Reactive graphtic carbon nanofiber reinforced polymeric composites

Abstract

Composites comprising at least one graphite-carbon nanofiber (GCNF) and a polymer phase covalently linked to a surface thereof.

What is claimed is: 
     
         1 . A method of making a composite including at least one graphite-carbon nanofiber (GCNF) and a polymer phase covalently linked to a surface thereof wherein said GCNF surface is covalently linked to said polymer phase by at least one linker molecule comprising:
 a) providing at least one GCNF having at least one surface suitable for functionalization;   b) functionalizing said surface of the GCNF;   c) derivatizing said surface of the GCNF by reacting the functionalized GCNF with a linker molecule having at least two reactive, functional substituents, at least one of said substituents being capable of forming a covalent bond with said functionalized surface of said GCNF and another of said substituents being capable of forming a covalent bond with at least one component of said polymer phase;   d) providing a polymerization reaction medium comprising said at least one component wherein said component comprises a monomer, an oligomer, optionally a curing or cross-linking agent or mixtures thereof capable of polymerization or copolymerization to provide said polymer phase;   e) contacting said derivatized GCNF with said polymerization medium under conditions such that the substituent of said linker molecule capable of forming a covalent bond with said at least one component reacts with at least a portion thereof to form said covalent bond; and   f) subjecting the derivatized GCNF/polymerization medium to polymerization conditions to provide the polymer phase of said composite, wherein at least a portion of said GCNF is covalently attached to the polymer phase.   
     
     
         2 . The method of  claim 1 , wherein the linker molecule has a length of at least approximately 5 Å. 
     
     
         3 . The method of  claim 1 , wherein said linker molecule has a steric rigidity sufficient to substantially prevent the functional substituent that reacts with the said monomer or oligomer from reacting with said surface of said functionalized GCNF. 
     
     
         4 . The method of  claim 1 , wherein the functionalization step comprises: oxidizing said GCNF surface to form carboxyl groups thereon. 
     
     
         5 . The method of  claim 4 , wherein said functionalized GCNF surface is further activated by converting said carboxyl groups to acyl groups. 
     
     
         6 . The method of  claim 5 , wherein said carboxyl groups are converted to acyl halide groups. 
     
     
         7 . The method of  claim 6 , wherein said carboxyl groups are converted to acyl chloride groups. 
     
     
         8 . The method of  claim 1 , wherein the polymer phase comprises a thermoset polymer. 
     
     
         9 . The method of  claim 8 , wherein said thermoset polymer is an epoxy resin. 
     
     
         10 . The method of  claim 1 , wherein the polymer phase comprises a thermoplastic polymer. 
     
     
         11 . The method of  claim 10 , wherein said thermoplastic polymer is a polystyrene, polyolefin, polyvinyl polymer, polyester, polyamide or mixtures thereof. 
     
     
         12 . The method of  claim 1 , wherein said linker molecule is a diamine or triamine: (1) aliphatic diamines, 1,6-hexamethylenediamine (HDA) and p-xylylenediamine (XDA); (2) aromatic diamines, 1,4-phenylenediamine (PDA) and 3,4′-oxydianiline (ODA); (3) aromatic triamines, tris(4-aminophenylene)amine (TAPA), 1,3,5-tris(4-aminophenoxy)benzene (TAB), and tris[4-(4-aminophenoxy)phenyl]ethane (TAPE). 
     
     
         13 . A composition of matter, comprising surface-functionalized GCNF. 
     
     
         14 . The composition of matter of  claim 13 , wherein said surface-functionalized CCNF is functionalized by oxidation to form carboxyl groups on the surface thereof. 
     
     
         15 . The composition of matter of  claim 14 , wherein said carboxyl groups have been converted to active acyl groups. 
     
     
         16 . The composition of matter of  claim 15 , wherein said active acyl groups are acyl halide groups. 
     
     
         17 . The composition of matter of  claim 16 , wherein said halide is chlorine. 
     
     
         18 . A method of forming surface-functionalized GCNF comprising oxidizing said surface to form carboxyl groups thereon. 
     
     
         19 . The method of  claim 18 , further comprising converting said carboxyl groups to active acyl groups. 
     
     
         20 . The method of  claim 19 , wherein said active acyl groups are acyl halide groups. 
     
     
         21 . The method of  claim 20 , wherein said halide is chlorine. 
     
     
         22 . An article of manufacture formed from the composition of matter of  claim 13 . 
     
     
         23 . A composition of matter, comprising surface-derivatized GCNF. 
     
     
         24 . A composition of matter, comprising surface-derivatized GCNF formed by reacting functionalized GCNF with a linker molecule having at least two reactive, functional substituents, at least one of said substituents being capable of forming a covalent bond with said functionalized surface of said GCNF and another of said substituents being capable of forming a covalent bond with another substrate. 
     
     
         25 . The composition of matter of  claim 24 , wherein said linker molecule is a diamine or triamine: (1) aliphatic diamines, 1,6-hexamethylenediamine (HDA) and p-xylylenediamine (XDA); (2) aromatic diamines, 1,4-phenylenediamine (PDA) and 3,4′-oxydianiline (ODA); (3) aromatic triamines, tris(4-aminophenylene)amine (TAPA), 1,3,5-tris(4-aminophenoxy)benzene (TAB), and tris[4-(4-aminophenoxy)phenyl]ethane (TAPE). 
     
     
         26 . A method of forming surface derivatized GCNF comprising:
 a) providing at least one GCNF having at least one surface suitable for functionalization;   c) functionalizing said surface of the GCNF;   d) derivatizing said surface of the GCNF by reacting the functionalized GCNF with a linker molecule having at least two reactive, functional substituents, at least one of said substituents being capable of forming a covalent bond with said functionalized surface of said GCNF and another of said substituents being capable of forming a covalent bond with at least one other substrate.   
     
     
         27 . The method of  claim 26 , wherein said GCNF is functionalized by oxidizing said surface to form carboxyl groups thereon. 
     
     
         28 . The method of  claim 27 , further comprising converting said carboxyl groups to active acyl groups. 
     
     
         29 . The method of  claim 28 , wherein said active acyl groups are acyl halide groups. 
     
     
         30 . The method of  claim 29 , wherein said halide is chlorine. 
     
     
         31 . The method of  claim 26 , wherein said linker molecule is a diamine or triamine: (1) aliphatic diamines, 1,6-hexamethylenediamine (HDA) and p-xylylenediamine (XDA); (2) aromatic diamines, 1,4-phenylenediamine (PDA) and 3,4′-oxydianiline (ODA); (3) aromatic triamines, tris(4-aminophenylene)amine (TAPA), 1,3,5-tris(4-aminophenoxy)benzene (TAB), and tris[4-(4-aminophenoxy)phenyl]ethane (TAPE). 
     
     
         32 . An article of manufacture formed from the composition of matter of  claim 23 .