Composite carbon fibers

Patent metadata

Field	Value
Publication number	US-10894868-B2
Application number	US-201715850790-A
Country	US
Kind code	B2
Filing date	Dec 21, 2017
Priority date	Dec 21, 2017
Publication date	Jan 19, 2021
Grant date	Jan 19, 2021

Abstract

Provided is composite carbon fibers in which polymers having an amino containing group are covalently bonded to the surface of the carbon fiber. Aspects are also directed to processes for preparing the composite carbon fibers. Additional aspects are directed to reinforced composites comprising a resin matrix and the composite carbon fibers, and to processes of making such reinforced composites.

First claim

The invention claimed is:

1. A composite carbon fiber comprising a carbon fiber having an amino-containing polymer electro-grafted onto a surface thereof via an amino linkage directly from the carbon fiber surface to an amino-containing end group, amino-containing pendant group, amino-containing main group, or combination thereof of the polymer.

2. The composite carbon fiber of claim 1 , wherein the polymer is selected from the group consisting of polyamides, polyetheramides, polyimides, polyamide-imides, polyetherimides, polyethersulfones, polyetherethersulfones, and diene-based rubbers.

3. The composite carbon fiber of claim 1 , wherein the polymer is selected from the group consisting of amine-terminated polyimides, amine-terminated polyetherimides, amine-terminated polyether sulfones, amine-terminated diene-based rubbers, and amine-terminated polyamides.

4. The composite carbon fiber of claim 1 wherein the amino-containing end group or amino-containing pendant group comprises a primary or secondary amine.

5. The composite carbon fiber of claim 1 , wherein the polymer comprises a polyether block amide (PEBA) that is functionalized to include a terminal or pendant amino-containing group.

6. The composite carbon fiber of claim 1 , wherein the polymer comprises a polyimide.

7. The composite carbon fiber of claim 1 , wherein the polymer comprises an amino-terminated sulfone polymer having the general formula aryl-SO 2 -aryl.

8. The composite carbon fiber of claim 7 , wherein the polymer has the formula

where n is a number from about 2 to 500.

9. The composite carbon fiber of claim 1 , wherein the polymer comprises a diene rubber polymer comprising two or more monomers selected from the group consisting of butadiene, isoprene, acrylates, methacrylates, acrylonitriles, and ethylene-propylene dienes.

10. The composite carbon fiber of claim 1 , wherein the polymer is selected from the following:

where m and n are independently a number from about 2 to 500;

where the polymer backbone is terminated with one or more amino-containing groups, contains one or more amino-containing pendant groups, or a mixture thereof,
R is an alkyl group (C 1 -C 10 ), ether, ester, or aryl group; and n is a number from about 2 to 500;

where the polymer backbone is terminated with one or more amino-containing groups, contains one or more amino-containing pendant groups, or a mixture thereof, and n is a number from about 2 to 500;

where the polymer backbone is terminated with one or more amino-containing groups, contains one or more amino-containing pendant groups, or a mixture thereof, and n is a number from about 2 to 500;

where the polymer backbone is terminated with one or more amino-containing groups, contains one or more amino-containing pendant groups, or a mixture thereof, and n is a number from about 2 to 500;

where the polymer backbone is terminated with one or more amino-containing groups, contains one or more amino-containing pendant groups, or a mixture thereof, and n is a number from about 2 to 500;

where the polymer backbone is terminated with one or more amino-containing groups, contains one or more amino-containing pendant groups, or a mixture thereof, and n is a number from about 2 to 500; and

where m is a number from about 20 to 100, and n is a number from about 10 to 50.

11. The composite carbon fiber of claim 1 , wherein the amount of polymer covalently attached to the surface of the carbon fiber is from about 0.05 to 3 weight percent, based on the total weight of the composite carbon fiber.

12. The composite carbon fiber of claim 1 , wherein the amount of polymer covalently attached to the surface of the carbon fiber is from about 0.1 to 0.5 weight percent, based on the total weight of the composite carbon fiber.

13. The composite carbon fiber of claim 1 , wherein the polymer only has an amino group at the end of a backbone of the polymer, and the polymer does not include any amino-containing pendant groups.

14. A fiber reinforced composite comprising a plurality of carbon fibers, wherein each carbon fiber has an amino-containing polymer electro-grafted onto a surface thereof via an amino-containing end group or amino-containing pendant group of the polymer, and a resin matrix infused into the plurality of carbon fibers, wherein the fiber reinforced composite when cured exhibits an increase in fracture toughness from about 10 to 60% in comparison to an identical fiber reinforced composite with the exception that the surfaces of the plurality of carbon fibers do not include an amine-containing polymer electrografted to the surface of the plurality of carbon fibers.

15. The fiber reinforced composite according to claim 14 , wherein the fiber reinforced composite when cured exhibits an interlaminar strength of about 17 to 25 ksi as characterized by Short Beam Shear (SBS) testing.

16. The fiber reinforced composite of claim 14 , wherein the resin is selected from the group consisting of epoxy based resins, bismaleimide based resins, cyanate ester based resins, and phenolic based resins.

17. The fiber reinforced composite of claim 14 , wherein the polymer is selected from the group consisting of polyamides, polyetheramides, polyimides, polyamide-imides, polyetherimides, polyethersulfones, and diene-based rubbers.

18. The fiber reinforced composite of claim 14 , wherein the polymer is selected from the group consisting of the following:

where m and n are independently a number from about 2 to 500;

where the polymer backbone is terminated with one or more amino-containing groups, contains one or more amino-containing pendant groups, or a mixture thereof,
R is an alkyl group (C 1 -C 10 ), ether, ester, or aryl group; and n is a number from about 2 to 500;

where the polymer backbone is terminated with one or more amino-containing groups, contains one or more amino-containing pendant groups, or a mixture thereof, and n is a number from about 2 to 500;

where the polymer backbone is terminated with one or more amino-containing groups, contains one or more amino-containing pendant groups, or a mixture thereof, and n is a number from about 2

Assignees

• Hexcel Corp

Inventors

• Yurchenko Michael E

Classifications

• D01F11/14

  with organic compounds, e.g. macromolecular compounds · CPC title

• C08J2377/08

  from polyamines and polymerised unsaturated fatty acids · CPC title

• D06M14/36

  on to carbon fibres · CPC title

• C08J2377/12

  Polyester-amides · CPC title

• C08J2379/02

  Polyamines · CPC title