Composite Materials Including Carbon Nanotube Yarns and Methods

Abstract

Methods of forming composite materials, which may include filament winding two or more carbon nanotube yarns to form one or more material layers, contacting the yarns with a resin, and applying one or more stretching forces to the material layers. Composite materials also are provided.

1 . A composite material comprising:
 at least one material layer comprising two or more substantially aligned carbon nanotube yarns; and   a cured resin, wherein the cured resin at least partially penetrates the two or more substantially aligned carbon nanotube yarns;   wherein the two or more substantially aligned carbon nanotube yarns are present in the composite material at an amount of about 50% to about 75%, by weight, based on the weight of the composite material.   
     
     
         2 . The composite material of  claim 1 , wherein the composite material has—
 (i) a density of about 1.60 g/cm 3  to about 1.8 g/cm 3 , 
 (ii) a tensile strength of about 1.8 GPa to about 2 GPa, 
 (iii) a tensile modulus of about 340 GPa to about 360 GPa, 
 (iv) a tensile failure strain of about 1.0% to about 1.4%, 
 (v) a flexural strength of about 0.85 GPa to about 0.99 GPa, 
 (vi) a flexural modulus of about 150 GPa to about 170 GPa, 
 (vii) a flexural failure strain of about 4% to about 6%, 
 (viii) a short beam shear strength of about 90 MPa to about 100 MPa, 
 (ix) a compressive modulus of about 95 GPa to about 115 GPa, or 
 (x) a combination thereof. 
 
     
     
         3 . The composite material of  claim 1 , wherein the axial electrical conductivity (S/cm) of the composite material is about 700 S/cm to about 715 S/cm. 
     
     
         4 . The composite material of  claim 1 , wherein (i) the transverse electrical conductivity of the composite material is about 30 S/cm to about 50 S/cm, (ii) the out-of-plane conductivity of the composite material is about 25 S/cm to about 40 S/cm, or (iii) a combination thereof. 
     
     
         5 . The composite material of  claim 1 , wherein the two or more substantially aligned carbon nanotube yarns are present in the composite material at an amount of about 60% to about 75%, by weight, based on the weight of the composite material. 
     
     
         6 . The composite material of  claim 1 , wherein the two or more substantially aligned carbon nanotube yarns are present in the composite material at an amount of about 70% to about 75%, by weight, based on the weight of the composite material. 
     
     
         7 . The composite material of  claim 1 , wherein the composite material comprises a first material layer and a second material layer. 
     
     
         8 . The composite material of  claim 7 , wherein the second material layer is arranged on and in contact with the first material layer. 
     
     
         9 . The composite material of  claim 1 , wherein the resin comprises a bismaleimide. 
     
     
         10 . The composite material of  claim 1 , wherein the two or more substantially aligned carbon nanotube yarns comprise spun carbon nanotube yarns. 
     
     
         11 . The composite material of  claim 1 , wherein the two or more substantially aligned carbon nanotube yarns comprise unspun carbon nanotube yarns. 
     
     
         12 . The composite material of  claim 1 , wherein a surface of the two or more substantially aligned carbon nanotube yarns is oxidized. 
     
     
         13 . The composite material of  claim 1 , wherein a surface of the two or more substantially aligned carbon nanotube yarns is acid functionalized. 
     
     
         14 . A composite material comprising:
 a plurality of carbon nanotube yarns;   a first material layer comprising two or more of the carbon nanotube yarns;   a second material layer comprising two or more of the carbon nanotube yarns; and   a cured resin, wherein the cured resin at least partially penetrates the plurality of carbon nanotube yarns;   wherein the two or more carbon nanotube yarns of the first material layer are substantially aligned in the first material layer, and the two or more carbon nanotube yarns of the second material layer are substantially aligned in the second material layer;   wherein the plurality of carbon nanotube yarns is present in the composite material at an amount of about 50% to about 75%, by weight, based on the weight of the composite material.   
     
     
         15 . The composite material of  claim 14 , wherein the plurality of carbon nanotube yarns is present in the composite material at an amount of about 70% to about 75%, by weight, based on the weight of the composite material. 
     
     
         16 . The composite material of  claim 14 , wherein the second material layer is arranged on and in contact with the first material layer. 
     
     
         17 . The composite material of  claim 14 , wherein a surface of the plurality of carbon nanotube yarns is oxidized. 
     
     
         18 . The composite material of  claim 14 , wherein a surface of the plurality of carbon nanotube yarns is acid functionalized. 
     
     
         19 . The composite material of  claim 14 , wherein the plurality of carbon nanotube yarns is impregnated with the resin.