Patent Application
20250230291
The presently described inventive concepts relate to carbon composites with unique and advantageous mechanical properties, particularly carbon fiber compositions reinforced with graphene, and applications therefor.
Ongoing efforts in the field of material synthesis seek continuing improvements in the quality and efficiency of fabricating various compositions of matter for myriad industrial, commercial, locomotive, and other applications. Of particular interest is the ability to fabricate stronger, lighter materials while concurrently reducing the cost of fabrication, both from a financial perspective and in terms of reducing amount of raw materials required to produce final products.
One promising candidate is carbon fiber. A carbon fiber is an engineered strand with hundreds or thousands of parallel filaments. Carbon fibers composed of anisotropic carbon are typically manufactured through a series of controlled thermal treatments of precursor polymer fibers. Multiple carbon fibers can be twisted into yards, woven into fabrics, or mixed with other materials to produce a carbon fiber composite. Because carbon fibers have high tensile strength, low density, high modulus, and excellent creep and chemical resistance, carbon fiber composites have a high strength-weight ratio suitable for a wide variety of applications in aerospace, military, high-end electrical vehicles, mechanical parts, and civil engineering, among others.
However, simply shifting from using conventional polymers to using carbon fibers is insufficient to address challenges presented in the context of modern material fabrication. For instance, carbon fibers are known to suffer from poor compression strength, poor interlaminar shear strength, and tend to fall apart under relatively low forces applied at angles deviating substantially from parallel to the common longitudinal axis of the fiber, e.g., via tension applied at an angle perpendicular to the longitudinal axis of the fiber.
As such, there is thus a need for improving the mechanical strength of carbon fibers, as well as addressing other issues associated with the prior art.
Polymer matrix composite compositions of matter, and methods of fabricating the same are disclosed. The compositions of matter generally comprise carbon fibers having carbon fiber filaments (which may include three-dimensional (3D) graphene) disposed within the bulk, on exterior surface(s), and/or structurally coupled to the carbon fibers. In the latter case, carbon fiber filaments may be present in an optional polymer matrix, which is at least partially in contact with surface(s) and/or interior voids of the carbon fiber. In all cases, inclusion of the carbon fiber filaments improves mechanical strength of the resulting material according to several important metrics including but not limited to compressive strength and interlaminar shear strength. In addition, particularly in implementations including 3D graphene, additional functionalization, surface modification, and tuning of properties of the composite material are enabled. Various aspects and advantages of utilizing the inventive concepts described herein will become clear upon a full review of the specification and drawings. The exemplary aspects presented immediately below are intended to be illustrative, and should not be considered limiting on the scope of the invention.
According to one aspect, a composition of matter includes a carbon fiber having a plurality of carbon fiber filaments disposed therein and/or disposed on surfaces of the carbon fiber, wherein at least some of the plurality of carbon fiber filaments are each independently characterized by a longitudinal axis oriented at an angle substantially deviating from parallel to a longitudinal axis of the carbon fiber.
According to another aspect, a composition of matter includes a carbon fiber having a plurality of graphene platelets disposed therein and/or disposed (e.g., sized) on surface(s) of the carbon fiber, wherein at least some of the graphene platelets comprise 3D graphene.
Optionally, the 3D graphene may be part of one or more carbon filaments disposed in or on the carbon fiber. Further still, at least some carbon atoms of the 3D graphene may be characterized by sp3 orbital hybridization in some approaches. Preferably, the 3D graphene comprises a plurality of ligands integrated into: a bulk of the carbon fiber; an exterior surface of the carbon fiber; or both the bulk and the exterior surface of the carbon fiber. For example, carbon filaments and/or graphene platelets may be sized on surface(s) of the carbon fibers. With continuing reference to the graphene platelets, in some aspects the plurality of graphene platelets may each independently comprise each a single-layer graphene (SLG), a few-layer graphene (FLG), a multi-layer graphene (MLG), or any combination thereof. In further implementations, at least some of the graphene platelets may comprise one or more polycyclic aromatic hydrocarbons (PAHs) adsorbed to one or more adsorption sites on one or more surfaces of the graphene platelets.
In some aspects, longitudinal axes of at least some of the plurality of carbon fiber filaments are characterized by a substantially random distribution of orientation angles each independently deviating from parallel to the longitudinal axis of the carbon fiber. Moreover, longitudinal axes of other of the plurality of carbon fiber filaments may be aligned substantially in parallel with the longitudinal axis of the carbon fiber. Where the composition includes graphene platelets, planes of orientation of at least some of the graphene platelets may each independently be oriented at an angle substantially deviating from parallel to a longitudinal axis of the carbon fiber.
In more aspects, the carbon fiber filaments include either discontinuous filaments, continuous filaments, or both.
Preferably, some or all of the carbon fiber filaments are characterized by an aspect ratio in a range from about 100:1 to about 1000:1.
Advantageously, according to select implementations, the composition substantially excludes oxygen. Excluding oxygen may refer to exclusion of molecular oxygen (e.g., gas present in voids within the carbon fiber) or of atomic oxygen in the chemical composition of various components of the inventive compositions of matter.
Of course, certain implementations may include a plurality of carbon fibers. In such approaches, the plurality of the carbon fibers are preferably substantially aligned in parallel along the longitudinal axes thereof; and at least some of the carbon fiber filaments crosslink the plurality of carbon fibers, and/or at least some ligands of the 3D graphene crosslink the plurality of carbon fibers, lending additional mechanical strength to the composition of matter.
Thus, according to various aspects, it shall be understood that the presently disclosed inventive concepts include implementations in which carbon fiber filaments and/or graphene platelets (either or both of which may comprise three-dimensional graphene and any associated characteristics thereof as described herein) are present in the bulk volume of carbon fiber(s), sized onto external surface(s) of carbon fiber(s), present in a binder matrix and structurally coupled to the carbon fiber(s), or any permutation or combination of these structural arrangements. Furthermore, whether the composition of matter includes one or a plurality of carbon fibers, the composition of matter may optionally include a polymer matrix or other suitable binder matrix which itself may have carbon fiber filaments and/or graphene platelets disposed therein. Furthermore, these filaments and/or platelets are structurally coupled to some or all of the carbon fibers, lending even further mechanical strength and other improvements to the composite material.
For instance, in one approach a composition of matter includes a carbon fiber having a plurality of carbon fiber filaments sized on one or more external surfaces thereof, wherein the carbon fiber filaments are characterized by either: comprising graphene platelets; having a longitudinal axis of some or all of the carbon fiber filaments oriented at an angle substantially deviating from parallel to a longitudinal axis of the carbon fiber; or both comprising the graphene platelets and having the longitudinal axis of some or all of the carbon fiber filaments oriented at the angle substantially deviating from parallel to the longitudinal axis of the carbon fiber. The carbon fiber may additionally or alternatively include (or exclude) any of the foregoing features, limitations, structural arrangements, etc. in any permutation or combination without departing from the scope of the presently disclosed inventive concepts.
In another exemplary approach, a composition of matter includes a carbon fiber; and a binder matrix, wherein the binder matrix is structurally coupled to the carbon fiber via either: a plurality of carbon fiber filaments in the binder matrix; a plurality of graphene platelets in the binder matrix; or both the plurality of carbon fiber filaments in the binder matrix and the plurality of graphene platelets in the binder matrix. The carbon fiber may additionally or alternatively include (or exclude) any of the foregoing features, limitations, structural arrangements, etc. in any permutation or combination without departing from the scope of the presently disclosed inventive concepts.
A composition of matter according to yet another approach includes: a carbon fiber having a plurality of carbon fiber filaments sized on one or more external surfaces thereof. The carbon fiber filaments are characterized by either: comprising graphene platelets; having a longitudinal axis of some or all of the carbon fiber filaments oriented at an angle substantially deviating from parallel to a longitudinal axis of the carbon fiber; or both comprising the graphene platelets and having the longitudinal axis of some or all of the carbon fiber filaments oriented at the angle substantially deviating from parallel to the longitudinal axis of the carbon fiber.
Turning now to methods of fabrication, according to one aspect, a method of fabricating a carbon fiber filament includes: receiving a spinning dope containing a plurality of polymer particles in a liquid form and a plurality of graphene platelets; extruding the spinning dope through one or more openings, and solidifying the extruded spinning dope into one or more polymer filaments.
According to another aspect, a method of fabricating a carbon fiber filament includes: exposing the extruded spinning dope to a plurality of graphene platelets. It should be noted that this method, in select approaches, may be performed concurrently with solidifying the extruded spinning dope into one or more polymer filaments, or after doing so.
According to yet another aspect, a method of fabricating a carbon fiber filament includes: oxidizing the one or more polymer filaments at a first temperature; carbonizing the one or more polymer filaments at a second temperature; and graphitizing the one or more polymer filaments at a third temperature. In various implementations, this method may be performed independently, or after solidifying the extruded spinning dope into one or more polymer filaments.
According to still yet another aspect, a method of fabricating a carbon fiber filament includes: applying a sizing layer containing a plurality of graphene platelets onto a carbon fiber filament.
In more implementations, products may be fabricated in whole or in part using the inventive compositions.
In one approach, said products may include: one or more carbon fibers incorporated into a bulk of the product and/or sized on one or more surfaces of the product. The one or more carbon fibers independently have a plurality of carbon fiber filaments disposed therein; and at least some of the plurality of carbon fiber filaments are each independently characterized by a longitudinal axis oriented at an angle substantially deviating from parallel to a longitudinal axis of the carbon fiber.
In another approach, a product includes a carbon fiber incorporated into a bulk of the product and/or sized on one or more surfaces of the product; where the carbon fiber has a plurality of graphene platelets disposed therein; and at least some of the graphene platelets comprise three-dimensional (3D) graphene.
According to yet another approach, a product includes: a carbon fiber having a plurality of carbon fiber filaments sized on one or more external surfaces thereof. The carbon fiber filaments are characterized by either: comprising graphene platelets; having a longitudinal axis of some or all of the carbon fiber filaments oriented at an angle substantially deviating from parallel to a longitudinal axis of the carbon fiber; or both comprising the graphene platelets and having the longitudinal axis of some or all of the carbon fiber filaments oriented at the angle substantially deviating from parallel to the longitudinal axis of the carbon fiber.
Again, the foregoing exemplary aspects and implementations are presented by way of illustration rather than limitation. Additional features and advantages of the presently described inventive concepts are disclosed in the following detailed description and shown in the various drawings.
Like reference numbers and designations in the various drawings indicate like elements.
Aspects of the disclosure are provided in the following description and related drawings directed to various examples provided for illustration purposes. Alternate aspects may be devised without departing from the scope of the disclosure. Additionally, well-known elements of the disclosure will not be described in detail or will be omitted so as not to obscure the relevant details of the disclosure.
Carbon fibers (CFs) are commonly used as a type of reinforcing material in composites for lightweight composite applications. Even though carbon fibers have certain desirable mechanical properties for some high-end applications, CFs generally have low compression strength. Additionally, the use of carbon fiber composite in other areas is limited because of high manufacturing costs. Currently commercially available carbon fibers are predominately manufactured using an expensive precursor material, such as polyacrylonitrile (PAN), which counts for more than 50% of the manufacturing cost of PAN-based CFs. Moreover, the time and energy-consuming manufacturing process of PAN-based CFs further increases the manufacturing costs. Low-cost precursor material such as pitch, rayon and other polymers have been utilized to produce CFs. However, the mechanical properties of CFs derived from these low-cost precursors are inadequate to be used in many applications, including as a reinforcing material. Additional details regarding exemplary applications, utilities, and implementations of the inventive concepts presented herein are provided below.
Implementations of the subject matter described in this disclosure may be used for manufacturing a carbon fiber from lower-cost precursors having mechanical properties that are the same or superior to the more expensive PAN-based carbon fibers. The implementations of the subject matter described in this disclosure may also be used for reducing the time and energy associated with manufacturing PAN-based carbon fibers, thereby lowering the manufacturing cost of such carbon fibers. A carbon fiber may consist of hundreds or thousands of carbon fiber filaments. The carbon fiber filaments are produced by polymer filaments, which become carbon fiber filaments after oxidization, carbonization, and graphitization. In some implementations, the polymer filaments may be produced via wet spinning, electrospinning, or melt spinning. In some aspects, a plurality of graphene platelets may be added in the spinning process of the polymer filaments to minimize internal voids or defects in the microstructure of the polymer filaments.
Adding graphene platelets into the spinning process may also allow increased graphitic microstructure in the resulting carbon fiber filaments. In some other aspects, the plurality of graphene platelets may be added to the carbon fiber filaments as a coating or a sizing to improve adhesion between the carbon fiber filaments and the surrounding binder matrix. As utilized herein, the term “sizing” shall be understood as referring to any process of covering or coating a fiber or equivalent filamentous structure, in whole or in part, where the covering or coating enhances or detriments one or more existing properties or features of the fiber (or fiber equivalent), conveys one or more new properties or features on the fiber (or fiber equivalent), eliminates one or more existing properties or features of the fiber (or fiber equivalent), or any combination thereof that would be appreciated by a person having ordinary skill in the art upon reading the present disclosure.
The carbon fiber filaments may be produced by techniques described herein, or may be obtained from a commercial manufacturer. In some instances, the plurality of graphene platelets may be surface modified to have one side polar and the opposite side nonpolar. For example, polycyclic aromatic hydrocarbons (PAHs) may be adsorbed at one or more adsorption sites on a first side of the graphene platelet to increase the polarity of the first side of the graphene platelet relative to the second side of the platelet.
Particular implementations of the subject matter described in this disclosure can be implemented to realize one or more of the following potential advantages. Existing PAN-based carbon fibers may not be suitable for many cost-sensitive applications, such as an electric vehicle with a high fuel efficiency for an average consumer. In some implementations, the techniques disclosed herein can be used to manufacture a plurality of carbon fiber filaments from low-cost precursors having mechanical properties the same or superior to those of PAN-based carbon fibers. Such mechanical properties include (but are not limited to) tensile strength, tensile modulus, and compression strength in the direction parallel to the carbon fiber axis, tensile strength, tensile modulus, and compression strength in the direction orthogonal to the carbon fiber axis, in-plain shear strength and modulus, interlaminar shear strength, and flexural strength and modulus. In this way, carbon fibers and carbon fiber composites produced using techniques described herein may have desirable mechanical properties at a market price deemed more affordable by an average consumer.
For the example of
For example, as shown and discussed in greater detail below with reference to
In preferred approaches, at least about 5% of the carbon fiber filaments 130 are characterized by each independently have a longitudinal axis that is oriented at an angle deviating from parallel to the longitudinal axis of the respective carbon fiber 110 in which the carbon fiber filament 130 is disposed. For example, according to various implementations, at least about 5%, at least about 10%, at least about 20%, at least about 25%, at least about 33%, at least about 40%, at least about 50%, at least about 60%, at least about 66%, at least about 75%, at least about 80%, at least about 90%, at least about 95%, at least about 97%, at least about 98%, at least about 99%, about 99% or more, or even 100% of the carbon fiber filaments 130 disposed in the carbon fiber 110 are characterized by each independently have a longitudinal axis that is oriented at an angle deviating from parallel to the longitudinal axis of the respective carbon fiber 110. In preferred approaches, the proportion of carbon fiber filaments 130 having an angle of orientation substantially deviating from parallel to the longitudinal axis of the carbon fiber 110 is in a range from about 0.01% to about 47%.
As referenced herein, an angle of orientation is considered “deviating” or “substantially deviating” from parallel to a given reference point or feature (e.g., an axis, preferably a longitudinal axis, of a filamentous or elongated structure, most preferably a longitudinal axis of a carbon fiber) when the angle of orientation deviates from parallel by an amount of at least 30 degrees, an amount of at least 45 degrees, an amount of at least 60 degrees, an amount of at least 75 degrees, or an amount of 90 degrees (i.e., perpendicular or orthogonal), according to various embodiments.
Those having ordinary skill in the art will further appreciate that different implementations of the inventive concepts herein may include substantially uniform reinforcement of the entire volume and/or surface(s) of fibers, or non-uniform reinforcement thereof. For example, it may be advantageous to selectively reinforce only portions of the fiber that are known or expected to experience mechanical failure under a given stress. In other embodiments, it may be desirable to omit reinforcing certain portions of the fiber in order to include intended failure points that are likely to experience mechanical failure under a given stress. These and other equivalent engineering considerations may be implemented in any suitable manner without departing from the scope of the presently disclosed inventive concepts.
In some instances, the carbon fiber filament 130 may be a continuous fiber with a length that is identical to the length of the carbon fiber 110. In some other instances, the carbon fiber filaments 130 may be discontinuous, and have a length that is shorter than the length of the carbon fiber 110 due to one or more breakages 136. For instance, in various approaches, carbon fiber filaments 130 may be characterized by an aspect ratio in a range from about 100:1 to about 1000:1. For instance, and without limitation, the carbon fiber filaments may have an aspect ratio of about 100:1, about 150:1, about 250:1, about 400:1, about 500:1, about 666:1, about 750:1, about 800:1, about 900:1, about 950:1, about 975:1, about 990:1, about 999:1, or about 1000:1, according to various implementations. As will be appreciated by those having ordinary skill in the art upon reading the present disclosure, preferred embodiments of inventive carbon composite materials described herein include at least some discontinuous fibers having small diameters, and a total amount of fiber present is preferably lower than conventional carbon fibers. For instance, the total amount of fiber is preferably in a range from about 50 wt % to about 75 wt % with respect to the overall amount of material. The total amount of fiber may thus be about 50 wt %, about 60 wt %, about 66 wt %, about 70 wt %, about 75 wt %, etc., according to various implementations. Reducing the amount of fiber present advantageously reduces impact and cost of fabrication, distribution, and utilization of the inventive materials and corresponding products produced therewith. This is possible due to the improved mechanical strength of the inventive carbon composite materials described herein.
In various implementations, the plurality of carbon fiber filaments 130 may be manufactured from a plurality of polymer filaments fabricated by a spinning process, such as wet spinning, electrospinning, or melt spinning, and subsequently treated with stabilization, physical stretch, oxidation, carbonization, graphitization, and any other suitable physical or chemical processes. In some implementations, the plurality of polymer filaments may be physically bundled into fibers before carbonization. In some other implementations, the plurality of polymer filaments may be used to produce the plurality of carbon fiber filament 130, and then physically bundled into the one or more carbon fibers 110.
In some implementations, the polymer filament 200 may be fabricated using a spinning process of a spinning dope. The spinning process may be wet spinning, electrospinning, melt spinning, or any combination thereof. In some other implementations, the polymer filament 200 may be fabricated using other suitable chemical processing techniques. The spinning dope may have a plurality of polymer particles in a liquid form. The plurality of polymer particles may contain synthetic, semisynthetic, or non-synthetic polymers. For example, the plurality of polymer particles may be or contain PAN, pitch, rayon, or any combination thereof. In some instances, the plurality of graphene platelets 230 may be added to prepare the spinning dope. In some other instances, the plurality of graphene platelets 230 may be added when solidifying the spinning dope after being extruded. In various implementations, the weight percentage of the plurality of graphene platelets being added may be less than 1 wt %. Upon extrusion through one or more openings in a spinning process, the flow of the spinning dope may induce the plurality of graphene platelets 230 to be aligned in parallel with one another and oriented with the longest side along the length of the longitudinal body 210 and with graphene layers stacking in a direction perpendicular to the length of the longitudinal body 210.
In this way, the plurality of graphene platelets 230 may serve as a structure-directing template to guide molecular chain alignment in a polymer. The plurality of graphene platelets 230 may also function as nucleating agents to increase polymer coagulation during the solidification process, thereby minimizing the size of voids or defects inside the fabricated polymer filament 200. When the polymer filament 200 undergoes oxidation, carbonization, and graphitization to form the carbon fiber filament 130 of
For context and comparison,
Accordingly, to further reduce the negative consequences associated with retaining voids in the conventional carbon fiber, a filler material may be included in the carbon fiber. However, as known in the art, attempts to rectify the problems caused by voids are complicated and often fail due to dissimilar chemistry with respect to the filler material composition and the carbon fiber (or precursors thereof). Thus, using filler to address mechanical weakness in conventional carbon fibers is an unsatisfactory solution.
For example, fillers employing conventional graphene-based materials (i.e., graphene materials mined from graphite) require chemicals and/or mechanical methods to break down the material in a suitable fashion. This process leaves the ‘graphene’ with significant defects (e.g., basal plane holes, other lattice defects, etching chemistry left behind in the process, etc.) meaning conventional graphene is typically weaker than fiber and/or polymer leading to minimal increases, if any, in mechanical strength improvements. Other materials, such as quartz, silicas, talc powder, etc. have the limitation of brittleness and/or inferior innate properties thus adding minimal value to the composite material. For instance, conventional mica is characterized by a Young's modulus on the order of about 5.4 GPa, silica has a Young's modulus less than 100 GPa, and talc powder has a Young's modulus on the order of less than about 50 GPa. These types of materials typically detract from the overall system by introducing additional void content and/or inclusions within and/or around the fiber/polymer interface or throughout the polymer.
Moreover, conventional materials typically include an undesirably high amount of water content. For example, muscovite is typically about 5 wt % water content, and other inorganic materials often include water in an amount ranging from greater than 1 wt % to about 2 wt %.
The inventive precursor materials utilized herein, by contrast, have 1.5 wt % or less water content, e.g., about 1.5 wt % or less, about 1.0 wt % or less, etc. as would be understood by a person having ordinary skill in the art upon reading the present disclosure. In the final composite, water may be present in an amount less than 0.5 wt %, e.g., about 0 wt %, greater than 0 wt % but less than about 0.1 wt %, greater than 0 wt % but less than about 0.25 wt %, greater than 0 wt % but less than about 0.33 wt %, greater than 0 wt % but less than about 0.5 wt %, etc. as would be understood by a person having ordinary skill in the art upon reading the present disclosure.
In addition, the size of the filler material particles becomes increasing important relative to the fiber diameter. For instance, when filler material size becomes approximately five times (or more) larger than the fiber material (e.g., as is the case for mica flakes having millimeter scale particle size, with corresponding fiber size in the 5-30 micrometer scale) this imbalance can undesirably yield decreased bonding sites between fiber/polymer.
Dispersion throughout precursor materials is also a challenge for conventional filler. While functionalization might allow for these materials to be dispersible, the resulting filler still fails to improve the final system strength due to the aforementioned issues/challenges.
Further considerations for conventional filler materials include viscosity, such as ion viscosity, dynamic viscosity, status viscosity, curing viscosity, or similar metrics, which has to be carefully managed through the fabrication of conventional materials using carbon fiber.
Further still, the ‘cure index’ measured at the end of conventional carbon fiber systems typically indicates less then desirable cures, i.e., less than about 100% cure. This is due to the conventional materials interfering with the crosslinking of the two-part system, for thermosetting systems, and/or impeding the flow of a polymer to mix/melt around a fiber, leading to decreased wetting of the fiber with the filler material.
Increased oxygen from the functionalization and/or introduced from the particle (typically in the form of free oxygen within the pores and/or due to increased surface area of the particle) have a negative effect on the overall system through 1) decreased curing kinetics; 2) decreased cure rate; 3) undesirable viscosity increase/decrease; 4) and adverse modification of the embedded chemistries within the polymer (e.g., antioxidant depletion or) any combination of or a secondary effect leading back to one of the foregoing. It should be noted that the impurities of some of these materials could further minimize their usefulness and potential purpose of their use.
For instance, exemplary conventional filler materials that have been found to be undesirable for use with carbon fibers include other graphenes, carbon allotropes, CNTs, carbon black, silica, Muscovite, quartz, silicates, and other organic/inorganics. These materials exhibit properties such as inappropriately large or small aspect ratios, including an undesirably high amount of molecular oxygen, having a surface chemistry that creates adverse results upon attempting to functionalize the surface, or having a mechanical strength (e.g., as may be measured according to any metric described herein and equivalents thereof that would be understood by a person having ordinary skill in the art upon reviewing the present disclosure) that is lower than a mechanical strength of the fiber(s) to be repaired or reinforced, or any combination thereof.
By contrast, the presently disclosed inventive concepts approach problems with mechanical weakness by directly integrating supportive material (e.g., carbon filaments, 3D graphene, etc. as described herein) with the carbon fiber (and/or precursors thereof) that has compatible chemistry, particularly surface chemistry, due to the similar nature of the compounds used (e.g., pitch, PAN, rayon, etc. as described herein and according to various approaches).
For instance, carbon fibers are generally hydrophobic, while polymers used in conjunction therewith are hydrophilic. The carbon filaments, and particularly 3D graphene described in accordance with the inventive concepts presented herein bridge this gap and allow substantial improvement with respect to mechanical strength of the resulting fibers. Additionally, the 3D graphene materials can be engineered to have different surface chemistries, e.g., hydrophilicity tuning leading to hydrophobic and hydrophilic surfaces within the same 3D graphene structure. This type of engineering allows for the 3D graphene to bridge, e.g., via interfacial bonding, between the carbon fiber(layer1)-polymer matrix-carbon fiber(layer 2)-et al. constructure. 3D graphene also advantageously acts as a catalyst for pyrolysis, particularly of pitch, further facilitating fabrication of stronger materials Additionally, the utilization of pitch for fibers has been limited by the inferior resultant mechanical properties of a fiber produced with pitch, however, with the additional of 3D graphene to enhance said fiber, pitch having equal/superior properties to other carbon fibers, e.g., those derived from PAN are considered an advantageous aspect of the presently disclosed inventive concepts.
Moreover, the ability to tune and control the orientation of carbon filaments that are disposed within carbon fibers conveys substantial improvement to compression strength and tension applied at angles deviating from substantially parallel to the longitudinal axis of the carbon fiber. Of course, other improvements such as modulus strength, in-plane shear strength, interlaminar shear strength, flexural strength, etc. as described herein are also realized via implementing the inventive materials and techniques described herein.
Further, the ability to disperse carbon filaments and 3D graphene throughout the composition allows for additional anchor points, and improved fiber/polymer interaction compared to conventional carbon fiber formulations and methods of fabrication.
Referring now to
For the example of
According to various applications, graphene platelets or other forms of 3D graphene may be present in a range from less than 1 wt % to about 100 wt % of the fiber. For instance, the 3D graphene or graphene platelets may be present in an amount less than about 1 wt %, an amount of about 1 wt %, about 2 wt %, about 5 wt %, about 10 wt %, about 15 wt %, about 20 wt %, about 25 wt %, about 30 wt %, about 33 wt %, about 40 wt %, about 50 wt %, about 60 wt %, about 66 wt %, about 70 wt %, about 75 wt %, about 80 wt %, about 90 wt %, about 95 wt %, about 98 wt %, about 99 wt %, about 99.9 wt %, or any range including these values and/or values therebetween.
In some implementations, 3D and/or graphene platelets may be present (e.g., via sizing) on external surface(s) of the fiber in an amount ranging from less than 1 wt % to about 20 wt %. For instance, the amount of 3D graphene and/or graphene platelets sized on the external surface(s) of the fiber may be less than about 1 wt %, about 1 wt %, about 2 wt %, about 5 wt %, about 7.5 wt %, about 10 wt %, about 12.5 wt %, about 15 wt %, about 17.5 wt %, about 20 wt % or any range including these values and/or values therebetween, In one particularly preferred embodiment, the weight percentage of the plurality of graphene platelets being sized on the external surface 320 may be less than 1 wt % of the total weight of the fiber.
In other implementations, graphene and/or 3D graphene precursor materials may comprise from less than 1 wt % to about 100 wt % of the fiber. For instance, the 3D graphene or graphene platelets may be present in an amount less than about 1 wt %, an amount of about 1 wt %, about 2 wt %, about 5 wt %, about 10 wt %, about 15 wt %, about 20 wt %, about 25 wt %, about 30 wt %, about 33 wt %, about 40 wt %, about 50 wt %, about 60 wt %, about 66 wt %, about 70 wt %, about 75 wt %, about 80 wt %, about 90 wt %, about 95 wt %, about 98 wt %, about 99 wt %, about 99.9 wt %, or any range including these values and/or values therebetween.
As shown in
Accordingly, the plurality of graphene platelets 330 may prevent adhesive failure that generally happens in an interphase between the carbon fiber filament 300 and the surrounding polymer in the binder matrix 120 of
Again, while the illustrative implementation depicted in
For the example of
The intermeshing of ligands in the bulk volume of fibers provides a multitude of “anchors” by which individual fibers may be crosslinked, reinforcing composite materials made from inventive carbon fibers as disclosed herein, according to some approaches. In addition, integration of graphene platelets and/or ligands within the bulk volume of an individual fiber advantageously reinforces the structural integrity of the individual fiber, particularly with respect to compression strength and tensile strength applied in a direction substantially deviating from parallel to the longitudinal axis of the fiber. However, it shall be appreciated that in accordance with various embodiments of the presently described inventive concepts, fibers may be reinforced, e.g., by filamentous carbon-based structures as described herein, via such reinforcing structures being present within the bulk volume of the fiber, sized (or otherwise disposed) on surface(s) of the fiber, or in close proximity to the fiber, e.g. via being present in a resin or binder matrix structurally coupled to the fiber.
For instance,
Further, skilled artisans will understand that, as an engineered material, three-dimensional graphene and control over the formation process allows tuning the surfaces of the material to improve bonding of various types with various compounds, providing tunable surface chemistry. Further owing to the engineered nature of the structure, three-dimensional graphene in select embodiments may impart the ability to couple with a coupling agent and bring together fibers and polymers (especially polymers that also have three-dimensional graphene included therein/sized thereon), lending improved mechanical strength to the resulting composite material.
In some implementations, each of a plurality of graphene platelets may contain a single-layer graphene (SLG), a few-layer graphene (FLG), a multi-layer graphene (MLG), or any combination thereof. In various implementations, the plurality of graphene platelets may be modified via chemical techniques so that each graphene platelet may have one side polar and the opposite site nonpolar. For example, the chemical techniques may include functionalization with chemical functional groups, adsorption with chemical compounds, or a combination thereof. In some instances, each graphene platelet may have PAH adsorbed at one or more adsorption sites on a first side of the graphene platelet. As an example, the PAH may be naphthalene, acenaphthylene, acenaphthene, fluorene, phenanthrene, fluoranthene, pyrene, anthracene, benzo(a)anthracene, chrysene benzo(b)fluoranthene, benzo(k)fluoranthene, benzo(a)pyrene dibenzo(a,h)anthracene, benzo (g,h,i)perylene, indeno(1,2,3-cd)pyrene, or any combination thereof.
In some aspects, the operation 1000 begins at block 1002 with receiving a spinning dope containing a plurality of polymer particles in a liquid form and a plurality of graphene platelets. The operation 1000 continues at block 1004 with extruding the spinning dope through one or more openings. In some instances, the one or more openings may be a spinneret with multiple holes. In some other instances, the one or more openings may be a tip of a needle or a syringe. The operation 1000 continues at block 1006 with solidifying the extruded spinning dope into one or more polymer filaments. In some implementations, the extruded spinning dope may be immersed in a liquid coagulation bath for solidification. In some other implementations, the extruded spinning dope may be subject to cooling, solvent evaporation, or other suitable treatment for solidification.
In various implementations, a plurality of carbon fiber filaments may be physically bundled together to form one or more carbon fibers as shown in
In some approaches, the carbon fibers, carbon fiber filaments, and/or graphene may include or be present in the form of one or more carbon allotropes such as three-dimensional graphene (3DG), two-dimensional graphene, graphene platelets, graphene nodules, graphene flakes, graphene nanoparticles, graphene platelets, etc. (each of which may include two-dimensional graphene and/or 3DG), graphite, pyrolytic graphite, carbon black, carbon nano-onions (CNOs), necked CNOs, carbon nanospheres, fullerenes, hybrid fullerenes, single-walled carbon nanotubes, multi-walled carbon nanotubes, or any combination thereof. Preferably, at least the graphene components include 3DG flakes, CNOs, or a combination of 3DG flakes and CNOs.
In select implementations, carbon fibers may be characterized by a large initial aspect ratio of about 750 to about 1500. During fabrication, some of the carbon fibers may compound, and after compounding may break down, in which case the characteristic aspect ratio may reduce to a value in a range from about 100 to about 500. The graphene particles, on the other hand, may be characterized by an aspect ratio in a range from about 40 to about 80, e.g. an aspect ratio of ˜60 based on diffraction and TEM observations in accordance with one embodiment. The graphene particles may also form aggregates during fabrication of the inventive compositions and products described herein, in which case the aspect ratio of the graphene particles may be reduced even further. For carbon nodules or CNOs the aspect ratio is even lower, e.g. in a range from about 1 to about 10. Again, according to several implementations, graphene particles commonly include at least 3DG flakes, CNOs, or a combination of 3DG flakes and CNOs.
In more approaches, the foregoing allotropes may form carbonaceous aggregates, each aggregate having a principal dimension of approximately 50 microns, or greater than 100 microns, or greater than 200 microns, or greater than 300 microns, or greater than 500 microns, or greater than 1,000 microns, or from 1 to 1,000 microns, or from 10 microns to 1,000 microns, or from 100 microns to 1,000 microns, or from 100 microns to 500 microns.
Referring now to
Moreover, the graphene particles, which are preferably in the form of graphene platelets, have a thickness in a range from about 1 to about 200 layers of graphene, or anywhere therein (e.g., about 2 layers, about 3 layers, about 5 layers, about 6 layers, about 10 layers, about 12 layers, about 15 layers, about 20 layers, about 25 layers, about 33 layers, about 40 layers, about 50 layers, about 60 layers, about 66 layers, about 70 layers, about 75 layers, about 80 layers, about 85 layers, about 90 layers, about 95 layers, about 99 layers, about 100 layers, about 110 layers, about 125 layers, about 133 layers, about 150 layers, about 166 layers, about 175 layers, about 180 layers, about 190 layers, about 200 layers, or any other number of layers in the range from about 1 to about 200 layers) or in other words a thickness in a range from about 0.3 nm to about 60 nm (e.g., a thickness determined by the number of layers of graphene, with each layer contributing about 0.335 nm to the total thickness of the particle).
Preferably, the polymer matrix includes one or more polymers suitable for use in additive manufacturing, particularly preferably thermoplastic polymers. For instance, in various embodiments, illustrative appropriate polymers include polylactic acid, acrylonitrile butadiene styrene, polyethylene terephthalate glycol, thermoplastic polyurethane, polyetheretherketone, polypropylene, polyphenylsulfone, polyvinyl alcohol, polyetherimide, polyethylene, polyoxymethylene, polyamide, polycarbamate, or any combination or equivalent(s) thereof that would be appreciated as suitable by those having ordinary skill in the art upon reading the present disclosure. In other embodiments, thermoset resins such as epoxy resins, acrylates and methacrylates, polyurethanes, cyanate esters, vinyl esters, silicone resins, phenolic resins, urethane acrylates, thiol-ene resins, or other UV or thermally curable resin, or any combination or equivalent(s) thereof that would be appreciated as suitable by those having ordinary skill in the art upon reading the present disclosure.
Moreover, in various embodiments the polymer matrix may be loaded with carbon fiber in an amount ranging from about 1 wt % to about 30 wt %, and with graphene in an amount ranging from about 0.01 wt % to about 10 wt %. For instance, carbon fiber may be present in the matrix in an amount of about 1 wt %, about 2.5 wt %, about 3.3 wt %, about 5 wt %, about 6.66 wt %, about 7.5 wt %, about 8.0 wt %, about 9.0 wt %, about 9.5 wt %, about 9.9 wt %, about 10 wt %, about 12.5 wt %, about 13.3 wt %, about 15 wt %, about 16.6 wt %, about 17.5 wt %, about 18 wt %, about 20 wt %, about 22.5 wt %, about 25 wt %, about 27.5 wt %, about 28 wt %, about 29 wt %, about 30 wt %, or any value therebetween.
Similarly, graphene, which is preferably in the form of three-dimensional graphene (3DG), may be present in an amount of about 0.01 wt %, 0.05 wt %, 0.1 wt %, about 0.2 wt %, about 0.25 wt %, about 0.33 wt %, about 0.5 wt %, about 0.66 wt %, about 0.75 wt %, about 0.8 wt %, about 0.85 wt %, about 0.9 wt %, about 1.0 wt %, about 1.25 wt %, about 1.33 wt %, about 1.5 wt %, about 1.6 wt %, about 1.75 wt %, about 1.8 wt %, about 1.9 wt %, about 2.0 wt %, about 2.25 wt %, about 2.33 wt %, about 2.5 wt %, about 2.75 wt %, about 3.0 wt %, about 3.33 wt %, about 3.5 wt %, about 3.75 wt %, about 4.0 wt %, about 4.5 wt %, about 5.0 wt %, about 6.66 wt %, about 7.5 wt %, about 8.0 wt %, about 9.0 wt %, about 9.5 wt %, about 9.8 wt %, about 9.9 wt %, about 9.99 wt %, about 10 wt %, or any value therebetween.
As will be appreciated by those having ordinary skill in the art upon reading the present disclosure, inclusion of graphene, particularly 3DG, further reinforces mechanical strength of the composite material beyond the improvements conveyed by loading with carbon fiber alone. As expected, mechanical strength improvements conveyed via including carbon fiber generally increase as a function of the amount of carbon fiber included in the polymer matrix. However, surprisingly and unexpectedly, the degree of improvement conveyed by including graphene, especially 3DG, peaked at very low concentrations, e.g., in amounts from about 0.05 wt % to about 1.0 wt %. Without wishing to be bound to any particular theory, the inventors postulate that the relative small (nanoscale) size of the graphene platelets facilitates more uniform distribution of the graphene throughout the matrix, and allows a homogenously distributed reinforcement of the polymer/carbon composite. Put another way, including equal volumes of carbon fiber and graphene particles into a substrate such as a binder matrix results in a different distribution of the carbon fiber compared to the graphene particles, because the graphene particles smaller size facilitates more uniform distribution throughout the matrix. The graphene particles disperse into and populate the polymer rich regions that are void of carbon fiber and enable proper reinforcement of otherwise unreinforced polymer.
In addition to enabling more uniform distribution throughout the binder matrix, the inventors propose graphene, particularly 3DG, acts as a load bearing component when incorporated into the polymer matrix and/or sized on surfaces of the polymer matrix. This enables substantial improvements to mechanical strength, even at very low loading of graphene.
This effect is demonstrated optically in
According to several exemplary implementations, quantitative strength improvements are summarized in the graphs shown in
Note the data shown in
Table 2 provides illustrative data summarizing various properties of resins and products including a binder matrix reinforced with carbon fiber and graphene. The representative data were compiled from a plurality of samples tested according to various standard methods as listed below. Note that the data summarized in Table 2 was observed from samples that were fabricated using additive manufacturing. Skilled artisans will appreciate that samples fabricated using other techniques, including injection molding, may exhibit higher (stronger) mechanical properties.
The exemplary property values shown in Table 2 are intended as guides, not specifications. All testing specimens were printed in the x-y plane using the recommended conditions, with 100% rectilinear infill and 3 outer walls. All tests were performed after cooling parts in the print chamber overnight. Moreover, properties designated have been determined using methods which are in accordance with, or substantially in accordance with, the specified testing standards.
According to the experimental testing data reflected in Table 2, the secant modulus value was about 1% strain. Strength was recorded at 5% strain, as samples did not fracture. The ASTM D638 Type IV specimen was characterized by a 2.0″ (50.08 mm) per minute test speed at 0.16″ (4 mm) thickness.
As referenced hereinabove, the inventive compositions of matter described herein are useful in myriad applications and implementations. These include, but in no way are limited to, automotive, aerospace, aviation, medical, dental, marine, and unmanned aerial vehicles parts, prototyping, small scale manufacturing, military equipment, ammunition, etc. as will be appreciated by those having ordinary skill in the art upon reading the present disclosure.
While a principal advantage of including the inventive compositions of matter in various (parts or components of) products or systems includes dramatic improvements to mechanical strength, in other approaches skilled artisans will appreciate the inventive compositions may convey other, e.g., functional, characteristics such as electrical conductivity (or lack thereof), thermal conductivity (or lack thereof), optical transparency (or lack thereof), surface chemistry, hydrophobicity, hydrophilicity, corrosion resistance, radiation resistance, light absorption, melting temperature, solubility in various materials, etc. as will be appreciated by those having ordinary skill in the art upon reading the present disclosure.
In particularly preferred implementations, incorporating the inventive compositions of matter described herein into such products and systems involves fabricating the products, systems, or parts or components thereof using additive manufacturing techniques. The additive manufacturing techniques may include any suitable additive manufacturing technique as is known in the art and/or would be appreciated by those having ordinary skill in the art upon reading the present descriptions. For example, extrusion-based additive manufacturing techniques, deposition-based additive manufacturing techniques, jetting-based additive manufacturing techniques, photopolymerization-based additive manufacturing techniques, lamination-based additive manufacturing techniques, fusion-based additive manufacturing techniques, direct printing additive manufacturing techniques, etc. or any combination or equivalent(s) thereof. Of course, the foregoing exemplary types of additive manufacturing techniques are presented by way of example rather than limitation, and any additive manufacturing techniques that are known in the art or would be appreciated as suitable by skilled artisans upon reading the present disclosure may be employed without departing from the scope of the inventive techniques and materials described herein. Moreover, the inventive concepts may be practiced using techniques other than additive manufacturing techniques, optionally in combination with additive manufacturing techniques, again without departing from the scope of the inventive techniques and materials described herein.
The large length of carbon fibers presents a challenge for 3D printing, as small nozzle diameters down to 0.1 mm is used. Longer fibers can clog and block the equipment nozzle during additive manufacturing, and issue that is exacerbated at higher carbon fiber loading levels. This limitation effectively restricts both the fiber length and loading in the filament. Due to the small particle size of the graphene particles, it can be used to further enhance the carbon loading and mechanical properties without concern for clogging.
For example, in the context of land vehicles, such as cars, trucks, motorcycles, racing vehicles, or any other version of a vehicle typically driven on a road (or off-road) using wheels, tracks, treads, etc. the presently disclosed inventive compositions of matter may be incorporated into, or formed into (e.g., using additive manufacturing techniques) body components, including the trim, bonnet/hood, car cover, support stick, hinges and springs, bumper, unexposed bumper, exposed bumper, cowl screen, decklid, fender (wing or mudguard), fascia, grille (also called grill), pillar and hard trim, quarter panel, radiator core support, rocker, roof rack, spoiler, front spoiler (air dam), rear spoiler (wing), rims, hubcap, tire, track, tread, etc., trim package, trunk/boot/hatch, trunk/boot latch, valance, welded assembly, doors, anti-intrusion bar, outer door handle, inner door handle, window motor, door control module, door seal, door water-shield, hinge, door latch, door lock and power door locks, central-locking, fuel tank (or fuel filler) door, windows, glass, sunroof, sunroof motor, sunroof rail, sunroof glass, window motor, window regulator, windshield (or windscreen), windshield washer (or windscreen wiper) motor, window seal, low voltage/auxiliary electrical system and electronics, audio/video devices, antenna assembly, antenna cable, alternator, battery, performance battery, battery box, battery cable terminal, battery cable, battery control system, battery plate, battery tray, battery cap, voltage regulator, gauges and meters, ammeter, clinometer, dynamometer, fuel gauge, manometer, hydrometer, odometer (also called milometer or mileometers), speedometer (also called a speed indicator), tachometer (also called rev counters), temperature gauge, tire pressure gauge, vacuum gauge, voltmeter, water temperature meter, oil pressure gauge, ignition system, sparking cable, distributor, distributor cap, electronic timing controller, ignition box, ignition coil, ignition coil connector, ignition coil parts, ignition magneto, spark plug, glow plug, lighting and signaling system, main article: automotive lighting, engine bay lighting, fog light (also called foglamp), spotlight, headlight (also called headlamp), headlight motor, interior light and lamp, center dome, vanity-sun visor and rear side, floor and door-front, back, boot lamp or trunk lamp, license plate lamp (also called number plate lamp or registration plate lamp), side lighting, brake light, third or center brake light, tail light, tail light cover, indicator light, sensors, abs sensor, airbag sensors, automatic transmission speed sensor, brake sensor, camshaft position sensor, crankshaft position sensor, coolant temperature sensor, fuel level sensor, fuel pressure sensor, knock sensor, light sensor, map sensor, mass airflow sensor, oil level sensor, oil pressure sensor, oxygen sensor (o2), throttle position sensor, starting system, starter, starter drive, starter pinion gear, starter motor, starter solenoid, glowplug, electrical switches, battery, door switch, ignition switch, power window switch, steering column switch, switch cover, switch panel, thermostat, frame switch, fan ditch, parts and functions of starter system, neutral safety switch, wiring harnesses, (wiring loom or cable loom), air conditioning harness, engine compartment harness, interior harness, floor harness, main harness, control harness, miscellaneous, air bag control module, alarm and siren, central locking system, chassis control computer, cruise control computer, door contact, engine computer and management system, engine control unit, fuse, fuse box, ground strap, grab handle, navigation system/gps navigation device, performance chip, performance monitor, relay connector, remote lock, shift improver, speed controller, speedometer calibrator, transmission computer, wiring connector, interior, floor components and parts, carpet and rubber and other floor material, center console (front and rear), other components, roll cage or exo cage, dash panels, car seat, arm rest, bench seat, bucket seat, children and baby car seat, fastener, headrest, seat belt, seat bracket, seat cover, seat track, other seat components, back seat, front seat, power-train and chassis, see also: frame (vehicle), braking system, anti-lock braking system (abs), abs steel pin, fr side sensor, fl side sensor, rr side sensor, rl side sensor, abs motor circuit, adjusting mechanism (adjuster star wheel), anchor, bleed nipple, brake backing plate, brake backing pad, brake cooling duct, brake disc, brake fluid, brake drum, brake lining, brake pad, brake pedal, brake piston, brake pump, brake roll, brake rotor, brake servo, brake shoe, brake lining, shoe web, brake warning light, calibrated friction brake, caliper, combination valve, dual circuit brake system, hold-down springs (retainer springs), hose, brake booster hose, air brake nylon hose, brake duct hose, hydraulic booster unit, load-sensing valve, master cylinder, metering valve, park brake lever/handle (hand brake), pressure differential valve, proportioning valve, reservoir, shoe return spring, tire, vacuum brake booster, wheel cylinder (slave cylinder), wheel stud, electrified powertrain components, electric motor, induction motor, synchronous motor, high voltage battery pack, battery management system, nickel-metal hydride battery, lithium-ion battery, fuel cell, hydrogen tank, dc-dc converter, inverter, charge port, sae j1772 (type 1 connector), type 2 connector, chademo, ccs, thermal management system, radiator, fan, antifreeze, charger, engine components and parts, diesel engine, petrol engine (gasoline engine), accessory belt, air duct, air intake housing, air intake manifold, camshaft, camshaft bearing, camshaft fastener, camshaft follower, camshaft locking plate, camshaft pushrod, camshaft spacer ring, camshaft phase variator, connecting rod, connecting rod bearing, connecting rod bolt, connecting rod washer, crank case, crank pulley, crankshaft, crankshaft oil seal (or rear main seal), cylinder head, cylinder head cover, other cylinder head cover parts, cylinder head gasket, distributor, distributor cap, drive belt, engine block, engine cradle, engine shake damper and vibration absorber, engine valve, fan belt, gudgeon pin (wrist pin), harmonic balancer, heater, mounting, piston, piston pin and crank pin, piston pin bush, piston ring and circlip, poppet valve, positive crankcase ventilation valve (pcv valve), pulley part, rocker arm, rocker cover, starter motor, starter pinion, starter ring, turbocharger and supercharger, tappet, timing belt, timing tape, valve cover, valve housing, valve spring, valve stem seal, water pump pulley, engine cooling system, air blower, coolant hose (clamp), cooling fan, fan belt, fan clutch, radiator, radiator bolt, radiator (fan) shroud, radiator gasket, radiator pressure cap, overflow tank, thermostat, water neck, water neck o-ring, water pipe, water pump, water pump gasket, water tank, engine oil systems, oil filter, oil gasket, oil pan, oil pipe, oil pump, oil strainer, oil suction filter, exhaust system, see also: exhaust gas recirculation, catalytic converter, exhaust clamp and bracket, exhaust flange gasket, exhaust gasket, exhaust manifold, exhaust manifold gasket, exhaust pipe, heat shield, heat sleeving and tape, resonator, muffler (silencer), spacer ring, fuel supply system, air filter, carburetor, choke cable, exhaust gas recirculation valve (egr valve), fuel cap or fuel filler cap, fuel cell, fuel cell component, fuel cooler, fuel distributor, fuel filter, fuel filter seal, fuel injector, fuel injector nozzle, fuel line, fuel pump, fuel pump gasket, fuel pressure regulator, fuel rail, fuel tank, fuel tank cover, fuel water separator, intake manifold, intake manifold gasket, lpg (liquefied petroleum gas) system assembly, throttle body, suspension and steering systems, axle, ball joint, beam axle, camber arm, control arm, idler arm, kingpin, lateral link, panhard rod, pitman arm, power steering assembly and component, rack end, shock absorber, spindle, spring, air spring, coil spring, leaf and parabolic leaf spring, rubber spring, spiral spring, stabilizer bars and link, steering arm, steering box, steering pump, steering column assembly, steering rack (a form of steering gear; see also rack and pinion and recirculating ball), steering shaft, steering wheel (driving wheel), strut, stub axle, suspension link and bolt, tie rod end, trailing arm, transmission system, adjustable pedal, axle shaft, bell housing, universal joint, carrier assembly, chain wheel and sprocket, clutch assembly, clutch cable, clutch disk, clutch fan, clutch fork, clutch hose, clutch lever, clutch lining, clutch pedal, clutch pressure plate, clutch shoe, clutch spring, differential, differential case, pinion bearing, differential clutch, spider gears, differential casing, differential flange, differential gear, differential seal, flywheel, flywheel ring gear, flywheel clutch, gear, gear coupling, gear pump, gear ring, gear stick (gear-stick, gear lever, selection lever, shift stick, gear shifter), gearbox, idler gear, knuckle, master cylinder, output shaft, pinion, planetary gear set, prop shaft (drive shaft, propeller shaft), shift cable, shift fork, shift knob, slave cylinder, speed reducer, speedometer gear, steering gear, torque converter, trans-axle housing, transfer case, transmission gear, transmission pan, transmission seal and bonded piston, transmission spring, transmission yoke, miscellaneous auto parts, air conditioning system (a/c), automobile air conditioning, a/c clutch, a/c compressor, a/c condenser, a/c hose high pressure, a/c kit, a/c relay, a/c valve, a/c expansion valve, a/c low-pressure valve, a/c schroeder valve, a/c inner plate, a/c cooler, a/c evaporator, a/c suction hose pipe, a/c discharge hose pipe, a/c gas receiver, a/c condenser filter, a/c cabin filter (pollen filter), bearings, grooved ball bearing, needle bearing, roller bearing, sleeve bearing, wheel bearing, hose, fuel vapour hose, reinforced hose (high-pressure hose), non-reinforced hose, radiator hose, other miscellaneous parts, logo, adhesive tape and foil, air bag, bolt cap, license plate bracket, cables, speedometer cable, cotter pin, dashboard, center console, glove compartment, drag link, dynamic seal, fastener, gasket: flat, molded, profiled, hood and trunk release cable, horn and trumpet horn, injection-molded parts, instrument cluster, label, mirror, name plate, nut, flange nut, hex nut, o-ring, paint, rivet, rubber (extruded and/or molded), screw, shim, sun visor, washer, etc., or any combination or equivalent thereof that would be appreciated by those having ordinary skill in the art upon reading the present disclosure.
Further, in the context of aircraft (or, equivalently, aeronautical vehicles), such as airplanes, jets, helicopters, unmanned aerial vehicles (UAVs), etc., the inventive compositions of matter described herein may be incorporated into parts including but not limited to the accessory drive, airfoil, air frame, aft pressure bulkhead, air cycle machine, air data boom, aircraft fairing, aircraft safety card, airframe, airstair, arming plug, auxiliary power unit, ballute, blades (e.g., of a propellor or rotor), bracing (aeronautics), canard (aeronautics), clutch, cockpit, compressor, constant speed drive, cook-craigie plan, cowling, crack arrestor, drag-reducing aerospike, drogue parachute, droop nose (aeronautics), dry bay, duramold, empennage, engine, engine-indicating and crew-alerting system, exint pod, firewall (engine), flame damper, flettner rotor, flight helmet, flight recorder, flight test instrumentation, former, fuel system, fuselage, glass cockpit, gravel kit, high-lift device, hub, landing gear, legs, line-replaceable unit, list of countries by aircraft component exports, longeron, monocoque, naca cowling, nacelle, nose cone, outboard tail, tire, turbine, rudder pedal, semi-monocoque, shop-replaceable unit, skin (aeronautics), smart intelligent aircraft structure, speed tape, sponson, spy basket, stick pusher, strake (aeronautics), surface radiator, synthetic air data system, takeoff acceleration monitoring system, toroidal propeller, trailing-arm suspension, transmission, tube-and-fabric construction, unapproved aircraft part, vortex generator, wheel, wing, wingbox, wire strike protection system), or any other example or equivalent(s) thereof that would be appreciated by those having ordinary skill in the art upon reading the present disclosure.
Further still, in the context of aerospace vehicles such as satellites, rockets, spaceplanes, etc., the inventive compositions of matter disclosed herein may be incorporated into, or implemented in, parts such as the hull, wings, engines, nose cone, fuselage, solar panels, rivets, heat shield, cabling, support structures or systems, flotation systems, joints, tanks, skirts, brakes, nozzles, hatches, siphons, parachutes, connection mechanisms, separation mechanisms, casings, flaps, etc., or any other example or equivalent(s) thereof that would be appreciated by those having ordinary skill in the art upon reading the present disclosure.
Yet further still, in the context of aquatic and/or amphibious vehicles, such as boats, ships, hovercraft, jet-skis, catamarans, etc., inventive compositions of matter disclosed herein may be incorporated into, or implemented in, parts such as the hull, cleats, windscreen, engines, propellers, mast, rudder, rigging, sails, beam, cabin, anchor, bilge, deck, jib, or any combination or equivalent thereof that would be appreciated by those having ordinary skill in the art upon reading the present disclosure.
In particularly preferred embodiments, the presently described compositions of matter may be formed into, or incorporated into, parts, components, etc. of high-end racing vehicles, electric vehicles, driverless trucks, or other high-end (i.e., not mass produced) vehicles, including but not limited to aeronautical or aerospace vehicles (e.g. airplanes, jets, helicopters, gliders, balloons, blimps, rockets, missiles, satellites, paramotors, etc.), high-end aquatic vehicles (such as racing boats of various types), or any other example or equivalent(s) thereof that would be appreciated by those having ordinary skill in the art upon reading the present disclosure.
Of course, the inventive compositions described herein may be incorporated into parts of other vehicles including but not limited to commuter vehicles (e.g., cars, trucks, vans, buses, motorcycles, bicycles, tricycles, etc.), agricultural machinery (e.g., tractors, combines, harvesters, seeders, cultivators, harrows, plows, transplanters, mowers, etc.), industrial machinery (e.g., cranes, bulldozers, forklifts, pavers, transporters, stock chasers, lift trucks, excavators, construction equipment, etc.), recreational vehicles (e.g., all-terrain vehicles (ATVs), motorhomes, campers, haulers, trailers, unmanned aerial vehicles (UAVs), etc.), aquatic vehicles (e.g., submarines, motorboats, sailboats, jet-skis, dinghies, catamarans, speedboats, rigged-hulled inflatable boats (RHIBs), etc.), amphibious vehicles (e.g., of any type listed hereinabove, as well as hovercraft), military vehicles (e.g., of any type listed hereinabove but adapted for military use, as well as armored personnel carriers (APCs), armored trucks, tanks, mine detection and mine removal vehicles, gunships, battleships, aircraft carriers, other aquatic combat vehicles, etc.). Simplified schematics of several such exemplary vehicles are shown in
The foregoing descriptions set forth several exemplary classes of vehicles and other systems that may incorporate the inventive compositions of matter described herein in one or more parts thereof. Those having ordinary skill in the art will appreciate that the foregoing lists of vehicles and corresponding parts are presented by way of illustration rather than limitation. To the extent that any particular class of vehicle or other system may, or is known to, include a part or component described herein with reference to another class of vehicle or other system, it shall be understood that such part(s) or component(s) may be included in all the various classes of vehicles and other systems described herein, as well as any equivalent(s) thereof that are known in the art or would be appreciated upon reading the present descriptions.
Moreover, the presently described inventive compositions may be included in parts, products, systems, etc. other than vehicles without departing from the scope of the concepts described herein. For example, additional suitable applications include tools of various types (e.g., hand-held, motorized, large scale, etc., including saws, presses, lathes, robotic arms, mills, drills, etc.), biomedical materials and related applications (e.g., prosthetics, implants, etc.), industrial materials (e.g., materials for use in additively manufacturing buildings such as walls, support beams, roofing, flooring, plumbing, etc.), appliances (e.g., environmental control systems, ovens, food storage systems, washers, dryers, etc.), metallurgical applications (e.g., furnaces, crucibles, anvils, etc.), firearms and munitions, energy generation, transmission, and/or storage applications (e.g. cooling stacks, towers, batteries, generators, capacitors, flywheels, turbines, etc.), garments (especially special-use garments such as personal armor, space suits, underwater exploration suits, HAZMAT suits, etc. or other protective garments such as helmets, pads, vests, guards, footwear, etc.), or any other suitable application that would be appreciated by those having ordinary skill in the art upon reading the present disclosure.
It should be understood that the arrangement of components illustrated in the FIGS. described are exemplary and that other arrangements are possible. It should also be understood that the various system components (and means) defined by the claims, described below, and illustrated in the various block diagrams represent logical components in some systems configured according to the subject matter disclosed herein.
In accordance with one implementation, a composition of matter includes: a carbon fiber having a plurality of carbon fiber filaments disposed therein, where at least some of the plurality of carbon fiber filaments are each independently characterized by a longitudinal axis oriented at an angle substantially deviating from parallel to a longitudinal axis of the carbon fiber. Optionally, longitudinal axes of at least some of the plurality of carbon fiber filaments are characterized by a substantially random distribution of orientation angles each independently deviating from parallel to the longitudinal axis of the carbon fiber. Similarly, longitudinal axes of other of the plurality of carbon fiber filaments may be aligned substantially in parallel with the longitudinal axis of the carbon fiber. At least some of the carbon fiber filaments may be discontinuous, while other of the carbon fiber filaments may be continuous. For instance, the carbon fiber filaments may be characterized by an aspect ratio in a range from about 100:1 to about 1000:1. Moreover, at least some of the carbon fiber filaments may independently comprise one or more graphene platelets. In such approaches, at least some of the one or more graphene platelets may comprise three-dimensional (3D) graphene, and/or at least some at least some carbon atoms of the 3D graphene may be characterized by sp3 orbital hybridization. The plurality of graphene platelets may each independently comprise each a single-layer graphene (SLG), a few-layer graphene (FLG), a multi-layer graphene (MLG), or any combination thereof. At least some of the graphene platelets may comprise one or more polycyclic aromatic hydrocarbons (PAHs) adsorbed to one or more adsorption sites on one or more surfaces of the graphene platelets. Optionally, planes of orientation of at least some of the graphene platelets may each be independently oriented at an angle substantially deviating from parallel to a longitudinal axis of the carbon fiber. The 3D graphene may, in various approaches, be present in an amount ranging from less than one weight percent of a total weight of the carbon fiber to about one hundred weight percent of the total weight of the carbon fiber. Further, at least some of the plurality of carbon fiber filaments may be sized on one or more exterior surfaces of the carbon fiber. The composition of matter may be provided in the form of a plurality of the carbon fibers substantially aligned in parallel along the longitudinal axes thereof, where at least some of the carbon fiber filaments preferably crosslink some or all of the plurality of carbon fibers. Similarly, the composition of matter may include a binder matrix having a second plurality of carbon fiber filaments disposed therein, where at least some of the second plurality of carbon fiber filaments preferably crosslink some or all of the plurality of carbon fibers. Moreover, the composition may substantially exclude oxygen.
According to another implementation, a composition of matter includes: a carbon fiber having a plurality of graphene platelets disposed therein, where at least some of the graphene platelets comprise three-dimensional (3D) graphene. The 3D graphene may, in various approaches, be present in an amount ranging from less than one weight percent of a total weight of the carbon fiber to about one hundred weight percent of the total weight of the carbon fiber. Optionally, at least some carbon atoms of the 3D graphene are characterized by sp3 orbital hybridization. Preferably, the 3D graphene comprises a plurality of ligands integrated into: a bulk of the carbon fiber; an exterior surface of the carbon fiber; or both the bulk and the exterior surface of the carbon fiber. Planes of orientation of at least some of the graphene platelets may each be independently oriented at an angle substantially deviating from parallel to a longitudinal axis of the carbon fiber. The plurality of graphene platelets may each independently comprise each a single-layer graphene (SLG), a few-layer graphene (FLG), a multi-layer graphene (MLG), or any combination thereof. At least some of the graphene platelets may comprise one or more polycyclic aromatic hydrocarbons (PAHs) adsorbed to one or more adsorption sites on one or more surfaces of the graphene platelets. Moreover, at least some of the plurality of graphene platelets may be sized on one or more external surfaces of the carbon fiber. The composition of matter may be provided in the form of a plurality of the carbon fibers substantially aligned in parallel along the longitudinal axes thereof; where at least some of the graphene platelets preferably crosslink some or all of the plurality of carbon fibers. Additionally or alternatively, the carbon fiber may have a plurality of carbon fiber filaments disposed therein, where at least some of the plurality of carbon fiber filaments are each independently characterized by a longitudinal axis oriented at an angle substantially deviating from parallel to a longitudinal axis of the carbon fiber. Optionally, longitudinal axes of at least some of the plurality of carbon fiber filaments are characterized by a substantially random distribution of orientation angles each independently deviating from parallel to the longitudinal axis of the carbon fiber. Similarly, longitudinal axes of other of the plurality of carbon fiber filaments may be aligned substantially in parallel with the longitudinal axis of the carbon fiber. At least some of the carbon fiber filaments may be discontinuous, while other of the carbon fiber filaments may be continuous. For instance, the carbon fiber filaments may be characterized by an aspect ratio in a range from about 100:1 to about 1000:1. Further, at least some of the plurality of carbon fiber filaments may be sized on one or more exterior surfaces of the carbon fiber. The composition of matter may include an optional binder matrix having a second plurality of carbon fiber filaments disposed therein, where at least some of the second plurality of carbon fiber filaments preferably crosslink some or all of the plurality of carbon fibers. Moreover, the composition may substantially exclude oxygen.
According to yet another implementation, a composition of matter includes: a carbon fiber having a plurality of carbon fiber filaments sized on one or more external surfaces thereof, where the carbon fiber filaments are characterized by either: comprising graphene platelets; having a longitudinal axis of some or all of the carbon fiber filaments oriented at an angle substantially deviating from parallel to a longitudinal axis of the carbon fiber; or both comprising the graphene platelets and having the longitudinal axis of some or all of the carbon fiber filaments oriented at the angle substantially deviating from parallel to the longitudinal axis of the carbon fiber. At least some of the graphene platelets may comprise one or more polycyclic aromatic hydrocarbons (PAHs) adsorbed to one or more adsorption sites on one or more surfaces of the graphene platelets. Preferably, at least some of the graphene platelets comprise three-dimensional (3D) graphene, and at least some carbon atoms of the 3D graphene are characterized by sp3 orbital hybridization. The 3D graphene may, in various approaches, be present in an amount ranging from less than one weight percent of a total weight of the carbon fiber to about one hundred weight percent of the total weight of the carbon fiber. Preferably, the 3D graphene comprises a plurality of ligands integrated into: a bulk of the carbon fiber; an exterior surface of the carbon fiber; or both the bulk and the exterior surface of the carbon fiber. Planes of orientation of at least some of the graphene platelets may each be independently oriented at an angle substantially deviating from parallel to a longitudinal axis of the carbon fiber. The plurality of graphene platelets may each independently comprise each a single-layer graphene (SLG), a few-layer graphene (FLG), a multi-layer graphene (MLG), or any combination thereof. At least some of the graphene platelets may comprise one or more polycyclic aromatic hydrocarbons (PAHs) adsorbed to one or more adsorption sites on one or more surfaces of the graphene platelets. Moreover, at least some of the plurality of graphene platelets may be sized on one or more external surfaces of the carbon fiber. The composition of matter may be provided in the form of a plurality of the carbon fibers substantially aligned in parallel along the longitudinal axes thereof; where at least some of the carbon fiber filaments (which, again, may comprise graphene platelets) preferably crosslink some or all of the plurality of carbon fibers. Additionally or alternatively, the carbon fiber may have a plurality of carbon fiber filaments disposed therein, where at least some of the plurality of carbon fiber filaments are each independently characterized by a longitudinal axis oriented at an angle substantially deviating from parallel to a longitudinal axis of the carbon fiber. Optionally, longitudinal axes of at least some of the plurality of carbon fiber filaments are characterized by a substantially random distribution of orientation angles each independently deviating from parallel to the longitudinal axis of the carbon fiber. Similarly, longitudinal axes of other of the plurality of carbon fiber filaments may be aligned substantially in parallel with the longitudinal axis of the carbon fiber. At least some of the carbon fiber filaments may be discontinuous, while other of the carbon fiber filaments may be continuous. For instance, the carbon fiber filaments may be characterized by an aspect ratio in a range from about 100:1 to about 1000:1. Further, at least some of the plurality of carbon fiber filaments may be sized on one or more exterior surfaces of the carbon fiber. The composition of matter may include an optional binder matrix having a second plurality of carbon fiber filaments disposed therein, where at least some of the second plurality of carbon fiber filaments preferably crosslink some or all of the plurality of carbon fibers. Moreover, the composition may substantially exclude oxygen.
According to still yet another implementation, a composition of matter includes: a carbon fiber; and a binder matrix, wherein the binder matrix is structurally coupled to the carbon fiber via either: a plurality of carbon fiber filaments in the binder matrix; a plurality of graphene platelets in the binder matrix; or both the plurality of carbon fiber filaments in the binder matrix and the plurality of graphene platelets in the binder matrix. Preferably, the plurality of carbon fiber filaments in the binder matrix and/or the plurality of graphene platelets in the binder matrix are structurally coupled to the carbon fiber via crosslinking the binder matrix and the carbon fiber. The carbon fiber may comprise a second plurality of carbon fiber filaments disposed therein. In various approaches, at least some of the plurality of carbon fiber filaments and/or the second plurality of carbon fiber filaments are each independently characterized by a longitudinal axis oriented at an angle substantially deviating from parallel to a longitudinal axis of the carbon fiber. Optionally, longitudinal axes of at least some of the plurality of carbon fiber filaments and/or the second plurality of carbon fiber filaments are characterized by a substantially random distribution of orientation angles each independently deviating from parallel to the longitudinal axis of the carbon fiber. Similarly, longitudinal axes of other of the plurality of carbon fiber filaments and/or the second plurality of carbon fiber filaments may be aligned substantially in parallel with the longitudinal axis of the carbon fiber. At least some of the carbon fiber filaments and/or the second carbon fiber filaments may be discontinuous, while other of the carbon fiber filaments and/or the second carbon fiber filaments may be continuous. For instance, the carbon fiber filaments and/or the second carbon fiber filaments may be characterized by an aspect ratio in a range from about 100:1 to about 1000:1. Moreover, at least some of the carbon fiber filaments and/or the second carbon fiber filaments may independently comprise one or more graphene platelets. In such approaches, at least some of the one or more graphene platelets may comprise three-dimensional (3D) graphene, and/or at least some at least some carbon atoms of the 3D graphene may be characterized by sp3 orbital hybridization. The plurality of graphene platelets may each independently comprise each a single-layer graphene (SLG), a few-layer graphene (FLG), a multi-layer graphene (MLG), or any combination thereof. At least some of the graphene platelets may comprise one or more polycyclic aromatic hydrocarbons (PAHs) adsorbed to one or more adsorption sites on one or more surfaces of the graphene platelets. Optionally, planes of orientation of at least some of the graphene platelets may each be independently oriented at an angle substantially deviating from parallel to a longitudinal axis of the carbon fiber. The 3D graphene may, in various approaches, be present in an amount ranging from less than one weight percent of a total weight of the carbon fiber to about one hundred weight percent of the total weight of the carbon fiber. Further, at least some of the plurality of carbon fiber filaments, the second plurality of carbon fiber filaments, and/or the graphene platelets may be sized on one or more exterior surfaces of the carbon fiber. The composition of matter may be provided in the form of a plurality of the carbon fibers substantially aligned in parallel along the longitudinal axes thereof, where at least some of the carbon fiber filaments and/or the second carbon fiber filaments preferably crosslink some or all of the plurality of carbon fibers. Additionally or alternatively, graphene platelets in the binder matrix and/or the carbon fiber(s) may crosslink the plurality of carbon fibers. Moreover, the composition may substantially exclude oxygen.
In more implementations, products may be fabricated in whole or in part using the inventive compositions.
In one approach, said products may include: one or more carbon fibers incorporated into a bulk of the product and/or sized on one or more surfaces of the product. The one or more carbon fibers independently have a plurality of carbon fiber filaments disposed therein; and at least some of the plurality of carbon fiber filaments are each independently characterized by a longitudinal axis oriented at an angle substantially deviating from parallel to a longitudinal axis of the carbon fiber.
In another approach, a product includes a carbon fiber incorporated into a bulk of the product and/or sized on one or more surfaces of the product; where the carbon fiber has a plurality of graphene platelets disposed therein; and at least some of the graphene platelets comprise three-dimensional (3D) graphene.
According to yet another approach, a product includes: a carbon fiber having a plurality of carbon fiber filaments sized on one or more external surfaces thereof. The carbon fiber filaments are characterized by either: comprising graphene platelets; having a longitudinal axis of some or all of the carbon fiber filaments oriented at an angle substantially deviating from parallel to a longitudinal axis of the carbon fiber; or both comprising the graphene platelets and having the longitudinal axis of some or all of the carbon fiber filaments oriented at the angle substantially deviating from parallel to the longitudinal axis of the carbon fiber.
The inventive products, according to various implementations, may include any suitable combination of features described herein, such as having carbon fibers present in an amount ranging from about 1 wt % to about 30 wt %. The product may comprise one or more thermoplastic polymers. The product may include one or more polymers selected from the group consisting of: polylactic acid, acrylonitrile butadiene styrene, polyethylene terephthalate glycol, thermoplastic polyurethane, polyetheretherketone, polypropylene, polyphenylsulfone, polyvinyl alcohol, polyetherimide, polyethylene, polyoxymethylene, polyamide, polycarbamate, and combinations thereof. Graphene may be incorporated into the bulk of the product and/or sized on one or more surfaces of the product. The graphene may be present in an amount ranging from about 0.01 wt % to about 10 wt %. The product may be an additively manufactured part having a predefined substantially two-dimensional (2D) or substantially three-dimensional (3D) physical form factor. The product may have a physical form factor configured for use in a particular system or a particular application. The particular system may include a vehicle, and the product may be an additively manufactured part of the vehicle. The vehicle may be a land vehicle, an aquatic vehicle, an amphibious vehicle, an aeronautical vehicle, an aerospace vehicle, an agricultural vehicle, or a military vehicle. Alternatively, the particular system may be a garment. The particular application may be a biomedical application, an industrial application, an agricultural application, or a military application.
Moreover, one or more of the system components (and means) may be realized, in whole or in part, by at least some of the components illustrated in the arrangements illustrated in the described FIGS. In addition, while at least one of these components are implemented at least partially as an electronic hardware component, and therefore constitutes a machine, the other components may be implemented in software that when included in an execution environment constitutes a machine, hardware, or a combination of software and hardware.
More particularly, at least one component defined by the claims is implemented at least partially as an electronic hardware component, such as an instruction execution machine (e.g., a processor-based or processor-containing machine) and/or as specialized circuits or circuitry (e.g., discreet logic gates interconnected to perform a specialized function). Other components may be implemented in software, hardware, or a combination of software and hardware. Moreover, some or all of these other components may be combined, some may be omitted altogether, and additional components may be added while still achieving the functionality described herein. Thus, the subject matter described herein may be embodied in many different variations, and all such variations are contemplated to be within the scope of what is claimed.
To facilitate an understanding of the subject matter described herein, many aspects are described in terms of sequences of actions. At least one of these aspects defined by the claims is performed by an electronic hardware component. For example, it will be recognized that the various actions may be performed by specialized circuits or circuitry, by program instructions being executed by one or more processors, or by a combination of both. The description herein of any sequence of actions is not intended to imply that the specific order described for performing that sequence must be followed. All methods described herein may be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the subject matter (particularly in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation, as the scope of protection sought is defined by the claims as set forth hereinafter together with any equivalents thereof entitled to. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illustrate the subject matter and does not pose a limitation on the scope of the subject matter unless otherwise claimed. The use of the term “based on” and other like phrases indicating a condition for bringing about a result, both in the claims and in the written description, is not intended to foreclose any other conditions that bring about that result. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention as claimed.
Similarly, a phrase referring to “at least one of”, “one or more of”, “some or all of”, or equivalent references to a list of items refers to any combination of those items, including single members. As an example, “at least one of: a, b, or c” is intended to cover: a, b, c, a-b, a-c, b-c, and a-b-c. The various illustrative logics, logical blocks, modules, circuits and algorithm processes described in connection with the implementations disclosed herein may be implemented as electronic hardware, computer software, or combinations of both. The interchangeability of hardware and software has been described generally, in terms of functionality, and illustrated in the various illustrative components, blocks, modules, circuits and processes described above. Whether such functionality is implemented in hardware or software depends upon the particular application and design constraints imposed on the overall system.
Moreover, the term “about” as utilized herein, particularly with reference to numerical ranges, shall be understood as including the recited value, and a ±10% margin thereof. For instance, “about 1.0” shall be understood as including values in the range from 0.9 to 1.1, inclusively. Similarly, “about 500” shall be understood as including values in the range from 450 to 550. Skilled artisans will thus be distinctly aware of the full range included in any recitation of numerical values herein modified by the term “about” according to various approaches.
Various modifications to the implementations described in this disclosure may be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other implementations without departing from the spirit or scope of this disclosure. Thus, the claims are not intended to be limited to the implementations shown herein but are to be accorded the widest scope consistent with this disclosure, the principles and the novel features disclosed herein. Similarly, various features described hereinabove with respect to different implementations, embodiments, aspects, etc. of the inventive concepts presently disclosed may be combined in any suitable manner that would be appreciated by a person having ordinary skill in the art and apprised of the contents of the application. Individual features are thus to be understood as “modular”, and capable of being arranged, configured, included, etc. in any suitable manner unless expressly disclaimed herein, or understood as incompatible based on knowledge available in the art as of the present application's priority date.
The embodiments described herein included the one or more modes known to the inventor for carrying out the claimed subject matter. Of course, variations of those embodiments will become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventor expects skilled artisans to employ such variations as appropriate, and the inventor intends for the claimed subject matter to be practiced otherwise than as specifically described herein. Accordingly, this claimed subject matter includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed unless otherwise indicated herein or otherwise clearly contradicted by context.
The present application is a continuation-in-part of U.S. patent application Ser. No. 18/115,643, filed Feb. 28, 2023 and entitled “POLYMER MATRIX COMPOSITES, AND METHODS OF MAKING THE SAME” (subsequently published as U.S. Patent Publication No. US 2023/0287197 on Sep. 14, 2023), which claims priority to U.S. Provisional Patent Application No. 63/318,213, filed Mar. 9, 2022 and entitled “GRAPHENE REINFORCED CARBON FIBERS”, to each of which priority is claimed, and the contents of each of which are herein incorporated by reference in entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63318213 | Mar 2022 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 18115643 | Feb 2023 | US |
| Child | 19019185 | US |
