Impregnated continuous graphitic fiber tows and composites containing same
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B32B-005/12
H01B-001/24
D01F-009/12
D01D-005/04
출원번호
US-0987528
(2013-08-05)
등록번호
US-9362018
(2016-06-07)
발명자
/ 주소
Zhamu, Aruna
Jang, Bor Z
출원인 / 주소
Nanotek Instruments, Inc.
인용정보
피인용 횟수 :
0인용 특허 :
4
초록▼
An impregnated fiber tow comprising multiple unitary graphene-based continuous graphitic fibers impregnated with a matrix material, wherein at least one of the continuous graphitic fibers comprises at least 90% by weight of graphene planes that are chemically bonded with one another having an inter-
An impregnated fiber tow comprising multiple unitary graphene-based continuous graphitic fibers impregnated with a matrix material, wherein at least one of the continuous graphitic fibers comprises at least 90% by weight of graphene planes that are chemically bonded with one another having an inter-planar spacing d002 from 0.3354 nm to 0.4 nm as determined by X-ray diffraction and an oxygen content less than 5% by weight, wherein the graphene planes are parallel to one another and parallel to a fiber axis direction and the graphitic fiber contains no core-shell structure, has no helically arranged graphene domains or domain boundary, and has a porosity level less than 5% by volume.
대표청구항▼
1. An impregnated fiber tow comprising one or multiple continuous unitary graphene fibers and a matrix material, wherein at least one of said continuous graphene fibers consists of at least 90% by weight of graphene planes that are chemically bonded with one another having an inter-planar spacing d0
1. An impregnated fiber tow comprising one or multiple continuous unitary graphene fibers and a matrix material, wherein at least one of said continuous graphene fibers consists of at least 90% by weight of graphene planes that are chemically bonded with one another having an inter-planar spacing d002 from 0.3354 nm to 0.4 nm as determined by X-ray diffraction, an oxygen content less than 5% by weight, and said continuous graphene fiber is a unitary or monolith neat graphene structure containing no binder, no adhesive, no matrix material, no graphite flakes, and no graphene platelets therein, wherein said graphene planes are parallel to one another and parallel to a fiber axis direction and said graphene fiber contains no core-shell structure, has no helically arranged graphene domains, and has a porosity level less than 5% by volume. 2. The impregnated fiber tow of claim 1, wherein said inter-planar spacing d002 is from 0.3354 nm to 0.36 nm, the oxygen content is less than 2% by weight, and/or the porosity level is less than 2% by volume. 3. The impregnated fiber tow of claim 1, wherein the tow or the continuous graphene fiber has a cross-section that is rectangular or flat-shaped, having a width and a thickness. 4. The impregnated fiber tow of claim 3, wherein the tow or the continuous graphene fiber has a width-to-thickness ratio greater than 5. 5. The impregnated fiber tow of claim 1, wherein the tow has a thickness less than 1 μm. 6. The impregnated fiber tow of claim 1, wherein the tow has a thickness less than 100 nm. 7. The impregnated fiber tow of claim 1, wherein the continuous graphene fibers occupy a volume fraction greater than 60% in said impregnated tow. 8. The impregnated fiber tow of claim 1, wherein the continuous graphene fibers occupy a volume fraction greater than 70% in said impregnated tow. 9. The impregnated fiber tow of claim 1, wherein the continuous graphene fibers occupy a volume fraction greater than 80% in said impregnated tow. 10. The impregnated fiber tow of claim 1, wherein said matrix material is selected from a polymer, metal, glass, ceramic, non-polymeric organic, carbon, pitch, or a combination thereof. 11. The impregnated fiber tow of claim 1, wherein said matrix material is selected from a thermoplastic, thermoset resin, interpenetrating network, semi-interpenetrating network, rubber or elastomer, or a combination thereof. 12. The impregnated fiber tow of claim 1, wherein said continuous graphene fiber has an oxygen content less than 1%, an inter-graphene spacing less than 0.345 nm, a thermal conductivity of at least 1,000 W/mK, and/or an electrical conductivity no less than 3,000 S/cm. 13. The impregnated fiber tow of claim 1, wherein said continuous graphene fiber has an oxygen content less than 0.01%, an inter-graphene spacing less than 0.337 nm, a thermal conductivity of at least 1,200 W/mK, and/or an electrical conductivity no less than 5,000 S/cm. 14. The impregnated fiber tow of claim 1, wherein said continuous graphene fiber has an oxygen content no greater than 0.001%, an inter-graphene spacing less than 0.336 nm, a mosaic spread value no greater than 0.7, a thermal conductivity of at least 1,500 W/mK, and/or an electrical conductivity no less than 8,000 S/cm. 15. The impregnated fiber tow of claim 1, wherein said continuous graphene fiber has an inter-graphene spacing less than 0.336 nm, a mosaic spread value no greater than 0.4, a thermal conductivity greater than 1,700 W/mK, and/or an electrical conductivity greater than 12,000 S/cm. 16. The impregnated fiber tow of claim 1, wherein said continuous graphene fiber has an inter-graphene spacing less than 0.337 nm and a mosaic spread value less than 1.0. 17. The impregnated fiber tow of claim 1, wherein said continuous graphene fiber has a degree of graphitization no less than 40% and/or a mosaic spread value less than 0.7. 18. The impregnated fiber tow of claim 1, wherein said continuous graphene fiber has a degree of graphitization no less than 80% and/or a mosaic spread value no greater than 0.4. 19. The impregnated fiber tow of claim 1, wherein said continuous graphene fiber contains chemically bonded graphene molecules or chemically merged graphene planes that are parallel to one another. 20. The impregnated fiber tow of claim 1, wherein said continuous graphene fiber contains a first graphene domain containing bonded graphene planes parallel to one another and having a first crystallographic c-axis, and a second graphene domain containing bonded graphene planes parallel to one another and having a second crystallographic c-axis wherein the first crystallographic c-axis and the second crystallographic c-axis are inclined with respect to each other at an angle less than 10 degrees. 21. The impregnated fiber tow of claim 1, wherein said continuous graphene fiber contains a poly-crystal graphite structure with graphene molecules being oriented along a fiber axis direction. 22. The impregnated fiber tow of claim 1, wherein said continuous graphene fiber has a poly-crystal graphitic structure having a grain size larger than 10 μm. 23. The impregnated fiber tow of claim 1, wherein said continuous graphene fiber has a poly-crystal graphitic structure having a grain size larger than 100 μm. 24. The impregnated fiber tow of claim 1, wherein said continuous graphene fiber has a poly-crystal graphitic structure having a grain size larger than 1 mm. 25. The impregnated fiber tow of claim 1, wherein said continuous graphene fiber has an electrical conductivity greater than 3,000 S/cm, a thermal conductivity greater than 600 W/mK, a physical density greater than 1.7 g/cm3, a Young's modulus greater than 60 GPa, and/or a tensile strength greater than 1.2 GPa. 26. The impregnated fiber tow of claim 1, wherein said continuous graphene fiber has an electrical conductivity greater than 5,000 S/cm, a thermal conductivity greater than 1,000 W/mK, a physical density greater than 1.8 g/cm3, a Young's modulus greater than 200 GPa, and/or a tensile strength greater than 3.2 GPa. 27. The impregnated fiber tow of claim 1, wherein said continuous graphene fiber has an electrical conductivity greater than 15,000 S/cm, a thermal conductivity greater than 1,500 W/mK, a physical density greater than 1.9 g/cm3, a Young's modulus greater than 300 GPa, and/or a tensile strength greater than 5.0 GPa. 28. The impregnated fiber tow of claim 1, wherein said continuous graphene fiber has an electrical conductivity greater than 18,000 S/cm, a thermal conductivity greater than 1,700 W/mK, a physical density greater than 1.9 g/cm3, a Young's modulus greater than 600 GPa, and/or a tensile strength greater than 8.0 GPa. 29. The impregnated fiber tow of claim 1, wherein said tow comprises at least one fiber selected from the group consisting of wool, cotton, asbestos, nylon, synthetic, carbon nanotubes, and graphene-based graphitic fiber obtained from coagulation-spinning. 30. An impregnated fiber tow consisting of one or multiple continuous unitary graphene fibers and a matrix material, wherein at least one of said continuous graphene fibers is a unitary or monolith neat graphene structure containing no binder, no adhesive, no matrix material, and no discrete graphene sheets., and contains no core-shell structure, has no helically arranged graphene domains, and has a porosity level less than 5% by volume. 31. The impregnated fiber tow of claim 30, wherein said continuous graphene fibers are produced from graphene oxide gel or functionalized graphene. 32. The impregnated fiber tow of claim 30, wherein said continuous graphene fibers are produced from a process comprising: (a) preparing a graphene suspension having graphene sheets dispersed in a fluid medium;(b) dispensing and depositing at least a continuous filament of said graphene suspension onto a supporting substrate under the influence of a stress field to induce alignment or ordering of said graphene sheets along a filament axis direction;(c) partially or completely removing said fluid medium from said continuous filament to form a continuous graphene fiber containing closely packed and parallel graphene sheets; and(d) heat treating the continuous graphene fiber to form said continuous graphitic fiber at a heat treatment temperature higher than 600° C. to an extent that an inter-plane spacing d002 is decreased to a value in the range from 0.3354 nm to 0.4 run. 33. A composite material comprising an impregnated fiber tow of claim 1. 34. A composite material comprising an impregnated fiber tow of claim 1, which is aligned along a first direction of said composite material. 35. A composite material comprising a first impregnated fiber tow of claim 1 aligned along a first direction and a second impregnated fiber tow aligned along a second direction, which is different than the first direction or perpendicular to the first direction, wherein the first direction and the second direction define a plane. 36. The composite material of claim 35, further comprising a third impregnated fiber tow aligned along a third direction not lying on said plane defined by the first and second directions. 37. The composite material of claim 35, further comprising a third impregnated fiber tow aligned along a third direction, which is perpendicular to the plane defined by the first and second directions.
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