Composite yarn and method of making a carbon nanotube composite yarn

Patent metadata

Field	Value
Publication number	US-11325833-B2
Application number	US-201916446389-A
Country	US
Kind code	B2
Filing date	Jun 19, 2019
Priority date	Mar 4, 2019
Publication date	May 10, 2022
Grant date	May 10, 2022

Abstract

A method of making a carbon nanotube composite yarn, the method including growing floating carbon nanotubes in a reactor, forming a mat of carbon nanotubes from the floating carbon nanotubes, a deposition step including depositing secondary particles on at least a portion of the mat of carbon nanotubes to provide a carbon nanotube composite mat, and a densification step including densifying the carbon nanotube composite mat to provide a carbon nanotube composite yarn.

First claim

What is claimed is:

1. A method of making a carbon nanotube composite yarn, the method comprising:
growing floating carbon nanotubes in a reactor,
forming a mat of carbon nanotubes from the floating carbon nanotubes in the reactor;
a deposition step comprising depositing secondary particles from a secondary particle chamber on at least a portion of the mat of carbon nanotubes to provide a carbon nanotube composite mat, wherein the mat of carbon nanotubes is continuously fed from the reactor to the secondary particle chamber, and
a densification step comprising densifying the carbon nanotube composite mat to provide a carbon nanotube composite yarn.

2. The method according to claim 1 , wherein growing the floating carbon nanotubes comprises providing a carbon source and a catalyst and/or catalyst precursor to the reactor and heating the reactor.

3. The method according to claim 2 , wherein:
the carbon source is selected from the group consisting of a hydrocarbon, an alcohol, an ester, a ketone, an aromatic, an aldehyde, and combinations thereof;
the catalyst is selected from the group consisting of a transition metal, a lanthanide metal, an actinide metal, and combinations thereof and
the catalyst precursor is selected from the group consisting of a transition metal salt, a hydrate thereof, and combinations thereof.

4. The method according to claim 1 , wherein the secondary particles are deposited on the at least the portion of the mat of carbon nanotubes as a powder.

5. The method according to claim 4 , wherein the densification step comprises a spinning densification step wherein the carbon nanotube composite mat is spun through a rolling press to provide the carbon nanotube composite yarn.

6. The method according to claim 4 , wherein the densification step comprises a liquid bath densification step wherein the carbon nanotube composite mat is subjected to a liquid bath comprising a solvent to provide the carbon nanotube composite yarn.

7. The method according to claim 1 , wherein the deposition step comprises depositing the secondary particles on the at least the portion of the mat of carbon nanotubes via a carrier.

8. The method according to claim 7 , wherein the deposition step and the densification step are performed simultaneously.

9. The method according to claim 8 , wherein the carrier comprises a solvent.

10. The method according to claim 1 , wherein the secondary particles comprise a secondary material selected from the group consisting of metals, metal oxides, ceramics, carbon- based materials, and combinations thereof.

11. The method of claim 1 , wherein the carbon nanotube composite yarn comprises 10% (w/w) or less carbon nanotubes and 90% (w/w) or more secondary particles.

12. A method of making a composite yarn, the method comprising:
providing a structure comprising a plurality of carbon nanotubes in a reactor;
a deposition step comprising continuously feeding the structure from the reactor to a secondary particle chamber in order to deposit particles on the structure to form a composite structure; and
a densification step comprising densifying the composite structure to form a composite yarn.

13. The method according to claim 12 , wherein the particles are deposited on the structure as a powder.

14. The method according to claim 13 , wherein the densification step comprises a spinning densification step wherein the composite structure is spun through a rolling press to provide the composite yarn.

15. The method according to claim 13 , wherein the densification step comprises a liquid bath densification step wherein the composite structure is subjected to a liquid bath comprising a solvent to provide the composite yarn.

16. The method according to claim 12 , wherein the deposition step and the densification step are performed simultaneously.

17. The method according to claim 12 , wherein the particles comprise a secondary material selected from the group consisting of metals, metal oxides, ceramics, carbon-based materials, and combinations thereof.

18. The method of claim 12 , wherein the composite yarn comprises 10% (w/w) or less carbon nanotubes and 90% (w/w) or more particles.

19. A method of making a carbon nanotube composite yarn, the method comprising:
providing a web of carbon nanotubes in a reactor;
continuously feeding the web of carbon nanotubes from the reactor to a secondary particle chamber in order to deposit secondary particles on at least a portion of the web of carbon nanotubes to form a composite web, and
densifying the composite web to form a carbon nanotube composite yarn.

Assignees

• Honda Motor Co Ltd

Inventors

• Harutyunyan Avetik

Classifications

• D02G3/16

  Yarns or threads made from mineral substances · CPC title

• B82Y30/00

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

• D01F11/12

  with inorganic substances {; Intercalation} · CPC title

• C01B32/168

  After-treatment · CPC title

• B82Y40/00

  Manufacture or treatment of nanostructures · CPC title