Cnt-infused carbon fiber materials and process therefor

Abstract

A composition includes a carbon nanotube (CNT)-infused carbon fiber material that includes a carbon fiber material of spoolable dimensions and carbon nanotubes (CNTs) infused to the carbon fiber material. The infused CNTs are uniform in length and uniform in distribution. The CNT infused carbon fiber material also includes a barrier coating conformally disposed about the carbon fiber material, while the CNTs are substantially free of the barrier coating. A continuous CNT infusion process includes: (a) functionalizing a carbon fiber material; (b) disposing a barrier coating on the functionalized carbon fiber material (c) disposing a carbon nanotube (CNT)-forming catalyst on the functionalized carbon fiber material; and (d) synthesizing carbon nanotubes, thereby forming a carbon nanotube-infused carbon fiber material.

1 . A system for the continuous production of carbon nanotubes on a carbon fiber material comprising:
 a catalyst application station comprising a colloidal solution of CNT growth catalyst nanoparticles;   a barrier coating station; and   a CNT growth station comprising at least one purge zone and a growth chamber; said growth station adapted for CNT growth on the carbon fiber material by continuously feeding the carbon fiber material through the growth station;   said system being capable of reel to reel growth of CNTs on the carbon fiber material continuously by providing a payout bobbin and an uptake bobbin; said carbon fiber material being provided in spoolable form.   
     
     
         2 . The system of  claim 1 , wherein said CNT growth station is open to, but separated from the outside environment by the use of an inert gas flow. 
     
     
         3 . The system of  claim 1  further comprising a payout and tensioner station. 
     
     
         4 . The system of  claim 1  further comprising a fiber spreading station. 
     
     
         5 . The system of  claim 1  further comprising a plasma station adapted to roughen the surface of the carbon fiber material. 
     
     
         6 . The system of  claim 1  further comprising a barrier coating station adapted to conformally deposit a barrier coating on said carbon fiber material; said barrier coating having CNT growth catalyst embedded therein. 
     
     
         7 . The system of  claim 5 , wherein the catalyst application station and barrier coating station are combined. 
     
     
         8 . The system of  claim 5 , wherein said barrier coating station comprises at least one of spin-on glass, an alumina, a silane, an alkoxysilane, and a liquid ceramic. 
     
     
         9 . The system of  claim 1  further comprising a fiber sizing removal station. 
     
     
         10 . The system of  claim 1  further comprising a resin application station downstream of said CNT growth station. 
     
     
         11 . The system of  claim 1  which is capable of operating speeds in a range from between about 0.5 ft/min to about 36 ft/min. 
     
     
         12 . The system of  claim 1  further comprising a controller station; said controller station capable of controlling at least one of linespeed, an inert gas flow rate, a carbon feedstock flowrate, temperature in the CNT growth chamber, temperature of the inert gas, and temperature of the carbon feedstock gas. 
     
     
         13 . The system of  claim 1 , wherein a material residence time in the growth chamber between about 5 to about 30 seconds produces CNTs having a length between about 1 micron to about 10 microns. 
     
     
         14 . The system of  claim 1 , wherein a material residence time in the growth chamber of about 30 to about 180 seconds produces CNTs having a length between about 10 microns to about 100 microns. 
     
     
         15 . The system of  claim 1 , wherein a material residence time in the growth chamber of about 180 to about 300 seconds produces CNTs having a length between about 100 microns to about 500 microns. 
     
     
         16 . A system for the continuous production of carbon nanotubes on a fiber material comprising:
 a catalyst application station comprising a colloidal solution of CNT growth catalyst nanoparticles;   a barrier coating station; and   a CNT growth station comprising at least one purge zone and a growth chamber; said growth station adapted for CNT growth on the fiber material by continuously feeding the fiber material through the growth station;   said system being capable of reel to reel growth of CNTs on the fiber material continuously by providing a payout bobbin and an uptake bobbin; said fiber material being provided in spoolable form.