CNT-infused carbon fiber materials and process therefor

A continuous CNT infusion process comprising:

• functionalizing a carbon fiber material to form a functionalized carbon fiber material;
• disposing a barrier coating on said functionalized carbon fiber material;
• partially curing said barrier coating and then disposing a carbon nanotube (CNT)-forming catalyst on said functionalized carbon fiber material;
• wherein said barrier coating is conformally disposed on said functionalized carbon fiber material prior to disposing said CNT-forming catalyst on said functionalized carbon fiber material;
• and
• synthesizing carbon nanotubes on said functionalized carbon fiber material, thereby forming a carbon nanotube-infused carbon fiber material;
• wherein the functionalized carbon fiber material is moving while disposing the barrier coating and the CNT-forming catalyst, and while synthesizing the carbon nanotubes.

A continuous CNT infusion process comprising:

• functionalizing a carbon fiber material to form a functionalized carbon fiber material;
• disposing a barrier coating on said functionalized carbon fiber material;
• fully curing said barrier coating to form a fully cured barrier coating;
• exposing said fully cured barrier coating to a plasma and then
• disposing a carbon nanotube (CNT)-forming catalyst on said functionalized carbon fiber material;
• and
• synthesizing carbon nanotubes on said functionalized carbon fiber material, thereby forming a carbon nanotube-infused carbon fiber material;
• wherein the functionalized carbon fiber material is moving while disposing the barrier coating and the CNT-forming catalyst, and while synthesizing the carbon nanotubes.