Methods of making nanoreinforced carbon fiber and components comprising nanoreinforced carbon fiber

Abstract

Methods for enhancing the strength and stiffness of fibers, including nanoreinforced fibers and fiber tows, composite materials including the nanoreinforced fibers and tows, and articles of manufacture including the composite materials, are disclosed. The methods involve adhering random or aligned nanoreinforcement materials, such as carbon nanotubes, nanofibers, graphene plates, nanowires, nanoparticles, into or onto a spread carbon tow or yarn to form modified fibers wherein nanoreinforcement is adhered or trapped within the carbon tow. The carbon nanotubes or nanofibers can be aligned. Carbon fiber tows including the modified carbon fibers can be processed or woven for impregnation with a thermoset resin or thermoplastic to form a composite structure. The performance increase of the modified fibers relative to the unmodified fibers can be greater than the weight increase caused by the modification. Increased fiber stiffness and strength can result in a significant weight saving.

1 - 67 . (canceled) 
     
     
         68 . A method of making a nanoreinforced carbon fiber comprising:
 coating a nanoreinforcement material with a powder coat to form a powder coated nanoreinforcement material, wherein the powder coat is a thermoplastic or adhesive; and   contacting at least one carbon fiber with the powder coated nanoreinforcement material to form a coated carbon fiber.   
     
     
         69 . The method of  claim 68 , wherein the at least one carbon fiber is contacted with the powder coated nanoreinforcement material so that the carbon fiber contains from 0.1 to 20 percent by weight of nanoreinforcement material. 
     
     
         70 . The method of  claim 69 , wherein theft at least one carbon fiber is contacted with the powder coated nanoreinforcement material so that the carbon fiber contains from 2 to 8 percent by weight of nanoreinforcement material. 
     
     
         71 . The method of  claim 69 , wherein the carbon fiber is comprised of carbon, glass, aramid or boron. 
     
     
         72 . The method of  claim 69 , wherein the nanoreinforcement material comprises carbon nanotubes, carbon nanofibers, graphene sheets, fullerenes, nanoparticles, nanowires, or a combination thereof. 
     
     
         73 . The method of  claim 69 , further comprising bundling a plurality of the coated carbon fiber to form a tow or yarn. 
     
     
         74 . The method of  claim 69 , wherein the coated carbon fiber is sized. 
     
     
         75 . The method of  claim 73 , further comprising the step of aligning the nanoreinforcement material within the tow or yarn. 
     
     
         76 . The method of  claim 68 , further comprising a step of heating or pressing the coated carbon fiber, or a combination thereof. 
     
     
         77 . Aircraft and aircraft components, comprising composite material containing carbon fiber, wherein the carbon fiber comprises from 0.1 to 20 percent by weight nanoreinforcement material. 
     
     
         78 . The aircraft components of  claim 77 , wherein the aircraft components are nacelles or nacelle components for use in aircraft. 
     
     
         79 . The aircraft and aircraft components of  claim 77 , wherein the carbon fiber comprises from 2 to 8 percent by weight nanoreinforcement materials. 
     
     
         80 . The aircraft and aircraft components of  claim 77 , in which the nanoreinforcement material is selected from the group consisting of carbon nanotubes, carbon nanofibers, graphene sheets, nanowires, nanoparticles of elements, nanoparticles of binary compounds, nanoparticles of complex compounds, and combinations thereof. 
     
     
         81 . The aircraft and aircraft components of  claim 77 , wherein the nanoreinforcement material is sized or metallic coated or thermoplastic coated to assist in dispersion, application, or multifunctionality. 
     
     
         82 . The aircraft and aircraft components of  claim 80 , wherein the nanoreinforcement material is comprised of carbon nanotubes. 
     
     
         83 . The aircraft and aircraft components of  claim 77 , wherein the fiber comprises carbon, glass, aramid, or polymer fibers, alone or in combination. 
     
     
         84 . The aircraft and aircraft components of  claim 83 , wherein a plurality of fibers are bundled to form a tow or yarn. 
     
     
         85 . The aircraft and aircraft components of  claim 84 , wherein the fibers are sized. 
     
     
         86 . The aircraft and aircraft components of  claim 84 , wherein the nanoreinforcement material is aligned within the tow or yarn. 
     
     
         87 . The aircraft and aircraft components of  claim 84 , wherein the fiber tow comprises one or more carbon, glass, aramid and polymer fibers, alone or in combination.