Fabricating method and fabricating apparatus for multilayered, nanoparticle-coated fiber material
The layer-by-layer deposition system addresses unevenness and cost issues in pyrolytic carbon coatings by applying multilayer nanoparticle coatings uniformly, enabling cost-effective and continuous production of high-strength composite materials.
Patent Information
- Application Number
- JP2024090581
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-06-13
- Filing Date
- 2024-06-04
- Publication Date
- 2024-12-25
AI Technical Summary
Existing methods for applying pyrolytic carbon coatings on fibers result in unevenness, require specialized equipment and controlled conditions, and are limited by batch processing, leading to high manufacturing costs and variability in composite strength.
A method and apparatus using layer-by-layer deposition systems to apply multilayer nanoparticle coatings on fibers, allowing for uniform thickness and ionic charge polarity manipulation, enabling continuous production without specialized equipment or controlled conditions.
The method achieves uniform and strong multilayer nanoparticle coatings on fibers, reducing manufacturing costs and variability, suitable for continuous production of high-strength composite materials.
Smart Images
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Abstract
Description
[Technical field]
[0001]
[0001] The present disclosure relates generally to coating materials, and more particularly to methods and apparatus for producing multi-layer nanoparticle coated fibrous materials. [Background technology]
[0002]
[0002] Materials containing one or more coating layers, such as coated fibers, produced by known manufacturing methods are prone to unevenness in the coating layer or layers.
[0003]
[0003] As an example, pyrolytic carbon (pyC) coatings on fibers are prone to one or more coating inconsistencies that result in inconsistent composite strength when the coated fibers are combined with a ceramic matrix to make a ceramic-matrix composite (CMC). The intent of the pyC coating in a CMC is to create a weak interface between the matrix and the fibers, allowing the fibers to move relative to the matrix under a given load, thereby allowing the composite to deform and carry a larger load than would be possible with a strong fiber-matrix interface.
[0004] Furthermore, the pyC coating must be applied using chemical vapor deposition (CVD), which requires specialized equipment and controlled temperatures and pressures.
[0005]
[0005] However, another drawback of pyC coatings is that such coatings cannot be applied continuously: a batch process must be used, which means that the length of the fibers that can be coated is limited by the size of the CVD chamber.
[0006]
[0006] As a result, manufacturing costs are high and it is not possible to coat the fibers continuously when using CVD to apply a pyC coating to the fibers that are then combined with a ceramic matrix to make a CMC.
[0007]
[0007] Despite existing advances, those skilled in the art continue to pursue research and development efforts in the area of producing coating materials, such as the coated fiber materials used to make CMCs. Summary of the Invention
[0008] A method for producing a multi-layer nanoparticle coated fiber is disclosed.
[0009] In one embodiment, a method of manufacture is disclosed that includes coating a textile substrate with a first type of nanoparticles to provide a first coating layer of a multi-layer nanoparticle-coated textile material. The manufacture also includes coating the first coating layer with a second type of nanoparticles to provide a second coating layer of a multi-layer nanoparticle-coated textile material.
[0010] In another embodiment, a method of manufacturing is disclosed that includes treating a surface of each of the plurality of fibers to impart an ionic charge polarity to the surface. The manufacturing also includes coating the surface of each of the plurality of fibers with nanoparticles having an ionic charge polarity opposite to the ionic charge polarity of the surface of each of the plurality of fibers to provide a first layer of nanoparticle-coated multi-layered plurality of fibers. The manufacturing further includes coating the first layer with nanoparticles having an ionic charge polarity opposite to the ionic charge polarity of the first layer to provide a second layer of nanoparticle-coated multi-layered plurality of fibers.
[0011]
[0011] Also disclosed are carbon fiber and ceramic-matrix composites made by the process.
[0012] Also disclosed is an apparatus for producing a multi-layer nanoparticle coated textile material.
[0013] In one embodiment, the manufacturing apparatus includes a first coating vessel containing a first nanoparticle-based solution through which the substrate can be passed to apply a first nanoparticle coating to the substrate, and a second coating vessel containing a second nanoparticle-based solution through which the substrate having the first nanoparticle coating can be passed to apply a second nanoparticle coating to the substrate coated with the first nanoparticle coating, thereby providing a multi-layer nanoparticle-coated fiber material.
[0014] Other embodiments of the disclosed manufacturing method and apparatus will become apparent from the following detailed description, the accompanying drawings, and the claims. [Brief description of the drawings]
[0015] [Figure 1] FIG. 1 is a schematic block diagram of a layer-by-layer (LBL) deposition system embodying an apparatus for producing a multi-layer nanoparticle coated fibrous material. [Figure 2A-B]
[0016] FIG. 2A is a schematic diagram of the manufacturing apparatus of FIG. 1 constructed in accordance with an exemplary embodiment.
[0017] FIG. 2B is a schematic diagram showing an exemplary relationship between the coating vessel and the cleaning vessel of the manufacturing apparatus of FIG. 2A. [Figure 2C-D]
[0018] FIG. 2C is a schematic diagram of an exemplary minimum size production line setup for the manufacturing apparatus of FIG. 2A.
[0019] FIG. 2D is an exemplary post-processing setup that can be used following the manufacturing apparatus of FIG. 2A. [Diagram 3]
[0020] FIG. 1A is a schematic elevational view of the different layers of the produced multi-layer nanoparticle-coated fiber material.
[0021] FIG. 1B is a schematic elevational view of the different layers of another multi-layer nanoparticle-coated fibrous material produced. [Figure 4]
[0022] FIG. 1 is a flow diagram illustrating a manufacturing method according to an example implementation. [Diagram 5]
[0023] FIG. 4 is a flow diagram illustrating a manufacturing method according to another exemplary embodiment. [Figure 6]
[0024] FIG. 1 is a block diagram of an aircraft manufacturing and service methodology. [Figure 7]
[0025] FIG. 1 is a schematic diagram of an aircraft. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016]
[0026] This application is directed to a manufacturing apparatus and method using a layer-by-layer (LBL) deposition system. The specific configuration of the apparatus and method therefor, and the industries in which the apparatus and method are implemented, are varied. It should be understood that the following disclosure provides multiple embodiments or examples for implementing different features of various embodiments. To simplify the disclosure, specific examples of components and configurations are described. These are merely examples and are not intended to be limiting.
[0017]
[0027] By way of example, the present disclosure describes an apparatus and method for manufacturing a multi-layer nanoparticle coated textile material for use in the manufacture of aerospace parts. The apparatus and method may be implemented by original equipment manufacturers (OEMs) that comply with military and space regulations. It is believed that the disclosed apparatus and method may also be implemented in many other industries.
[0018]
[0028] Referring to Figure 1, a schematic block diagram of a layer-by-layer deposition system 10 is shown. The layer-by-layer deposition system 10 embodies an apparatus 100 for producing multi-layer nanoparticle coated fiber materials and is constructed in accordance with one exemplary embodiment. Examples of fiber materials include carbon fiber materials. Other types of fiber substrates are also possible.
[0019]
[0029] Referring to FIG. 2A, a schematic diagram of a manufacturing apparatus 100 is shown. The manufacturing apparatus 100 includes a first coating vessel 110 containing a first nanoparticle-based solution 112 through which a fiber substrate 102 (e.g., a carbon fiber material) can pass along a path 104 (e.g., a fiber production line or a fiber processing path using roll-to-roll processing) to impart a first coating of nanoparticles 114 to the fiber substrate 102 to provide a first coated substrate 116. In other words, the fiber substrate 102 is imparted with a first coating of nanoparticles 114 to form a monolayer of the first coating of nanoparticles 114. The fiber substrate 102 has an ionic charge polarity (i.e., cationic or anionic charge) and can be treated (e.g., acid or base cleaned, or plasma) to impart such an ionic charge. The nanoparticles contained in the first coating vessel 110 have an ionic charge polarity opposite to that of the fiber substrate 102. The nanoparticles contained in the first coating vessel 110 may be selected from graphene, BN, SiN, TiC, TiO2, and combinations and mixtures thereof. Other types of nanoparticle materials are possible. The first nanoparticle-based solution 112 includes a polymer that acts as a carrier for the nanoparticles contained in the first coating vessel 110.
[0020]
[0030] The manufacturing apparatus 100 also includes a first cleaning vessel 120 containing a cleaning solution 122 (e.g., an aqueous solution) for cleaning the first coated substrate 116 to provide a first cleaned coated substrate 124, which is then dried. Drying may be performed at ambient conditions or at an elevated temperature. An exemplary relationship between the first coating vessel 110 and the first cleaning vessel 120 is shown in FIG. 2B, where multiple rollers 125 are used to provide a production line type setup.
[0021]
[0031] Specifically, the first cleaning vessel 120 contains a solution free of nanoparticles through which the fiber substrate 102 having the first coating of nanoparticles 114 can be passed to remove excess nanoparticles from the first coating of nanoparticles 114 from the fiber substrate 102, leaving only the nanoparticles attached to the fiber substrate 102. The first cleaned coated substrate 124 forms a monolayer of the first coating of nanoparticles 114. The monolayer of the first coating of nanoparticles 114 has a thickness between about 5 nanometers and about 1000 nanometers, for example, about 100 nanometers to about 500 nanometers, or about 200 nanometers to about 400 nanometers.
[0022]
[0032] The manufacturing apparatus 100 further includes a second coating vessel 130 containing a second nanoparticle-based solution 132 through which the first cleaned coated substrate 124 can pass to impart a second coating of nanoparticles 134 to the first cleaned coated substrate 124 to provide a second coated substrate 136. The nanoparticles contained in the second coating vessel 130 have an ionic charge polarity similar to that of the fiber substrate 102 (e.g., carbon fiber) and therefore have an ionic charge polarity opposite to that of the nanoparticles contained in the first coating vessel 110. The nanoparticles contained in the second coating vessel 130 can be selected from at least one of graphene, BN, SiN, TiC, TiO2, and mixtures or combinations thereof. Other types of nanoparticle materials are also possible. The second nanoparticle-based solution 132 includes a polymer that acts as a carrier for the nanoparticles contained in the second coating vessel 130.
[0023]
[0033] The manufacturing apparatus 100 also includes a second cleaning vessel 140 containing a cleaning solution 142 (e.g., an aqueous solution) for cleaning the second coated substrate 136 to provide a second cleaned coated substrate 144, which is then dried (e.g., at ambient conditions or at an elevated temperature).
[0024]
[0034] Specifically, the second cleaning vessel 140 contains a second solution free of nanoparticles, through which the textile substrate 102 having the first and second coatings of nanoparticles 114, 134 can be passed to remove excess particles from the second coating of nanoparticles 134 from the textile substrate 102 coated with the first coating of nanoparticles 114, leaving only nanoparticles from the second coating attached to the nanoparticles from the first coating attached to the textile substrate 102. The second cleaned coated substrate 144 forms a monolayer of the second coating of nanoparticles 134. The monolayer of the second coating of nanoparticles 134 has a thickness between about 5 nanometers and about 1000 nanometers, for example, about 100 nanometers to about 500 nanometers, or about 200 nanometers to about 400 nanometers. After the fiber substrate 102 passes through the first coating vessel 110, the first washing vessel 120, the second coating vessel 130, and the second washing vessel 140 as described above, a multi-layer nanoparticle coated fiber material 150 (i.e., the second washed coated substrate 144 after drying) is produced.
[0025]
[0035] 3A, there is shown a schematic elevational view of the different layers of the produced multi-layer nanoparticle coated textile material 150. A monolayer of a first coating of nanoparticles 114 is disposed on the textile substrate 102, and a monolayer of a second coating of nanoparticles 134 is disposed on the first coating of nanoparticles 114. The monolayer of the first coating of nanoparticles 114 has an ionic charge polarity opposite to that of the textile substrate 102 and the second coating of nanoparticles 134, resulting in a strong bond with the layers above and below.
[0026]
[0036] Although only two cycles of coating and washing are described above, this process can be repeated as many times as desired to achieve a desired number of deposited layers, a desired coating density and / or handleability of the textile material or weave of textile material. For example, referring again to FIG. 2A, the manufacturing apparatus 100 can further include a third coating vessel 160 containing a third nanoparticle-based solution 162 through which the second washed coated substrate 144 passes to impart a third coating of nanoparticles 164 to the second washed coated substrate 144 to provide a third coated substrate 166. The manufacturing apparatus 100 also includes a third washing vessel 170 containing a washing solution 172 (e.g., an aqueous solution) for washing the third coated substrate 166 to provide a third washed coated substrate 174, which is then dried. The dried third washed coated substrate 174 includes a thicker multi-layer nanoparticle coated textile material 152. As shown in FIG. 3B, the thicker multi-layer nanoparticle coated fiber material 152 has another monolayer of nanoparticles (i.e., a third coating of nanoparticles 164) in addition to the monolayer of a first coating of nanoparticles 114 and a monolayer of a second coating of nanoparticles 134 on the fiber substrate 102.
[0027]
[0037] Although the production line setup is described above, it can be envisioned to arrange the production paths and vessels so that the fibers can be exposed to the same nanoparticle solution or the same washing solution multiple times, minimizing the number of solution vessels and washing vessels required to minimize the size of the setup. An exemplary minimum size production line setup is shown in FIG. 2C. As shown in FIG. 2C, the first coating vessel 110, the first washing vessel 120, the second coating vessel 130, and the second washing vessel 140 are arranged in a circular production line setup and can be repeated as many times as desired. In addition, the excess nanoparticles contained in the washing vessels can be removed and recycled to minimize costs.
[0028]
[0038] It will be apparent that a layer-by-layer deposition system may be configured to apply multiple nanoparticle coating layers to the fiber to generate a desired interfacial coating between the layers. As an example, the coating layers may include high temperature materials such as graphene nanoplatelets to generate a desired weak interfacial coating when bonding the fiber with a ceramic matrix to form a ceramic matrix composite.
[0029]
[0039] Each coating layer is self-assembled due to particle shape and charge and is individually deposited on top of the previous coating layer. The coating deposition can be repeated as many times as desired or necessary, for example, three or five times. Other numbers of coating layers are possible. Each coating layer is also of substantially uniform thickness throughout to provide a substantially uniform strength with little variation along the length of each layer.
[0030]
[0040] The multi-layer nanoparticle coated fiber material produced according to the present disclosure, as shown in Figures 3A and 3B, can be post-treated for subsequent use. Post-treatment can include exposure to heat, UV light, or other means to modify the coating to have more desirable handling properties or desirable use properties than the untreated fiber material. As an example, the produced multi-layer nanoparticle coated fiber material 150, 152 can be creeled to produce a woven fabric including nanoparticle coated fibers. As another example, the produced multi-layer nanoparticle coated fiber material 150, 152 can be used as a reinforcement in a ceramic matrix to create a composite. The post-treatment device can be located at the end of a fiber production line, as shown in Figure 2A, or can be located away from the fiber production line.
[0031]
[0041] Referring to FIG. 2D, an exemplary post-processing setup 180 that can be used following the manufacturing apparatus 100 of FIG. 2A is shown. In block 182, the manufactured multi-layer nanoparticle coated fiber material 150, 152 of FIG. 3A or FIG. 3B is formed into a desired part shape and then subjected to a pyrolysis process in block 184. Then, in block 186, a chemical vapor infiltration / chemical vapor deposition (CVI / CVD) process can be applied for the required number of cycles and then subjected to another pyrolysis process shown in block 188. The process of block 186 and the process of block 188 can also be repeated as many times as desired or necessary before the post-processing setup 180 provides a fully densified part 190.
[0032]
[0042] 4, a flow diagram 400 of a method for manufacturing a multi-layer nanoparticle coated fiber using layer-by-layer nanoparticle deposition is shown, according to an exemplary embodiment. At block 410, a fiber substrate is coated with a first type of nanoparticles to provide a first coating layer of a multi-layer nanoparticle coated fiber material. The process proceeds to block 420, where the first coating layer is coated with a second type of nanoparticles to provide a second coating layer of a multi-layer nanoparticle coated fiber material. The process then ends.
[0033]
[0043] In some embodiments, one or both of the first type of nanoparticles and the second type of nanoparticles comprise high temperature nanoparticles, hi some embodiments, the high temperature nanoparticles comprise graphene nanoparticles.
[0034]
[0044] In some embodiments, layer-by-layer deposition is performed to deposit nanoparticles onto the surfaces of the fibers that make up the textile fabric.
[0035]
[0045] In some embodiments, the layer-by-layer deposition is carried out at or near ambient conditions.
[0036]
[0046] In some embodiments, the manufacturing further includes washing the first coating layer to form a monolayer of the first coating layer, and washing the second coating layer to form a monolayer of the second coating layer.
[0037]
[0047] In some embodiments, each of the first and second coating layer monolayers has a thickness between about 5 nanometers and about 100 nanometers.
[0038]
[0048] In some embodiments, the manufacturing further comprises coating the second coating layer with a third type of nanoparticles to provide a third coating layer of the multi-layer nanoparticle coating material. In some embodiments, the third type of nanoparticles is of the same type as the first type of nanoparticles.
[0039]
[0049] In some embodiments, the carbon fibers are formed according to the manufacturing method disclosed in FIG.
[0040]
[0050] Referring to Figure 5, a flow diagram 500 of a method of manufacturing according to another exemplary embodiment is shown. At block 510, a surface of each of the plurality of fibers is treated to impart an ionic charge polarity to the surface. The process proceeds to block 520, where the surface of each of the plurality of fibers is coated with nanoparticles having an ionic charge polarity opposite to the ionic charge polarity of the surface of each of the plurality of fibers to provide a first layer of nanoparticle-coated multi-layered plurality of fibers. Then, at block 530, the first layer is coated with nanoparticles having an ionic charge polarity opposite to the ionic charge polarity of the first layer to provide a second layer of nanoparticle-coated multi-layered plurality of fibers. The process then ends.
[0041]
[0051] In some embodiments, the fabrication further includes cleaning the first layer to form a first layer monolayer and cleaning the second layer to form a second layer monolayer, each of the first and second layer monolayers having a thickness between about 5 nanometers and about 100 nanometers.
[0042]
[0052] In some embodiments, the manufacturing further comprises spreading out a plurality of fibers to maximize the surface area that can be coated with nanoparticles.
[0043]
[0053] In some embodiments, the manufacturing further includes drying each of the first and second layers to modify a combination of handling and use properties of the multi-layered plurality of nanoparticle-coated fibers.
[0044]
[0054] In some embodiments, the ceramic matrix composite is made according to the manufacturing method disclosed in FIG.
[0045]
[0055] Producing the multi-layer nanoparticle coated fiber material disclosed herein offers several advantages, one being that hot nanoparticles can be applied to the fiber at or near ambient conditions.
[0046]
[0056] Another advantage is that a very dense coating of nanoparticles can be formed on the fibers.
[0047]
[0057] Yet another advantage is that neither specialized (and therefore typically expensive) equipment nor highly controlled conditions (e.g., temperature and pressure) are required to produce the multi-layer nanoparticle coated fibers disclosed herein.
[0048]
[0058] Yet another advantage is that the amount of multi-layer nanoparticle coated fiber material required can be obtained along a production line setup such as that shown in FIG. 2A, eliminating the need for batch processing.
[0049]
[0059] An embodiment of the disclosure may be described with respect to an aircraft manufacturing and service method 1100 shown in FIG. 6 and an aircraft 1102 shown in FIG. 7. The aircraft manufacturing and service method 1100 may include specification and design 1104 of the aircraft 1102 and material procurement 1106 during a pre-production phase. During production, component / subassembly manufacturing 1108 and system integration 1110 of the aircraft 1102 occurs. The aircraft 1102 then goes through certification and delivery 1112 and is placed into service 1114. While in service by a customer, the aircraft 1102 is scheduled for routine maintenance and service 1116, which may include modifications, reconfigurations, refurbishment, etc.
[0050]
[0060] 7, the aircraft 1102 produced by the example method 1100 may include an airframe 1118 with a number of systems 1120 and an interior 1122. Examples of the number of systems 1120 may include one or more of a propulsion system 1124, an electrical system 1126, a hydraulic system 1128, and an environmental system 1130. Any number of other systems may be included.
[0051]
[0061] The disclosed apparatus and methods may be employed in any one or more of the stages of aircraft manufacturing and service method 1100. As an example, components or subassemblies corresponding to component / subassembly manufacturing 1108, system integration 1110, and / or maintenance and service 1116 may be assembled using the disclosed apparatus and methods. As another example, an airframe 1118 may be constructed using the disclosed apparatus and methods. Also, one or more of the example apparatus, example method, or combinations thereof may be utilized in component / subassembly manufacturing 1108 and / or system integration 1110 by significantly streamlining or reducing the cost of assembling the aircraft 1102, such as the airframe 1118 and / or interior 1122. Similarly, one or more of the example apparatus, example method, or combinations thereof may be utilized in maintenance and service 1116, such as, but not limited to, while the aircraft 1102 is in service.
[0052]
[0062] Different embodiments of the devices and methods disclosed herein include various components, features, and functionality. It is understood that various embodiments of the devices and methods disclosed herein can include any of the components, features, and functionality of other embodiments of the devices and methods disclosed herein, in any combination, and all such possibilities are intended to be within the scope of the present disclosure.
[0053]
[0063] The above-described apparatus and methods are described with respect to aircraft. However, one skilled in the art will readily recognize that the disclosed apparatus and methods are suitable for a variety of applications and the present disclosure is not limited to aircraft manufacturing applications. For example, the disclosed apparatus and methods may be implemented in a variety of types of vehicles including, for example, re-entry aerospace vehicles, high speed aerospace vehicles, helicopters, passenger ships, automobiles, marine products (boats, motors, etc.). Non-vehicle applications are also contemplated.
[0054]
[0064] Although the above describes an apparatus and method for producing multi-layer nanoparticle coated textile materials in the aviation industry in accordance with military and space regulations, it is envisioned that the apparatus and method may be implemented to facilitate the production of multi-layer nanoparticle coated textile materials in any industry in accordance with applicable industry standards. Specific apparatus and methods may be selected and tailored depending on the particular application.
[0055]
[0065] Moreover, while various examples of the disclosed embodiments have been shown and described, modifications will occur to those skilled in the art upon reading this specification, and the present application includes such modifications and is limited only by the scope of the claims.
Claims
1. A manufacturing method (400) for producing a multi-layer nanoparticle coated textile material (150) using a layer-by-layer nanoparticle deposition system (10), comprising: coating (410) a textile substrate (102) with a first type of nanoparticles (114) to provide a first coating layer (116) of said multi-layer nanoparticle coated textile material (150); and Coating (420) the first coating layer (116) with a second type of nanoparticles (134) to provide a second coating layer (136) of the multi-layer nanoparticle coated fiber material (150). A manufacturing method (400) comprising:
2. Coating (420) the second coating layer (136) with a third type of nanoparticles (164) to provide a third coating layer (166) of the multi-layer nanoparticle coated fiber material (150). The method of claim 1 further comprising:
3. The method (400) of claim 1 , wherein one or both of the first type of nanoparticles (114) and the second type of nanoparticles (134) comprise high temperature nanoparticles.
4. The method of claim 3 , wherein (i) the high temperature nanoparticles comprise graphene nanoparticles, and (ii) the fiber substrate comprises a carbon fiber material.
5. The method (400) of claim 1, wherein layer-by-layer nanoparticle deposition is performed to deposit nanoparticles on a surface of a fiber comprising the fiber substrate (102).
6. The method (400) of claim 1, wherein the layer-by-layer deposition (10) is performed at or near ambient conditions.
7. washing the first coating layer (116) to form a monolayer of the first coating layer (116); and washing said second coating layer (136) to form a monolayer of said second coating layer (136); The method of claim 1 further comprising:
8. 8. The method (400) of claim 7, wherein each of the first coating layer (116) and the second coating layer (136) has a thickness between about 5 nanometers and about 1000 nanometers.
9. Coating the second coating layer (136) with a third type of nanoparticles (164) to provide a third coating layer (166) of the multi-layer nanoparticle coated fiber material (150). The method of claim 1 further comprising:
10. The method (400) of claim 9, wherein the third type of nanoparticles (164) are of the same type as the first type of nanoparticles (114).
11. 13. A carbon fiber produced according to the method (400) of claim 1.
12. Treating (510) a surface of each of a plurality of fibers of a fibrous substrate (102) to impart an ionic charge polarity to said surface; coating (520) the surface of each of the plurality of fibers of the fiber substrate (102) with nanoparticles (114) having an ionic charge polarity opposite to the ionic charge polarity of the surface of each of the plurality of fibers of the fiber substrate (102) to provide a first layer (116) of a multi-layer nanoparticle coated fiber material (150); and coating (530) the first layer (116) with nanoparticles (134) having an ionic charge polarity opposite to the ionic charge polarity of the first layer (116) to provide a second layer (136) of the multi-layer nanoparticle coated fiber material (150); A manufacturing method (500) comprising:
13. washing the first layer (116) to form a monolayer of the first layer (116); and washing said second layer (136) to form a monolayer of said second layer (136); Further comprising:
13. The method (500) of claim 12, wherein each of the monolayers of the first layer (116) and the second layer (136) has a thickness between about 5 nanometers and about 1000 nanometers.
14. Spreading out the plurality of fibers of the fiber substrate (102) to maximize the surface area that can be coated with nanoparticles. The method of claim 12 further comprising:
15. drying each of the first layer (116) and the second layer (136) to modify a combination of handling and use properties of the multi-layer nanoparticle coated fibrous material (150). The method of claim 12 further comprising:
16. A ceramic matrix composite made according to the method (500) of claim 12.
17. An apparatus (100) for producing a multi-layer nanoparticle coated textile material (150), comprising: a first coating reservoir (110) containing a first nanoparticle-based solution (112) through which the textile substrate (102) can be passed to apply a first coating of nanoparticles (114) to the textile substrate (102); and a second coating vessel (130) containing a second nanoparticle-based solution (132) through which the textile substrate (102) having the first coating of nanoparticles (114) can be passed to impart a second coating of nanoparticles (134) to the textile substrate (102) coated with the first coating of nanoparticles (114), thereby providing the multi-layer nanoparticle-coated textile material (150); A manufacturing apparatus (100) comprising:
18. 20. The manufacturing apparatus (100) of claim 17, wherein (i) the fiber substrate (102) has an ionic charge polarity, (ii) the nanoparticles contained in the first coating vessel (110) have an ionic charge polarity opposite to the ionic charge polarity of the fiber substrate (102), and (iii) the nanoparticles contained in the second coating vessel (130) have an ionic charge polarity similar to the ionic charge polarity of the fiber substrate (102).
19. 20. The manufacturing apparatus (100) of claim 17, wherein (i) the first nanoparticle-based solution (112) comprises a polymer that acts as a transport agent for the nanoparticles contained in the first coating vessel (110), and (ii) the second nanoparticle-based solution (132) comprises a polymer that acts as a transport agent for the nanoparticles contained in the second coating vessel (130).
20. The nanoparticles contained in each of the first coating vessel (110) and the second coating vessel (130) are selected from the group consisting of graphene, BN, SiN, TiC, and TiO. ２ The manufacturing apparatus (100) of claim 17, wherein the combination of
21. a first washing vessel (120) containing a washing solution (122) for washing the textile substrate (102) provided with the first coating of nanoparticles (114) to form a monolayer of the first coating of nanoparticles (114); and a second washing vessel (140) containing a washing solution (142) for washing the textile substrate (102) coated with the second coating of nanoparticles (134) to form a monolayer of the second coating of nanoparticles (134); The manufacturing apparatus (100) of claim 17, further comprising:
22. 22. The manufacturing apparatus (100) of claim 21, wherein each of the monolayer of the first coating of nanoparticles (114) and the monolayer of the second coating of nanoparticles (134) has a thickness between about 5 nanometers and about 100 nanometers.
23. a third coating vessel (160) containing a third nanoparticle-based solution (162) through which the textile substrate (102) having the first coating of nanoparticles (114) and the second coating of nanoparticles (134) is passed to apply a third coating of nanoparticles (164) to the textile substrate (102) coated with the first coating of nanoparticles (114) and the second coating of nanoparticles (134), thereby providing a thicker multi-layer nanoparticle-coated textile material (152); The manufacturing apparatus (100) of claim 21 further comprising:
24. a third washing vessel (170) containing a washing solution (172) for washing said textile substrate (102) coated with said third coating of nanoparticles (164) to form a monolayer of said third coating of nanoparticles (164); The manufacturing apparatus (100) of claim 23, further comprising: