Fabric of continuous graphene fiber yarns from functionalized graphene sheets

Patent metadata

Field	Value
Publication number	US-10927478-B2
Application number	US-201815985045-A
Country	US
Kind code	B2
Filing date	May 21, 2018
Priority date	May 21, 2018
Publication date	Feb 23, 2021
Grant date	Feb 23, 2021

Abstract

Provided is a fabric comprising a layer of yarns combined (by weaving, braiding, knitting, or non-woven) to form the fabric wherein the yarns comprise one or a plurality of graphene-based long or continuous fibers. The long or continuous fiber comprises chemically functionalized graphene sheets that are chemically bonded with one another having an inter-planar spacing d002 from 0.36 nm to 1.5 nm as determined by X-ray diffraction and a non-carbon element content of 0.1% to 40% by weight, wherein the functionalized graphene sheets are substantially parallel to one another and parallel to the fiber axis direction and the fiber contains no core-shell structure, have no helically arranged graphene domains, and have a length no less than 0.5 cm and a physical density from 1.5 to 2.25 g/cm3. The graphene fiber typically has a thermal conductivity from 300 to 1,600 W/mK, an electrical conductivity from 600 to 15,000 S/cm, or a tensile strength higher than 1.0 GPa.

First claim

We claim:

1. A fabric comprising multiple yarns combined to form the fabric wherein at least one of said yarns comprises one or a plurality of graphene-based long or continuous fibers, wherein said graphene-based long or continuous fiber comprises chemically functionalized graphene sheets that are chemically bonded or interconnected with one another having an inter-planar spacing d 002 from 0.36 nm to 1.5 nm as determined by X-ray diffraction and a non-carbon element content of 0.1% to 47% by weight, wherein said functionalized graphene sheets are substantially parallel to one another and parallel to a fiber axis direction and said fiber contains no core-shell structure, has no helically arranged graphene domains, and has a length no less than 0.5 cm and a physical density from 1.5 to 2.25 g/cm 3 , wherein said functionalized graphene sheets are interconnected with one another via chemical bonding or reactions between chemically active functional groups attached to respective adjacent functional groups in a face-to-edge manner and an edge-to-edge manner, wherein the graphene-based long or continuous fiber comprises a combination of sp 2 and sp 3 electronic configurations.

2. The fabric of claim 1 , wherein the fabric, the yarn, or the graphene-based long or continuous fiber has a cross-section that is rectangular or flat-shaped, having a width and a thickness.

3. The fabric of claim 2 , wherein the fabric, the yarn, or the graphene-based long or continuous fiber has a width-to-thickness ratio greater than 5.

4. The fabric of claim 1 , wherein the fabric or a yarn has a thickness less than 1 μm.

5. The fabric of claim 1 , wherein the fabric or a yarn has a thickness less than 100 nm.

6. The fabric of claim 1 , wherein the yarn has a packing factor greater than 60%.

7. The fabric of claim 1 , wherein the yarn has a packing factor greater than 70%.

8. The fabric of claim 1 , wherein the yarn has a packing factor greater than 80%.

9. The fabric of claim 1 , wherein said chemically functionalized graphene sheets comprise:
(a) an oxygenated chemical functional group selected from the group consisting of hydroxyl, peroxide, ether, keto, aldehyde, and combinations thereof;
(b) a chemical functional group selected from the group consisting of alkyl or aryl silane, alkyl or aralkyl group, hydroxyl group, carboxyl group, carboxylic group, amine group, sulfonate group (—SO 3 H), aldehydic group, quinoidal, fluorocarbon, derivatives thereof, and combinations thereof;
(c) a chemical functional group selected from the group consisting of 10,12-pentacosadiyn-1-ol, hydroiodic acid, 1-pyrenebutyric acid N-hydroxysuccinimide ester, 1-aminopyrene, derivatives thereof, and combinations thereof; or
(d) a chemical functional group selected from the group consisting of amidoamines, polyamides, aliphatic amines, modified aliphatic amines, cycloaliphatic amines, aromatic amines, anhydrides, ketimines, diethylenetriamine (DETA), triethylene-tetramine (TETA), tetraethylene-pentamine (TEPA), polyethylene polyamine, polyamine epoxy adduct, phenolic hardener, non-brominated curing agent, non-amine curatives, derivatives thereof, and combinations thereof.

10. The fabric of claim 1 , wherein said chemically functionalized graphene sheets comprise a chemical functional group selected from a derivative of an azide compound selected from the group consisting of 2-azidoethanol, 3-azidopropan-1-amine, 4-(2-azidoethoxy)-4-oxobutanoic acid, 2-azidoethyl-2-bromo-2-methylpropanoate, chlorocarbonate, azidocarbonate, dichlorocarbene, carbene, aryne, nitrene, (R-)-oxycarbonyl nitrenes, where R=any one of the following groups,

and combinations thereof.

11. The fabric of claim 1 , wherein said chemically functionalized graphene sheets comprise a chemical functional group selected from the group consisting of —SO 3 H, —COOH, —NH 2 , —OH, —R′CHOH, —CHO, —CN, —COCl, halide, —COSH, —SH, —COOR′, —SR′, —SiR′ 3 , —Si(—OR′—) y R′ 3-y , —Si(—O—SiR′ 2 —)OR′, —R″, Li, AlR′ 2 , Hg—X, TlZ 2 and Mg—X; wherein y is an integer equal to or less than 3, R′ is hydrogen, alkyl, aryl, cycloalkyl, or aralkyl, cycloaryl, or poly(alkylether), R″ is fluoroalkyl, fluoroaryl, fluorocycloalkyl, fluoroaralkyl or cycloaryl, X is halide, and Z is carboxylate or trifluoroacetate, derivatives thereof, and combinations thereof.

12. The fabric of claim 1 , wherein said chemically functionalized graphene sheets comprise a chemical functional group selected from OY, NHY, O═C—OY, P═C—NR′Y, O═C—SY, O═C—Y, —CR′1-OY, N′Y or C′Y, a derivative thereof, or a combination thereof, and Y is a functional group of a protein, a peptide, an amino acid, an enzyme, an antibody, a nucleotide, an oligonucleotide, an antigen, or an enzyme substrate, enzyme inhibitor or the transition state analog of an enzyme substrate or is selected from R′—OH, R′—NR′ 2 , R′SH, R′CHO, R′CN, R′X, R′N + (R′) 3 X − , R′SiR′ 3 , R′Si(—OR′—) y R′ 3-y , R′Si(—O—SiR′ 2 —)OR′, R′—R″, R′—N—CO, (C 2 H 4 O—) w H, (—C 3 H 6 O—) w H, (—C 2 H 4 O) w —R′, (C 3 H 6 O) w —R′, R′, and w is an integer greater than one and less than 200.

13. The fabric of claim 1 , wherein said inter-plane spacing d 002 is from 0.4 nm to 1.2 nm, the non-carbon element content is from 1% to 20%, or physical density from 1.7 to 2.15 g/cm 3 .

14. The fabric of claim 1 , wherein the graphene-based long or continuous fiber has a cross-section that is circular, elliptical, rectangular, flat-shaped, or hollow.

15. The fabric of claim 1 , wherein the graphene-based long or continuous fiber has a length from 1 cm to 10,000 meters, a cross-section having a width or second largest dimension from 1 μm to 5 mm, and a thickness or smallest dimension from 10 nm to 500 μm, and a width-to-thickness ratio from 1 to 10,000.

16. The fabric of claim 1 , wherein the graphene-based long or continuous fiber has a thickness from 100 nm to 100 μm.

17. The fabric of claim 1 , wherein the graphene-based long or continuous fiber has a thermal conductivity from 200 to 1,600 W/mK, or an electrical conductivity from 600 to 15,000 S/cm.

18. The fabric of claim 1 , wherein the graphene-based long or continuous fiber has a thermal conductivity of at least 350 W/mK, or an electrical conductivity no less than 1,000 S/cm.

19. The fabric of claim 1 , wherein the graphene-based long or continuous fiber has a thermal conductivity of at least 600 W/mK, or an electrical conductivity no less than 2,500 S/cm.

20. The fabric of claim 1 , wherein the graphene-based long or continuous fiber has a thermal conductivity of at least 1,000 W/mK, or an electrical conductivity no less than 5,000 S/cm.

21. The fabric of claim 1 , wherein the graphene-based long or continuous fiber a thermal conductivity of at least 1,200 W/mK, or an electrical conductivity no less than 8,000 S/cm.

22. The fabric of claim 1 , wherein the graphene-based long or continuous fiber has a degree of orientation from 86% to 99%.

23. The fabric of claim 1 , wherein the graphene-based long or continuous fiber has a Young's modulus from 20 GPa to 300 GPa or a tensile strength from 1.0 GPa to 5.0 GPa.

24. The fabric of claim 1 , wherein the graphene-based long or continuous fiber has a Young's modulus from 30 GPa to 150 GPa or a tensile strength from 1.2 GPa to 3.0 GPa.

Assignees

• Nanotek Instruments Inc
• Global Graphene Group Inc

Inventors

• Zhamu Aruna
• Jang Bor Z

Classifications

• D10B2401/16

  antistatic; conductive · CPC title

• D10B2401/04

  Heat-responsive characteristics · CPC title

• C01P2006/32

  Thermal properties · CPC title

• D01F11/02

  of cellulose, cellulose derivatives, or proteins · CPC title

• C01B2204/065

  characterized by their width or by their aspect ratio · CPC title