JP2022518347A - 複合体の製造法 - Google Patents
複合体の製造法 Download PDFInfo
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- JP2022518347A JP2022518347A JP2021534208A JP2021534208A JP2022518347A JP 2022518347 A JP2022518347 A JP 2022518347A JP 2021534208 A JP2021534208 A JP 2021534208A JP 2021534208 A JP2021534208 A JP 2021534208A JP 2022518347 A JP2022518347 A JP 2022518347A
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- carbon nanotube
- prepreg
- sheet
- curing
- nanotube sheets
- Prior art date
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Images
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Abstract
Description
本出願は、2018年12月12日に出願された米国特許仮出願第62/778,737号明細書の利益および優先権を主張し、その内容は全部、引用により本明細書に編入する。
なし
は本明細書では「室温保存」と互換的に使用される。
本開示と関連して使用されるカーボンナノチューブは、様々な取り組みを使用して作製することができる。現在、ナノチューブを成長させるための多くのプロセスおよびそれらの変更法が存在し、それらには以下を含む:(1)化学蒸着(CVD)、大気圧付近または高圧、および約400℃より高い温度で行うことができる一般的プロセス、(2)Arc放電、高度な完全性(perfection)を有するチューブに行うことができる高温プロセス、および(3)レーザーアブレーション。
本明細書で使用するように用語「カーボンナノチューブシート」は、シートの一般的外観、およびシートとして取り扱うことになる十分な構造的一体性(integrity)を有するカーボンナノチューブ(本明細書にすでに記載したものを含む)の不織物品を一般的に対象としている。すなわち1つの態様では、カーボンナノチューブシートは、実質的に非整列のカーボンナノチューブの自己支持型不織シートである。そのようなシートは例えば限定するわけではないが、圧縮された実質的に非整列のマトリックスから、および混ざったカーボンナノチューブ、カーボンナノチューブの束、または絡み合ったカーボンナノチューブから、シートとして取り扱われる十分な構造的一体性を持って生成され得る。
。いずれの場合でも「実質的に非整列」とはカーボンナノチューブが実質的に垂直に整列していないことを明らかに意味している。
(すなわち触媒処理アルキル-フェニルホルムアルデヒド)、ポリビニルアルコール(“PVA”)、または液体樹脂、または加熱処理するとガラス炭素を形成することが知られている任意の材料を含む。もちろん他の市販されているガラス炭素材料または前駆体材料を使用することができる。
1つの観点によれば、本開示はプリプレグおよびプリプレグの上および/または下に配置される1もしくは複数のカーボンナノチューブシートを含んでなる硬化系を対象とする。
留意されたい。これらのエポキシ樹脂をハロゲン化することにより調製されるハロゲン化エポキシ樹脂も使用できる。さらに2以上のこれらエポキシ樹脂の混合物、およびモノエポキシ化合物を硬化性樹脂に使用できる。
本開示の1つの特定の観点は、複合積層体を形成するために単一プリプレグをカーボンナノチューブシートで硬化する方法を対象とする。この方法は、(i)プリプレグ、および1もしくは複数ノカーボンナノチューブシートを準備し、ここで少なくとも1つのカーボンナノチューブシートはプリプレグの上および/または下に配置され;そして(ii)(a)プリプレグの少なくとも一部が硬化されるように電流を1もしくは複数のカーボン
ナノチューブシートに流すか、(b)プリプレグの少なくとも一部が硬化されるように硬化系を交流電磁場(EMFs)に供するか、または(c)プリプレグの少なくとも一部が硬化されるように電流を1もしくは複数のカーボンナノチューブシート流し、かつプリプレグの少なくとも一部が硬化されるように交流電磁場に硬化系を供する両方のいずれかにより、硬化系を少なくとも部分的に硬化することを含む。
ができる。プリプレグまたはプリプレグのスタックの硬化条件を能動的に制御するためのそのような能力は、生じる複合体に実質的に均一な硬化を導く。
本開示の別の観点は、液体硬化性組成物の硬化法を対象とする。この方法は(i)
カーボンナノチューブシートを硬化性組成物と接触させ、ここでカーボンナノチューブシートと接触する硬化性組成物の量は、カーボンナノチューブシート上に約1mmから160mm、または約5mmから約155mm、または約10mmから約140mm、または約20mmから約130mm、または約50mmから約100mm、または約50mmから約80mmの厚さを有する層を形成するために十分であり;そして(ii)(a)液体硬化性組成物の少なくとも一部が硬化されるように電流を1もしくは複数のカーボンナノチューブシートに流すか、(b)液体硬化性組成物の少なくとも一部が硬化されるように硬化系を交流電磁場(EMFs)に供するか、または(c)液体硬化性組成物の少なくとも一部が硬化されるように電流を1もしくは複数のカーボンナノチューブシートに流し、かつ硬化系を交流電磁場に供する両方のいずれかにより、液体硬化性組成物を少なくとも部分的に硬化する(すなわち液体硬化性組成物を、液体硬化性組成物が少なくとも部分的に硬化される程度まで硬化する)ことを含む。
より限定するわけではないが、触媒または硬化剤、酸化防止剤、強化剤、UV安定化剤および難燃剤を含む1もしくは複数の添加剤を含んでなる。
Claims (19)
- 複合積層体の製造法であって:
(i)-2以上のプリプレグのスタック;および
-1もしくは複数のカーボンナノチューブシート、ここで前記カーボンナノチューブシートの少なくとも1つが2以上のプリプレグの間に配置され、そしてここで前記カーボンナノチューブシートは、実質的に非整列のカーボンナノチューブの自己支持型不織シートである;
を含んでなる硬化系を準備し;そして
(ii)(a)前記プリプレグの少なくとも一部が硬化されるように電流を前記1もしくは複数のカーボンナノチューブシートに流すか、(b)プリプレグの少なくとも一部が硬化されるように硬化系を交流電磁場に供するか、または(c)前記プリプレグの少なくとも一部が硬化されるように電流を前記1もしくは複数のカーボンナノチューブシート流しおよび硬化系を交流電磁場に供することの両方、のいずれかにより硬化系を少なくとも部分的に硬化する、
ことを含んでなる前記方法。 - 各プリプレグが繊維強化材および硬化性樹脂の混合物を含んでなる請求項1に記載の方法。
- 前記繊維強化材が導電性繊維、非導電性繊維およびそれらの組み合わせから選択される繊維からなる請求項2に記載の方法。
- 前記繊維強化材が導電性繊維を含んでなる請求項3に記載の方法。
- 非導電シートがそれぞれの1もしくは複数のカーボンナノチューブシートとプリプレグの間に配置される請求項4に記載の方法。
- 前記カーボンナノチューブシートがそれらの中に包含された硬化性樹脂をさらに含んでなる請求項1に記載の方法。
- 2以上のプリプレグの前記スタックが0.1mmから160mmの範囲の厚さを有する請求項1に記載の方法。
- 2以上のプリプレグの前記スタックが50mmから約80mmの範囲の厚さを有する請求項1に記載の方法。
- 前記カーボンナノチューブシートが前記プリプレグ間の異なる場所に離れて配置されることができる請求項1に記載の方法。
- 前記プリプレグの厚さが、前記1もしくは複数のカーボンナノチューブシートの両側で実質的に同じになるように、前記1もしくは複数のカーボンナノチューブシートが2以上のプリプレグの前記スタックの中央に配置される請求項1に記載の方法。
- 前記硬化系を少なくとも部分的に硬化する工程が、前記プリプレグの少なくとも一部が硬化されるように電流を前記1もしくは複数のカーボンナノチューブシートに流すことを含んでなる請求項1に記載の方法。
- 前記硬化系を少なくとも部分的に硬化する工程が、前記プリプレグの少なくとも一部が硬化されるように硬化系を交流電磁場に供することを含んでなる請求項1に記載の方法。
- 前記硬化系が実質的に均一に硬化される請求項11または12に記載の方法。
- 液体硬化性組成物の硬化法であって:
-カーボンナノチューブシートを液体硬化性組成物と接触させることを含んでなり、ここで(i)前記カーボンナノチューブシートと接触する硬化性組成物の量は、前記カーボンナノチューブシート上に1mmから160mmの厚さを有する層を形成するために十分であり、そして(ii)前記カーボンナノチューブシートは実質的に非整列のカーボンナノチューブの自己支持型不織シートである;および
-(a)前記プリプレグの少なくとも一部が硬化されるように電流を1もしくは複数のカーボンナノチューブシートに流すか、(b)前記プリプレグの少なくとも一部が硬化されるように硬化系を交流電磁場に供するか、または(c)前記プリプレグの少なくとも一部が硬化されるように電流を前記1もしくは複数のカーボンナノチューブシートに流し、かつ硬化系を交流電磁場に供する両方のいずれかにより、硬化系を少なくとも部分的に硬化することを含んでなる、
前記方法。 - 前記カーボンナノチューブシートが、型に最初に配置される請求項14に記載の方法。
- 前記カーボンナノチューブシートが、その中に少なくとも部分的に包含された硬化性樹脂をさらに含んでなる請求項14に記載の方法。
- 前記カーボンナノチューブシートが、シリコン基材および/またはポリオレフィン、ナイロン、フッ化ポリマー、エチレン-ビニルアセテート、またはそれらの組み合わせの積層体により少なくとも部分的に覆われている請求項14に記載の方法。
- 複合積層体の製造法であって:
(i)-プリプレグ、および
-1もしくは複数ノカーボンナノチューブシート、ここで前記カーボンナノチューブシートの少なくとも1つはプリプレグの上および/または下に配置され、そしてここで前記カーボンナノチューブシートは、実質的に非整列のカーボンナノチューブの自己支持型不織シートである;
を含んでなる硬化系を準備し;そして
(ii)(a)前記プリプレグの少なくとも一部が硬化されるように電流を前記1もしくは複数のカーボンナノチューブシートに流すか、(b)硬化系を交流電磁場(EMFs)に供するか、または(c)前記プリプレグの少なくとも一部が硬化されるように電流を前記1もしくは複数のカーボンナノチューブシート流しおよび硬化系を交流電磁場に供することの両方、のいずれかにより硬化系を少なくとも部分的に硬化する、
ことを含んでなる前記方法。 - 請求項1,14または18のいずれか1つの方法により得られる複合体。
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