Methods for forming porous nanotube fabrics

Patent metadata

Field	Value
Publication number	US-11174166-B2
Application number	US-201916722779-A
Country	US
Kind code	B2
Filing date	Dec 20, 2019
Priority date	Dec 20, 2019
Publication date	Nov 16, 2021
Grant date	Nov 16, 2021

Abstract

Methods for making porous nanotube fabrics are disclosed. Within the methods of the present disclosure, a porogen-loaded nanotube application solution is formed by combining a first volume of nanotube elements with a second volume of fuel material in a liquid medium to form a porogen-loaded nanotube application solution. In some aspects of the present disclosure, a third volume of oxidizer material is also combined into the liquid medium. A porogen-loaded nanotube fabric is formed by depositing the porogen-loaded nanotube application solution. In some aspects of the present disclosure, the fuel material within the porogen-loaded nanotube application solution will react with oxidizer material when heat is applied to a sufficient degree and volatize. The off-gassed fuel material will then leave behind voids in the nanotube fabric, rendering the fabric porous.

First claim

The invention claimed is:

1. A method for forming a porous nanotube fabric, comprising:
combining a first volume of nanotube elements and a second volume of fuel material in a liquid medium to form a porogen-loaded nanotube application solution;
depositing said porogen-loaded nanotube application solution over a material layer to form a porogen-loaded nanotube fabric;
heating said porogen-loaded nanotube fabric to induce in-situ volatilization of said fuel material within said porogen-loaded nanotube fabric to form a porous nanotube fabric;
wherein substantially all of said fuel material is volatized.

2. The method of claim 1 wherein said step of combining further comprises combining a third volume of oxidizer material to form said porogen-loaded nanotube application solution.

3. The method of claim 2 wherein said step of heating induces a chemical reaction of said fuel material with said oxidizer material.

4. The method of claim 3 wherein substantially all of said oxidizer material is volatized.

5. The method of claim 2 wherein said oxidizer material is tetramethyl ammonium nitrate and said fuel material is 2-hydroxypropyl-β-cyclodextrin.

6. The method of claim 5 wherein said step of heating comprises exposing said porogen-loaded nanotube fabric layer to an environment with an ambient temperature of 350 degrees Celsius.

7. The method of claim 2 wherein said oxidizer material is ammonium nitrate and said fuel material is a block copolymer.

8. The method of claim 7 wherein said step of heating comprises exposing said porogen-loaded nanotube fabric layer to an environment with an ambient temperature of 200 degrees Celsius.

9. The method of claim 2 wherein said oxidizer material is ammonium nitrate and said fuel material is sucrose.

10. The method of claim 9 wherein said step of heating comprises exposing said porogen-loaded nanotube fabric layer to an environment with an ambient temperature of 200 degrees Celsius.

11. The method of claim 1 wherein said fuel material has a molecular structure that includes a fuel part and an oxidizer part.

12. The method of claim 11 wherein said in-situ volatilization results from a chemical reaction of said fuel part with said oxidizer part under said applied heat.

13. The method of claim 11 where said fuel material is one of benzoyl peroxide and ethylhydrazine oxalate.

14. The method of claim 13 wherein said step of heating comprises exposing said porogen-loaded nanotube fabric layer to an environment with an ambient temperature of 200 degrees Celsius.

15. The method of claim 1 wherein said step of heating is performed with said porogen-loaded fabric exposed to an atmosphere that includes an ambient oxidizer.

16. The method of claim 15 wherein said step of heating induces a chemical reaction of said fuel material with said ambient oxidizer.

17. The method of claim 15 wherein said fuel material is block copolymer and said atmosphere is air.

18. The method of claim 17 wherein said step of heating comprises exposing said porogen-loaded nanotube fabric layer to an environment with an ambient temperature of 250 degrees Celsius.

19. The method of claim 15 wherein said fuel material is block copolymer and said atmosphere is one of NO 2 , N 2 O, air, or mixtures thereof.

20. The method of claim 19 wherein said step of heating comprises exposing said porogen-loaded nanotube fabric layer to an environment with an ambient temperature of 200 degrees Celsius.

21. The method of claim 1 wherein said fuel material is a material that will thermally decompose under applied heat.

22. The method of claim 21 wherein said step of heating is performed with said porogen-loaded nanotube fabric in an inert atmosphere.

23. The method of claim 22 wherein said inert atmosphere is nitrogen.

24. The method of claim 21 wherein said fuel material is one of a block copolymer, a sugar, or polyvinyl alcohol.

25. The method of claim 24 wherein said step of heating comprises exposing said porogen-loaded nanotube fabric layer to an environment with an ambient temperature of 400 degrees Celsius.

26. The method of claim 1 wherein the porosity of said porous nanotube fabric is above a selected threshold value.

27. The method of claim 26 wherein said threshold value is one of 3%, 5%, 10%, 15%, and 20%.

28. The method of claim 1 wherein said nanotube elements are carbon nanotubes.

29. The method of claim 28 wherein said carbon nanotubes are one of singled walled carbon nanotubes, multiwalled carbon nanotubes, or mixtures thereof.

Assignees

• Zeon Corp

Inventors

• Sen Rahul
• Mcdermott Joseph James
• Pal Sushanta K
• Rueckes Thomas

Classifications

• B82Y30/00

  Nanotechnology for materials or surface science, e.g. nanocomposites · CPC title

• B82Y40/00

  Manufacture or treatment of nanostructures · CPC title

• D01F9/127

  by thermal decomposition of hydrocarbon gases or vapours {or other carbon-containing compounds in the form of gas or vapour, e.g. carbon monoxide, alcohols} · CPC title

• D01F9/12

  Carbon filaments; Apparatus specially adapted for the manufacture thereof · CPC title

• C01B2202/02

  Single-walled nanotubes · CPC title