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Patent Issued for Carbon Fiber Substrates Having Carbon Nanotubes Grown Thereon and Processes for Production

September 10, 2014



By a News Reporter-Staff News Editor at Journal of Engineering -- Applied NanoStructured Solutions, LLC (Baltimore, MD) has been issued patent number 8815341, according to news reporting originating out of Alexandria, Virginia, by VerticalNews editors.

The patent's inventors are Malet, Brandon K. (Baltimore, MD); Shah, Tushar K. (Fulton, MD).

This patent was filed on September 13, 2011 and was published online on August 26, 2014.

From the background information supplied by the inventors, news correspondents obtained the following quote: "Carbon nanotubes have been proposed to have utility in a number of applications due to their large effective surface area, mechanical strength, and thermal and electrical conductivity, among other properties. Many of these applications are particularly well suited for carbon nanotubes that have been grown on carbon fiber substrates. When grown on carbon fiber substrates, the properties of the carbon fiber substrates can be enhanced by the carbon nanotubes. For example, when carbon nanotubes are grown thereon, the mechanical strength of the carbon fiber substrates can be enhanced, and the carbon fiber substrates can become electrically conductive.

"In order to synthesize carbon nanotubes, a catalyst is generally needed to mediate carbon nanotube growth. Most often, the catalyst is a metal nanoparticle, particularly a zero-valent transition metal nanoparticle. A number of processes for synthesizing carbon nanotubes are known in the art including, for example, micro-cavity, thermal- or plasma-enhanced chemical vapor deposition (CVD) techniques, laser ablation, arc discharge, flame synthesis, and high pressure carbon monoxide (HiPCO) techniques. Generally, such processes for synthesizing carbon nanotubes can involve generating reactive gas phase carbon species under conditions suitable for carbon nanotube growth.

"Synthesis of carbon nanotubes on solid substrates can be carried out using many of these techniques. However, it is considered very difficult in the art to grow carbon nanotubes on carbon fiber substrates. It is believed that a primary impediment to this effort has been the difficulty of dissolving sufficiently high quantities of the reactive gas phase carbon species in metal nanoparticle catalysts to support carbon nanotube growth. Unlike other types of substrates (e.g., metals, glass and the like), carbon fiber substrates and the reactive gas phase carbon species are both composed of carbon, which greatly increases their interaction with one another and makes the reactive carbon species less likely to dissolve in the metal nanoparticles to facilitate carbon nanotube growth. In addition, unfavorable interactions between metal nanoparticles and carbon fiber substrates can further limit the ability of reactive gas phase carbon species to diffuse into the metal nanoparticles, further impeding carbon nanotube growth.

"In view of the foregoing, reliable processes for growing carbon nanotubes on carbon fiber substrates would be of substantial benefit in the art. The present disclosure satisfies this need and provides related advantages as well."

Supplementing the background information on this patent, VerticalNews reporters also obtained the inventors' summary information for this patent: "In some embodiments, carbon nanotube growth processes described herein include depositing a catalyst precursor on a carbon fiber substrate; depositing a non-catalytic material on the carbon fiber substrate; and after depositing the catalyst precursor and the non-catalytic material, exposing the carbon fiber substrate to carbon nanotube growth conditions so as to grow carbon nanotubes thereon. The carbon nanotube growth conditions convert the catalyst precursor into a catalyst that is operable for growing carbon nanotubes.

"In some embodiments, carbon nanotube growth processes described herein include depositing a catalyst precursor on a carbon fiber substrate that is free of a sizing agent; depositing a non-catalytic material on the carbon fiber substrate; after depositing the catalyst precursor and the non-catalytic material, exposing the carbon fiber substrate to carbon nanotube growth conditions so as to grow carbon nanotubes thereon; and transporting the carbon fiber substrate while the carbon nanotubes are being grown. The non-catalytic material is deposited prior to, after or concurrently with the catalyst precursor. The carbon nanotube growth conditions convert the catalyst precursor into a catalyst that is operable for growing carbon nanotubes.

"In some embodiments, carbon nanotube growth processes described herein include providing a carbon fiber substrate that is free of a sizing agent and has a barrier coating deposited thereon; depositing a catalyst precursor on the barrier coating; after depositing the catalyst precursor, exposing the carbon fiber substrate to carbon nanotube growth conditions so as to grow carbon nanotubes thereon; and transporting the carbon fiber substrate while the carbon nanotubes are being grown. The barrier coating is selected from the group consisting of an alkoxysilane, an alkylsiloxane, an alumoxane, alumina nanoparticles, spin on glass, glass nanoparticles, and combinations thereof. The carbon nanotube growth conditions convert the catalyst precursor into a catalyst that is operable for growing carbon nanotubes.

"In some embodiments, carbon fiber substrates having carbon nanotubes grown thereon by the present carbon nanotube growth processes are described herein.

"The foregoing has outlined rather broadly the features of the present disclosure in order that the detailed description that follows can be better understood. Additional features and advantages of the disclosure will be described hereinafter, which form the subject of the claims."

For the URL and additional information on this patent, see: Malet, Brandon K.; Shah, Tushar K.. Carbon Fiber Substrates Having Carbon Nanotubes Grown Thereon and Processes for Production. U.S. Patent Number 8815341, filed September 13, 2011, and published online on August 26, 2014. Patent URL: http://patft.uspto.gov/netacgi/nph-Parser?Sect1=PTO1&Sect2=HITOFF&d=PALL&p=1&u=%2Fnetahtml%2FPTO%2Fsrchnum.htm&r=1&f=G&l=50&s1=8815341.PN.&OS=PN/8815341RS=PN/8815341

Keywords for this news article include: Applied NanoStructured Solutions, Applied NanoStructured Solutions LLC, Carbon Nanotubes, Emerging Technologies, Fullerenes, Metal Nanoparticles, Nanotechnology.

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Source: Journal of Engineering


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