# US 2014/0151111 A1 · Carbon nanostructure-coated fibers of low areal weight and methods for producing the same

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- Number: US 2014/0151111 A1
- Document ID: US20140151111A1
- Status: Published application
- Kind: A1
- Application number: 14/089,673
- Filed: 2013-11-25
- Published: 2014-06-05
- Earliest claimed: 2012-12-04
- Assignees: Applied Nanostructured Solutions, LLC
- Applicants: Applied Nanostructured Solutions, LLC
- Inventors: Tushar K. Shah; Han Liu; Jess Michael Goldfinger; John J. Morber
- Web page: https://patentgrep.com/patent/US20140151111A1

## CPC

- H05K 9/009: {comprising electro-conductive fibres, e.g. metal fibres, carbon fibres, metallised textile fibres, electro-conductive mesh, woven, non-woven mat, fleece, cross-linked}
- H05K 1/0218: {by printed shielding conductors, ground planes or power plane (H05K1/0236 takes precedence)}
- H05K 1/09: Use of materials for the {conductive, e.g. } metallic pattern
- H05K 2201/026: Nanotubes or nanowires
- H05K 2201/0323: Carbon
- Y02P 20/582: Recycling of unreacted starting or intermediate materials
- H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

Carbon nanostructures can convey enhanced electrical conductivity to various substrates, while maintaining a high surface area and low density per unit area. Such substrates can provide good shielding against electromagnetic radiation over a wide range of frequencies. Electrically conductive structures can include a support layer containing a plurality of fibers having apertures defined between the fibers, and a plurality of carbon nanostructures at least partially conformally coating the fibers and bridging across the apertures defined between adjacent fibers to form a continuous carbon nanostructure layer. Each carbon nanostructure can include a plurality of carbon nanotubes that are branched, crosslinked, and share common walls with one another.

## Claims

### Claim 1

An electrically conductive structure comprising:
a support layer comprising a plurality of fibers having apertures defined between the fibers; and
a plurality of carbon nanostructures at least partially conformally coating the fibers and bridging across the apertures defined between adjacent fibers to form a continuous carbon nanostructure layer;
wherein each carbon nanostructure comprises a plurality of carbon nanotubes that are branched, crosslinked, and share common walls with one another.

### Claim 2 (depends on 1)

The electrically conductive structure of claim 1, wherein the fibers comprise carbon fibers, glass fibers, or any combination thereof.

### Claim 3 (depends on 1)

The electrically conductive structure of claim 1, wherein the fibers are coated with a metallization layer.

### Claim 4 (depends on 3)

The electrically conductive structure of claim 3, wherein the metallization layer comprises a metal selected from the group consisting of nickel, copper, and any combination thereof.

### Claim 5 (depends on 1)

The electrically conductive structure of claim 1, wherein the plurality of fibers in the support layer are oriented randomly with respect to one another.

### Claim 6 (depends on 1)

The electrically conductive structure of claim 1, wherein the carbon nanostructures are free of a growth substrate adhered to the carbon nanostructures.

### Claim 7 (depends on 6)

The electrically conductive structure of claim 6, wherein the carbon nanostructures are in the form of a carbon nanostructure flake material.

### Claim 8 (depends on 1)

The electrically conductive structure of claim 1, wherein the carbon nanotubes in each carbon nanostructure are formed with branching, crosslinking, and sharing common walls with one another during formation of the carbon nanostructures on a growth substrate.

### Claim 9 (depends on 1)

The electrically conductive structure of claim 1, wherein the electrically conductive structure is substantially planar.

### Claim 10 (depends on 1)

The electrically conductive structure of claim 1, wherein the electrically conductive structure is substantially cylindrical.

### Claim 11 (depends on 1)

The electrically conductive structure of claim 1, wherein the plurality of fibers comprise a plurality of carbon nanostructure-infused fibers having carbon nanostructures grown from a surface of a fiber material.

### Claim 12 (depends on 1)

The electrically conductive structure of claim 1, further comprising:
a surface to which the electrically conductive structure is applied.

### Claim 13 (depends on 1)

The electrically conductive structure of claim 1, wherein the electrically conductive structure exhibits shielding against electromagnetic radiation over a frequency range between at least about 30 MHz to about 8 GHz.

### Claim 14

A method comprising:
providing a mixture comprising a solvent and a plurality of carbon nanostructures;
wherein each carbon nanostructure comprises a plurality of carbon nanotubes that are branched, crosslinked, and share common walls with one another;
dispersing the carbon nanostructures in the solvent until the carbon nanostructures are substantially non-agglomerated; and
passing the solvent through a support layer comprising a plurality of fibers having apertures defined between the fibers, whereby the carbon nanostructures become at least partially conformally coated around the fibers and bridge across the apertures defined between adjacent fibers to form a continuous carbon nanostructure layer.

### Claim 15 (depends on 14)

The method of claim 14, wherein passing the solvent through the support layer takes place with vacuum assistance.

### Claim 16 (depends on 14)

The method of claim 14, wherein dispersing the carbon nanostructures in the solvent comprises sonicating the mixture comprising the carbon nanostructures.

### Claim 17 (depends on 14)

The method of claim 14, wherein the fibers comprise carbon fibers, glass fibers, or any combination thereof.

### Claim 18 (depends on 14)

The method of claim 14, wherein the fibers are coated with a metallization layer.

### Claim 19 (depends on 18)

The method of claim 18, wherein the metallization layer comprises a metal selected from the group consisting of nickel, copper, and any combination thereof.

### Claim 20 (depends on 14)

The method of claim 14, wherein the carbon nanostructures are free of a growth substrate adhered to the carbon nanostructures.

### Claim 21 (depends on 20)

The method of claim 20, wherein the carbon nanostructures are in the form of a carbon nanostructure flake material.

### Claim 22 (depends on 14)

The method of claim 14, wherein the plurality of fibers in the support layer are oriented randomly with respect to one another.

### Claim 23

A method comprising:
forming a mixture comprising a plurality of carbon nanostructures and a plurality of chopped fibers in a solvent;
wherein each carbon nanostructure comprises a plurality of carbon nanotubes that are branched, crosslinked, and share common walls with one another; and
filtering the mixture to collect the chopped fibers and carbon nanostructures as a layer structure in which the carbon nanostructures at least partially conformally coat the fibers and bridge across apertures defined between adjacent fibers.

### Claim 24 (depends on 23)

The method of claim 23, wherein the chopped fibers comprise a carbon nanostructure-infused fiber material having carbon nanostructures grown from a surface of a fiber material.

### Claim 25 (depends on 23)

The method of claim 23, wherein the chopped fibers comprise carbon fibers, glass fibers, or any combination thereof.

### Claim 26 (depends on 23)

The method of claim 23, wherein filtering the mixture takes place by vacuum filtration.

### Claim 27 (depends on 23)

The method of claim 23, further comprising:
dispersing the carbon nanostructures in the solvent with sonication until the carbon nanostructures are substantially non-agglomerated.

### Claim 28 (depends on 23)

The method of claim 23, wherein the fibers are coated with a metallization layer.

### Claim 29 (depends on 28)

The method of claim 28, wherein the metallization layer comprises a metal selected from the group consisting of nickel, copper, and any combination thereof.

### Claim 30 (depends on 23)

The method of claim 23, wherein the carbon nanostructures are free of a growth substrate adhered to the carbon nanostructures.

### Claim 31 (depends on 30)

The method of claim 30, wherein the carbon nanostructures are in the form of a carbon nanostructure flake material.