Systems and Methods for Continuous Manufacture of Buckypaper Materials

Patent metadata

Field	Value
Publication number	US-2016177511-A1
Application number	US-201514972371-A
Country	US
Kind code	A1
Filing date	Dec 17, 2015
Priority date	Dec 17, 2014
Publication date	Jun 23, 2016
Grant date	—

Abstract

Systems and methods are provided for producing continuous buckypapers. The systems may permit the in-line characterization and crosslinking of the continuous buckypapers. The systems include roll-to-roll systems in which a continuous buckypaper is created and then separated from the filter paper in an automated process.

First claim

We claim:

1 . A method for the continuous manufacture of a buckypaper comprising:
providing a suspension of CNTs in a suspension tank, transferring the suspension of CNTs in the suspension tank to a suspension chamber of a filtration unit comprising a filtration area, contacting the filtration area and the suspension of CNTs in the suspension chamber with a first portion of a filter paper provided by two or more rollers, applying vacuum pressure to the filtration area to form a portion of a continuous buckypaper on the portion of the filter paper, advancing the two or more rollers to contact the filtration area with a second portion of the filter paper, and drying the portion of the continuous buckypaper.

2 . The method of claim 1 , further comprising separating the portion of the continuous buckypaper from the first portion of the filter paper, and collecting the portion of the continuous buckypaper on one or more rollers.

3 . The method of claim 1 , wherein providing the suspension of CNTs in the suspension tank comprises sonicating CNTs and a nonsolvent in a sonication unit in fluid communication with the suspension tank, and transferring the suspension of CNTs to the suspension tank.

4 . The method of claim 1 , wherein contacting the filtration area and the suspension of CNTs in the suspension chamber with at least a portion of the filter paper comprises advancing at least one of the two or more rollers.

5 . The method of claim 1 , wherein drying the portion of the continuous buckypaper comprises advancing at least one of the two or more rollers to position the portion of the continuous buckypaper in a drying area comprising substantially raised portions that contact the filter paper.

6 . The method of claim 1 , wherein the portion of the continuous buckypaper has an areal density of from about 1 GSM to about 10 GSM.

7 . The method of claim 1 , wherein at least one of providing, transferring, contacting, applying, advancing, and drying, is automated and controlled by a microcontroller.

8 . The method of claim 1 , further comprising exposing the portion of the continuous buckypaper to UV irradiation of a wavelength and duration sufficient to cross-link two or more CNTs of the portion of the continuous buckypaper.

9 . The method of claim 1 , further comprising aligning the CNTs.

10 . The method of claim 9 , wherein aligning comprises exposing the suspension of CNTs to a magnetic force, an electrical field, or a combination thereof.

11 . The method of claim 9 , wherein aligning comprises mechanically stretching the portion of the continuous buckypaper.

12 . The method of claim 1 , further comprising continuously characterizing and monitoring the suspension of CNTs.

13 . The method of claim 1 , further comprising continuously monitoring the continuous buckypaper with an in-line Raman characterization setup.

14 . A system for the continuous manufacture of buckypaper materials comprising:
a suspension tank containing a suspension of CNTs, and a filtration unit comprising (i) a suspension chamber in fluid communication with the suspension tank, (ii) a filter paper associated with two or more rollers, (iii) a filtration area associated with a vacuum pump, (iv) a drying area, and (v) a roll for collecting a continuous buckypaper.

15 . The system of claim 14 , further comprising a sonication unit in fluid communication with the suspension tank.

16 . The system of claim 14 , further comprising a microcontroller.

17 . The system of claim 14 , further comprising a Micro PLC Controller which controls filter paper movement.

18 . The system of claim 14 , further comprising a vacuum suspension valve for controlling the vacuum pump.

19 . The system of claim 14 , further comprising an in-line Raman characterization setup.

20 . The system of claim 14 , further comprising a UV irradiation source.

Assignees

• Univ Florida State Res Found

Inventors

• Horne Gerald
• Liang Zhiyong

Classifications

• B01D2323/42

  Details of membrane preparation apparatus · CPC title

• B82Y30/00

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

• D21F9/00

  Complete machines for making continuous webs of paper · CPC title

• B82Y40/00

  Manufacture or treatment of nanostructures · CPC title

• D21F11/00

  Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines · CPC title