Dispersion of carbon enhanced reinforcement fibers in aqueous or non-aqueous media
View Patent ↗The general inventive concepts relate generally to carbon enhanced reinforcement (CER) fibers, and more particularly, to the controlled dispersion of CER fibers within aqueous or non-aqueous media. The general inventive concepts particularly relate to the controlled dispersion of CER fibers within aqueous or non-aqueous media for forming a nonwoven chopped CER fiber mat. The general inventive concepts also relate to the controlled dispersion of CNSs harvested from CER fibers within aqueous or non-aqueous media for forming a nonwoven CNS mat. Methods for dispersing the CNSs or the CER fibers in aqueous or non-aqueous media are also provided.
1. A method of controlling the dispersion of carbon enhanced reinforcement fibers in an aqueous or non-aqueous solution, said method comprising:
forming one or more carbon enhanced reinforcement fibers comprising a plurality of carbon nanostructures disposed on a fiber substrate;
chopping said carbon enhanced reinforcement fibers to form chopped carbon enhanced reinforcement fibers; and
forming a slurry by adding a plurality of said chopped carbon enhanced reinforcement fibers into a whitewater solution,
wherein said whitewater solution comprises at least one of (i) an oil dispersion medium, (ii) a viscosity modifier, (iii) a biocide, (iv) a de-foaming agent, and (v) a surfactant package, and
wherein said carbon enhanced reinforcement fibers are homogenously dispersed in said slurry.
2. The method of claim 1 , wherein said carbon enhanced reinforcement fibers comprise a plurality of carbon nanostructures grown in situ on a fiber.
3. The method of claim 1 , wherein said whitewater solution comprises an oil dispersion medium and a surfactant package.
4. The method of claim 3 , wherein said surfactant package comprises at least one non-ionic surfactant.
5. The method of claim 3 , wherein said surfactant package comprises at least one of Surfynol® 465, Nanosperse AQ, Triton® X-100, Tetronic® 90R4, Pluronic® 10R5, and polyvinyl alcohol.
6. The method of claim 3 , wherein said surfactant package comprises at least two surfactants.
7. The method of claim 1 , further comprising aerating said whitewater solution.
8. The method of claim 1 , wherein said carbon nanostructures are functionalized to enhance the solubility of the carbon enhanced reinforcement fibers in the aqueous or non-aqueous medium.
9. The method of claim 8 , wherein said carbon nanostructures are functionalized by interacting the carbon nanostructures with an oxidizing agent.
10. The method of claim 8 , wherein said oxidizing agent comprises at least one of potassium persulfate, potassium permanganate, peroxides, and ozone.
11. The method of claim 1 , wherein said fiber substrate is formed from at least one of glass, carbon, polymer, woven fabric, and nonwoven fabric.
12. The method of claim 11 , wherein said fiber substrate comprises glass.
13. The method of claim 1 , wherein said carbon enhanced reinforcement fibers include 10-20% by weight carbon nanostructure loading.
14. The method of claim 1 , wherein said oil dispersion medium is mineral oil.