Methods for forming dispersed carbon nanomaterials for use in polymer composites and coatings
The present disclosure describes methods of deagglomerating, debundling, dispersing, and functionalizing carbon nanomaterials in a medium using a process that does not damage the properties of the carbon nanomaterials. Three exemplary types of carbon nanomaterials are conductive carbon black, graphene, and carbon nanotubes (CNT), including single-wall carbon nanotubes (SWCNT). Once the carbon nanomaterials are dispersed in the medium, the resulting carbon nanomaterial dispersion can be subjected to further processing or blended with additional components to form a coating or polymer composite material suitable for molding structural components. The dispersed carbon nanomaterial can provide the resulting part or component with desirable mechanical and electrical properties such as static dissipation and conductivity.
1 . A method of using a planar milling process to obtain a carbon nanomaterials masterbatch for use in thermoset composite and coating applications, the method comprising:
providing a carbon nanomaterial dispersion prepared by steps of:
combining components comprising a plurality of carbon nanomaterials with a liquid medium and a polyhedral oligomeric silsesquioxane derivative; and
blending the components using a planar milling processes to form a carbon nanomaterial dispersion and combining the carbon nanomaterial dispersion with a thermosetting resin and carbon black; and
blending the carbon nanomaterial dispersion, thermosetting resin, and carbon black to form a carbon nanomaterial masterbatch including a multiplicity of zero-dimensional, one-dimensional, two-dimensional, and/or three-dimensional carbon nanoparticles.
2 . The method of claim 1 , wherein a ratio of components is approximately 25%-94.95% thermosetting resin, 5%-25% carbon black, and 0.05%-50% of the carbon nanomaterial dispersion.
3 . The method of claim 1 , wherein the planar milling process is a two-roll milling process or a three-roll milling process, or a turbine milling process.
4 . The method of claim 1 , wherein a turbine milling or basket milling process is used in the step of blending the carbon nanomaterial dispersion, thermosetting resin, and carbon black.
5 . The method of claim 1 , wherein the carbon nanomaterial dispersion comprises 80 parts per hundred (PPH) C12-C14 aliphatic monoglycidyl ether, 10 PPH single wall carbon nanotubes (SWCNT), and 10 PPH polyhedral oligomeric silsesquioxane derivative.
6 . The method of claim 1 , wherein the carbon nanomaterials of the carbon nanomaterial dispersion are single wall carbon nanotubes (SWCNT).
7 . The method of claim 1 , further comprising forming a thermosetting resin product comprising the carbon nanomaterial masterbatch of claim 1 in an amount of 0.01% to 50% depending on a final amount of thermosetting resin in the thermosetting resin product, so that the thermosetting resin product has electrically conductive properties.
8 . The method of claim 1 , further comprising forming a polyester resin by adding the carbon nanomaterial masterbatch of claim 1 to composite materials necessary to form a polyester resin for molding or forming structural components or coatings.
9 . The method of claim 1 , further comprising forming a coating or a composite material by adding the carbon nanomaterial masterbatch of claim 1 to coating or polymer composite materials to form the coating or the composite material.
10 . A method of preparing a polymeric composite material comprising:
deagglomerating, debundling and dispersing carbon nanotubes within a mixture of a liquid medium and a polyhedral oligomeric silsesquioxane derivative to form a carbon nanomaterial dispersion; and
blending the carbon nanomaterial dispersion with a polymeric resin that is a thermosetting resin and carbon black to form a polymeric composite material for molding structural components or coatings.
11 . The method of claim 10 , wherein the polymeric composite material is capable of being used for coatings.
12 . The method of claim 10 , wherein the step of deagglomerizing, debundling and dispersing the carbon nanotubes within the mixture to form the carbon nanomaterial dispersion occurs by a planar milling process and the step of blending the carbon nanomaterial dispersion with the polymeric resin and carbon black to form the polymeric composite material occurs by a process of turbine milling or basket milling process.
13 . The method of claim 10 , wherein a ratio of components is approximately 25%-94.95% thermosetting resin, 5%-25% carbon black, and 0.05%-50% of the carbon nanomaterial dispersion.
14 . A method of preparing a polymeric composite material comprising:
using a planar milling process to deagglomerize, debundle and disperse carbon nanotubes within a mixture of a liquid medium and a polyhedral oligomeric silsesquioxane derivative to form a carbon nanomaterial dispersion; and
using a process of turbine milling or basket milling process to blend the carbon nanomaterial dispersion with a polymeric resin and carbon black to form a polymeric composite material for molding structural components or coatings.
15 . The method of claim 14 , wherein the polymeric resin is a thermosetting resin.
16 . The method of claim 14 , wherein the polymeric composite material is capable of being used for coatings.
17 . The method of claim 14 , wherein a ratio of components is approximately 25%-94.95% polymeric resin, 5%-25% carbon black, and 0.05%-50% of the carbon nanomaterial dispersion.