Carbon Nanotube Foams with Controllable Architecture and Methods

Patent metadata

Field	Value
Publication number	US-2018201508-A1
Application number	US-201815921294-A
Country	US
Kind code	A1
Filing date	Mar 14, 2018
Priority date	Oct 7, 2013
Publication date	Jul 19, 2018
Grant date	—

Abstract

CNT foams and methods are provided. The methods may include forming, in a non-solvent liquid, a suspension of CNTs and particles of a pyrolytic polymer; removing the non-solvent liquid; and removing the particles of the pyrolytic polymer to produce a CNT foam having cells that at least substantially correspond to the dimensions of the particles of the pyrolytic polymer. CNT foams having porous structures also are provided.

First claim

I claim:

1 . A method for making a carbon nanotube (CNT) foam, the method comprising:
forming a suspension comprising a non-solvent liquid in which CNTs and particles of a pyrolytic polymer are dispersed; removing the non-solvent liquid; and removing the particles of the pyrolytic polymer to produce a CNT foam having cells that at least substantially correspond to the dimensions of the particles of the pyrolytic polymer.

2 . The method of claim 1 , wherein forming the suspension comprises (i) dispersing CNTs in the non-solvent liquid to form a CNT suspension, and (ii) adding the particles of the pyrolytic polymer to the CNT suspension.

3 . The method of claim 1 , wherein the pyrolytic polymer comprises a thermoplastic polymer.

4 . The method of claim 3 , wherein the thermoplastic polymer comprises poly(methylmethacrylate), nylon, polyesters, or a combination thereof.

5 . The method of claim 1 , wherein the particles of the pyrolytic polymer have an average diameter of from about 0.1 micrometers to about 1,000 micrometers.

6 . The method of claim 1 , wherein the average length of the CNTs is at least two times the average diameter of the particles of the pyrolytic polymer.

7 . The method of claim 1 , wherein the average length of the CNTs is at least fifteen times the average diameter of the particles of the pyrolytic polymer.

8 . The method of claim 7 , wherein the average length of the CNTs is about 500 micrometers and the average diameter of the particles of the pyrolytic polymer is about 30 micrometers.

9 . The method of claim 1 , wherein the particles of the pyrolytic polymer are at least substantially spherical.

10 . The method of claim 1 , wherein the weight ratio of pyrolytic polymer to CNTs in the suspension ranges from about 1:1 to about 60:1.

11 . The method of claim 1 , wherein removing the particles of the pyrolytic polymer comprises a first heat treatment at a temperature effective to pyrolyze and evaporate the particles of the pyrolytic polymer.

12 . The method of claim 1 , further comprising adding a carbonaceous binder precursor to the suspension prior to removing the non-solvent liquid, and converting the carbonaceous binder precursor to graphitic structures after removing the non-solvent liquid.

13 . The method of claim 12 , wherein converting the carbonaceous binder precursor to graphitic structures comprises a second heat treatment.

14 . The method of claim 13 , wherein the second heat treatment comprises heating the CNT foam to at least 800° C.

15 . The method of claim 12 , wherein the weight ratio of carbonaceous binder precursor to CNTs in the suspension ranges from about 0.1:1 to about 5:1.

16 . The method of claim 12 , wherein the carbonaceous binder precursor is selected from polyacrylonitrile, pitch, or a combination thereof.

17 . A method for making a carbon nanotube (CNT) foam, the method comprising:
forming a suspension comprising a non-solvent liquid in which CNTs, particles of a pyrolytic polymer, and a carbonaeceous binder precursor are dispersed; removing the non-solvent liquid; removing the particles of the pyrolytic polymer to produce a CNT foam having cells that at least substantially correspond to the dimensions of the particles of the pyrolytic polymer; and converting the carbonaceous binder precursor to graphitic structures.

Assignees

• Univ Florida State Res Found

Inventors

• Zhang Mei

Classifications

• C09K3/32

  for absorbing liquids to remove pollution, e.g. oil, gasoline, fat · CPC title

• C01P2006/12

  Surface area · CPC title

• C01B32/16

  Preparation · CPC title

• C09K5/063

  Materials absorbing or liberating heat during crystallisation; Heat storage materials · CPC title

• C01B32/174

  Derivatisation; Solubilisation; Dispersion in solvents · CPC title