JP2012525012A - Cnt浸出emi遮蔽複合材料及びコーティング - Google Patents
Cnt浸出emi遮蔽複合材料及びコーティング Download PDFInfo
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- H05K9/0073—Shielding materials
- H05K9/0081—Electromagnetic shielding materials, e.g. EMI, RFI shielding
- H05K9/009—Electromagnetic shielding materials, e.g. EMI, RFI shielding comprising electro-conductive fibres, e.g. metal fibres, carbon fibres, metallised textile fibres, electro-conductive mesh, woven, non-woven mat, fleece, cross-linked
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Abstract
マトリクス材の一部に、前記マトリクス材内でCNT浸出繊維材料の配向が制御された状態でCNT浸出繊維材料を配置することと、前記マトリクス材を硬化することとを含む複合材料の製造方法。
複合材料を含み、EMI遮蔽用途に使用される装置と適合するよう調整可能なパネル。前記パネルは、電気接地をさらに備える。
【選択図】図1
Description
本出願は、2009年4月24日に出願された米国仮出願第61/172,503号及び2009年4月28日に出願された米国仮出願第61/173,435号の利益を主張し、これらの出願の全ての内容は参照により本出願に組み込まれる。
当該技術分野で周知の典型的なCNT合成反応器の断面は円形である。これには、例えば、歴史的理由(研究所では大抵円筒形反応器が使用される)、利便性(円筒形反応器では流動力学のモデル化が容易であり、加熱システムは円環(クオーツ(quartz)等)に容易に対応する)、及び製造の容易さを含む多くの理由がある。円筒形の慣習から離れ、本発明は、断面が長方形のCNT合成反応器を提供する。離れる理由は以下の通りである。1.反応器により処理することができる多くの炭素繊維材料は、平らなテープ又はシート様形態等のように比較的平面的なので、円形断面は反応器体積の使用が非効率である。この非効率は、例えば、a)十分なシステムパージ(system purge)を維持すること(増加した反応器体積は、同レベルのガスパージを維持するために、さらなるガス流量を必要とする)を含む、円筒形CNT合成反応器にいくつかの欠点を生じさせる。これは、開放環境におけるCNTの大量生産による非効率なシステムを生じさせる。b)増加した炭素原料ガス流(不活性ガス流内での相対的な増加は、上記a)のように、さらなる炭素原料ガス流を必要とする)。12K炭素繊維トウの体積は、断面が長方形の合成反応器の全体積の2000分の1であると考えられたい。同等成長円筒形反応器(すなわち、長方形断面反応器と同様の平面的な炭素繊維材料に対応する幅を有する円筒形反応器)において、炭素繊維材料の体積は、前記チャンバーの17500分の1である。一般に、CVD等のガス蒸着処理は、圧力又は温度にもっぱら影響されるが、体積は蒸着の効率に大きな影響力を有する。それでもまだ、長方形反応器の体積は過剰である。この過剰体積は望ましくない反応を促進するが、しかし円筒形反応器はこの約8倍の体積を有するのである。競合する反応が生じるこの大きな機会により、所望の反応は、円筒形反応器チャンバー内で事実上緩やかに生じる。CNT成長のこのような減速は、連続処理の進行において問題となっている。長方形反応器構成の1つの恩恵は、高さの低い長方形チャンバーを使用することにより、反応器体積を減少させ、これによって、この体積比を良好にし、反応を効率的にすることである。本発明のある実施形態において、長方形合成反応器の全体積は、合成反応器を通過している炭素繊維材料の全体積の約3000倍に過ぎない。さらなる実施形態において、長方形合成反応器の全体積は、合成反応器を通過している炭素繊維材料の全体積の約4000倍に過ぎない。またさらなる実施形態において、長方形合成反応器の全体積は、合成反応器を通過している炭素繊維材料の全体積の約10000倍未満である。さらに、円筒形反応器を使用した場合、長方形断面の反応器と同様の流率(flow percent)を提供するために、より多くの炭素原料ガスが必要となることは注目すべきである。他の実施形態において、合成反応器は、長方形ではないが、比較的それに類似しており、円形断面の反応器に対して反応器体積を同様に減少させる多角形形状で表される断面を有することは十分に評価されてよい。c)問題のある温度分布。比較的小さな直径の反応器が使用された場合、チャンバーの中央部からその壁面までの温度勾配は最小となる。しかし、工業規模の生産に使用される等、規模が大きくなるにつれ、温度勾配は大きくなる。このような温度勾配は、炭素繊維基質全域での製品品質のばらつきを生じさせる(すなわち、製品の品質は、半径方向の位置の関数として変化する)。長方形断面の反応器を使用した場合、この問題は大きく避けられる。特に、平面的な基質が使用された場合、反応器の高さを、基質の上向きの大きさに一定に保つことができる。反応器の頂部と底部との間の温度勾配は、基本的にごくわずかであり、結果として、熱問題及びこれにより生じる製品品質のばらつきは避けられる。2.ガス導入。当該技術分野では管状炉が通常使用されるため、一般的なCNT合成反応器は、ガスを一端から導入し、反応器を通じてそれを他端へ引き込む。本明細書に記載のある実施形態において、ガスは、反応器の側面又は頂板及び底板を通って、反応器の中央部又は目標となる成長領域に、対照的に導入され得る。流入する原料ガスがシステムの最も高温の(CNT成長が最も盛んな)部分に連続的に補給されるため、これはCNT成長率全体を向上させる。この持続するガス補給は、長方形CNT反応器が示す高い成長率における重要な側面である。
比較的低温のパージ領域を提供するチャンバーは、長方形合成反応器の両端に左右される。出願人は、高温のガスが外部環境(すなわち、反応器の外側)と接した場合、炭素繊維材料の劣化が増すことを究明している。低温のパージ領域は、内部システムと外部環境との間の緩衝材を提供する。当該技術分野で周知の典型的なCNT合成反応器構成は、基質を注意深く(そして緩やかに)冷却することが通常求められる。この長方形CNT成長反応器の出口の低温パージ領域は、連続インライン処理に必要とされる短時間で冷却することができる。
ある実施形態において、金属(特にステンレス鋼)製の高温壁反応器が使用される。金属(特にステンレス鋼)は、炭素堆積(すなわち、煤及び副生成物形成)の影響を受けやすいため、これは直感に反するように思える。したがって、ほとんどのCNT反応器構成は、炭素の堆積が少なく、石英は清掃が容易であり、石英は試料の観察を容易にするため、石英反応器を使用する。しかしながら、出願人は、ステンレス鋼上の煤及び炭素堆積の増大の結果、より着実で、より速く、より効率的で、より安定したCNT成長が起きることを観察している。理論に制限されることなく、大気稼働と関連して、反応器内で生じるCVD処理は拡散律速であることが示されている。すなわち、触媒は、その相対的に(反応器が不完全真空下で稼働していた場合より)高い分圧により、反応器システム内で得られる多すぎる炭素を「過剰供給」される。結果として、開放システム(特にクリーン(clean)なもの)において、多すぎる炭素が触媒粒子に付着し、そのCNT合成能力を低下させる。ある実施形態において、長方形反応器は、反応器が「汚れている(dirty)」(すなわち、金属反応器壁面に煤が堆積している)場合、故意に稼働される。炭素が反応器の壁面の単分子層として堆積すると、炭素はその上に容易に堆積するだろう。このメカニズムにより、得られる炭素の一部が「回収される」ため、ラジカルの形態で残っている炭素原料は、触媒を害さない速度で触媒と反応する。既存のシステムは、「クリーンに」稼働し、もしそれが連続処理のために開放していれば、低い成長速度でCNTのはるかに低い収率を生じさせるだろう。
本明細書に開示のCNT合成反応器において、触媒還元とCNT成長とはいずれも反応器ないで生じる。もし別々の工程として行われた場合、連続処理で使用するのに十分適時に還元ステップを行うことができないため、これは重要である。当該技術分野で周知の典型的な処理において、還元ステップを行うのに通常は1〜12時間かかる。両方の工程は、少なくとも一部には、炭素原料ガスが(円筒形反応器を使用する当該技術分野においては典型的な端部ではなく)反応器の中央部から導入されることにより、本発明の係る反応器内で生じる。繊維が加熱領域に入るにつれ、前記還元処理が生じる。この時点までには、ガスは、触媒と反応し(水素ラジカル相互作用を介した)酸化還元を引き起こす前に、壁面と反応し冷却される時間を得てしまっている。還元はこの遷移領域で行われる。システム内で最も高温の等温領域で、CNT成長は生じ、反応器の中央部付近のガス吸入口近傍で最大成長速度が生じる。
本実施例は、高いEMI遮蔽特性を目的とする連続処理において、どのようにCNTが炭素繊維材料に浸出されるかを示す。
本実施例は、高いEMI遮蔽特性を必要とする用途のための連続処理において、どのようにCNTが初期のガラス繊維材料に浸出されるかを示す。
Claims (13)
- マトリクス材の少なくとも一部に配置されたカーボンナノチューブ(CNT)浸出繊維材料を含んで構成された電磁妨害(EMI)遮蔽用途に使用される複合材料であって、
前記複合材料は約0.01MHzから約18GHzの範囲の周波数において、電磁(EM)放射の吸収、EM放射の反射、又はその両方が可能であり、
前記複合材料の前記EM遮蔽能力は、約40デシベル(dB)から約130dBの範囲の電磁妨害(EMI)遮蔽有効性(SE)として計測される複合材料。 - 多数の遷移金属ナノ粒子をさらに含んで構成された請求項1に記載の複合材料。
- 前記ナノ粒子は、鉄を含んで構成された請求項2に記載の複合材料。
- 前記SEは、K帯域レーダーにおいて、約90dBから約110dBの範囲である請求項1に記載の複合材料。
- 前記SEは、X帯域レーダーにおいて、約90dBから約100dBの範囲である請求項1に記載の複合材料。
- 前記SEは、C帯域レーダーにおいて、約80dBから約90dBの範囲である請求項1に記載の複合材料。
- 前記SEは、S帯域レーダーにおいて、約70dBから約80dBの範囲である請求項1に記載の複合材料。
- 前記SEは、L帯域レーダーにおいて、約50dBから約60dBの範囲である請求項1に記載の複合材料。
- 前記CNTは、前記複合材料の約1重量%から約20重量%の範囲で存在する請求項1に記載の複合材料。
- 前記CNT浸出繊維材料は、ガラス、炭素、セラミックから選択される繊維を含んで構成される請求項1に記載の複合材料。
- 前記繊維材料上に浸出された前記CNTは、前記複合材料内で制御された配向を有する請求項1に記載の複合材料。
- 複合材料の製造方法であって、
前記複合材料は、マトリクス材の少なくとも一部に配置されたカーボンナノチューブ(CNT)浸出繊維材料を含んで構成され、約0.01MHzから約18GHzの範囲の周波数において、電磁(EM)放射の吸収、EM放射の反射、又はその両方が可能であり、
前記複合材料のEM遮蔽能力は、約40デシベル(dB)から約130dBの範囲の電磁妨害(EMI)遮蔽有効性(SE)として計測され、
前記方法は、マトリクス材の一部に、前記マトリクス材内でCNT浸出繊維材料の配向が制御された状態でCNT浸出繊維材料を配置することと、前記マトリクス材を硬化することと、を含んで構成され、
前記CNT浸出繊維材料の前記制御された配向は、そこに浸出されたCNTの相対配向を制御する複合材料の製造方法。 - 複合材料を含んで構成されるパネルであって、
前記複合材料は、マトリクス材の少なくとも一部に配置されたカーボンナノチューブ(CNT)浸出繊維材料を含んで構成され、約0.01MHzから約18GHzの範囲の周波数において、電磁(EM)放射の吸収、EM放射の反射、又はその両方が可能であり、
前記複合材料のEM遮蔽能力は、約40デシベル(dB)から約130dBの範囲の電磁妨害(EMI)遮蔽有効性(SE)として計測され、
前記パネルは、EMI遮蔽用途に使用される装置と適合するよう調整可能であり、電気接地をさらに備えるパネル。
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EP2421702A1 (en) | 2012-02-29 |
ZA201107299B (en) | 2012-06-27 |
JP2015144294A (ja) | 2015-08-06 |
JP2012524685A (ja) | 2012-10-18 |
KR101763583B1 (ko) | 2017-08-01 |
WO2010144183A1 (en) | 2010-12-16 |
JP5465779B2 (ja) | 2014-04-09 |
CN102458825A (zh) | 2012-05-16 |
US20100271253A1 (en) | 2010-10-28 |
AU2010259173A1 (en) | 2011-10-27 |
CA2758570A1 (en) | 2010-12-16 |
BRPI1016244A2 (pt) | 2016-04-26 |
US8325079B2 (en) | 2012-12-04 |
CN102461361A (zh) | 2012-05-16 |
US20100270069A1 (en) | 2010-10-28 |
US9241433B2 (en) | 2016-01-19 |
KR20120023640A (ko) | 2012-03-13 |
EP2421702A4 (en) | 2013-01-02 |
EP2422595A1 (en) | 2012-02-29 |
ZA201108270B (en) | 2012-07-25 |
CA2758568A1 (en) | 2010-10-28 |
WO2010124260A1 (en) | 2010-10-28 |
BRPI1016242A2 (pt) | 2016-04-26 |
KR20120017034A (ko) | 2012-02-27 |
AU2010259173B2 (en) | 2015-03-19 |
AU2010238610A1 (en) | 2011-10-27 |
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