Dispersion of carbon enhanced reinforcement fibers in aqueous or non-aqueous media

• US 9,506,194 B2
• Filed: 09/04/2013
• Issued: 11/29/2016
• Est. Priority Date: 09/04/2012
• Status: Active Grant

• Current Assignee: Owens Corning Intellectual Capital, LLC (Owens Corning)
• Original Assignee: Ocv Intellectual Capital, Llc (Owens Corning)
• Inventors: Schweiger, Scott William, Rinne, Stephanie Ann, Adzima, Leonard Joseph
• Primary Examiner(s): Halpern, Mark
• Application Number:
  US14/424,130
• Publication Number:
  US 20150299956A1
• Time in Patent Office: 1,182 Days
• Field of Search: 162/158
• US Class Current: 1/1
• CPC Class Codes: C03C 25/26 Macromolecular compounds or prepolymers
• CPC Class Codes: C03C 25/44 Carbon, e.g. graphite
• CPC Class Codes: D04H 1/4242 Carbon fibres
• CPC Class Codes: D04H 1/732 by fluid current, e.g. air-lay
• CPC Class Codes: D21H 13/50 Carbon fibres
• CPC Class Codes: D21H 15/02 characterised by configuration
• CPC Class Codes: D21H 17/00 Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
• CPC Class Codes: D21H 21/18 Reinforcing agents

Abstract

The general inventive concepts relate generally to carbon enhanced reinforcement (CER) fibers, and more particularly, to the controlled dispersion of CER fibers within aqueous or non-aqueous media. The general inventive concepts particularly relate to the controlled dispersion of CER fibers within aqueous or non-aqueous media for forming a nonwoven chopped CER fiber mat. The general inventive concepts also relate to the controlled dispersion of CNSs harvested from CER fibers within aqueous or non-aqueous media for forming a nonwoven CNS mat. Methods for dispersing the CNSs or the CER fibers in aqueous or non-aqueous media are also provided.

Claims

1. A method of controlling the dispersion of carbon enhanced reinforcement fibers in an aqueous or non-aqueous solution, said method comprising:

forming one or more carbon enhanced reinforcement fibers comprising a plurality of carbon nanostructures disposed on a fiber substrate;

chopping said carbon enhanced reinforcement fibers to form chopped carbon enhanced reinforcement fibers; and

forming a slurry by adding a plurality of said chopped carbon enhanced reinforcement fibers into a whitewater solution,

wherein said whitewater solution comprises at least one of (i) an oil dispersion medium, (ii) a viscosity modifier, (iii) a biocide, (iv) a de-foaming agent, and (v) a surfactant package, and

wherein said carbon enhanced reinforcement fibers are homogenously dispersed in said slurry.

2. The method of claim 1, wherein said carbon enhanced reinforcement fibers comprise a plurality of carbon nanostructures grown in situ on a fiber.

3. The method of claim 1, wherein said whitewater solution comprises an oil dispersion medium and a surfactant package.

4. The method of claim 3, wherein said surfactant package comprises at least one non-ionic surfactant.

5. The method of claim 3, wherein said surfactant package comprises at least one of Surfynol®

465, Nanosperse AQ, Triton®

X-100, Tetronic®

90R4, Pluronic®

10R5, and polyvinyl alcohol.

6. The method of claim 3, wherein said surfactant package comprises at least two surfactants.

7. The method of claim 1, further comprising aerating said whitewater solution.

8. The method of claim 1, wherein said carbon nanostructures are functionalized to enhance the solubility of the carbon enhanced reinforcement fibers in the aqueous or non-aqueous medium.

9. The method of claim 8, wherein said carbon nanostructures are functionalized by interacting the carbon nanostructures with an oxidizing agent.

10. The method of claim 8, wherein said oxidizing agent comprises at least one of potassium persulfate, potassium permanganate, peroxides, and ozone.

11. The method of claim 1, wherein said fiber substrate is formed from at least one of glass, carbon, polymer, woven fabric, and nonwoven fabric.

12. The method of claim 11, wherein said fiber substrate comprises glass.

13. The method of claim 1, wherein said carbon enhanced reinforcement fibers include 10-20% by weight carbon nanostructure loading.

14. The method of claim 1, wherein said oil dispersion medium is mineral oil.