JP6703113B2 - 形状適応性複数層複合材 - Google Patents
形状適応性複数層複合材 Download PDFInfo
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- JP6703113B2 JP6703113B2 JP2018532545A JP2018532545A JP6703113B2 JP 6703113 B2 JP6703113 B2 JP 6703113B2 JP 2018532545 A JP2018532545 A JP 2018532545A JP 2018532545 A JP2018532545 A JP 2018532545A JP 6703113 B2 JP6703113 B2 JP 6703113B2
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Classifications
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- B32B9/005—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile
- B32B9/007—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile comprising carbon, e.g. graphite, composite carbon
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- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10807—Making laminated safety glass or glazing; Apparatus therefor
- B32B17/10889—Making laminated safety glass or glazing; Apparatus therefor shaping the sheets, e.g. by using a mould
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- B32B27/00—Layered products comprising a layer of synthetic resin
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- B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
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- Adhesives Or Adhesive Processes (AREA)
Description
本明細書において、用語「ナノファイバー」とは、1μm未満の平均径を有する繊維を意味する。本明細書の実施形態は主にカーボンナノチューブから作製されるものとして述べられているが、グラフェン、ミクロンもしくはナノスケールのグラファイト繊維及び/又はプレートのいずれかに関わらず他の炭素同素体も、更には窒化ホウ素などのナノスケール繊維の他の組成物も、以下に記載される技術を使用してナノファイバーシートを作製するために使用し得ることが認識されるであろう。本開示の目的のためには、炭素系材料(例えばカーボンナノチューブ)と非炭素系材料の両方を「ナノファイバー」とみなすことができる。
主題の開示の様々な実施形態によれば、ナノファイバー(カーボンナノチューブが含まれるが、これに限定されない)は、本明細書で「フォレスト」と呼ばれる構造を含む様々な構造で配置されていてもよい。本明細書において、ナノファイバーまたはカーボンナノチューブの「フォレスト」とは、基材の上でお互いに実質的に配向した配列の、ほぼ等しい寸法を有するナノファイバーの配列のことをいう。ナノファイバーは、特にこれらの根元で基材に対して実質的に垂直である。図1は基材上のナノファイバーの例示的なフォレストを示している。基材は任意の形状であってもよいが、いくつかの実施形態においては基材は平らな表面を有し、その上にフォレストが集積している。図1から分かるように、フォレスト中のナノファイバーは高さ及び/又は直径がほぼ等しくてもよい。
主題の開示に従って、ナノファイバーフォレストの製造のために様々な方法を使用することができる。例えば、いくつかの実施形態においては、ナノファイバーは高温炉の中で成長させることができる。いくつかのそのような実施形態においては、触媒は反応器の中に配置されている基材の上で堆積されてもよく、その後反応器に供給される燃料化合物に曝されてもよい。基材は800℃超1000℃までの温度に耐えることができ、これは不活性材料であってもよい。基材は、Siウェハーの代わりに他のセラミック基材が使用されてもよいものの(例えばアルミニウム、ジルコニア、SiO2、及びガラスセラミック)、下にあるシリコン(Si)ウェハー上に配置したステンレス鋼またはアルミニウムが含まれていてもよい。フォレストのナノファイバーがカーボンナノチューブである例においては、アセチレン、メタン、及びエタンなどの脂肪族炭化水素を含む炭素を主体とする化合物が炭素原子源として使用されてもよい。反応器に入れられた後、燃料化合物(複数可)はその後分解し、得られる炭素原子は触媒上に堆積することができ、基材から上方へ成長することによってナノチューブの集積を開始してナノファイバーのフォレストを形成する。
フォレスト構造の中での配置に加えて、主題の用途のナノファイバーは、シート構造に配列されていてもよい。本明細書において、用語「ナノファイバーシート」、「ナノチューブシート」、または単純に「シート」とは、ナノファイバーが端から端へ平面に並んでおり、シートの厚さの100倍よりも大きい長さ及び/又は幅を有する、ナノファイバーの配列のことをいう。ナノファイバーシートは、例えば約5nm〜20μmの厚さ、並びに意図される用途に好適な任意の長さ及び幅を有していてもよい。いくつかの実施形態においては、ナノファイバーシートは100m超の長さと1m超の幅を有していてもよい。図示の相対的な寸法を有する例示的なナノファイバーシートが図3に示されている。図3から分かるように、ナノファイバーが端から端へ並んでいる方向は、ナノファイバーの配向の方向と呼ばれる。いくつかの実施形態においては、ナノファイバーの配向の方向はナノファイバーシート全体にわたって連続的であってもよい。
様々な実施形態として、ナノチューブシートはポリマーシートの外表面に接合させることができ、これはポリマーシートの中に埋め込まれていてもよく、あるいはポリマーシートの中に部分的に埋め込まれていてもよい。別の実施形態においては、2つ又は3つ以上のポリマーシートの間に1つ又は複数のナノチューブシートが挟まれているサンドイッチ構造を採用することができる。サンドイッチ構造においては、2つ又は3つ以上のナノチューブシートが互いに直接接触していてもよい。2つ又は3つ以上のポリマーシートの間の中に1つ又は複数のナノチューブシートがあるこの交互構造は、一体に積層されている構造が2、3、4、または5回など、任意の回数繰り返されていてもよい。同じ構造の中で、異なる種類のナノチューブシート及び異なる種類のポリマーシートを使用することができる。例えば、ナノチューブシートは溶融により形状適応可能なポリマーと導電性ポリマーとの間に挟まれていてもよく、あるいは溶融により形状適応可能なポリマーと熱硬化性ポリマーとの間に挟まれていてもよい。
Claims (18)
- カーボンナノチューブを含むナノファイバーシートであって、前記カーボンナノチューブが前記ナノファイバーシートの端から端へと平面に並んでおり、1000オーム/スクウェア未満の電気抵抗を有するナノファイバーシートと、
前記ナノファイバーシートに接着しており、ホットメルトポリマーを含んでなるポリマー層であって、熱により形状適応可能なポリマー層と
を備えるナノファイバー複合材であって、
前記ナノファイバーシートの表面上に金属層を更に備え、前記金属層の少なくとも一部が前記ポリマー層を介して露出しているナノファイバー複合材。 - カーボンナノチューブを含むナノファイバーシートであって、前記カーボンナノチューブが前記ナノファイバーシートの端から端へと平面に並んでおり、1000オーム/スクウェア未満の電気抵抗を有するナノファイバーシートと、
前記ナノファイバーシートに接着しており、熱により形状適応可能なポリマー層と
を備えるナノファイバー複合材であって、
前記ナノファイバーシート中の前記カーボンナノチューブの表面上に炭化物形成金属の緩衝層を備え、前記緩衝層上に銅の形状適応層を更に備えるナノファイバー複合材。 - 前記ナノファイバーシートが100nm未満の平均厚さを有する請求項1又は2に記載のナノファイバー複合材。
- 前記ナノファイバーシートが前記ポリマー層に埋め込まれている請求項1又は2に記載のナノファイバー複合材。
- 複数のナノファイバーシートを備える請求項1に記載のナノファイバー複合材。
- 前記複数のナノファイバーシートが互いに電気的に接触している請求項5に記載のナノファイバー複合材。
- 前記複数のナノファイバーシートが互いに電気的に絶縁されている請求項5に記載のナノファイバー複合材。
- 前記形状適応可能なポリマー層が前記複数のナノファイバーシートの間に重ねられている請求項5に記載のナノファイバー複合材。
- カーボンナノチューブを含むナノファイバーシートであって、前記カーボンナノチューブが前記ナノファイバーシートの端から端へと平面に並んでおり、1000オーム/スクウェア未満の電気抵抗を有するナノファイバーシートと、
前記ナノファイバーシートに接着しており、ホットメルトポリマーを含んでなるポリマー層であって、熱により形状適応可能なポリマー層と
を備えるナノファイバー複合材であって、
前記複合材が、前記ナノファイバー複合材の表面に対して90°の可視光の50%超、75%超、90%超、95%超、98%超、または99%超を透過するものである、ナノファイバー複合材。 - ガラス、またはセラミック、または透明ポリマーを更に備える請求項1又は2に記載のナノファイバー複合材。
- カーボンナノチューブを含むナノファイバーシートであって、前記カーボンナノチューブが前記ナノファイバーシートの端から端へと平面に並んでおり、1000オーム/スクウェア未満の電気抵抗を有するナノファイバーシートと、
前記ナノファイバーシートに接着しており、ホットメルトポリマーを含んでなるポリマー層であって、熱により形状適応可能なポリマー層と
を備えるナノファイバー複合材であって、
前記熱により形状適応可能なポリマー層がポリビニルブチラールまたはエチレン−ビニルアセテートを含む、ナノファイバー複合材。 - 前記複合材が、乗り物用のフロントガラスまたは窓を備える請求項1又は2に記載のナノファイバー複合材。
- ナノファイバー複合材の使用方法であって、
少なくとも1つのカーボンナノファイバーシートと少なくとも1つの熱により形状適応可能なポリマーとを備える複合材に熱を加えるステップであって、前記カーボンナノファイバーシートは、カーボンナノチューブが前記カーボンナノファイバーシートの端から端へと平面に並んでいるものであり、前記熱により形状適応可能なポリマーは、ホットメルトポリマーを含んでなり、前記ナノファイバー複合材は金属化されている、ステップと、
前記ナノファイバー複合材の形状を変えて、その下にある装置の形状に適応させるステップと、
前記ナノファイバー複合材を冷まして、前記ナノファイバー複合材が前記装置に接合する形状に前記ナノファイバー複合材を硬化させるステップと
を含む方法。 - 前記ナノファイバー複合材の形状を変えるステップが、真空を用いることを含む請求項13に記載の方法。
- 前記ナノファイバー複合材の表面を加圧して、前記ナノファイバー複合材を前記装置の形状に適応させるステップを更に含む請求項13に記載の方法。
- 前記熱が、ジュール加熱、誘導加熱、放射加熱、伝導加熱、または対流加熱によって加えられる請求項13に記載の方法。
- 前記熱が、前記ナノファイバー複合材中のナノファイバー層を加熱することにより加えられる請求項13に記載の方法。
- 前記ナノファイバー複合材が、前記装置に到達する電磁放射線の量を減らす請求項13〜17のいずれか1項に記載の方法。
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