting a first functionality to the structure, the first functionality selected from tensile strength, compressive strength, shear strength, and flexural strength; and

a second material different from the first material, the second material comprising CNT-infused fibers imparting a second functionality to the structure, the second functionality selected from damage sensing, de-icing, crack resistance, electromagnetic interference shielding, lightning strike protection, and radar absorption.

22. The method of claim 21, wherein the first material and the second material overlap.

23. The method of claim 21, further comprising:

determining the first functionality; and

selecting a CNT loading of the first material based on the first functionality.

24. The method of claim 21, further comprising:

determining the second functionality; and

selecting a CNT loading of the second material based on the second functionality.