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  • C08F281/00—Macromolecular compounds obtained by polymerising monomers on to polymers of monomers having carbon-to-carbon triple bonds as defined in group C08F38/00
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  • C08F293/00—Macromolecular compounds obtained by polymerisation on to a macromolecule having groups capable of inducing the formation of new polymer chains bound exclusively at one or both ends of the starting macromolecule
  • C08F293/005—Macromolecular compounds obtained by polymerisation on to a macromolecule having groups capable of inducing the formation of new polymer chains bound exclusively at one or both ends of the starting macromolecule using free radical "living" or "controlled" polymerisation, e.g. using a complexing agent
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  • C09C—TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES ; PREPARATION OF CARBON BLACK  ; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS
  • C09C1/00—Treatment of specific inorganic materials other than fibrous fillers; Preparation of carbon black
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  • C01P2004/10—Particle morphology extending in one dimension, e.g. needle-like
  • C01P2004/13—Nanotubes
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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  • Y10S977/00—Nanotechnology
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  • Y10S977/842—Manufacture, treatment, or detection of nanostructure for carbon nanotubes or fullerenes
  • Y10S977/847—Surface modifications, e.g. functionalization, coating

Definitions

• This invention relates to the field of nanotechnology. More particularly, it relates to carbon nanotubes, and to methods of attaching carbon nanotubes to structural materials such as epoxy resins.
• Carbon nanotubes are hollow carbon architectures made of concentric graphene sheets. They exhibit exceptional mechanical, electrical and thermal properties; the best of any known material. Combined with their very high aspect ratios that can reach well over 1000, CNT are truly the ultimate additives for the fabrication of multifunctional composites. Their diameter is of the order of a few nanometers, and up to several millimeters in length. Carbon nanotubes can be divided into two general classes: single-walled (SWCNT-only one graphene sheet) and multi- walled (MWCNT-multiple graphene sheets nested into one another). It is generally agreed that for composite work, SWCNT are superior to MWCNT especially if multifunctionality is sought.
• CNT Due to the extended sp 2 hybridization network and their ability to form bundles, CNT are chemically very stable with poor compatibility with practically any solvents and matrices. To circumvent this problem, CNT need to be "chemically primed" to facilitate their integration and produce a good bonding interface. Chemical priming is achieved by anchoring of chemical functions at the surface.
• This invention refers to methods to integrate SWCNT in epoxy resins. The methods are applicable to CNTs of all kinds.
• Example 1 Step l: SWCNT + Li/NH 3 ⁇ Li intercalated SWCNT
• Step 3 Hydrolyzation SWCNT-R-NH-Fmoc + piperidine -> SWCNT-R-NH 2
• Step 4 SWCNT-R-NH 2 + Epoxy resin -> SWCNT functionalized resins
• step 1 The origin of step 1 and similarly of step 2 can be found in the following paper: Liang et ah, NanoLetters, 4, 1257 (2004).
• Step 1 SWCNT + HOOC-R-COO-OOC-R-COOH+ heat -» SWCNT-R-COOH + CO 2
• Step 2 SWCNT-R-COOH + epoxy resin -> SWCNT-R-COO-CH 2 -CH(OH)-CH 2 -. (esterification)
• Steps 1 and 2 originate from work by Billups et ⁇ /.,Org. Lett.,5, 1471 (2003) and is not efficient but has been demonstrated by Margrave et ah, Nanolett, 3, 1107 (2003).
• Multi-step functionalization of neutral CNT works but it is time consuming and costly. The control over functionalization degree remains to be demonstrated. In addition, the effect of the chain length bearing the functional groups on the overall property of the composites is not known. Chemical functionalization is more costly than the production cost of CNT, especially for SWCNT.
• Figure 1 is a schematic drawing of the process of nucleophilic attack of CNT employed in one aspect of the present invention
• Figure 2 is a diagrammatic illustration of a general procedure to prepare reduced CNT (Penicaud's method) useful in preparing starting materials for the present invention
• Figure 3 is a diagrammatic presentation of an alternateative procedure to prepare reduced CNT useful in preparing starting materials for the present invention
• Figure 4 is a diagrammatic illustration of direct attachment of reduced CNT to epoxide functional groups in accordance with an embodiment of the invention
• Figure 5 is a diagrammatic illustration of attachment of functionalized CNT to epoxy resins through base catalyzed ring opening, in accordance with another embodiment of the invention
• Figure 6 is a diagrammatic illustration of a process of functionalizing CNT with a chain bearing a hydroxyl function, for subsequent use in an embodiment of the invention
• Figure 7 is a diagrammatic illustration of an alternative process for functionalizing CNT with a chain bearing a hydroxyl function
• Figure 8 is a diagrammatic illustration of a process of using negatively charged CNT as an initiator of polymerization, to make materials in accordance with the invention
• Figure 9 is a diagrammatic illustration of a process of graft polymerization onto CNT followed by reaction thereof with epoxide moieties.
• FIG. 10 is a schematic illustration of a process of reacting negatively charged (reduced) CNT with various functional groups in accordance with the invention. DESCRIPTION OF THE INVENTION
• CNT are primed to induce negative charges thereon, indicated by Nu- on Fig. 1.
• the CNT can be primed in one of two ways. In the first method, neutral CNT can be made to react with appropriate reagents to arrive at functionalized CNT in which negative charges are present.
• a second, presently preferred, method is to use reduced CNT.
• Reduced CNT can be prepared according to the method developed by Penicaud et al. (PCT application: WO 2005/073127: JACS 127, 8 (2005)). This method effectively charges up the CNT or its surroundings negatively by using radical anions. The reduced tubes thus acquire nucleophilic character.
• the general procedure to prepare reduced CNT with Penicaud's method is diagrammatically illustrated in accompanying Figure 2.
• Penicaud's procedure is carried out in THF and it has the advantage of dispersing the CNT at the single tube level or at least in very small bundles because of electrostatic repulsion between adjacent CNT.
• toluene, ether, hexane and/or THF tetrahydrofuran
• THF tetrahydrofuran
• alkali benzophenone complexes Such complexes can be stabilized in toluene.
• the electron donor is a benzophenone radical anion.
• Negatively charged (reduced) CNT can react with various functional groups as shown in Figure 10.
• Method 1 Direct attachment of reduced CNT to epoxide functional groups.
• the term "direct” indicates that the epoxide groups react directly with the partially negative carbon atoms making the side walls of CNT.
• the partial negative charge on each carbon atom forming the CNT results from electron transfer from the radical anions.
• the epoxide functional groups may be on any molecule with properties suited for its intended application.
• R can be alkyl, such as C 1 - C 100 Q, C 5 - C 5 oo, Cg - Qoo, C 15 - C 50 .
• R may be alkane, alkene, alkyne, linear or branched, or aromatic. It may include other functional groups and heteroatoms which do not significantly interfere with the desired reaction by F 1 and F 2 .
• the reduced SWCNT were washed under inert atmosphere with dry THF twice to remove excess of sodium naphthalene salts and free naphthalene.
• the paste (or precipitate) of reduced SWCNTs was re-suspended in dry THF and mixed up with de-oxygenated (by sparging with Ar or N 2 ) epoxy resin MY0510 (triglycidyl-p-aminophenol resin, obtainable from Huntsman Chemical) under strong mechanical or magnetic stirring and under nitrogen or argon flow.
• the SWCNTs loading can range from 0 up to 10 wt % or higher.
• the THF solvent was evaporated by sparging with strong Ar or N 2 flow.
• a very important aspect of this method is that the amount of cross linking and hence the final viscosity can be controlled by controlling the amount of oxidizing and hydrolyzing agents into the sample, which is done by sparging with wet air rather than inert atmosphere.
• the final product can be a viscous liquid, a rubbery solid or a solid depending on the sparging conditions used. This method affords the possibility of eliminating curing agents. Good control is exercised over the final product mixture.
• alkyl halides such as 1-Bromo(or Iodo)dodecane, 1-Bromoalcohol, 1-Bromoethylene amine, Bromo-carboxylic acid, Bromo-carboxylate ester, succinic anhydride, Epibromoanhydride, DMSO, and all kind of currently available commercial epoxy resins
• the sample was prepared by sparging air into the sample.
• the moisture and oxygen from air effectively neutralized (oxidized) the reduced SWCNT and hydrolyzed the nucleophilic centers and thus terminate further cross-linking.
• Method 2 Attachment of functionalized CNT to epoxy resins through base catalyzed ring opening.
• the general idea is to first functionalize neutral CNT with chains bearing hydroxyl functional groups which are then deprotonated with alkali metal to form alkoxides or aryloxides. Alkoxides and aryloxides are known to react readily with epoxide moieties. The difference with method 1 is that here the CNT are separated from the epoxy resin backbone by a spacer of fixed length.
• R may be any number of things in the structure
• a suspension of 1.145 g (95.4 mmol) of SWCNT in 250 ml of 1,2-ODCB and 120 ml of acetonitrile was mixed with 2.3 equivalents of 4-aminobenzyl alcohol (27g, 219.2 mmol) and 3 equivalents of isoamyl nitrite (33.5 g, 38.2 ml).
• the mixture was heated up to 70 0 C over a weekend. After cooling down to around 5O 0 C, the mixture was diluted with DMF and filtrated.
• the quantity of resin was adjusted based on the requirement of the SWCNT loading by weight (0.2, 0.4% etc). The mixture was stirred for a day, then sparged with wet air or wet nitrogen to terminate the cross linking process and to evaporate the main part of the solvent (if the mixture was kept under nitrogen and barged with dry nitrogen, the resin will eventually solidify). Again, the procedure offers some control over the degree of cross-linking required. The remaining trace of solvent was completely removed in vacuum oven at 6O 0 C overnight.
• reaction is not limited to CNTs with -OH groups.
• thiol functionalized CNTs may be used.
• Hydroxyl functionalized SWCNT can also be prepared through the scheme illustrated diagrammatically in Fig. 7 and which is somewhat similar to: (NanoLett, 4, 1257 (2004)) and described in the patent literature by Billups et al., (WO 2005/090233).
• Method 3 Block functionalization of reduced CNT using length controllable monomer, oligomer or polymers as spacer.
• SWCNTs obtained from a green solution by centrifugation and washing technique (see method 1). The mixture was shaken vigorously and sonicated, then further mixed on a Vortex-mixer for a few hours. The mixture was shaken for another two days, then diluted with THF. After centrifugation, the precipitate was washed with THF, CHCl 3 and THF a few times through a sonication-centrifugation cycle.
• the method described above provides materials with 1) better solubility in common solvents, 2) better dispersion properties in various epoxy formulations, and 3) more handles for property adjustment for composite formulations.
• the monomer selected permits the easy formation of a radical through various initiation processes (photolysis, thermolysis).
• initiation processes photolysis, thermolysis

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