CNS-infused carbon nanomaterials and process therefor

• US 9,005,755 B2
• Filed: 06/05/2012
• Issued: 04/14/2015
• Est. Priority Date: 01/03/2007
• Status: Expired due to Fees

• Current Assignee: Applied NanoStructured Solutions, LLC (Cabot Corporation)
• Original Assignee: Applied NanoStructured Solutions, LLC (Cabot Corporation)
• Inventors: Ledford, Jordan T., Laszewski, Matthew R., Malecki, Harry C.
• Primary Examiner(s): Pierce, Jeremy R
• Application Number:
  US13/489,366
• Publication Number:
  US 20120263935A1
• Time in Patent Office: 1,043 Days
• Field of Search: 428/293.4, 428/296.7, 428/368, 428/370, 442/188, 977/742, 977/750, 977/752, 977/843
• US Class Current: 428/368
• CPC Class Codes: D02G 3/16 Yarns or threads made from mineral substances
• CPC Class Codes: D03D 15/00 Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
• CPC Class Codes: D03D 15/275 Carbon fibres
• CPC Class Codes: D04H 1/4242 Carbon fibres
• CPC Class Codes: D04H 1/76 otherwise than in a plane, e.g. in a tubular way
• CPC Class Codes: D10B 2101/122 Nanocarbons
• CPC Class Codes: Y10T 428/249928 Fiber embedded in a ceramic, glass, or carbon matrix
• CPC Class Codes: Y10T 428/249938 Composite or conjugate fiber [e.g., fiber contains more than one chemically different material in monofilament or multifilament form, etc.]
• CPC Class Codes: Y10T 428/292 In coating or impregnation
• CPC Class Codes: Y10T 428/2924 Composite

Abstract

A composition includes a carbon nanotube (CNT) yarn or sheet and a plurality of carbon nanostructures (CNSs) infused to a surface of the CNT yarn or sheet, wherein the CNSs are disposed substantially radially from the surface of the CNT yarn or outwardly from the sheet. Such compositions can be used in various combinations in composite articles.

Claims

1. A composition comprising:

a carbon nanotube (CNT) yarn;

a plurality of carbon nanostructures (CNSs) infused to a surface of the carbon nanotube yarn;

wherein the CNSs are disposed substantially radially from the surface of the the CNT yarn;

wherein the CNSs comprise a carbon nanotube array that includes individual carbon nanotubes, branched carbon nanotubes, and crosslinked carbon nanotubes in a random distribution with one another; and

a barrier coating on the CNT yarn from which the CNSs are grown, the barrier coating comprising a material selected from the group consisting of an alkoxysilane, a methylsiloxane, and alumoxane, spin on glass, and glass nanoparticles.

2. The composition of claim 1, wherein the CNT yarn comprises single-walled carbon nanotubes, double-walled carbon nanotubes, multi-walled carbon nanotubes, or mixtures thereof.

3. The composition of claim 2, wherein the CNT yarn comprises single-walled carbon nanotubes.

4. The composition of claim 1, wherein the plurality of CNSs comprise elements of single-walled carbon nanotubes, double-walled carbon nanotubes, multi-walled carbon nanotubes, or mixtures thereof.

5. The composition of claim 1, further comprising a matrix material to provide a composite.

6. The composition of claim 5, wherein the matrix material comprises one selected from the group consisting of a thermoplastic resin, a thermoset resin, a further carbon phase, a ceramic and a metal.

7. An article comprising a plurality of carbon nanotube (CNT) yarns in a bundle, each of the plurality of CNT yarns of the bundle comprising a plurality of carbon nanostructures (CNSs) infused to a surface of each of the plurality CNT yarns, the CNSs being disposed substantially radially from the surfaces of each of the plurality of CNT yarns;

wherein the CNSs comprise a carbon nanotube array that includes individual carbon nanotubes, branched carbon nanotubes, and crosslinked carbon nanotubes in a random distribution with one another; and

a barrier coating on the CNT yarns from which the CNSs are grown, the barrier coating comprising a material selected from the group consisting of an alkoxysilane, a methylsiloxane, and alumoxane, spin on glass, and glass nanoparticles.

8. A composition comprising:

a carbon nanotube sheet;

a plurality of carbon nanostructures infused to at least one surface of the carbon nanotube sheet, the carbon nanostructures being disposed substantially outward from the at least one surface of the carbon nanotube sheet;

wherein the carbon nanostructures comprise a carbon nanotube array that includes individual carbon nanotubes, branched carbon nanotubes, and crosslinked carbon nanotubes in a random distribution with one another; and

a barrier coating on the carbon nanotube sheet from which the carbon nanostructures are grown, the barrier coating comprising a material selected from the group consisting of an alkoxysilane, a methylsiloxane, an alumoxane, spin on glass, and glass nanoparticles.

9. The composition of claim 8, wherein the carbon nanotube sheet comprises single-walled carbon nanotubes, double-walled carbon nanotubes, multi-walled carbon nanotubes, or mixtures thereof.

10. The composition of claim 9, wherein the carbon nanotube sheet comprises single-walled carbon nanotubes.

11. The composition of claim 8, wherein the carbon nanotube array comprises elements of single-walled carbon nanotubes, double-walled carbon nanotubes, multi-walled carbon nanotubes, or mixtures thereof.

12. The composition of claim 8, further comprising a matrix material to provide a composite.

13. The composition of claim 12, wherein the matrix material comprises one selected from the group consisting of a thermoplastic resin, a thermoset resin, a further carbon phase, a ceramic and a metal.

14. A multilayered article comprising:

a plurality of carbon nanotube sheets stacked upon one another, each carbon nanotube sheet comprising a plurality of carbon nanostructures infused to at least one surface of each of the plurality of carbon nanotube sheets;

wherein the carbon nanostructures comprise a carbon nanotube array that includes individual carbon nanotubes, branched carbon nanotubes, and crosslinked carbon nanotubes in a random distribution with one another; and

a barrier coating on the carbon nanotube sheets from which the carbon nanostructures are grown, the barrier coating comprising a material selected from the group consisting of an alkoxysilane, a methylsiloxane, an alumoxane, spin on glass, and glass nanoparticles.