Graphene-Based Threads, Fibers or Yarns with Nth-Order Layers and Twisting and Methods of Fabricating Same
A representative embodiment includes a graphene-based fiber comprising: a starting strand; and a plurality of coatings of aligned graphene comprising: a first coating of aligned graphene axially offset at a first angle from an axis of the starting strand; a second coating of aligned graphene over the first coating and axially offset at a second angle from the axis of the starting strand; and at least one next coating of aligned graphene over a preceding coating and axially offset at a next angle from the axis of the starting strand. Another embodiment includes a plurality of intertwined and twisted graphene-based fibers. In various embodiments, the graphene may be graphene ribbons or carbon nanotubes or both. The graphene ribbon includes a plurality of aligned and overlapping graphene flakes in a polymer. Methods of fabrication are also disclosed.
1 . A graphene-based fiber comprising:
a starting strand; and
a plurality of coatings of aligned graphene comprising:
a first coating of aligned graphene axially offset at a first angle from an axis of the starting strand;
a second coating of aligned graphene over the first coating and axially offset at a second angle from the axis of the starting strand; and
at least one next coating of aligned graphene over a preceding coating and axially offset at a next angle from the axis of the starting strand.
2 . The graphene-based fiber of claim 1 , wherein the graphene comprises at least one graphene ribbon.
3 . The graphene-based fiber of claim 2 , wherein the at least one graphene ribbon comprises a plurality of aligned and overlapping graphene flakes in a polymer.
4 . The graphene-based fiber of claim 2 , wherein the at least one graphene ribbon comprises a plurality of aligned and overlapping graphene flakes in a polymer and on a substrate.
5 . The graphene-based fiber of claim 2 , wherein the plurality of coatings further comprise a plurality of winding layers of a plurality of the graphene ribbons.
6 . The graphene-based fiber of claim 1 , wherein the graphene comprises a plurality of carbon nanotubes in a polymer.
7 . The graphene-based fiber of claim 6 , wherein the carbon nanotubes further comprise a metallic chirality or a semiconducting chirality.
8 . The graphene-based fiber of claim 6 , wherein the first angle is about 0°, the second angle is about 45°, and the at least one next angle comprises a third angle of about 135° and a fourth angle of about 90°.
9 . The graphene-based fiber of claim 1 , wherein the starting strand comprises a metal, or a polymer, or a combination of a metal and a polymer.
10 . The graphene-based fiber of claim 1 , wherein the first coating further comprises a first twist direction of the aligned graphene, the second coating further comprises a second, opposite twist direction of the aligned graphene, and the at least one next coating further comprises the first or the second twist direction of the aligned graphene.
11 . A graphene-based yarn comprising:
a plurality of intertwined and twisted graphene-based fibers, each graphene-based fiber of the plurality of intertwined and twisted graphene-based fibers comprising:
a starting strand; and
a plurality of coatings of aligned graphene comprising:
a first coating of aligned graphene axially offset at a first angle from an axis of the starting strand;
a second coating of aligned graphene over the first coating and axially offset at a second angle from the axis of the starting strand; and
at least one next coating of aligned graphene over a preceding coating and axially offset at a next angle from the axis of the starting strand.
12 . The graphene-based yarn of claim 11 , wherein the graphene comprises at least one graphene ribbon.
13 . The graphene-based yarn of claim 12 , wherein the at least one graphene ribbon comprises a plurality of aligned and overlapping graphene flakes in a polymer.
14 . The graphene-based yarn of claim 12 , wherein the at least one graphene ribbon comprises a plurality of aligned and overlapping graphene flakes in a polymer and on a substrate.
15 . The graphene-based yarn of claim 12 , wherein the plurality of coatings further comprise a plurality of winding layers of a plurality of the graphene ribbons.
16 . The graphene-based yarn of claim 11 , wherein the graphene comprises a plurality of carbon nanotubes in a polymer.
17 . The graphene-based yarn of claim 16 , wherein the carbon nanotubes further comprise a metallic chirality or a semiconducting chirality.
18 . The graphene-based yarn of claim 16 , wherein the first angle is about 0°, the second angle is about 45°, and the at least one next angle comprises a third angle of about 135° and a fourth angle of about 90°.
19 . The graphene-based yarn of claim 11 , wherein the starting strand comprises a metal, or a polymer, or a combination of a metal and a polymer.
20 . The graphene-based yarn of claim 11 , wherein the first coating further comprises a first twist direction of the aligned graphene, the second coating further comprises a second, opposite twist direction of the aligned graphene, and the at least one next coating further comprises the first or the second twist direction of the aligned graphene.
21 . A method of manufacturing a graphene-based yarn, the method comprising:
using a starting strand, applying first coating of aligned graphene axially offset at a first angle from an axis of the starting strand;
applying a second coating of aligned graphene over the first coating and axially offset at a second angle from the axis of the starting strand; and
applying at least one next coating of aligned graphene over a preceding coating and axially offset at a next angle from the axis of the starting strand.
22 . The method of manufacturing a graphene-based yarn of claim 21 , wherein the graphene comprises a plurality of graphene ribbons and the application steps further comprise winding or spinning a plurality of layers of the plurality of graphene ribbons.
23 . The method of manufacturing a graphene-based yarn of claim 21 , wherein each graphene ribbon of the plurality of graphene ribbons comprises a plurality of aligned and overlapping graphene flakes in a polymer.
24 . The method of manufacturing a graphene-based yarn of claim 23 , further comprising:
forming the plurality of graphene ribbons by applying, using a shearing force, the plurality of graphene flakes in the polymer onto a substrate.
25 . The method of manufacturing a graphene-based yarn of claim 24 , further comprising:
cutting the substrate having the plurality of graphene flakes in the polymer into a plurality of strips; and
winding the plurality of strips onto one or more reels.
26 . The method of manufacturing a graphene-based yarn of claim 25 , further comprising:
removing the substrate to form the plurality of graphene ribbons; and
winding or spinning the plurality of graphene ribbons.
27 . The method of manufacturing a graphene-based yarn of claim 21 , wherein the graphene comprises a plurality of carbon nanotubes in a polymer.
28 . The method of manufacturing a graphene-based yarn of claim 27 , wherein the application steps further comprise:
orienting the carbon nanotubes using an applied electromagnetic field.
29 . The method of manufacturing a graphene-based yarn of claim 28 , wherein the electromagnetic field is applied at the first angle of about 0°, the electromagnetic field is applied at the second angle of about 45°, and the electromagnetic field is applied at the least one next angle comprising a third angle of about 135° and a fourth angle of about 90°.
30 . The method of manufacturing a graphene-based yarn of claim 21 , wherein the starting strand comprises a metal, or a polymer, or a combination of a metal and a polymer.
31 . The method of manufacturing a graphene-based yarn of claim 21 , further comprising:
applying the first coating using a first twist direction of the aligned graphene;
applying the second coating using a second, opposite twist direction of the aligned graphene; and
applying the at least one next coating using the first or the second twist direction of the aligned graphene.
32 . The method of manufacturing a graphene-based yarn of claim 21 , further comprising:
repeating the application steps to form a plurality of graphene-based fibers;
twisting and intertwining the plurality of graphene-based fibers to form a plurality of next-order graphene-based fibers; and
twisting and intertwining the plurality of next-order graphene-based fibers to form a graphene-based yarn.
33 . A method of manufacturing a graphene-based yarn, the method comprising:
using a starting strand and a plurality of graphene ribbons, applying first coating of aligned graphene by spinning a first graphene ribbon, of the plurality of graphene ribbons, about a starting strand at a first angle axially offset from an axis of the starting strand, each graphene ribbon of the plurality of graphene ribbons comprising a plurality of aligned and overlapping graphene flakes in a polymer;
applying a second coating of aligned graphene by spinning a second graphene ribbon, of the plurality of graphene ribbons, over the first coating at a second angle axially offset from an axis of the starting strand;
applying at least one next coating of aligned graphene by spinning a next graphene ribbon, of the plurality of graphene ribbons, over a preceding coating at a next angle axially offset from the axis of the starting strand;
repeating the application steps to form a plurality of graphene-based fibers;
twisting and intertwining the plurality of graphene-based fibers to form a plurality of next-order graphene-based fibers; and
twisting and intertwining the plurality of next-order graphene-based fibers to form a graphene-based yarn.