WO2011163129A2 - Modified carbon nanotubes, methods for production thereof and products obtained therefrom - Google Patents

Modified carbon nanotubes, methods for production thereof and products obtained therefrom Download PDF

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Publication number
WO2011163129A2
WO2011163129A2 PCT/US2011/041078 US2011041078W WO2011163129A2 WO 2011163129 A2 WO2011163129 A2 WO 2011163129A2 US 2011041078 W US2011041078 W US 2011041078W WO 2011163129 A2 WO2011163129 A2 WO 2011163129A2
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Prior art keywords
fibers
carbon nanotubes
nanotube
composition
exfoliated
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English (en)
French (fr)
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WO2011163129A3 (en
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Clive P. Bosnyak
Kurt W. Swogger
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Designed Nanotubes LLC
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Designed Nanotubes LLC
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Priority to EP11741332.8A priority Critical patent/EP2585402A2/en
Priority to KR1020137001598A priority patent/KR20130121079A/ko
Priority to CN2011800378679A priority patent/CN103189308A/zh
Priority to JP2013516655A priority patent/JP5912109B2/ja
Priority to CA2803136A priority patent/CA2803136A1/en
Priority to PCT/EP2011/072426 priority patent/WO2012080159A1/en
Priority to PCT/EP2011/072427 priority patent/WO2012080160A1/en
Priority to TW100145782A priority patent/TW201233719A/zh
Priority to SG10201600280YA priority patent/SG10201600280YA/en
Priority to US13/992,848 priority patent/US20130261221A1/en
Priority to CN201710180065.2A priority patent/CN106883476A/zh
Priority to CN2011800674085A priority patent/CN103459313A/zh
Priority to SG2013043187A priority patent/SG190751A1/en
Priority to KR1020137017382A priority patent/KR101898303B1/ko
Priority to EP11802026.2A priority patent/EP2651820A1/en
Priority to CN2011800650894A priority patent/CN103313934A/zh
Priority to US13/993,206 priority patent/US9212273B2/en
Priority to SG2013041553A priority patent/SG190926A1/en
Priority to CA2834697A priority patent/CA2834697A1/en
Priority to EP11796988.1A priority patent/EP2651819A1/en
Priority to PCT/EP2011/072425 priority patent/WO2012080158A1/en
Priority to TW100145783A priority patent/TW201237082A/zh
Priority to JP2013543677A priority patent/JP6169973B2/ja
Priority to KR1020137017381A priority patent/KR101784544B1/ko
Priority to JP2013543678A priority patent/JP5902193B2/ja
Priority to EP11804526.9A priority patent/EP2651821A1/en
Priority to TW100145779A priority patent/TWI586733B/zh
Priority to KR1020137018434A priority patent/KR101905210B1/ko
Priority to CN2011800650926A priority patent/CN103313935A/zh
Publication of WO2011163129A2 publication Critical patent/WO2011163129A2/en
Publication of WO2011163129A3 publication Critical patent/WO2011163129A3/en
Anticipated expiration legal-status Critical
Priority to JP2016045743A priority patent/JP6314165B2/ja
Priority to JP2017193407A priority patent/JP2018003030A/ja
Ceased legal-status Critical Current

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    • 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
    • Y10S977/70—Nanostructure
    • Y10S977/734—Fullerenes, i.e. graphene-based structures, such as nanohorns, nanococoons, nanoscrolls or fullerene-like structures, e.g. WS2 or MoS2 chalcogenide nanotubes, planar C3N4, etc.
    • Y10S977/742—Carbon nanotubes, CNTs
    • Y10S977/745—Carbon nanotubes, CNTs having a modified surface
    • Y10S977/748—Modified with atoms or molecules bonded to the surface
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    • Y10S977/00—Nanotechnology
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    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2918—Rod, strand, filament or fiber including free carbon or carbide or therewith [not as steel]

Definitions

  • Carbon nanotubes in their solid state are currently produced as agglomerated nanotube bundles in a mixture of chiral or non-chiral forms.
  • Various methods have been developed to debundle or disentangle carbon nanotubes in solution.
  • carbon nanotubes may be shortened extensively by aggressive oxidative means and then dispersed as individual nanotubes in dilute solution. These tubes have low aspect ratios not suitable for high strength composite materials.
  • Carbon nanotubes may also be dispersed in very dilute solution as individuals by sonication in the presence of a surfactant.
  • Illustrative surfactants used for dispersing carbon nanotubes in solution include, for example, sodium dodecyl sulfate and PLURONICS.
  • solutions of individualized carbon nanotubes may be prepared from polymer-wrapped carbon nanotubes.
  • Individualized single-wall carbon nanotube solutions have also been prepared in very dilute solutions using polysaccharides, polypeptides, water-soluble polymers, nucleic acids, DNA, polynucleotides, polyimides, and polyvinylpyrrolidone.
  • the dilution ranges are often in the mg/liter ranges and not suitable for commercial usage.
  • exfoliated carbon nanotubes and methods for efficiently exfoliating carbon nanotubes are of considerable interest in the art.
  • exfoliated carbon nanotubes are likely to exhibit considerably improved properties in applications including, for example, energy storage devices and polymer composites.
  • Further surface modification of the tubes for enhanced bonding to a material or attaching electroactive materials are facilitated by exfoliation.
  • These further surface modified carbon nanotubes are considered advantageous for energy applications such as batteries and capacitors and photovoltaics, and material-composite applications such as tires, adhesives, and engineering composites such as w ndblades.
  • a plurality of carbon nanotubes comprising single wall, double wall or multiwall carbon nanotube fibers having an aspect ratio (the ratio of length of the nanotube to the diameter of the nanotube) of from about 25 to about 500, preferably from about 60 to about 250, and a oxidation level of from about 3 weight % to about 15 weight %, preferably from about 5 weight% to about 12 weight % and most preferably 6 weight% to about 10 weight% (weight % is the ratio of the weight of a component divided by the total weight expressed as a percentage).
  • a neutralized water treatment of the fibers results in a pH of from about 4 to about 9, more preferably from about 6 to about 8.
  • the fibers can have oxidation species comprising of carboxylic acid or derivative carboxylate groups and are essentially discrete individual fibers, not entangled as a mass.
  • the fibers can be mixed with a material such as, but not limited to, an elastomer or thermoplastic or thermoset to form a material-carbon nanotube composite.
  • the method for preparing carbon nanotube fibers includes an acidic solution which comprises a solution of sulfuric acid and nitric acid wherein the nitric acid is present in a dry basis of from about 10 wt % to about 50 wt %, preferably from about 15 wt % to about 30 wt %.
  • the method for preparing carbon nanotube fibers includes the carbon nanotube fibers are present in a concentration of from greater than zero to less than about 4 weight percent of the suspended nanotube fiber composition.
  • the method for preparing carbon nanotube fibers includes wherein the sonic treatment is performed at an energy input of from about 200 to about 600 Joules/gram of suspended composition, preferably from about 250 to about 350 Joules/gram of suspended composition.
  • the method for preparing carbon nanotube fibers includes wherein the suspended discrete nanotube fiber composition in the acidic solution is controlled at a specific temperature environment from about 15 to about 65°C, preferably from about 25 to about 35°C.
  • the method for preparing carbon nanotube fibers includes wherein the composition is in contact with the acidic solution from about 1 hour to about 5 hours, preferably from about 2.5 to about 3.5 hours.
  • the method for preparing carbon nanotube fibers includes wherein said isolated resultant discrete carbon nanotube fibers from the composition prior to further treatment comprises at least about 10 weight percent water.
  • the discrete carbon nanotube fibers are made in at least a 30% yield from the initial charge of as-received non-discrete nanotubes with the preferred yield >80%.
  • the fibers are at least partially ( > 5 %) surface modified, or coated, with at least one modifier, or at least one surfactant.
  • the fibers are completely (>80%) surface modified, or coated,
  • the fibers are at least partially surface modified or coated wherein the surfactant or modifier is hydrogen bonded, covalently bonded, or ionically bonded to the carbon nanotube fibers.
  • the completely surface modified or coated fibers include wherein said surface modification or coating is substantially uniform.
  • At least partially, or fully surface modified fibers are further mixed or blended with at least one organic or inorganic material to form a material-nanotube fiber composition.
  • the at least partially, or fully surface modified fibers are further mixed or blended with at least one elastomer to form an elastomer nanotube fiber composition.
  • the epoxy nanotube fiber composition includes wherein the fiber surface modifier or surfactant is chemically bonded to the epoxy and/or fiber.
  • the elastomer nanotube fiber composition has a fatigue crack failure resistance of at least 2 to about 20 times the fatigue crack failure resistance of the elastomer tested without carbon nanotubes.
  • the epoxy/nanotube fiber composition has a coefficient of expansion in at least one dimension of at least 2/3 to 1/3 that of the epoxy tested without carbon nanotubes in the same dimension.
  • the nanotube fibers are further mixed or blended and/or sonicated with at least one elastomer and an inorganic nanoplate to form an elastomer nanotube fiber and nanoplate composition.
  • the methods for preparing exfoliated carbon nanotubes include preparing a solution of carbon nanotubes in a superacid and filtering the solution through a filter to collect exfoliated carbon nanotubes on the filter.
  • FIGURE 1 shows an illustrative arrangement of the basic elements of a Faradaic capacitor
  • FIGURE 2 shows an illustrative arrangement of the basic elements of an electric double layer capacitor
  • FIGURE 4 shows an illustrative electron micrograph of hydroxyapatite plates having diameters of 3 - 15 ⁇ ;
  • FIGURE 5 shows an illustrative electron micrograph of hydroxyapatite nanorods having lengths of 100 - 200 nm
  • FIGURE 8 shows an illustrative electron micrograph of exfoliated multi-wall carbon nanotubes after precipitation and washing
  • bundled or entangled carbon nanotubes can be debundled or unentangled according to the methods described herein to produce exfoliated carbon nanotube solids.
  • the carbon nanotubes being debundled or unentangled can be made from any known means such as, for example, chemical vapor deposition, laser ablation, and high pressure carbon monoxide synthesis (HiPco).
  • the bundled or entangled carbon nanotubes can be present in a variety of forms including, for example, soot, powder, fibers, and bucky paper.
  • the bundled or entangled carbon nanotubes may be of any length, diameter, or chirality.
  • a plurality of carbon nanotubes comprising single wall, double wall or multiwall carbon nanotube fibers having an aspect ratio of from about 25 to about 500, preferably from about 60 to about 200, and a oxidation level of from about 3 weight % to about 15 weight %, preferably from about 5 weight% to about 10 weight %.
  • the oxidation level is defined as the amount by weight of oxygenated species covalently bound to the carbon nanotube.
  • FIGURE 12 is an example of a thermogravimetric plot illustrative of the method of determination of the % weight of oxygenated species on the carbon nanotube.
  • thermogravimetric method involves taking about 5 mg of the dried oxidized carbon nanotube and heating at 5 °C/minute from room temperature to 1000 degrees centigrade in a dry nitrogen atmosphere. The % weight loss from 200 to 600 degrees centigrade is taken as the % weight loss of oxygenated species.
  • the oxygenated species can also be quantified using fourier transform infra-red spectroscopy, FTIR, FIGURE 13 and energy-dispersive X-ray (EDX) analyses.
  • the matt of fibers has an electrical conductivity of at least 0.1 Siemens/cm and as high as 100 Siemens/cm.
  • a convenient measurement of conductivity is made using a digital ohmmeter with copper strips 1cm apart on a matt of the fibers compressed with hand pressure between two polystyrene discs.
  • the fibers can be mixed with an organic or inorganic material to form a material -carbon nanotube composite.
  • Organic materials can include such as, but not limited to, an elastomer, thermoplastic or thermoset or combinations thereof.
  • elastomers include, but not limited to, polybutadiene, polyisoprene, polystyrene-butadiene, silicones, polyurethanes, polyolefins and polyether-esters.
  • thermoplastics include amorphous thermoplastics such as polystyrenics, polyacrylates, and polycarbonates, and semi- crystalline thermoplastics such as polyolefins, polypropylene, polyethylene, polyamides, polyesters, and the like.
  • the exfoliated carbon nanotube fibers of this invention impart significant strength and stiffness to the materials even at low loadings.
  • These new elastomer nanotube filler materials can improve or affect the frictional, adhesive, cohesive, noise and vibration, rolling resistance, tear, wear, fatigue and crack resistance, hysteresis, large strain effects (Mullins effect), small strain effects (Payne effect) and oscillation or frequency properties and swelling resistance to oil of the elastomers and elastomer compounds. This change in properties will be beneficial for applications such as tires r other fabricated rubber or rubber compounded parts.
  • the method also includes the carbon nanotube fibers being present in a concentration of from greater than zero to less than about 4 weight percent of the suspended nanotube fiber composition with a preference of 1 to 2 %. Above about 2% by weight the carbon nanotubes interact with each other such that the viscosity rises rapidly and stirring and sonication can become non-uniform, which can result in nonuniform oxidation of the fibers.
  • the method for preparing carbon nanotube fibers includes wherein the sonic treatment is performed at an energy input of from about 200 to about 600 Joules/gram of suspended composition, preferably from about 250 to about 350 Joules/gram of suspended composition. If there is a large excess of sonic energy much above about 600 joules/gram of suspended composition this excess energy can lead to the fibers being damaged and too short in length for optimum performance in applications such as material-fiber composites.
  • the method for preparing carbon nanotube fibers includes wherein the suspended nanotube fiber composition in the acidic solution is controlled at a specific temperature environment from about 15 to 65°C, preferably from about 25 to about 35°C. Above about 65°C in the acid medium, the rate of oxidation is very rapid and not well- controlled leading to severe degradation of the tube length and great difficulty in filtering the fibers. Below about 15°C the rate of oxidation can be too slow for economic production of the fibers.
  • the method for preparing carbon nanotube fibers includes wherein the composition is in contact with the acidic solution from about 1 hour to about 5 hours, preferably from about 2.5 to about 3.5 hours.
  • the choice of the time and temperature interval are given by the degree of oxidation of the exfoliated carbon nanotubes required for the end-use application
  • the mats can contain at least about 10 weight percent water. This method facilitates the subsequent exfoliation in other materials.
  • the discrete carbon nanotube fibers are made in at least a 30% yield from the initial charge of nanotubes as-received with the preferred yield >80%.
  • An illustrative process for producing oxidized carbon nanotubes follows: 3 liters of sulfuric acid. 97% sulfuric acid and 3% water, and 1 liter of concentrated nitric acid containing 70% nitric acid and 30% water, are added into a 10 liter temperature controlled reaction vessel fitted with a sonicator and stirrer. 400 grams of non-discrete carbon nanotubes, grade Flowtube 9000 from CNano corporation, are loaded into the reactor vessel while stirring the acid mixture and the temperature maintained at 25 °C. The sonicator power is set at 130- 150 watts and the reaction is continued for 3 hours.
  • the viscous solution is transferred to a filter with a 5 micron filter mesh and much of the acid mixture removed by filtering using a lOOpsi pressure.
  • the filter cake is washed 1 times with 4 liters of deionized water followed by 1 wash of 4 liters of an ammonium hydroxide solution at pH > 9 and then 2 more washes with 4 liters of deionized water.
  • the resultant pH of the final wash is > 4.5.
  • a small sample of the filter cake is dried in vacuo at 100 °C for 4 hours and a thermogravi metric analysis taken as described previously. The amount of oxidized species on the fiber is 8% weight.
  • FIGURE 12 An example of the control of carbon nanotube oxidation for a different carbon nanotube grade, Flowtube 20000 is given in FIGURE 12 which shows the weight loss of Flowtube 20000 at various times in contact with an acid mixture at 25 °C and after being separated from the acid mixture, washed with deionized water and dried.
  • the fibers are at least partially or fully surface modified or coated with at least one modifier or at least one surfactant.
  • the surface modifier or coating or surfactant is hydrogen bonded, covalently bonded, or ionically bonded to the carbon nanotube fibers.
  • Suitable surfactants include, but are not limited, to both ionic and non-ionic surfactants, sodium dodecyl sulfate, sodium dodecylbenezene sulfonate, and PLURONICS.
  • Cationic surfactants are chiefly used for dispersion in non-polar media, such as, for example, chloroform and toluene.
  • Other types of molecules such as, for example, cyclodextrins, polysaccharides, polypeptides, water soluble polymers, DNA, nucleic acids, polynucleotides, and polymers such as polyimides and polyvinyl pyrrolidone, can be used to redisperse the oxidized carbon nanotubes.
  • the surface modification or coating can be substantially uniform.
  • At least partially, or fully surface modified fibers are further mixed or blended and/or sonicated with at least one organic or inorganic material to form a material- nanotube fiber composition.
  • carbon nanotubes are oxidized to a level of 8% weight, with an average tube diameter of 12 nm and average length 600nm and mixed into various materials.
  • the 1% weight fiber is mixed with commercial styrene- butadiene, SBR, polymer obtained from Goodyear. This is labeled SBR 1 % MWNT in Table 1.
  • SBR commercial styrene- butadiene
  • a master-batch, MB is made of a concentrate of SBR and 10% weight fiber, followed by melt mixing with more SBR to give 1% weight fiber content.
  • SBR 1% MWN T MB This is labeled SBR 1% MWN T MB in FIGURE 14 and in Table 1.
  • a control of SBR without fiber is made under exactly the same thermal history and with the same curing package.
  • the curing package contains zinc oxide, stearic acid, sul fur and t-buty benzothiazole sulfonamide.
  • Tensile modulus is the ratio of engineering stress to strain at the beginning of the tensile test.
  • Engineering Stress is the load divided by the initial cross-sectional area of the specimen. Strain is defined as the distance traversed by the crosshead of the instrument divided by the initial distance between the grips.
  • the nanotube fibers are further mixed or blended and/or sonicated with at least one material and an inorganic nanoplate to form a material nanotube fiber and nanoplate composition.
  • the materials can be elastomers, thermoplastics and thermosets.
  • the nanoplates can be, for example, clays, transition metal containing phosphates or graphene structures.
  • the nanoplates have an individual plate thickness less than 20nm.
  • the nanotube fibers of this invention can disperse between the individual nanoplates.
  • the present disclosure describes compositions containing exfoliated carbon nanotubes.
  • the exfoliated carbon nanotubes are not dispersed in a continuous matrix that maintains the carbon nanotubes in an exfoliated state.
  • Illustrative continuous matrices include, for example, a solution or a polymer matrix that maintains the carbon nanotubes in at least a partially or substantially exfoliated state.
  • the exfoliated carbon nanotubes comprise a carbon nanotube mat.
  • the exfoliated carbon nanotubes of the present disclosure are distinguished over exfoliated carbon nanotubes presently known in the art, which may re-agglomerate once removed from solution.
  • the exfoliated carbon nanotubes of the present disclosure take advantage of physical properties offered by individual carbon nanotubes that are not apparent when the carbon nanotubes are aggregated into bundles.
  • the exfoliated carbon nanotubes may be advantageously used in a wide range of applications including capacitors, batteries, photovoltaics, sensors, membranes, static dissipators, electromagnetic shields, video displays, pharmaceuticals and medical devices, polymer composites and gas storage vessels.
  • the exfoliated carbon nanotubes may also be used in fabrication and assembly techniques including, for example, ink-jet printing, spraying, coating, melt extruding, thermoforming, blow-molding and injection molding.
  • the methods for preparing exfoliated carbon nanotubes include suspending carbon nanotubes in a solution containing hydroxyapatite, precipitating exfoliated carbon nanotubes from the solution and isolating the exfoliated carbon nanotubes.
  • the methods for preparing exfoliated carbon nanotubes further include utilizing a solution that contains both a surfactant and a quantity of a nanocrystalline material.
  • Surfactants are well known in the carbon nanotube art to aid in solubilization. Without being bound by theory or mechanism, Applicants believe that when a surfactant is used in preparing exfoliated carbon nanotubes, the surfactant may aid in the initial solubilization or suspension of the carbon nanotubes. Precipitation of exfoliated carbon nanotubes takes place thereafter.
  • the chiral polymers and/or surfactants may be mixtures of tactic molecules.
  • tactic polymers with a low thermal degradation temperature such as, for example, polypropylene carbonate
  • the isolated, exfoliated carbon nanotubes can be easily recovered by thermal degradation of the polymer.
  • polypropylene carbonate can be thermally degraded at less than about 300°C without damaging carbon nanotubes.
  • the tactic molecules may be a mixture dissolved in a hydrocarbon solvent such as, for example, toluene r decalin.
  • the electrode may contain exfoliated carbon nanotubes dispersed in a polymer or viscous liquid. After forming the electrode, in various embodiments, the may be laminated to another medium such as, for example, a dielectric or electrolyte.
  • FIGURE 6A shows an electron micrograph of as-received multi-wall carbon nanotubes
  • FIGURE 6B shows multi-wall carbon nanotubes exfoliated using hydroxyapatite nanorods.
  • FIGURE 10 shows an electron micrograph of exfoliated double- wall carbon nanotubes following acid exfoliation and treatment with sodium dodecyl sulfate.
  • Table 3 shows the mechanical strength improvement in the epoxy composite containing exfoliated multi-wall carbon nanotubes.
  • Kq is a the maximum stress before failure on tensile testing a notched specimen at 0.01 .min initial strain rate.
  • Relative fatigue lifetime improvement is the lifetime of the notched specimen counted as the number of cycles to failure at 1 Hz, at about 16.7 MPa maximum tensile stress with stress amplitude of 0.1 (stress minimum/stress maximum.)
  • Example I Capacitor Containing Exfoliated Multi-Wall Carbon Nanotubes.
  • Control 1 10 g of poly(ethylene oxide) (PEO; 500 molecular weight) was melted, and 1 mL of 4 N potassium hydroxide added to make the electrolyte. 1 wt % of as-received multi-wall carbon nanotubes were added to the electrolyte mixture and sonicated for 15 minutes in a sonicator bath. Approximately 2.1 g of the mixture was poured into one part of a polystyrene petri dish 6 cm in diameter with a strip of copper adhered as the current collector. A piece of clean writing paper was then placed on the molten liquid electrolyte, and 2 g of the electrolyte was poured on to the paper, taking care not to weep at the edges.
  • PEO poly(ethylene oxide)
  • Control 2 Control 2 was prepared as for control 1 , except as-received graphene (Rice University) was substituted for the multi-wall carbon nanotubes. The measured capacitance was 0.176 microfarads.
  • Exfoliated carbon nanotube capacitor The capacitor was prepared as for control 1, except oxidized multi-wall carbon nanotubes were used in place of as- received multi-wall carbon nanotubes. The measured capacitance was 0.904 microfarads, a 14- fold improvement over control 1 and a 5.1 -fold improvement over control 2.
  • Example J Exfoliated Carbon Nanotubes Decorated with Copper Nanopartieles.
  • 102 mg of oxidized multi-wall carbon nanotubes were added to 100 mg copper sulfate, 640 mg sodium EDTA, 15 mg of polyethylene glycol, 568 mg of sodium sulfate and 60 ml . of deionized water.
  • the mixture was sonicated for 10 minutes and then heated to 40°C. 3 mL of formaldehyde (37% solution) and 500 mg of sodium hydroxide were added to bring the pH to 12.2.
  • the mixture was stirred for 30 minutes at 85°C and then filtered using a 5 micron PVDF filter and washed with 200 mL of deionized water.
  • FIGURE 1 1 shows an electron micrograph of exfoliated carbon nanotubes decorated with copper oxide nanoparticles obtained from the mixture.

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SG2013041553A SG190926A1 (en) 2010-12-14 2011-12-12 Improved elastomer formulations
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US13/993,206 US9212273B2 (en) 2010-12-14 2011-12-12 Elastomer formulations
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