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Patent · US9422651B2 · B2 · US

Methods for arranging nanoscopic elements within networks, fabrics, and films

(11) Publication number
US9422651B2
(21) Application number
13/076,152
(22) Filing date
2011-03-30
(30) Priority date
2003-01-13
(43) Publication date
2016-08-23
(45) Date of grant
2016-08-23
(51) IPC
B29C 55/00; B82Y 30/00; B82Y 40/00; C01B 31/02; D01G 19/00; D04H 1/4242; D04H 1/4382; D04H 1/4391; D04H 1/74
(52) CPC
  • D04H Making textile fabrics, e.g. from fibres or filamentary material; fabrics made by such processes or apparatus, e.g. felts, non-woven fabrics; cotton-wool; wadding {; non-woven fabrics from staple fibres, filaments or yarns, bonded with at least one web-like material during their consolidation}: 1/4382, 1/4242, 1/43838, 1/4391, 1/43912, 1/74
  • B05D Processes for applying fluent materials to surfaces, in general: 1/005, 1/02, 1/18, 1/28, 1/32, 1/40
  • B82B Nanostructures formed by manipulation of individual atoms, molecules, or limited collections of atoms or molecules as discrete units; manufacture or treatment thereof: 1/005, 3/0076
  • B82Y Specific uses or applications of nanostructures; measurement or analysis of nanostructures; manufacture or treatment of nanostructures: 30/00, 40/00
  • C01B Non-metallic elements; compounds thereof; {metalloids or compounds thereof not covered by subclass C01C}: 31/0253, 32/05, 32/168
  • D01G Preliminary treatment of fibres, e.g. for spinning: 19/00
(73) Assignee
Nantero Inc
(72) Inventors
David A. Roberts; Hao-Yu Lin; Thomas R. Bengtson; Thomas Rueckes; Karl Robinson; H. Montgomery Manning; Rahul Sen; Michel Monteiro
(54) Title
Methods for arranging nanoscopic elements within networks, fabrics, and films
(57) Abstract

A method for arranging nanotube elements within nanotube fabric layers and films is disclosed. A directional force is applied over a nanotube fabric layer to render the fabric layer into an ordered network of nanotube elements. That is, a network of nanotube elements drawn together along their sidewalls and substantially oriented in a uniform direction. In some embodiments this directional force is applied by rolling a cylindrical element over the fabric layer. In other embodiments this directional force is applied by passing a rubbing material over the surface of a nanotube fabric layer. In other embodiments this directional force is applied by running a polishing material over the nanotube fabric layer for a predetermined time. Exemplary rolling, rubbing, and polishing apparatuses are also disclosed.

Full text
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Claims (37)

  1. A method for arranging nanotube elements within a nanotube fabric, comprising: providing a plurality of nanotube elements over a material layer, to obtain a substantially dry fully formed, fixed nanotube fabric comprising a plurality of nanotube elements in a first operation, wherein said nanotube fabric is substantially free of any suspension medium; and translating a directional force across at least a portion of said substantially dry fully formed, fixed nanotube fabric in a second operation to arrange at least a portion of said nanotube elements within said nanotube fabric into an ordered network; wherein said second operation is performed subsequent to said first operation.
  2. The method of claim 1 wherein said directional force is applied over said portion of said nanotube fabric at least once.
  3. The method of claim 1 wherein said directional force is applied along a single direction.
  4. The method of claim 1 wherein said directional force is applied along an arcing direction.
  5. The method of claim 1 further comprising repeatedly applying said directional force to said portion of said nanotube fabric.
  6. The method of claim 5 wherein said repeated application of said directional force follows a fixed path across said nanotube fabric.
  7. The method of claim 1 wherein said material layer is rigid.
  8. The method of claim 7 wherein said material layer is selected from a group consisting of elemental silicon, silicon oxide, silicon nitride, silicon carbides, PTFE, organic polymers, pvc, styrenes, polyvinyl alcohol, polyvinyl acetate, hydrocarbon polymers, inorganic backbone, boron nitride, gallium arsenide, group III/V compounds, group II/VI compounds, wood, metals, metal alloys, metal oxides, ceramics, and glass.
  9. The method of claim 1 wherein said material layer is a rigid structural composite.
  10. The method of claim 1 wherein said material layer is flexible.
  11. The method of claim 10 wherein said material is selected from a group consisting of polyethylene terephthalate (PET), polymethylmethacrylate, polyamides, polysulfones, and polycyclic olefins.
  12. The method of claim 1 wherein applying said directional force arranges at least a portion of said nanotube elements into a preselected orientation within at least one preselected region of said nanotube fabric.
  13. The method of claim 1 further comprising depositing a lubricating medium over a portion of said nanotube fabric prior to said application of said directional force.
  14. The method of claim 13 wherein said lubricating medium is comprised of at least one material selected from the list consisting of water, halocarbon liquids, liquefied gases, hydrocarbon liquids, functionalized organic liquids, organo-siloxane based cyclics, linear liquids, molybdenum disulfide, boron nitride, graphite, and styrene beads.
  15. The method of claim 1 wherein said nanotube fabric is formed via one of a spin coating operation, a spray coating operation, a dip coating operation, a silk screen printing operation, or a gravure printing operation.
  16. The method of claim 1 wherein said nanotube elements are carbon nanotubes.
  17. The method of claim 1 wherein said nanotube fabric is a composite mixture of carbon nanotubes and other materials.
  18. The method of claim 17 wherein said other materials are selected from the group consisting of buckyballs, amorphous carbon, silver nanotubes, quantum dots, colloidal silver, monodisperse polystyrene beads, and silica particles.
  19. The method of claim 1 wherein said nanotube elements are functionalized carbon nanotubes.
  20. The method of claim 19 wherein said functionalized carbon nanotubes are carbon nanotubes affixed with moieties which provide an electrically insulating barrier over the sidewalls of said carbon nanotubes.
  21. The method of claim 20 wherein said moieties are organic functional groups.
  22. The method of claim 20 wherein said moieties are silicon functional groups.
  23. The method of claim 20 wherein said moieties include at least one of organosilicate, silicon oxide, organo silicon oxide, methylsilsequioxane, hydrogen silsequioxane, organosiloxane, dimethylsiloxane/polyorgano ether, organopolymer, DNA, and polyamide.
  24. The method of claim 1 wherein said directional force is applied through a rubbing element.
  25. The method of claim 24 wherein said rubbing element comprises at least one material selected from the group consisting of elemental silicon, polytetrafluoroethylene (PTFE), cellulose acetate, cellulose (e.g., rayon), polyesters, polyamides (e.g., nylons), polymeric materials, and a semi-rigid slurries of starch and water.
  26. The method of claim 1 wherein said directional force is applied through a polishing element.
  27. The method of claim 26 wherein said polishing element in rotated within a plane parallel to said nanotube fabric layer.
  28. The method of claim 26 wherein said polishing element comprises at least one of polyester microfiber, polyamide microfiber, polyester, polyamide, styrene, polyvinylalcohol foam, cotton, wool, cellulose, and rayon.
  29. The method of claim 1 wherein said directional force is applied by rolling a cylindrical element over said nanotube fabric layer.
  30. The method of claim 29 wherein said cylindrical element comprises a material selected from the group consisting of iron, cobalt, nickel, zinc, tungsten, chromium, manganese, magnesium, titanium, aluminum, steel, rubber, plastic, polystyrene, melamine, silicone, polycarbonate, polyethylene, porcelain, silicon oxide, alumina, silicon carbide, and wood.
  31. The method of claim 1 wherein said directional force is applied through a cryokinetic spray.
  32. The method of claim 31 wherein said cryokinetic spray comprises one of carbon dioxide (CO 2) and argon (Ar).
  33. The method of claim 31 wherein said cryokinetic spray is translated across said nanotube fabric layer in a linear direction.
  34. The method of claim 1 wherein said directional force is applied within a roll-to-roll process.
  35. The method of claim 1 wherein said directional force is applied directly to said nanotube fabric.
  36. The method of claim 1 wherein said directional force is applied to said nanotube fabric through an intervening material.
  37. The method of claim 1 wherein said ordered network is substantially free of gaps and voids.

Description

U.S. Pat. No. 6,835,591, filed on Apr. 23, 2002, entitled METHODS OF NANOTUBE FILMS AND ARTICLES;

U.S. Pat. No. 7,335,395, filed on Jan. 13, 2003, entitled Methods of Using Pre-Formed Nanotubes to Make Carbon Nanotube Films, Layers, Fabrics, Ribbons, Elements, and Articles;

U.S. Pat. No. 7,259,410, filed on Feb. 11, 2004, entitled Devices Having Horizontally-Disposed Nanofabric Articles and Methods of Making the Same;

U.S. Pat. No. 6,924,538, filed on Feb. 11, 2004, entitled Devices Having Vertically-Disposed Nanofabric Articles and Methods of Making Same;

U.S. Pat. No. 7,375,369, filed on Jun. 3, 2004, entitled Spin-Coatable Liquid for Formation of High Purity Nanotube Films;

U.S. Pat. No. 7,365,632, filed on Sep. 20, 2005, entitled RESISTIVE ELEMENTS USING CARBON NANOTUBES; and

U.S. Pat. No. 7,567,414, filed on Nov. 2, 2005, entitled NANOTUBE ESD PROTECTIVE DEVICES AND CORRESPONDING NONVOLATILE AND VOLATILE NANOTUBE SWITCHES.

U.S. Patent App. No. 61/304,045, filed on Feb. 12, 2010, entitled METHODS FOR CONTROLLING DENSITY, POROSITY, AND/OR GAP SIZE WITHIN NANOTUBE FABRIC LAYERS AND FILMS.

1. Technical Field

The present disclosure relates generally to nanotube fabric layers and films and, more specifically, to methods for arranging nanotube elements within nanotube fabric layers and films via the application of a directional force.

2. Discussion of Related Art

Any discussion of the related art throughout this specification should in no way be considered as an admission that such art is widely known or forms part of the common general knowledge in the field.

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Record as JSON 
{
  "publication_number": "US9422651B2",
  "country": "US",
  "kind": "B2",
  "title": "Methods for arranging nanoscopic elements within networks, fabrics, and films",
  "abstract": "A method for arranging nanotube elements within nanotube fabric layers and films is disclosed. A directional force is applied over a nanotube fabric layer to render the fabric layer into an ordered network of nanotube elements. That is, a network of nanotube elements drawn together along their sidewalls and substantially oriented in a uniform direction. In some embodiments this directional force is applied by rolling a cylindrical element over the fabric layer. In other embodiments this directional force is applied by passing a rubbing material over the surface of a nanotube fabric layer. In other embodiments this directional force is applied by running a polishing material over the nanotube fabric layer for a predetermined time. Exemplary rolling, rubbing, and polishing apparatuses are also disclosed.",
  "claims": [
    "1. A method for arranging nanotube elements within a nanotube fabric, comprising: providing a plurality of nanotube elements over a material layer, to obtain a substantially dry fully formed, fixed nanotube fabric comprising a plurality of nanotube elements in a first operation, wherein said nanotube fabric is substantially free of any suspension medium; and translating a directional force across at least a portion of said substantially dry fully formed, fixed nanotube fabric in a second operation to arrange at least a portion of said nanotube elements within said nanotube fabric into an ordered network; wherein said second operation is performed subsequent to said first operation.",
    "2. The method of claim 1 wherein said directional force is applied over said portion of said nanotube fabric at least once.",
    "3. The method of claim 1 wherein said directional force is applied along a single direction.",
    "4. The method of claim 1 wherein said directional force is applied along an arcing direction.",
    "5. The method of claim 1 further comprising repeatedly applying said directional force to said portion of said nanotube fabric.",
    "6. The method of claim 5 wherein said repeated application of said directional force follows a fixed path across said nanotube fabric.",
    "7. The method of claim 1 wherein said material layer is rigid.",
    "8. The method of claim 7 wherein said material layer is selected from a group consisting of elemental silicon, silicon oxide, silicon nitride, silicon carbides, PTFE, organic polymers, pvc, styrenes, polyvinyl alcohol, polyvinyl acetate, hydrocarbon polymers, inorganic backbone, boron nitride, gallium arsenide, group III/V compounds, group II/VI compounds, wood, metals, metal alloys, metal oxides, ceramics, and glass.",
    "9. The method of claim 1 wherein said material layer is a rigid structural composite.",
    "10. The method of claim 1 wherein said material layer is flexible.",
    "11. The method of claim 10 wherein said material is selected from a group consisting of polyethylene terephthalate (PET), polymethylmethacrylate, polyamides, polysulfones, and polycyclic olefins.",
    "12. The method of claim 1 wherein applying said directional force arranges at least a portion of said nanotube elements into a preselected orientation within at least one preselected region of said nanotube fabric.",
    "13. The method of claim 1 further comprising depositing a lubricating medium over a portion of said nanotube fabric prior to said application of said directional force.",
    "14. The method of claim 13 wherein said lubricating medium is comprised of at least one material selected from the list consisting of water, halocarbon liquids, liquefied gases, hydrocarbon liquids, functionalized organic liquids, organo-siloxane based cyclics, linear liquids, molybdenum disulfide, boron nitride, graphite, and styrene beads.",
    "15. The method of claim 1 wherein said nanotube fabric is formed via one of a spin coating operation, a spray coating operation, a dip coating operation, a silk screen printing operation, or a gravure printing operation.",
    "16. The method of claim 1 wherein said nanotube elements are carbon nanotubes.",
    "17. The method of claim 1 wherein said nanotube fabric is a composite mixture of carbon nanotubes and other materials.",
    "18. The method of claim 17 wherein said other materials are selected from the group consisting of buckyballs, amorphous carbon, silver nanotubes, quantum dots, colloidal silver, monodisperse polystyrene beads, and silica particles.",
    "19. The method of claim 1 wherein said nanotube elements are functionalized carbon nanotubes.",
    "20. The method of claim 19 wherein said functionalized carbon nanotubes are carbon nanotubes affixed with moieties which provide an electrically insulating barrier over the sidewalls of said carbon nanotubes.",
    "21. The method of claim 20 wherein said moieties are organic functional groups.",
    "22. The method of claim 20 wherein said moieties are silicon functional groups.",
    "23. The method of claim 20 wherein said moieties include at least one of organosilicate, silicon oxide, organo silicon oxide, methylsilsequioxane, hydrogen silsequioxane, organosiloxane, dimethylsiloxane/polyorgano ether, organopolymer, DNA, and polyamide.",
    "24. The method of claim 1 wherein said directional force is applied through a rubbing element.",
    "25. The method of claim 24 wherein said rubbing element comprises at least one material selected from the group consisting of elemental silicon, polytetrafluoroethylene (PTFE), cellulose acetate, cellulose (e.g., rayon), polyesters, polyamides (e.g., nylons), polymeric materials, and a semi-rigid slurries of starch and water.",
    "26. The method of claim 1 wherein said directional force is applied through a polishing element.",
    "27. The method of claim 26 wherein said polishing element in rotated within a plane parallel to said nanotube fabric layer.",
    "28. The method of claim 26 wherein said polishing element comprises at least one of polyester microfiber, polyamide microfiber, polyester, polyamide, styrene, polyvinylalcohol foam, cotton, wool, cellulose, and rayon.",
    "29. The method of claim 1 wherein said directional force is applied by rolling a cylindrical element over said nanotube fabric layer.",
    "30. The method of claim 29 wherein said cylindrical element comprises a material selected from the group consisting of iron, cobalt, nickel, zinc, tungsten, chromium, manganese, magnesium, titanium, aluminum, steel, rubber, plastic, polystyrene, melamine, silicone, polycarbonate, polyethylene, porcelain, silicon oxide, alumina, silicon carbide, and wood.",
    "31. The method of claim 1 wherein said directional force is applied through a cryokinetic spray.",
    "32. The method of claim 31 wherein said cryokinetic spray comprises one of carbon dioxide (CO 2) and argon (Ar).",
    "33. The method of claim 31 wherein said cryokinetic spray is translated across said nanotube fabric layer in a linear direction.",
    "34. The method of claim 1 wherein said directional force is applied within a roll-to-roll process.",
    "35. The method of claim 1 wherein said directional force is applied directly to said nanotube fabric.",
    "36. The method of claim 1 wherein said directional force is applied to said nanotube fabric through an intervening material.",
    "37. The method of claim 1 wherein said ordered network is substantially free of gaps and voids."
  ],
  "description_excerpt": "U.S. Pat. No. 6,835,591, filed on Apr. 23, 2002, entitled METHODS OF NANOTUBE FILMS AND ARTICLES;\n\nU.S. Pat. No. 7,335,395, filed on Jan. 13, 2003, entitled Methods of Using Pre-Formed Nanotubes to Make Carbon Nanotube Films, Layers, Fabrics, Ribbons, Elements, and Articles;\n\nU.S. Pat. No. 7,259,410, filed on Feb. 11, 2004, entitled Devices Having Horizontally-Disposed Nanofabric Articles and Methods of Making the Same;\n\nU.S. Pat. No. 6,924,538, filed on Feb. 11, 2004, entitled Devices Having Vertically-Disposed Nanofabric Articles and Methods of Making Same;\n\nU.S. Pat. No. 7,375,369, filed on Jun. 3, 2004, entitled Spin-Coatable Liquid for Formation of High Purity Nanotube Films;\n\nU.S. Pat. No. 7,365,632, filed on Sep. 20, 2005, entitled RESISTIVE ELEMENTS USING CARBON NANOTUBES; and\n\nU.S. Pat. No. 7,567,414, filed on Nov. 2, 2005, entitled NANOTUBE ESD PROTECTIVE DEVICES AND CORRESPONDING NONVOLATILE AND VOLATILE NANOTUBE SWITCHES.\n\nU.S. Patent App. No. 61/304,045, filed on Feb. 12, 2010, entitled METHODS FOR CONTROLLING DENSITY, POROSITY, AND/OR GAP SIZE WITHIN NANOTUBE FABRIC LAYERS AND FILMS.\n\n1. Technical Field\n\nThe present disclosure relates generally to nanotube fabric layers and films and, more specifically, to methods for arranging nanotube elements within nanotube fabric layers and films via the application of a directional force.\n\n2. Discussion of Related Art\n\nAny discussion of the related art throughout this specification should in no way be considered as an admission that such art is widely known or forms part of the common general knowledge in the field.",
  "cpc": [
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    "B05D 1/005",
    "B05D 1/02",
    "B05D 1/18",
    "B05D 1/28",
    "B05D 1/32",
    "B05D 1/40",
    "B82B 1/005",
    "B82B 3/0076",
    "B82Y 30/00",
    "B82Y 40/00",
    "C01B 31/0253",
    "C01B 32/05",
    "C01B 32/168",
    "D01G 19/00",
    "D04H 1/4242",
    "D04H 1/43838",
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    "D04H 1/43912",
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  ],
  "assignees": [
    "Nantero Inc"
  ],
  "inventors": [
    "David A. Roberts",
    "Hao-Yu Lin",
    "Thomas R. Bengtson",
    "Thomas Rueckes",
    "Karl Robinson",
    "H. Montgomery Manning",
    "Rahul Sen",
    "Michel Monteiro"
  ],
  "filing_date": "2011-03-30",
  "publication_date": "2016-08-23",
  "grant_date": "2016-08-23",
  "priority_date": "2003-01-13",
  "application_number": "US-201113076152-A",
  "family_id": "44712613",
  "cited_by_count": 5,
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