Polyurethane polymers and compositions made using discrete carbon nanotube molecular rebar

Patent metadata

Field	Value
Publication number	US-10253162-B2
Application number	US-201715601438-A
Country	US
Kind code	B2
Filing date	May 22, 2017
Priority date	Jul 8, 2012
Publication date	Apr 9, 2019
Grant date	Apr 9, 2019

Abstract

In various embodiments a urethane/molecular rebar formulation comprising a specific composition is disclosed. The composition comprises a urethane polymer or prepolymer/discrete carbon nanotube formulation. Utility of the urethane/molecular rebar composition includes improved foams and adhesives.

First claim

The invention claimed is:

1. A foam comprising the reaction product of at least one urethane based polymer or pre-polymer and at least a portion of discrete oxidized multiwall carbon nanotubes having an original aspect ratio of from about 10 to about 500 wherein the retained aspect ratio of the discrete oxidized carbon nanotubes in the reaction product is at least about 60% or greater of the original aspect ratio; and
wherein the foam at a given density has one or more of the following characteristics: increased rigidity, increased strength, improved ability to form foams, improved crush resistance, or improved static electricity transmission, compared to a formulation without said portion of discrete oxidized multiwall carbon nanotubes.

2. The foam of claim 1 where the portion of discrete oxidized carbon nanotubes are open ended.

3. The foam of claim 1 further comprising at least one polymer other than the at least one urethane based polymer or prepolymer.

4. The foam of claim 1 wherein the portion of discrete oxidized carbon nanotubes are further functionalized.

5. The foam of claim 1 wherein the discrete oxidized carbon nanotubes have a residual metals level of less than about 4% by weight of the carbon nanotubes.

6. The foam of claim 3 wherein the at least one polymer other than the at least one urethane based polymer or prepolymer is selected from the group consisting of vinyl polymers; fluorinated polymers; conductive polymers; polymers derived from natural sources; cellulosic based materials; polyethers; polyesters; polyamides; and mixtures thereof.

7. The foam of claim 1 wherein the discrete oxidized carbon nanotubes comprise from about 0.1 to about 90 weight percent of the composition.

8. The foam of claim 1 wherein the portion of discrete oxidized carbon nanotubes are further functionalized and open ended.

9. The foam of claim 1 comprising additional inorganic structures.

10. The foam of claim 9 wherein the additional inorganic structures comprise elements selected from the groups two through fourteen of the Periodic Table of Elements.

11. The foam of claim 10 wherein the additional inorganic structures are selected from the group consisting of silver, gold, silicon, vanadium, titanium, chromium, iron, manganese, tin, nickel, palladium, platinum, cobalt, aluminum, gallium, germanium, indium, antimony, copper and zinc, cadmium, mercury, and mixtures thereof including oxides and other derivatives.

12. The foam of claim 10 wherein the additional inorganic structures are selected from the group consisting of zinc, zinc oxides, and other zinc derivatives.

13. The foam of claim 9 wherein the additional inorganic structures comprise non-fiber carbon structures.

14. The foam of claim 9 wherein the non-fiber carbon structures comprise components selected from the group consisting of carbon black, graphite, graphene, oxidized graphene, fullerenes and mixtures thereof.

15. A foam comprising the reaction product of at least one urethane based polymer or pre-polymer and at least a portion of discrete oxidized multiwall carbon nanotubes having an original aspect ratio of from about 10 to about 500, wherein the portion of discrete oxidized carbon nanotubes are open ended, and wherein the discrete oxidized carbon nanotubes have a residual metals level of less than about 4% by weight of the carbon nanotubes.

16. The foam of claim 15 further comprising at least one polymer other than the at least one urethane based polymer or prepolymer.

17. The foam of claim 16 wherein the at least one polymer other than the at least one urethane based polymer or prepolymer is selected from the group consisting of vinyl polymers; fluorinated polymers; conductive polymers; polymers derived from natural sources; cellulosic based materials; polyethers; polyesters; and mixtures thereof.

18. A foam comprising the reaction product of at least one urethane based polymer or pre-polymer and at least a portion of discrete oxidized multiwall carbon nanotubes having an original aspect ratio of from about 10 to about 500, wherein the urethane based polymer or prepolymer comprises at least one polyol and/or at least one isocyanate, and wherein the discrete oxidized carbon nanotubes are polymerized with the urethane polymer or pre-polymer and wherein the retained aspect ratio of the discrete oxidized carbon nanotubes in the reaction product is at least about 60% or greater of the original aspect ratio.

19. The foam of claim 18 wherein the urethane based polymer or pre-polymer comprises at least one polyol.

20. The foam of claim 18 wherein the isocyanate comprises aromatic or aliphatic groups.

Assignees

• Molecular Rebar Design Llc

Inventors

• Bosnyak Clive P
• Swogger Kurt W

Classifications

• C08J2300/22

  Thermoplastic resins · CPC title

• C08K9/04

  Ingredients treated with organic substances {(treated with macromolecular compounds C08K9/08)} · CPC title

• C08J2400/22

  Thermoplastic resins · CPC title

• C08J9/0076

  Nanofibres · CPC title

• C08J5/042

  with carbon fibres · CPC title