METHOD AND APPARATUS FOR USING A VERTICAL FURNACE TO INFUSE CARBON NANOTUBES TO FIBER
A method for forming a CNT infused substrate comprises exposing a catalyst nanoparticle, a carbon feedstock gas, and a carrier gas to a CNT synthesis temperature, allowing a CNT to form on the catalyst nanoparticle, cooling the CNT, and exposing the cooled CNT to a surface of a substrate to form a CNT infused substrate.
1 . A method comprising:
exposing a catalyst nanoparticle, a carbon feedstock gas, and a carrier gas to a CNT synthesis temperature;
allowing a CNT to form on the catalyst nanoparticle;
cooling the CNT; and
exposing the cooled CNT to a surface of a substrate to form a CNT infused substrate.
2 . The method of claim 1 further comprising functionalizing the substrate prior to exposing the substrate to the CNT.
3 . The method of claim 1 further comprising functionalizing the CNT infused substrate.
4 . The method of claim 2 wherein the substrate is functionalized by adding a functional group selected from the group consisting of an amine group, a carbonyl group, a carboxyl group, a fluorine-containing group, a silane group, a siloxane group, and any combination thereof.
5 . The method of claim 1 wherein the substrate comprises at least one material selected from the group consisting of: a carbon fiber, a graphite fiber, a cellulosic fiber, a glass fiber, a metal fiber, a ceramic fiber, a metallic-ceramic fiber, cellulosic fiber, an aramid fiber, and any combination thereof.
6 . The method of claim 1 wherein the CNT synthesis temperature is a temperature in the range of from about 450° C. to about 1000° C.
7 . The method of claim 1 wherein the CNT is cooled to a temperature in the range of from about 25° C. to about 450° C.
8 . The method of claim 1 further comprising:
providing a catalyst solution comprising a catalyst and a solvent; and
atomizing the catalyst solution and allowing the solvent to evaporate leaving the catalyst nanoparticle.
9 . The method of claim 1 wherein the catalyst nanoparticle comprises a d-block transition metal.
10 . A system comprising;
a carrier gas source that provides a carrier gas;
a catalyst source that provides a catalyst nanoparticle;
a carbon feedstock source that provides a carbon feedstock;
a substrate source that provides a substrate; and
a CNT growth reactor comprising:
an inlet device that receives the carrier gas, the catalyst nanoparticle, and the carbon feedstock and introduces the carrier gas, the catalyst nanoparticle, and the carbon feedstock into a CNT growth zone;
a heating element that heats the carrier gas, the catalyst nanoparticle, and the carbon feedstock to a CNT synthesis temperature within the CNT growth zone to allow a CNT to synthesize on the catalyst and form a synthesized CNT;
a dispersion hood that receives the synthesized CNT and cools the synthesized CNT; and
a CNT infusion chamber that receives the synthesized CNT and the substrate and exposes the substrate to the cooled synthesized CNT to produce a CNT infused substrate.
11 . The system of claim 10 wherein the substrate is functionalized.
12 . The system of claim 10 wherein the substrate comprises at least one material selected from the group consisting of: a carbon fiber, a graphite fiber, a cellulosic fiber, a glass fiber, a metal fiber, a ceramic fiber, a metallic-ceramic fiber, cellulosic fiber, an aramid fiber, and any combination thereof.
13 . The system of claim 10 wherein the CNT synthesis temperature is a temperature in the range of from about 450° C. to about 1000° C.
14 . The system of claim 10 wherein the dispersion hood cools the synthesized CNT to a temperature in the range of from about 25° C. to about 450° C.
15 . The system of claim 10 wherein the carbon feedstock comprises at least one compound selected from the group consisting of: acetylene, ethylene, methanol, methane, propane, benzene, natural gas, and any combination thereof.
16 . A method comprising:
providing a catalyst nanoparticle, a carbon feedstock gas, and a carrier gas;
heating the catalyst nanoparticle, the carbon feedstock gas, and the carrier gas to a CNT synthesis temperature;
allowing a CNT to form on the catalyst nanoparticle;
cooling the CNT;
providing a substrate;
exposing the substrate to the cooled CNT to form a CNT infused substrate; and
forming a composite material, wherein the composite material comprises the CNT infused substrate.
17 . The method of claim 16 wherein the substrate is functionalized.
18 . The method of claim 16 further comprising functionalizing the CNT infused substrate prior to forming a composite material.
19 . The method of claim 16 wherein the substrate is provided on a dynamic basis.
20 . The method of claim 16 wherein the composite material further comprises a matrix material, and wherein the matrix material comprises at least one material selected from the group consisting of: a thermosetting resin, a thermoplastic resin, a metal, a ceramic, a cement, and any combination thereof.