CN113519093A

CN113519093A - Product with multifunctional lead

Info

Publication number: CN113519093A
Application number: CN202080017759.4A
Authority: CN
Inventors: A·哈鲁特尤亚恩
Original assignee: Honda Motor Co Ltd
Current assignee: Honda Motor Co Ltd
Priority date: 2019-03-04
Filing date: 2020-03-04
Publication date: 2021-10-19
Also published as: DE112020001068T5

Abstract

Articles and devices comprising a multifunctional wire having a first electrode comprising a first carbon nanotube composite yarn comprising carbon nanotubes and auxiliary particles; a second electrode including a second carbon nanotube composite yarn including carbon nanotubes and auxiliary particles; a first separator surrounding the first electrode; a second separator surrounding the second electrode; an electrolyte surrounding the first electrode and the second electrode; a flexible insulating layer surrounding the electrolyte; and a flexible conductive layer at least partially surrounding the flexible insulating layer. The invention also provides methods of making and using the articles, devices, and multifunctional wires of the invention.

Description

Product with multifunctional lead

Cross Reference to Related Applications

This application claims priority from U.S. provisional patent application No.62/813516 entitled "Composite Yarn and Method of Making a Carbon Nanotube Composite Yarn", filed on 3, 4.2019. The present application claims priority from U.S. patent application No.16/446389 entitled "Composite Yarn and Method of Making a Carbon Nanotube Composite Yarn", filed on 19.6.2019, and from U.S. patent application No.16/805565 entitled "Multifunctional connecting Wire and Method of Making", filed on 28.2.2020. The disclosures of the aforementioned applications are incorporated herein by reference in their entirety.

Background

Devices comprising metal wires, in particular solid or stranded copper wires, have been produced and used for decades in many industrial sectors. However, recent demands for device miniaturization and energy efficiency optimization place new challenging demands on the high volume and high weight characteristics of metal wires, and new devices and articles comprising the new wires are needed. It is a focus of attention to find new synthesis, fabrication and engineering methods to add more functionality to the wire, rather than just as a current carrier. Conventional solid and stranded copper wire, which is typically used only as a power conductor, adds tons of weight to a commercial aircraft. The limitations of conventional solid and stranded copper wire are particularly important for vehicular motors, for example, in some electric vehicles, the motor may include about 76 kg of copper wire coils. With the added weight, batteries in electric vehicles can weigh hundreds of kilograms. Electric motors, generators and transformers that do not have conventional solid or stranded copper coils are lighter in weight and more efficient. Therefore, new articles and devices with advanced multi-functional wires are needed.

Disclosure of Invention

The present disclosure relates to articles and devices including multifunctional wires and methods of making articles and devices including multifunctional wires. The invention achieves an article of manufacture including a multi-function wire (MCW) having reduced weight and improved efficiency. The disclosed multi-function wire is capable of providing power in less length, weight, and space required than conventional conductors. The present invention discloses a device comprising a multifunctional wire that may have a built-in battery function to provide or store power while providing a current carrier. According to some aspects, the multi-function wire may replace solid or stranded copper wire in motors, generators, transformers, and electromagnetic devices. According to some aspects, the disclosed multifunctional wire may have a battery function, with two or more electrodes surrounded by an insulator with an electrically conductive layer on the outside, and an electrolyte, forming a multifunctional wire that can deliver alternating current as efficiently as a solid copper conductor, while also providing an internal battery. These and other aspects of the disclosure are disclosed in detail herein.

Drawings

Fig. 1A illustrates an exemplary schematic diagram of making a carbon nanotube composite yarn, according to aspects of the present disclosure.

Fig. 1B shows a schematic of two exemplary densification steps according to aspects of the present disclosure.

Fig. 2 shows a Scanning Electron Microscope (SEM) image of a pure carbon nanotube mat according to aspects of the present disclosure.

Fig. 3 shows a photograph of a pure carbon nanotube mat according to aspects of the present disclosure.

Fig. 4 shows an SEM image of a carbon nanotube composite pad according to aspects of the present disclosure.

Fig. 5A illustrates an exemplary multi-functional wire cable including battery electrodes according to some aspects of the present disclosure.

Fig. 5B illustrates an exemplary cross-sectional schematic view of a multi-functional wire according to some aspects of the present disclosure.

Fig. 5C illustrates an exemplary cross-sectional schematic view of a multi-functional wire according to some aspects of the present disclosure.

Fig. 5D illustrates an exemplary cross-sectional schematic view of a multi-functional wire according to some aspects of the present disclosure.

Fig. 5E illustrates an example cross-sectional schematic view of a multi-functional wire according to some aspects of the present disclosure.

Fig. 6A shows a conventional electric motor powered by one or more external batteries.

Fig. 6B illustrates an electric motor powered by a multi-function wire cable that houses a battery in the core, according to some aspects of the present disclosure.

Detailed Description

The present disclosure relates to articles and devices including a multifunctional wire and methods of making articles and devices including a multifunctional wire (MCW). According to some aspects, the multifunction wire may be a wire comprising a core cylinder sealed by an insulating layer covered by an outer copper layer or any other conductive metal layer. The core cylinder may be a cylindrical flexible battery that includes two or more self-supporting electrodes (e.g., carbon nanotube yarns with battery active material) separated by a separator and/or an electrolyte. According to some aspects, a cylindrical flexible battery in the core of the multifunctional wire may power or store electrical power for the electrical device. Depending on the application, one or more outer insulating layers may be applied to the outer conductive layer. Optionally, more layers of conductive material and more layers of insulating material may be applied.

According to some aspects of the multifunctional wire, the thickness of the outer conductive metal layer may vary depending on the desired frequency of the alternating current carried by the outer conductive layer. The thickness can be varied to optimize the conduction of the alternating current without the need for heavy central core metal (or copper) material to deliver small amounts of alternating current. Skin effect refers to the tendency of alternating current to have a maximum current density near the outer surface of a conductor, with the current density flowing into the conductor decreasing with increasing depth of the conductor, particularly with increasing frequency of the alternating current. The skin effect is caused by a counter-directed electromagnetic field with eddy currents created by self-induced magnetic flux in the conductor carrying the alternating current. For Direct Current (DC), the rate of change of the magnetic flux is zero, so there is no reverse electromagnetic field with eddy currents generated by the change of the magnetic flux. For direct current, the current is distributed evenly over the entire cross section of the conductor. For lower frequency alternating current, the central core of the solid wire carries little current; as the frequency of the alternating current increases, the outer surface of the solid wire carries most of the current. For higher frequency alternating current, the central core of the solid wire carries no current. Thus, when applied to the delivery of alternating current, the disclosed multi-functional wire may provide a core cylindrical battery at its core, with alternating current density being minimal at the core of the solid wire. According to some aspects, providing a core cylindrical battery in the core provides a multifunctional wire that is lighter in weight than a solid metal wire, while providing a power source/storage battery in the multifunctional wire.

The multi-function wire can also carry Direct Current (DC). Various components known in the art may be included to convert direct current, for example from a core cylindrical battery, to alternating current for carrying current in the outer conductive metal layer. In another example, the alternating current in the outer conductive metal layer may be converted to direct current for storage in a core cylindrical battery.

The shape of the multifunctional wire may be any shape. For example, a circular or cylindrical shape may be used for ease of manufacture or to resemble conventional metal wire. For example, when the multifunctional wire is wound into a coil, a square shape may be used to maximize efficiency. In some electric motors, the square shape of the multi-function wire may be utilized to maximize winding efficiency and minimize air space between the coil windings. Optionally, the outer shape is malleable and flexible.

The disclosed devices and articles including a multifunctional wire are not limited by the examples provided. For example, applications of multifunction wires include long-distance power transmission lines, weight can be reduced using multifunction wires, and power can be stored or transmitted in designated areas of multifunction wires. For example, the multifunction wire may contain a processor (external or embedded), a transmitter, a receiver, a wireless network, a sensor, a solar cell, and an electronic component that determine the area or portion of the multifunction wire that stores or delivers power. The multi-function wire may contain a diode or array to convert alternating current to direct current. For example, the multi-function wire may include, optical fibers, other conductors, other optical fibers, fasteners, located inside or outside. According to some aspects, vehicles, motors, machines, devices, and articles of manufacture including a multifunctional wire are disclosed. As an illustrative example, a commercial jet aircraft including a multifunction wire may weigh less than a commercial jet aircraft including solid, silver, or nickel plated copper wire. Using the multifunctional wire, the weight of the electric motor can be significantly reduced, and such electric motor can have an increased power-to-weight ratio compared to an electric motor using a solid metal wire. A generator motor, a large generator in a power plant, or an alternator, comprising a multifunctional wire, may weigh significantly less than when solid copper wire is used. The use of a multifunctional wire may allow for a weight reduction of a transformer containing a large coil. Transmitters, antennas, and inductors are other illustrative examples of devices that include a multi-function wire. The multifunctional wire stores power in wires, vehicles, machines and devices may reduce or eliminate the need for additional current carriers for delivering power to or from an external battery.

According to some aspects, an apparatus is disclosed that includes one or more multi-function wire coils, each coil comprising a multi-function wire coil that is rotated into a coil, spiral, or helix shape. Each coil may provide electromagnetic induction/generation while providing battery and/or storage capability. The multi-function wire coil can provide or store electrical energy and conduct electrical energy.

According to some aspects, the disclosed multifunctional leads may include two or more flexible electrodes, each of the flexible electrodes including a carbon nanotube composite yarn including carbon nanotubes and auxiliary particles, and optionally one or more membranes. According to some aspects, the one or more membranes may include a separate membrane disposed between two or more flexible electrodes. As used herein, the term "separated membrane" refers to a membrane that is not in direct contact with two or more flexible electrodes as described herein. Additionally or alternatively, each of the flexible electrodes may independently include a membrane outer layer. In some examples, the separator outer layer may eliminate the need for an additional separator to be placed between the electrodes. The multi-functional lead can also include an electrolyte positioned between the two or more flexible electrodes.

According to some aspects, two or more flexible electrodes may be wound around each other in a twisted configuration. It is known in the art that wrapping two wires around each other significantly reduces electromagnetic interference (also referred to as interference in the radio frequency, RF, radio frequency spectral region) in the wires. According to some aspects, wrapping or twisting two or more flexible electrodes around each other may reduce or eliminate electromagnetic interference in the two or more flexible electrodes from alternating current (in the outer conductive layer) or from environmental sources. Alternatively, two or more flexible electrodes may be in a parallel or quasi-parallel configuration, or not in contact with each other. A flexible insulating layer surrounding the two or more flexible electrodes, optional separator, and electrolyte may contain the two or more flexible electrodes and electrolyte within the multi-functional lead, thereby providing a battery within the multi-functional lead. A flexible conductive layer, such as a metal layer, may surround the flexible insulating layer, the thickness of the flexible conductive layer varying according to the frequency of the alternating current delivered by the flexible conductive layer. The flexible electrode in the multifunctional lead is a self-supporting flexible electrode due to the carbon nano tube. As used herein, the term "self-supporting electrode" refers to an electrode that is capable of operating without one or more components disposed as structural supports. It should be understood that, according to some aspects, any of the carbon nanotube composite yarns described herein may be a self-supporting electrode.

The invention discloses a method for manufacturing a self-supporting flexible electrode. The carbon nanotube composite yarn may be manufactured by: growing floating carbon nanotubes, continuously removing the floating carbon nanotube network to provide a carbon nanotube mat, and concurrently depositing auxiliary particles on at least a portion of the carbon nanotube mat to provide a carbon nanotube composite mat, and densifying the carbon nanotube composite mat to provide a carbon nanotube composite yarn.

The method may include growing floating carbon nanotubes in a reactor. As used herein, the term "nanotube" refers to a tube having at least one nanoscale dimension, i.e., at least one dimension between about 0.6 and 100 nm. For example, nanotubes may include tubes having diameters on the order of nanometers. According to some aspects, nanotubes according to the present disclosure may be selected from single-walled carbon nanotubes, multi-walled carbon nanotubes, and combinations thereof.

The floating carbon nanotubes may be grown in a reactor, such as a Chemical Vapor Deposition (CVD) reactor. For example, fig. 1A illustrates an exemplary reactor 11 that may be used in accordance with aspects of the present disclosure. As shown in fig. 1A, the reactor 11 may include at least a first inlet 12 in fluid communication with a carbon source chamber 13, the carbon source chamber 13 being configured to provide a carbon source, such as a carbon source gas.

Examples of carbon sources include, but are not limited to, one or more carbon-containing gases, one or more hydrocarbon solvents, and mixtures thereof. Specific examples include, but are not limited to, gases and/or solvents containing and/or consisting of hydrocarbons, alcohols, esters, ketones, aromatics, aldehydes, and combinations thereof. For example, the carbon source may be selected from the group consisting of xylene, toluene, propane, butane, butene, ethylene, ethanol, carbon monoxide, butadiene, pentane, pentene, methane, ethane, acetylene, carbon dioxide, naphthalene, hexane, cyclohexane, benzene, methanol, propanol, propylene, commercial fuel gases (e.g., liquefied petroleum gas, natural gas, etc.), and combinations thereof.

The carbon source chamber 13 may also be configured to provide a catalyst and/or a catalyst precursor, such as a catalyst and/or a catalyst precursor vapor. As used herein, the term "catalyst" refers to a component that initiates or accelerates a chemical reaction (e.g., synthesis of nanotubes). Examples of useful catalysts according to the present disclosure include, but are not limited to, transition metals, lanthanide metals, actinide metals, and combinations thereof. For example, the catalyst can include a transition metal, such as chromium (Cr), molybdenum (Mo), tungsten (W), iron (Fe), cobalt (Co), nickel (Ni), ruthenium (Ru), rhodium (Rh), palladium (Pd), osmium (Os), iridium (Ir), copper (Cu), silver (Ag), gold (Au), cadmium (Cd), scandium (Sc), yttrium (Y), lanthanum (La), platinum (Pt), and/or combinations thereof. The catalyst may be a supported catalyst or an unsupported catalyst. According to some aspects, a combination of two or more metals may be used, such as a mixture of iron, nickel, and cobalt. In one example, the mixture may comprise a 50: 50 mixture (by weight) of nickel and cobalt. The catalyst may comprise a pure metal, a metal oxide, a metal carbide, a metal nitrate, other compounds comprising one or more of the metals described herein, and/or combinations thereof.

As used herein, the term "catalyst precursor" refers to a component that can be converted to an active catalyst. Examples of catalyst precursors include, but are not limited to, transition metal salts such as nitrates, acetates, citrates, chlorides, fluorides, bromides, iodides, and/or hydrates thereof, and combinations thereof. For example, the catalyst precursor can be a metallocene, a metal acetylacetonate, a metal phthalocyanine, a metal porphyrin, a metal salt, a metal organic compound, a metal sulfate, a metal hydroxide, a metal carbonate, or a combination thereof. For example, the catalyst precursor can be ferrocene, nickelocene, cobaltocene, molybdenum-cyclopentadienyl, ruthenium-cyclopentadienyl, iron acetylacetonate, nickel acetylacetonate, cobalt acetylacetonate, molybdenum acetylacetonate, ruthenium acetylacetonate, iron phthalocyanine, nickel phthalocyanine, cobalt phthalocyanine, iron porphyrin, nickel porphyrin, cobalt porphyrin, iron salt, nickel salt, cobalt salt, molybdenum salt, ruthenium salt, or a combination thereof. The catalyst precursor may comprise a soluble salt, for example Fe (NO), dissolved in a liquid, for example water₃)₃、Ni(NO₃)₂Or Co (NO)₃)₂. The catalyst precursor can reach an intermediate catalyst state in a catalyst particle growth zone of the reactor and subsequently be converted to an active catalyst when exposed to nanostructure growth conditions in a nanostructure growth zone of the reactor. For example, the catalyst precursor may be a transition metal salt that is converted to a transition metal oxide in the catalyst particle growth zone and then converted to active catalytic nanoparticles in the nanostructure growth zone.

It should be understood that although fig. 1A shows a carbon source chamber 13 containing a carbon source and a catalyst and/or a catalyst precursor, the carbon source chamber 13 being in fluid communication with the reactor 11 via the first inlet 12, the carbon source and the catalyst and/or catalyst precursor may be provided in separate chambers, optionally being in fluid communication with the reactor 11 via separate inlets.

The carbon source and the catalyst and/or catalyst precursor may be provided to the reactor by a carrier gas, such as an inert carrier gas. For example, FIG. 1A shows a carbon source and a catalyst and/or catalyst precursor supplied to reactor 11 by helium (he) gas. Examples of inert gases useful according to the present disclosure include, but are not limited to, gases containing helium (he), radon (Rd), neon (Ne), argon (Ar), xenon (Xe), nitrogen (N), and combinations thereof.

As shown in fig. 1A, the reactor 11 may be provided with a second inlet 14. The second inlet 14 may be in fluid communication with, for example, a hydrogen source configured to provide higher growth yields and/or control the yield of single-walled versus multi-walled carbon nanotubes. Additionally or alternatively, hydrogen gas may be provided via a third inlet 15 in fluid communication with a carbon source chamber channel 16, the carbon source chamber channel 16 being configured to provide fluid communication between the carbon source chamber 13 and the first inlet 12. As shown in fig. 1A, floating carbon nanotubes 17 may be grown in the reactor 11. As used herein, the term "floating" refers to a state of suspension, e.g., in a gas or liquid. As shown in fig. 1A, the floating carbon nanotubes 17 may be suspended in an inert gas as described herein. One or

more heat sources

18a and 18b may be used to maintain and/or change the temperature of reactor 11. In one illustrative example,

heat sources

18a and 18b may individually or collectively comprise a furnace or lamp. One or

more heat sources

18a and 18b may be proximate to reactor 11 and may maintain the temperature of reactor 11 at a temperature suitable for reducing the catalyst precursor to an active catalyst and/or for synthesizing and/or forming carbon nanotubes. According to some aspects, one or

more heat sources

18a and 18b may maintain the temperature of reactor 11 between about 300 ℃ and 1800 ℃, optionally between about 450 ℃ and 1600 ℃.

The method may include providing a structure including, but not limited to, a carbon nanotube mat, or referred to herein as a "mesh". As used herein, the term "mat" or "web" refers to an entangled or bundled substance, such as an entangled non-dense substance formed by floating carbon nanotubes downstream of a nanotube growth zone. The carbon nanotube mat may for example be provided in and/or on the reactor and/or by continuously pulling floating carbon nanotubes from the reactor. For example, fig. 1A shows an example of floating carbon nanotubes 17 prepared in the nanotube growth zone of the reactor 11. Carbon nanotube mat 110 can then be formed in reactor 11 downstream of the nanotube growth zone. The carbon nanotube mat 110 may be deposited on the inner wall of the reactor 11 and/or along the edge of the outlet 19 of the reactor 11. Carbon nanotube mat 110 can be pulled from reactor 11 via outlet 19 by a high flow rate of carrier gas and/or hydrogen, as described herein. Fig. 2 shows an SEM image of a pure carbon nanotube mat, for example, carbon nanotube mat 110 as shown in fig. 1A. Fig. 3 shows a photograph of a pure carbon nanotube mat, for example, the carbon nanotube mat 110 shown in fig. 1A.

The method may include depositing an auxiliary material on at least a portion of the carbon nanotubes to provide a carbon nanotube composite yarn. According to some aspects, the method may include depositing an auxiliary material on at least a portion of the carbon nanotube mat to provide a carbon nanotube composite mat, followed by a densification step in which the carbon nanotube composite mat is densified to provide a carbon nanotube composite yarn. The method may include simultaneous deposition and densification steps, wherein the carbon nanotube mat is densified to provide a carbon nanotube composite yarn while the auxiliary material is deposited on at least a portion of the carbon nanotube mat. According to some aspects, the depositing and/or densifying step may be a continuous step performed in synchronization with the continuous pulling of the carbon nanotube mat from the reactor, as described herein.

As used herein, the term "auxiliary material" refers to a material that comprises at least one material that is different from the carbon nanotube mat material. Examples of materials that may be used as an auxiliary material according to the present disclosure include, but are not limited to, electrode active materials, metals, metal oxides, lithium iron phosphate, ceramics, carbon-based materials, and combinations thereof. Examples of carbon-based materials include, but are not limited to, graphite particles, graphite and graphene flakes, hard carbon, and combinations thereof.

In an illustrative example, the carbon-based material is an electrode active material for a battery electrode. The electrode active material may be a metal oxide. Examples of metal oxides include, but are not limited to, any metal oxide that can be used as an electrode active material in an electrode. In an illustrative example, the metal oxide is a material for the cathode of the battery. Non-limiting examples of metal oxides include those comprising nickel, manganese, cobalt, aluminum, magnesium, titanium, or any mixture thereof. The metal oxide may be lithiated. In an illustrative example, the metal oxide is lithium nickel manganese cobalt oxide (LiNiMnCoO)₂)、Li(Ni，Mn，Co)O₂Li-Ni-Mn-Co-O or (LiNi)_xMn_yCo_zO₂And x + y + z is 1). The metal oxide may be represented by Li-Me-O. The metal in the lithium metal oxide according to the present disclosure may include, but is not limited to, one or more alkali metals, alkaline earth metals, transition metals, aluminum, or post-transition metals, and hydrates thereof. According to some aspects, the electrode active material is selected from the group consisting of graphite, hard carbon, metal oxides, lithium metal oxides, and lithium iron phosphate. According to some aspects, the electrode active material for the anode may be a carbon-based material as described herein, including, but not limited to, graphite particles, graphite flakes, graphene flakes, hard carbon, and combinations thereof. The electrode active material may be any solid metal oxide powder capable of atomization. The metal oxide powder may have a particle size defined in a range between about 1 nanometer and about 100 micrometers. In a non-limiting example, the metal oxide particles have an average particle size of about 1 nanometer to about 10 nanometers.

According to some aspects, a composite flexible self-supporting electrode based on carbon nanotube yarn for anode and cathode is formed by respectively incorporating graphite flakes or Li-Me-O particles in the carbon nanotube yarn. Alternatively, the wire-like electrodes may be wound together and an electrolyte may be added and then covered with a polymer-based insulating material. A copper (or other metal) layer may be deposited on the surface of the wire cell at a desired thickness. The skin of the resulting cable or multifunction wire serves as a typical conductor for alternating current (e.g., for an electric vehicle motor), while the "core" of the cable can serve as a battery to provide power (fig. 6B). The thickness of the deposited copper layer may vary depending on the frequency of the alternating current used. The terms "cable" and "multi-function wire" may be used interchangeably herein to refer to various embodiments of multi-function wires. The term "cable" does not limit the multi-function wire disclosed herein to one insulating layer or one outer conductive metal layer, as in various embodiments, the multi-function wire disclosed herein may have more than one insulating layer and more than one conductive metal layer or current-carrying layer.

"alkali metal" is a metal of group I of the periodic Table of elements, such as lithium, sodium, potassium, rubidium, cesium or francium.

An "alkaline earth metal" is a metal of group II of the periodic Table of the elements, such as beryllium, magnesium, calcium, strontium, barium or radium.

"transition metals" are metals in the d-block of the periodic Table of the elements, including the lanthanides and actinides. Transition metals include, but are not limited to, scandium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, yttrium, zirconium, niobium, molybdenum, technetium, ruthenium, rhodium, palladium, silver, cadmium, lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium, hafnium, tantalum, tungsten, rhenium, osmium, iridium, platinum, gold, mercury, actinium, thorium, lutetium, uranium, neptunium, americium, curium, berkolin, californium, plutonium, malm, senium, morum, curium.

"post-transition metals" include, but are not limited to, gallium, indium, tin, thallium, lead, bismuth, or polonium.

The term "electrode" refers to an electrical conductor in which ions and electrons are exchanged with an electrolyte and an external circuit. "cathode" and "anode" are used synonymously in this specification to refer to the electrode in an electrochemical cell having a higher electrode potential (i.e., higher than the anode). "negative electrode" and "anode" are used synonymously in this specification to refer to the electrode in an electrochemical cell having a lower electrode potential (i.e., lower than the positive electrode). Cathodic reduction refers to electron gain of a chemical and anodic oxidation refers to electron loss of a chemical.

According to some aspects, the auxiliary material may be provided as auxiliary particles deposited on at least a portion of the carbon nanotube mat. According to some aspects, the particles may have a particle size of from about 1 nanometer to about 100 micrometers, optionally from about 1 nanometer to about 10 nanometers. Fig. 1A shows an auxiliary particle chamber 111 containing auxiliary particles 112 as described herein. The auxiliary particle chamber 111 may include at least one outlet 113 proximate the outlet 19 of the reactor 11. In this manner, carbon nanotube mat 110 exiting reactor 11 via outlet 19 may encounter auxiliary particles 112. Although fig. 1A shows only a single auxiliary particle chamber 111, two, three or more auxiliary particle chambers may be provided, wherein each of the plurality of auxiliary particle chambers comprises auxiliary particles of the same or different type as at least one other of the plurality of auxiliary particle chambers.

The auxiliary particle chamber 111 and the transport mechanism are not limited. In non-limiting examples, the auxiliary particle chamber 111 may include one or more of a belt feeder, a gravity feeder, a pneumatic feeder, a vacuum feeder, a screw feeder, a vibratory feeder, a volumetric feeder, and a valve.

According to some aspects, the auxiliary particles may be provided by one or more carriers. Examples of carriers include any substance known in the art that is configured to provide auxiliary particles to the substrate (e.g., carbon nanotube mat) described herein without damaging the carbon nanotubes and/or the auxiliary particles. Examples of suitable carriers include gaseous carriers, liquid carriers, and combinations thereof. Examples of gas carriers include, but are not limited to, Ar, He, N₂Dry air, and combinations thereof. Examples of liquid carriers include, but are not limited to, water, acetone, ethanol, and combinations thereof. According to some aspects, as shown in fig. 1A, one or more carriers may be provided in the auxiliary particle chamber 111 along with the auxiliary particles 112. Alternatively or additionally, one or more additional carrier chambers (not shown) may be provided such that the carrier and auxiliary particles are in communication prior to deposition on the carbon nanotube mat. It is also understood that the carrier may be excluded from the processes described herein such that the auxiliary particles are deposited on at least a portion of the carbon nanotube mat, e.g., as a powder.

Fig. 1A shows a carbon nanotube composite mat 114 containing at least a portion of the auxiliary particles 112. Fig. 4 shows an SEM image of a carbon nanotube composite pad, such as the carbon nanotube composite pad 114 shown in fig. 1A, comprising carbon nanotubes and metal oxide powder. According to some aspects, the carbon nanotube composite mat may comprise 90% (w/w) or less carbon nanotubes, optionally 80% (w/w) specific gravity or less, optionally 70% (w/w) specific gravity or less, optionally 60% (w/w) specific gravity or less, optionally 50% (w/w) specific gravity or less, optionally 40% (w/w) specific gravity or less, optionally 30% (w/w) specific gravity or less, optionally 20% (w/w) specific gravity or less, optionally 10% (w/w) specific gravity or less, optionally 9% (w/w) specific gravity or less, optionally 8% (w/w) specific gravity or less, optionally 7% (w/w) specific gravity or less, optionally 6% (w/w) specific gravity or less, optionally 5% (w/w) specific gravity or less, optionally 4% (w/w) specific gravity or less, optionally 3% (w/w) specific gravity or less, optionally 2% (w/w) specific gravity or less, and optionally 1% (w/w) specific gravity or less. According to some aspects, the carbon nanotube composite mat may comprise 10% (w/w) or more auxiliary particles, optionally 20% (w/w) or more auxiliary particles, optionally 30% (w/w) or more auxiliary particles, optionally 40% (w/w) or more auxiliary particles, optionally 50% (w/w) or more auxiliary particles, optionally 60% (w/w) or more auxiliary particles, optionally 70% (w/w) or more auxiliary particles, optionally 80% (w/w) or more auxiliary particles, optionally 90% (w/w) or more auxiliary particles, optionally 91% (w/w) or more, optionally 92% (w/w) or more, optionally 93% (w/w) or more, optionally 94% (w/w) or more, optionally 95% (w/w) or more, optionally 96% (w/w) or more, optionally 97% (w/w) or more, optionally 98% (w/w) or more, and optionally 99% (w/w) or more. According to some aspects, the carbon nanotube composite mat may include 0.1% to 4% (w/w) carbon nanotubes, with the remainder being auxiliary particles, and optionally one or more additives. Alternatively, the carbon nanotube composite mat may contain 0.2% to 3% (w/w) of carbon nanotubes, with the remainder being auxiliary particles, and optionally including one or more additives. Alternatively, the carbon nanotube composite mat may comprise 0.75% to 2% (w/w) carbon nanotubes, with the remainder being auxiliary particles, and optionally including one or more additives. The additives and/or dopants may be present in each range in an amount of 0 to 5% (w/w). In a non-limiting example, the carbon nanotube composite mat consists essentially of carbon nanotubes and auxiliary particles. In a non-limiting example, the carbon nanotube composite mat is composed of carbon nanotubes and auxiliary particles.

The method can include densifying the carbon nanotube composite mat to provide a carbon nanotube composite yarn as described herein. For example, the carbon nanotube composite mat may be subjected to a liquid bath and/or roller compactor and/or spindle and/or cylindrical tube and/or pipe, for example, to rotate, draw, and/or pass the carbon nanotube composite mat through or around the liquid bath and/or roller compactor and/or spindle and/or cylindrical tube and/or pipe. In this manner, for example, as shown in fig. 1A, the carbon nanotube composite mat 114 may be compacted to provide carbon nanotube composite yarns 115.

As shown in fig. 1A, the carbon nanotube composite yarn 115 may be further processed, for example, by rotating the carbon nanotube composite yarn 115 about a spool 116. Alternatively, or additionally, further processing steps may include removing excess auxiliary material from the carbon nanotube composite mat and/or the carbon nanotube composite yarn, for example, by shaking. One or more further processing steps may be performed before and/or after the densification step as described herein.

Fig. 1B shows two example densification steps as described herein. In particular, fig. 1B shows floating carbon nanotubes 17 grown in reactor 11 to provide carbon nanotube mat 110, such as described with respect to fig. 1A. Fig. 1B further shows an auxiliary particle chamber 111 containing auxiliary particles 112 as described in relation to fig. 1A. Fig. 1B further illustrates two exemplary densification steps, including a rotary densification step 117 and a liquid bath densification step 118. In particular, the rotational densification step 117 may include rotating the carbon nanotube composite mat 114 (the carbon nanotube composite mat 114 including at least a portion of the auxiliary particles 112 as described herein) through or around a roller press and/or spindle to form the carbon nanotube composite yarn 115 similar to the example shown in fig. 1A as described herein.

Fig. 1B also shows a liquid bath densification step 118, which may be performed instead of or in addition to the rotary densification step 117. As shown in fig. 1B, liquid bath densification step 118 may include subjecting carbon nanotube composite mat 114 as described herein to a liquid bath 119 comprising a solvent. According to some aspects, the solvent may be any solvent known in the art that is configured to densify a carbon nanotube mat as described herein. Exemplary solvents include, but are not limited to, water, acetone, ethanol, and combinations thereof. It should be understood that, as shown in fig. 1B, subjecting the carbon nanotube composite mat 114 to a liquid bath 119 containing a solvent may provide a carbon nanotube composite yarn 115, which may be further processed as described herein, for example, by rotating the carbon nanotube composite yarn 115 about the bobbin 116. The further processing step may be selected such that at least a portion of the solvent adhering to the carbon nanotube composite yarn 115 evaporates from the carbon nanotube composite yarn 115 after the carbon nanotube composite yarn 115 is subjected to the liquid bath 119.

The method may comprise a simultaneous deposition and densification step as described herein, wherein the carbon nanotube mat is simultaneously or substantially simultaneously densified to provide the carbon nanotube composite yarn when the auxiliary material is deposited on at least a portion of the carbon nanotube mat. For example, the carriers described herein can be configured to simultaneously deposit the auxiliary particles on the carbon nanotube mat and densify the carbon nanotube mat. One non-limiting example of such a step includes the use of a solvent as described herein, wherein the solvent is used as a carrier to deposit the auxiliary particles on the carbon nanotube mat as described herein. As described herein (e.g., as described with respect to the liquid bath densification step 118 shown in fig. 1B), at the same time, the solvent may densify the carbon nanotube mat to provide the carbon nanotube composite yarn. It should be understood that the simultaneous deposition and densification steps may be performed in place of or in addition to one or more other steps as described herein, including one or more additional deposition steps, one or more additional densification steps, one or more additional simultaneous deposition and densification steps, one or more additional processing steps, and combinations thereof, wherein each additional step is performed separately before or after the simultaneous deposition and densification step.

The entire process of manufacturing the carbon nanotube composite yarn may be a continuous process. For example, a carbon source may be continuously supplied to the reactor 11 so that a carbon nanotube mat may be continuously supplied to the auxiliary particle chamber 111 for continuous deposition of the auxiliary particles, and the resulting composite structure may be continuously processed to form a carbon nanotube composite yarn. However, it should be understood that one or more of the stages may be carried out separately in a continuous, batch, or semi-batch operation. For example, a single portion of a carbon nanotube mat may be fed to the auxiliary particle chamber 111 for deposition of particles thereon. The resulting composite structure may be subjected to additional processing to uniformly distribute the particles throughout the carbon nanotube mat.

After undergoing different degrees of densification, the carbon nanotube composite yarn is a self-supporting flexible electrode, and optionally, a membrane may be covered on the outside of the carbon nanotube composite yarn. As a self-supporting flexible electrode, the carbon nanotube composite yarn may comprise carbon nanotubes as described herein, on which auxiliary particles as described herein are deposited. The carbon nanotube yarn may be an electrode (e.g., an electrode for a battery), an electrode for a multifunctional wire, a supercapacitor, a solar cell, a thermoelectric material, a sensor, an actuator, an element of an electronic device, an interconnect, or an electronic textile, depending on densification, dopants, auxiliary particles, and various conditions used during or after production of the carbon nanotube composite yarn.

The self-supporting flexible electrode may be located inside a cable having at least two electrodes, and in some cases (e.g., where a liquid electrolyte is used), optionally one or more membranes located between the at least two electrodes, wherein at least one electrode comprises a carbon nanotube composite yarn as disclosed herein. According to some aspects, each of the at least two electrodes comprises a carbon nanotube composite yarn as disclosed herein. The cable may further include an electrolyte, an insulating layer, and a conductive layer.

Fig. 5A illustrates an exemplary cable or multi-function wire according to aspects of the present disclosure. Specifically, fig. 5A shows a cable having a first electrode 51 (e.g., an anode) and a second electrode 52 (e.g., a cathode), wherein each of the first and second electrodes individually comprises a carbon nanotube composite yarn as disclosed herein. For example, the first electrode 51 may include a carbon nanotube composite yarn, wherein the auxiliary material includes graphite flakes, and the second electrode 52 may include a carbon nanotube composite yarn, wherein the auxiliary material includes Li-Me-O particles.

According to some aspects, the cable or multi-functional wire may include a first electrode 51 and a second electrode 52 in a coaxial configuration, i.e., wherein the axis of the first electrode 51 and the axis of the second electrode 52 are parallel or quasi-parallel, as shown in fig. 5A. It should be understood that in this example, "quasi-parallel" refers to a relationship between the axes, i.e., such that the axes extend in the same direction and do not overlap each other. According to some aspects, the cable or multi-functional wire may include a first electrode 51 and a second electrode 52 in a twisted configuration. It should be understood that "twisted configuration" may refer to a configuration in which the first electrode 51 and the second electrode 52 are wound around each other

According to some aspects, the first electrode 51 and the second electrode 52 may be separated from each other by a separator (e.g., a nafion film). For example, fig. 5A shows an enlarged view 56 of a first electrode 51, the first electrode 51 comprising a carbon nanotube composite yarn as described herein. The first electrode 51 may be surrounded by a membrane 57 as described herein. The second electrode 52 may have a similar configuration. It should be understood that in some cases, neither the first electrode nor the second electrode may be surrounded by the membrane, one of the first electrode and the second electrode may be surrounded by the membrane, or both the first electrode and the second electrode may be surrounded by the membrane. According to some aspects, the first electrode 51 and the second electrode 52 are not in direct contact with each other.

The multifunctional wire or cable may further include an electrolyte 53 (e.g., a liquid, gel, solid, or combination thereof) substantially surrounding the first electrode 51 and the second electrode 51, an insulating layer 54 substantially surrounding the electrolyte 53, and a conductive layer 55 substantially surrounding the insulating layer 54.

Fig. 5B illustrates an exemplary cross-sectional schematic view of a multi-functional wire according to aspects of the present disclosure, including in fig. 5B a first electrode 51, a second electrode 52, as described herein, and an insulating layer 54 substantially surrounding an electrolyte 53 (in this example, a liquid electrolyte). In this example, the first electrode 51 and the second electrode 52 are surrounded by the

diaphragms

57a and 57b, respectively, as described herein.

Fig. 5C illustrates another exemplary cross-sectional schematic view of a multi-functional wire according to aspects of the present disclosure. Similar to fig. 5B, fig. 5C shows a first electrode 51, a second electrode 52, and an insulating layer 54 substantially surrounding an electrolyte 53 (in this example, a liquid electrolyte), as described herein. In this example, only the second electrode 52 is surrounded by the diaphragm 57b, as described herein. It should be understood that in some examples, only the first electrode 51 may be surrounded by a separator (not shown in fig. 5C).

Fig. 5D illustrates another exemplary cross-sectional schematic view of a multi-functional wire according to aspects of the present disclosure. Similar to fig. 5B and 5C, fig. 5D shows a first electrode 51, a second electrode 52, and an insulating layer 54 substantially surrounding an electrolyte 53 (in this example, a liquid electrolyte), as described herein. In this example, neither the first electrode 51 nor the second electrode 52 is surrounded by the diaphragm 57. In this example, a separate membrane 501 may be provided between the first electrode 51 and the second electrode 52.

Fig. 5E illustrates another exemplary cross-sectional schematic view of a multi-functional wire according to aspects of the present disclosure. Similar to fig. 5B-5D, fig. 5E shows a first electrode 51, a second electrode 52, and an insulating layer 54 substantially surrounding an electrolyte 53 as described herein. In this example, the electrolyte 53 may be a solid and/or gel electrolyte, and thus, a separator is not required.

Materials that can be used for the electrolyte include, but are not limited to, alkyl carbonates (e.g., Ethylene Carbonate (EC), dimethyl carbonate (DMC), diethyl carbonate (DEC), and ethyl-methyl carbonate (EMC)) and LiPF as an electrolyte solution₆Mixtures and gels ofAnd a solid electrolyte.

Materials that may be used for the insulating layer include, but are not limited to, non-conductive materials, such as polymer-based materials. Examples of non-conductive polymer-based materials include plastics, such as polyethylene.

Materials that may be used for the conductive layer include, but are not limited to, materials capable of conducting alternating current, such as copper, nickel, aluminum, and alloys thereof. In one example, conductive layer 55 comprises copper. According to some aspects, the thickness of the conductive layer 55 may be selected based on the frequency of the alternating current used. For example, the skin depth of alternating current is about 7 to 8.5mm when 60Hz is used in copper. For higher frequency alternating current, the thickness of the conductive layer can be thinner without increasing the resistance. According to some aspects, the expected current (amperage) may also determine the thickness of the conductive layer. According to some aspects, the thickness of the conductive layer may be between about 1 μm to about 10 mm. However, the thickness of the conductive layer is not limited. An insulating layer may be applied on the conductive layer and a further conductive layer may be applied on the insulating layer. For example, an electromagnetic shielding (or radio frequency shielding) layer may be applied to the entire multifunctional wire, and the shielding layer may be covered with an insulator.

The depth of penetration of the alternating current in the conductor may be defined by the skin depth, which may be described as the depth at which the current is reduced to 37% of its surface value. Skin depth decreases with increasing frequency. At low frequencies where the skin depth is greater than the wire diameter, the skin effect is negligible and the current distribution and resistance is practically the same as direct current. As the frequency increases, the skin depth becomes smaller than the wire diameter, the skin effect becomes significant, the current is concentrated more and more near the surface, and the resistance per unit length of wire increases above the resistance of its direct current. A non-limiting example of the skin depth of a copper wire at different frequencies is a copper wire having a skin depth of about 0.3 inches (7.6mm) at 60 Hz; at 60kHz, the skin depth of the copper wire is about 0.01 inch (0.25 mm); at 6MHz, the skin depth of the copper wire was about 0.001 inches (25 μm). Circular conductors (e.g., wires or cables with a depth greater than a few skin depths) do not conduct much current near their axis, and therefore the metal located in the center portion of the wire is not effectively utilized.

It should be understood that a cable or multi-function wire according to the present disclosure, such as shown in fig. 5A-5D, may be used as a conductor and battery for alternating current (e.g., for an electric vehicle motor). In particular, at least the first electrode, the second electrode and the electrolyte may together provide energy, while the electrically conductive layer may carry an electric current. The multi-functional wire disclosed herein can be used for direct current and, optionally, can be switched from alternating current to direct current, from direct current to alternating current, and can be used for any range of alternating current frequencies. According to some aspects, one or more conductive layers may include isolated conductors such that there are multiple conductors in the conductive layer. The multifunctional wire may have additional multifunctional wires at any layer around the multifunctional wire.

As shown in fig. 5A, the self-supporting flexible electrode may have one or more conductive battery tabs 58 that may provide an area for electrically connecting or attaching the electrode to an external component or device. The conductive battery tab may be used to connect an electrode to a conductive metal layer or current carrying layer of a multifunctional wire. The conductive battery tab may be attached to or embedded in the flexible self-supporting electrode by any means. The conductive battery tab is not a current collector, for example, a metal substrate of an electrode that is easily peeled off and broken. The self-supporting flexible electrodes disclosed herein may be free of current collectors and binders. According to some aspects, the battery tab may include different materials at or near the area of attachment to the flexible self-supporting electrode, as well as different materials external to or extending from the multifunctional wire. According to aspects of the present disclosure, the battery tab may be attached to the electrodes, or to a protrusion extending from a main body of the respective electrode and not overlapping with the other electrode; or to the body of the respective electrode at the cut-outs of the membrane and the counter electrode. According to some aspects, the battery tab is embedded in the electrode. Suitable battery tab materials and attachment methods include those known to those of ordinary skill in the art. According to some aspects, the conductive battery tab may include copper or lead for the anode. According to some aspects, the conductive battery tab may include aluminum or lead for the cathode. According to some aspects, the battery tab may include a metal at or near the attachment to the electrode and a different metal extending away from the electrode, e.g., a stretchable flexible spring metal that serves as a stretchable flexible battery tab attachment. According to some aspects, a flexible or non-flexible battery tab attachment 59 is attached to the conductive battery tab. The battery tab attachment portion 59 may be attached to the battery tab 58 by any means known in the art, such as welding, fusing, pressing, or interlocking components. Battery tab attachment 59 may be used to connect the electrode to any external component, article, or device. The battery tab 58 or battery tab attachment 59 may be used to connect the electrode to one or more conductive layers of a multi-function wire or a current carrier. For example, the battery tab or the battery tab attachment portion may be connected to a member for converting direct current into alternating current, and further connected to the conductive layer. The battery tab 58 or battery tab attachment portion 59 may be located at one or more exposed ends of the multifunction wire or may be located anywhere along the multifunction wire. According to some aspects, a length of multifunction wire may include a plurality of battery tabs 58 or battery tab attachments 59.

Any electrical device or article may incorporate a multifunctional wire as described herein, including, for example, an electric vehicle motor. Conventional electric vehicle motors, such as electric motor 61 shown in fig. 6A, typically require

external batteries

62A and 62B to generate torque by induced electromagnetic fields. As shown in fig. 6A, such an electric motor may generally include copper coils 63, the copper coils 63 transmitting a current that generates a magnetic field and/or accumulating a current induced by an external magnetic field. According to some aspects, solid copper wire in copper coil 63 may be replaced with a multifunctional wire; the multi-function wire may have a square or rectangular outer shape to improve nesting of coil windings in the electrical device.

Fig. 6B shows one illustrative aspect of the present disclosure, in particular an electric vehicle motor 601. As shown in fig. 6B, an electric vehicle motor 601 may include one or more multi-function wire coils 602 in place of one or more copper coils 63 typically provided in conventional electric vehicle motors (e.g., as shown in fig. 6A). The one or more multi-function wire coils 602 may include a multi-function wire coil having a configuration such as that described with respect to fig. 5A. As described with respect to fig. 5A, the multi-function wire coil may include two electrodes 603 in a twisted configuration, an electrolyte 604, an insulating layer 605, a conductive layer 606, and a battery tab attachment 59. According to some aspects, the multi-function wire coil 602 may be configured to both carry current and partially or fully power the electric vehicle motor 601, thereby reducing or eliminating the need for external batteries (e.g.,

external batteries

62A and 62B shown in fig. 6A). The electric motor 61 shown in fig. 6B is a non-limiting example and may represent a solenoid, a generator, an alternator, and a transformer, any of which includes a multi-function wire according to various aspects of the present disclosure.

In one example, an electric vehicle motor according to the present disclosure may include a stator having one or more stator coils and a rotor. According to some aspects, at least a portion of one or more stator coils may comprise a multi-function wire coil as described herein. Additionally or alternatively, the rotor may comprise one or more rotor coils, wherein at least a portion of the one or more rotor coils comprise a multi-function wire coil as described herein. The electric vehicle motor may also include, for example, a commutator in electrical communication with one or more rotor coils and brushes in contact with the commutator.

One non-limiting example of an electric vehicle motor that can be used in accordance with the present disclosure is described in U.S. published patent No.2019/068033 a1, the disclosure of which is incorporated herein in its entirety. It should be understood that the motor described in U.S. published patent No.2019/068033 a1 may include one or more multi-function wire coils as disclosed herein in addition to the coils described therein. For example, the permanent magnets of the stator may be formed of or replaced by stator coils that include multi-function wire coils that serve as permanent magnets. Additionally or alternatively, one or more of the coils described in U.S. published patent No.2019/068033 a1 may be replaced with one or more multi-function wire coils in accordance with the present disclosure.

The present invention also relates to methods of using carbon nanotube composite yarns prepared according to the methods described herein. For example, a method may include making an article or device comprising a carbon nanotube composite yarn as described herein. For example, the method may include weaving the carbon nanotube composite yarn to provide an electronic textile. The method may comprise preparing a multifunctional wire or cable as described herein. For example, the method may include providing a first electrode (e.g., an anode) and a second electrode (e.g., a cathode) in a selectable twisted configuration, and separated by one or more separators and/or electrolytes, wherein each of the first and second electrodes individually comprises a carbon nanotube composite yarn as disclosed herein. The method may further include providing an electrolyte surrounding the first electrode and the second electrode, providing an insulating layer surrounding the electrolyte, and providing a conductive layer surrounding the insulating layer.

According to some aspects, a method of manufacturing a multifunctional wire may include providing a first flexible electrode including a first carbon nanotube composite yarn including carbon nanotubes and a first auxiliary material (e.g., first auxiliary particles); providing a second flexible electrode comprising a second carbon nanotube composite yarn comprising carbon nanotubes and a second auxiliary material (e.g., second auxiliary particles); optionally, surrounding the first flexible electrode with a first membrane; optionally surrounding the second flexible electrode with a second membrane; surrounding the first compliant electrode and the second compliant electrode with an electrolyte; surrounding the electrolyte with a flexible insulating layer; and at least partially surrounding the flexible insulating layer with a flexible conductive layer.

It should be understood that the steps described herein are not limited to one order. For example, in the case of a liquid electrolyte, a method of manufacturing a multifunctional lead may include providing first and second flexible electrodes in a configuration described herein (e.g., in a parallel, quasi-parallel, or twisted configuration), wherein the first and second flexible electrodes are provided with first and second diaphragms, respectively, and/or a separate diaphragm is provided between the first and second flexible electrodes, as described herein. The method may further comprise providing the first and second compliant electrodes in an insulating layer as described herein, and subsequently surrounding the first and second compliant electrodes with an electrolyte as described herein. In this example, the flexible conductive layer may be provided before, during, or after any of the steps described herein.

In another example, in the case of a solid or gel electrolyte, a method of manufacturing a multifunctional lead can include providing an electrolyte in communication with (e.g., on a surface and/or immersed in) a first flexible electrode and a second flexible electrode, wherein the first flexible electrode and/or the second flexible electrode are independently provided with or without a first separator and/or a second separator, respectively. It is to be understood that the first separator and/or the second separator may be provided separately before, during, and/or after the electrolyte is provided, or may not include the first separator and/or the second separator. The method may further comprise subsequently providing the first electrode and the second electrode in a configuration described herein (e.g., a parallel, quasi-parallel, or twisted configuration). In this example, the first and second electrodes may be disposed in the insulating layer before, during, or after they are provided in the final configuration. Further, in this example, the flexible conductive layer may be provided before, during, or after any of the steps described herein.

According to some aspects, providing a flexible conductive layer as described herein may be performed by any useful technique according to the present disclosure. For example, the flexible conductive layer may be provided using electrodeposition techniques, electroplating techniques, or a combination thereof. In one non-limiting example, the flexible conductive layer can be provided by an electroplating technique that includes providing an electrical current that causes dissolved metal ions to attach to a surface, such as a surface of an insulating layer as described herein. In another non-limiting example, the flexible electrically conductive layer may be provided as a preformed structure (e.g., a preformed elongated hollow body, such as a tube) in which the first flexible electrode, the second flexible electrode, the first separator film, the second separator film, the electrolyte, and/or the flexible insulating layer may be provided as described herein.

Disclosed herein are methods of assembling an article or device comprising a multifunctional wire (MCW). For example, the multi-function wire may be attached to one or more electrical components of the device to assemble a device including the multi-function wire, wherein the multi-function wire may provide current transfer capability while providing or storing power for the device. The multifunctional wire may be wound into a coil, optionally a metal core coil, and the coil attached to a component to assemble a device or article comprising the multifunctional wire. According to some aspects, a device or article having a multifunctional wire may be assembled by attaching the multifunctional wire, which serves as a current carrier and a power source and/or an energy storage for components of the device or article.

A device or article comprising a multifunctional wire may utilize a multifunctional wire having a conductive layer of a particular thickness. According to some aspects, the thickness of the conductive layer may be determined according to the frequency of the alternating current in the device. For direct current, the resistance of a solid metal conductor depends on its cross-sectional area; for a given length, the resistance of a conductor with a larger area is lower. At high frequencies, the alternating current does not penetrate into the conductor due to eddy currents induced in the material; it tends to flow near the surface, which is the so-called skin effect. Because of the small cross-sectional area of the wire used, the resistance of the wire is greater than when direct current is used. The higher the frequency of the current, the smaller the depth of penetration of the current and the smaller and smaller the cross-sectional area the current is brought into along the surface, so that the resistance of the alternating current of the wire increases with the frequency.

This detailed description uses examples to present the disclosure, including preferred aspects and variations, and to enable any person skilled in the art to practice the disclosed aspects, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. Those of ordinary skill in the art may mix and match aspects of the various embodiments described, as well as other known equivalents for each such aspect, in accordance with the principles of the application to form additional embodiments and techniques.

According to some aspects, various electrical devices may incorporate a multi-function wire to make the electrical device more efficient, e.g., have a greater power-to-weight ratio, have power storage capability without an external battery, or have power provided by the multi-function wire. While the described aspects of the invention have been described in conjunction with the exemplary aspects outlined above, various alternatives, modifications, variations, improvements, and/or substantial equivalents, whether known or that are or may be presently unforeseen, may become apparent to those having ordinary skill in the art. Accordingly, the exemplary aspects described above are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the disclosure. Accordingly, the present disclosure is intended to embrace all known or later-developed alternatives, modifications, variations, improvements, and/or substantial equivalents.

Unless specifically stated otherwise, the singular forms of elements do not mean "one and only one" but rather "one or more". All structural and functional equivalents to the elements of the various aspects described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference. Moreover, nothing disclosed herein is intended to be dedicated to the public.

Moreover, the word "example" is used herein to mean "serving as an example, instance, or illustration" any aspect described herein as "example" is not necessarily to be construed as preferred or advantageous over other aspects. The term "some" means one or more unless otherwise specified. Combinations such as "A, B or at least one of C", "at least one of A, B and C", and "A, B, C or any combination thereof" include any combination of A, B and/or C, and may include multiples of a, multiples of B, or multiples of C. Specifically, combinations such as "at least one of A, B or C", "at least one of A, B and C", and "A, B, C, or any combination thereof" may be a only, B only, C only, a and B, a and C, B and C, or a and B and C, where any such combination may contain one or more elements of a, B, or C.

As used herein, the terms "about" and "approximately" are defined as being close to as understood by one of ordinary skill in the art. In one non-limiting embodiment, the terms "about" and "approximately" are defined as being within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.5%.

Claims

1. An electrical device, comprising:

a multi-functional wire, the multi-functional wire comprising:

an elongated hollow body comprising an electrically conductive material;

a first electrode comprising a first carbon nanotube composite yarn comprising carbon nanotubes and a first auxiliary material;

a second electrode comprising a second carbon nanotube composite yarn comprising carbon nanotubes and a second auxiliary material,

wherein the multifunctional wire is operable to carry electrical current and provide power to the electrical device and/or store power.

2. The electrical device of claim 1, wherein the multi-functional wire further comprises an electrolyte surrounding the first electrode and the second electrode.

3. The electrical device of claim 2, wherein the multi-function wire further comprises a flexible insulating layer surrounding the electrolyte, and wherein the electrically conductive material comprises a flexible electrically conductive layer at least partially surrounding the flexible insulating layer.

4. The electrical device of claim 3, wherein the multi-function wire further comprises an outer flexible insulating layer surrounding the flexible conductive layer.

5. The electrical device of claim 1, wherein the multi-function wire further comprises:

one or more electrically conductive battery tabs attached to the first electrode and/or the second electrode, and

one or more respective battery tab attachments to which the one or more electrically conductive battery tabs are attached.

6. The electrical device of claim 1, wherein at least one of the first electrode and the second electrode is surrounded by a membrane, and

wherein the first electrode and the second electrode are intertwined in a twisted configuration.

7. The electrical device of claim 1, wherein at least a portion of the multi-function wire is in a winding of one or more coils, each coil comprising a portion of the multi-function wire wound in a spiral or helical shape.

8. The electrical device of claim 7, wherein the portion of the multi-function wire in the windings of one or more coils has a square or rectangular outer shape operable to nest the multi-function wire in the windings of one or more coils.

9. The electrical device of claim 7, wherein the windings of one or more coils surround a metal core.

10. The electrical device of claim 3, wherein the flexible conductive layer has a thickness of about 1 micron to about 10 millimeters.

11. The electrical device of claim 1, wherein the electrical device is selected from the group consisting of an electric motor, a solenoid, a generator, an alternator, and a transformer.

12. The electrical device of claim 1, wherein the electrically conductive material comprises a flexible electrically conductive layer comprising copper.

13. The electrical device of claim 6, wherein the first and second diaphragms are not in contact with each other.

14. A method of manufacturing an electrical device comprising a multi-function wire, the method comprising:

providing a multifunctional lead;

connecting the multi-function wire to an electrical device such that the multi-function wire is operable to carry electrical current and provide power to the electrical device and/or store power.

15. The method of claim 14, further comprising winding at least a portion of the multi-functional wire in a winding of one or more coils, each coil comprising a portion of the multi-functional wire wound in a spiral or helical shape.

16. The method of claim 14, wherein providing the multifunctional wire comprises:

providing a first electrode comprising a first carbon nanotube composite yarn comprising carbon nanotubes and a first auxiliary material; and

providing a second electrode comprising a second carbon nanotube composite yarn comprising carbon nanotubes and a second auxiliary material.

17. The method of claim 16, wherein providing the multi-functional lead further comprises:

surrounding the first electrode and the second electrode with an electrolyte;

surrounding the electrolyte with a flexible insulating layer;

at least partially surrounding the flexible insulating layer with a flexible conductive layer; and

the flexible conductive layer is surrounded by an outer flexible insulating layer.

18. The method of claim 17, wherein providing the multi-functional lead further comprises:

attaching one or more electrically conductive battery tabs to the first electrode and/or the second electrode; and

attaching one or more respective battery tab attachments to one or more of the electrically conductive battery tabs.

19. The method of claim 16, wherein providing the multi-functional lead further comprises:

surrounding at least one of the first electrode and the second electrode with a separator; and

winding the first and second electrodes around each other in a twisted configuration.

20. The method of claim 16, wherein providing the first electrode comprises:

growing floating carbon nanotubes in a reactor;

removing the floating carbon nanotubes from the reactor to provide a carbon nanotube mat;

depositing auxiliary particles comprising the first auxiliary material on at least a portion of the carbon nanotube mat to provide a carbon nanotube composite mat; and

densifying the carbon nanotube composite mat to provide a carbon nanotube composite yarn.

21. An electric motor, comprising:

a rotor comprising one or more rotor coils; and

a stator comprising one or more stator coils,

wherein at least a portion of the one or more stator coils comprise a wire, and

wherein the wire comprises:

an elongated hollow body;

a first flexible electrode located in the hollow body and comprising a first composite yarn comprising carbon nanotubes and a first auxiliary material;

a second flexible electrode located in the hollow body and comprising a second composite yarn comprising carbon nanotubes and a second auxiliary material.

22. The electric motor of claim 21, wherein the wire further comprises an electrolyte surrounding the first and second electrodes.

23. The electric motor of claim 22, wherein the wire further comprises a flexible insulating layer surrounding the electrolyte, and wherein the conductive material comprises a flexible conductive layer at least partially surrounding the flexible insulating layer.

24. The electric motor of claim 23, wherein the wire further comprises an outer flexible insulating layer surrounding the flexible conductive layer.

25. The electric motor of claim 21, further comprising a commutator in electrical communication with the one or more rotor coils and a brush in contact with the commutator.