Composite Materials and Methods for Selective Placement of Nano-Particulates within Composites

Abstract

Composite materials and methods for making composites are provided. The method includes providing a nano-particulate-depletable material that includes a plurality of nano-particulates on or within a depletable material; positioning the nano-particulate-depletable material on or within a structural material; and depleting the depletable material such that the nano-particulates are selectively placed on or within the structural material. Depletion may include infusion of a resin into the structural material. The depletable material may be a polymeric foam, and the nano-particulates may be carbon nanotubes.

We claim: 
     
         1 . A method for making a composite comprising:
 providing a nano-particulate-depletable material comprising a plurality of nano-particulates on or within a depletable material;   positioning the nano-particulate-depletable material on or within a structural material; and   depleting the depletable material such that the nano-particulates are selectively placed on or within the structural material.   
     
     
         2 . The method of  claim 1 , wherein the nano-particulate-depletable material is in a solid form. 
     
     
         3 . The method of  claim 1 , wherein the depletable material comprises a polymer or a polymer precursor. 
     
     
         4 . The method of  claim 1 , wherein the nano-particulate-depletable material is in a porous solid form, which comprises a polymer with nanoscale fibers dispersed therein or thereon. 
     
     
         5 . The method of  claim 1 , wherein the providing a nano-particulate-depletable material comprises spraying onto the depletable material a suspension which comprises the nano-particulates dispersed in a fluid. 
     
     
         6 . The method of  claim 1 , wherein the nano-particulates comprise carbon nanotubes. 
     
     
         7 . The method of  claim 1 , wherein the structural material comprises a polymer, carbon fibers, glass fibers, or a combination thereof. 
     
     
         8 . The method of  claim 1 , wherein the depleting the depletable material comprises impregnating pores in the nano-particulate-depletable material with a fluid. 
     
     
         9 . The method of  claim 8 , wherein the fluid comprises a resin. 
     
     
         10 . The method of  claim 9 , wherein the resin is further impregnated into pores the structural material. 
     
     
         11 . The method of  claim 10 , further comprising curing the resin that has been impregnated into the pores. 
     
     
         12 . The method of  claim 1 , wherein the nano-particulates are present in the nano-particulate-depletable material in an amount ranging from about 10 weight % to about 90 weight % of nano-particulate-depletable material. 
     
     
         13 . The method of  claim 1 , wherein the nano-particulates are present in the nano-particulate-depletable material in an amount ranging from about 20 weight % to about 60 weight % of nano-particulate-depletable material. 
     
     
         14 . The method of  claim 1 , wherein the nano-particulates are present in the composite in an amount up to about 10 weight % of composite. 
     
     
         15 . The method of  claim 1 , wherein the nano-particulates are present in the composite in an amount ranging from about 5 weight % to about 10 weight % of composite. 
     
     
         16 . A composite material comprising:
 one or more first layers each of which comprises a plurality of nano-particulates dispersed in or a polymeric foam; and   one or more second layers, each of which comprises a fabric,   wherein at least one of the first layers is disposed adjacent to at least one of the second layers.   
     
     
         17 . The composite material of  claim 16 , wherein the polymeric foam comprises polystyrene. 
     
     
         18 . The composite material of  claim 16 , wherein the nano-particulates comprise nanoscale fibers. 
     
     
         19 . The composite material of  claim 16 , wherein the fabric comprises glass fibers, carbon fibers, aramid fibers, or a combination thereof