Method of co-processing nanocarbons in carbon black, and products therefrom

1. A method of forming a matrix composition by:

providing a matrix;

providing a co-processed nanocarbon-carbon black dispersion by:

co-processing nanocarbon agglomerates and carbon black agglomerates, consisting essentially of:

providing nanocarbon agglomerates, wherein nanocarbons in the nanocarbon agglomerates have a diameter of less than 50 nm;

providing carbon black agglomerates; and

mixing the nanocarbon agglomerates and the carbon black agglomerates such that the nanocarbon agglomerates disperse into:

a nanocarbon-carbon black dispersion with looser agglomerates of nanocarbons and carbon black; or

a nanocarbon-carbon black dispersion with individualized nanocarbons dispersed among the carbon black agglomerates; and

combining the matrix and the co-processed nanocarbons-carbon black dispersion to form the matrix composition, wherein the steps of providing nanocarbons agglomerates, and providing carbon black agglomerates consists essentially of providing:

50 wt. % or less nanocarbon agglomerates and 50 wt. % or more carbon black agglomerates;

30 wt. % or less nanocarbon agglomerates and 70 wt. % or more carbon black agglomerates; or

10 wt. % or less nanocarbon agglomerates and 90 wt. % or more carbon black agglomerates;

wherein the matrix composition consists essentially of the matrix, the nanocarbons with a diameter of 50 nm or less, and the carbon black.

2. The method of claim 1 , wherein the providing nanocarbon agglomerates comprises providing multiwall carbon nanotube agglomerates, wherein the nanocarbons-carbon black dispersion has an aggregate size of less than 1 μm.

3. A composition comprising:

a co-processed material consisting essentially of a mixture of nanofibers with a diameter of less than 50 nm and carbon black, wherein the co-processed material is formed by mixing the nanofibers and the carbon black to co-process the mixture into individualized nanofibers and the carbon black or loosened agglomerates of the nanofibers and the carbon black; and

a matrix material, wherein the co-processed material is incorporated within the matrix material to form the composition.

4. The composition of claim 3 , wherein the nanofibers comprise carbon nanotubes, and the co-processed material has agglomerates less than 1 μm.

5. The composition of claim 3 , wherein the composition comprises:

the matrix material, and

the co-processed material incorporated within the matrix material, wherein the co-processed material consists essentially of:

50 wt. % or less nanofibers with a diameter of 50 nm or less and 50 wt. % or more carbon black;

30 wt. % or less nanofibers with a diameter of 50 nm or less and 70 wt. % or more carbon black; or

10 wt. % or less nanofibers with a diameter of 50 nm or less and 90 wt. % or more carbon black.

6. The composition of claim 3 , wherein the matrix material comprises an organic polymer, metal, ceramic, cement, or asphalt.

7. The composition of claim 6 , wherein the matrix material is an organic polymer, and the organic polymer comprises a rubber or a thermoplastic.

8. The composition of claim 3 , wherein the co-processed material comprises loosened agglomerates of nanofibers and carbon black, and wherein the loosened agglomerates are formed by mixing nanofiber agglomerates with carbon black agglomerates with sufficient force or energy to form the loosened agglomerates of nanofibers and carbon black; and/or

wherein the co-processed material comprises individualized nanofibers within a carbon black aggregate, and wherein the individualized nanofibers within the carbon black aggregate are formed by mixing nanofiber agglomerates with carbon black agglomerates with sufficient force or energy to form the individualized nanofibers within the carbon black.

9. A composition comprising:

a matrix material; and

dispersed carbon nanotubes in carbon black comprising:

agglomerated carbon nanotubes, wherein the agglomerated carbon nanotubes each have a diameter of 50 nm or less;

individualized carbon nanotubes, wherein the individualized carbon nanotubes each have a diameter of 50 nm or less; and

carbon black,

wherein at least a portion of the individualized carbon nanotubes are dispersed in the matrix material to form the composition, wherein the composition consists essentially of:

the matrix material; and

the dispersed carbon nanotubes with a diameter of 50 nm or less in carbon black.

10. A composition comprising:

a matrix material; and

dispersed carbon nanotubes in carbon black comprising:

agglomerated carbon nanotubes, wherein the agglomerated carbon nanotubes each have a diameter of 50 nm or less;

individualized carbon nanotubes, wherein the individualized carbon nanotubes each have a diameter of 50 nm or less; and

carbon black,

wherein at least a portion of the individualized carbon nanotubes are dispersed in the matrix material to form the composition, wherein the composition consists essentially of:

the matrix material; and

the dispersed carbon nanotubes with a diameter of 50 nm or less in carbon black, wherein the matrix material comprises rubber.

11. A composition comprising:

a matrix material; and

dispersed carbon nanotubes in carbon black comprising:

agglomerated carbon nanotubes, wherein the agglomerated carbon nanotubes each have a diameter of 50 nm or less;

individualized carbon nanotubes, wherein the individualized carbon nanotubes each have a diameter of 50 nm or less; and

carbon black,

wherein at least a portion of the individualized carbon nanotubes are dispersed in the matrix material to form the composition, wherein the dispersed carbon nanotubes in carbon black consists essentially of:

agglomerated carbon nanotubes, wherein the agglomerated carbon nanotubes each have a diameter of 50 nm or less;

individualized carbon nanotubes, wherein the individualized carbon nanotubes each have a diameter of 50 nm or less; and

carbon black.

12. The composition of claim 9 , wherein the agglomerated carbon nanotubes and the individualized carbon nanotubes are in their as-made form.

13. The composition of claim 9 , wherein at least a portion of the the dispersed carbon nanotubes in carbon black form cloud-shaped co-processed carbon nanotube-carbon black agglomerates that are less than 1 μm in at least one dimension.

14. The composition of claim 9 , wherein the dispersed carbon nanotubes in carbon black consists essentially of:

carbon nanotubes with a diameter of less than 50 nm in an amount of 2-50 wt. %; and

carbon black in an amount of 50-98 wt %.