DE112020001068T5 - OBJECT WITH MULTIFUNCTIONAL CONDUCTIVE WIRE - Google Patents

Abstract

Articles and devices comprising a multifunctional conductive wire having a first electrode comprising a first carbon nanotube composite yarn containing carbon nanotubes and secondary particles; a second electrode comprising a second carbon nanotube composite yarn containing carbon nanotubes and secondary particles; a first separator membrane surrounding the first and second electrodes; a flexible insulator layer surrounding the electrolyte; and a flexible conductive layer at least partially surrounding the flexible insulator layer. Also provided is a method of making and using the articles, devices, and multifunctional conductive wires herein.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority from U.S. Provisional Patent Application No. 62 / 813,516 , filed on March 4, 2019, entitled "Composite Yarn and Method of Making a Carbon Nanotube Composite Yarn". This application claims priority from U.S. Patent Application No. 16 / 446,389 , filed on June 19, 2019, entitled “Composite Yarn and Method of Making a Carbon Nanotube Composite Yarn” . This application claims priority from U.S. Patent Application No. 16 / 805,565 , filed on February 28, 2020, entitled “Multifunctional Conductive Wire and Method of Making” . The disclosures of the preceding applications are hereby incorporated in their entirety by reference.

BACKGROUND

Devices comprising conductive metal wires, especially solid or stranded copper wires, have been manufactured and used in many industries for many decades. However, recent demands for device downsizing and optimization of energy efficiency make new demanding demands on the high volumetric and highly gravimetric properties of conductive metal wires, so that new devices and articles including new types of wire are necessary. The search for new methods of synthesis, manufacture and construction which give conductive wires more functions instead of just acting as current carriers is of central interest. Older solid and stranded copper wires, which normally only function as conductors of energy, can add tons of weight to commercial jets. The limitations of older solid and stranded copper wires are particularly critical for vehicle engines where, for example, in some electric vehicles, the engine can contain approximately 76 kilograms of copper coils. By adding extra weight, the batteries in electric vehicles can weigh hundreds of kilograms. Electric motors, generators and transformers without older solid or stranded copper coils could be lighter and more efficient. Thus, new articles and devices are needed that incorporate an advanced multifunctional conductive wire.

SUMMARY

The present disclosure is directed to articles and devices comprising multifunctional conductive wires and methods of making articles and devices comprising multifunctional conductive wires. Articles with reduced weight and improved efficiency which include multifunctional conductive wires (MCW) are made possible herein. The MCW disclosed herein can provide electrical power in less length, weight, and space compared to older conductors. Devices comprising MCW that can have a built-in battery function to simultaneously provide or store energy while providing power carriers are disclosed herein. In some aspects, MCWs can replace solid or stranded copper wire in motors, generators, transformers, and electromagnetic devices. In some aspects, the MCW disclosed herein can have a battery function with two or more electrodes and an electrolyte surrounded by an insulator with a conductive layer outside the insulator to form an MCW that is capable of generating alternating current to run efficiently like a solid copper conductor, but also to provide a built-in battery. These aspects and other aspects of the present disclosure are disclosed in detail herein.

Figure list

• 1A FIG. 10 shows an exemplary scheme for making a carbon nanotube composite yarn in accordance with aspects of the present disclosure.
• 1 B FIG. 10 shows a schematic of two exemplary compression steps in accordance with aspects of the present disclosure.
• 2 FIG. 10 shows a scanning electron microscope (SEM) image of a pure carbon nanotube mat in accordance with aspects of the present disclosure.
• 3 FIG. 10 shows a photograph of a pure carbon nanotube mat in accordance with aspects of the present disclosure.
• 4th FIG. 10 shows an SEM of a carbon nanotube mat in accordance with aspects of the present disclosure.
• 5A FIG. 10 shows an exemplary MCW cable including battery electrodes in accordance with some aspects of the present disclosure.
• 5B FIG. 10 shows an exemplary cross-sectional schematic of an MCW in accordance with some aspects of the present disclosure.
• 5C FIG. 10 shows an exemplary cross-sectional schematic of an MCW in accordance with some aspects of the present disclosure.
• 5D FIG. 10 shows an exemplary cross-sectional schematic of an MCW in accordance with some aspects of the present disclosure.
• 5E FIG. 10 shows an exemplary cross-sectional schematic of an MCW in accordance with some aspects of the present disclosure.
• 6A shows a conventional electric motor which is powered by one or more external batteries.
• 6B Figure 12 shows an electric motor powered by a multifunctional MCW cable that houses a battery in the core, in accordance with some aspects of the present disclosure.

DETAILED DESCRIPTION

The present disclosure is directed to articles and devices comprising a multifunctional conductive wire and methods of making articles and devices comprising a multifunctional conductive wire (MCW). In some aspects, the MCW can be a wire that includes a core cylinder that is sealed by a layer of insulator covered by an outer layer of copper or any other conductive metal. The core cylinder can be a cylindrical flexible battery which comprises two or more self-standing electrodes (e.g. carbon nanotube yarns with battery-active materials) which are insulated by (a) separator (s) and / or an electrolyte. In some aspects, the cylindrical flexible battery in the core of the MCW can supply or store power for an electrical device. Depending on the application, one or more outer insulator layers can be applied to the outer conductive layer. Optionally, further layers of conductive material and further layers of insulating material can be applied.

In some aspects of the MCW, the thickness of an outer conductive metal layer can be varied depending on the intended frequency of an alternating current (AC) that is to be carried by an outer conductive layer. The thickness can be varied to optimize conduction of alternating current, but without the need for a heavy metal (or copper) material for the central core, which carries little alternating current. The skin effect is a tendency of an alternating current to have a current density which is greatest near the outer surface of a conductor, with the current density in a conductor decreasing with greater depths in a conductor, particularly as the frequency of the alternating current increases. The skin effect is caused by the opposing electromagnetic field with an eddy current, which is generated by the self-induced magnetic flux in an alternating current-carrying conductor. With a direct current (DC), the rate of change of the flux is zero, so that there is no opposing electromagnetic field with an eddy current due to changes in the magnetic flux. With a direct current, the current is evenly distributed over the cross-section of the conductor. With alternating current at a lower frequency, the central core of a solid metal wire carries little current; as the frequency of the alternating current increases, the outer skin of a solid metal wire carries most of the current. In the case of alternating current with a higher frequency, the central core of a solid metal wire does not carry any current. Thus, the MCW disclosed herein, when applied to the transmission of alternating current, can provide in the core a core cylinder battery in which the alternating current density would be lowest in a solid wire conductor. In some aspects, providing a core cylinder battery in the core provides an MCW that is lighter in weight compared to solid metal wires, while at the same time providing a power source / storage battery in the MCW.

The MCW can also carry direct current (DC). Various components, as known in the art, may be included to convert direct current, for example from the core cylinder battery, to alternating current for carrying current in an outer conductive metal layer. In another example, alternating current in an outer conductive metal layer can be converted to direct current for storage in a core cylinder battery.

The external shape of the MCW can be any shape. For example, a round or cylindrical shape can be used for ease of manufacture or to resemble older metal wires. For example, a square shape can be used to maximize efficiency when winding an MCW into a spool. With some electric motors, a square shape of an MCW can be used to maximize winding efficiency and minimize air space between the windings of a coil. The outer shape can optionally be deformable and flexible.

The devices and articles disclosed herein that include an MCW are not limited by the examples provided. The applications of MCW include, for example, long-distance power transmission lines which, using MCW, may weigh less or store or deliver power in certain areas of the MCW. For example, the MCW can contain (either external or embedded in) processors, transmitters, receivers, Wi-Fi, sensors, solar cells and electronic components, determine which areas or segments of the MCW store or deliver energy. The MCW can contain diodes or arrays to convert AC power to DC power. For example, the MCW may contain internal or external optical fibers, other conductors, other fibers, or fasteners. In some aspects, vehicles, engines, machines, devices, and articles are disclosed herein that include an MCW. As an illustrative example, a commercial jet that includes an MCW may weigh less than a commercial jet that includes solid copper wire, silver-plated, or nickel-plated copper wire. An electric motor can weigh significantly less using an MCW and such an electric motor can have an improved energy-to-weight ratio compared to motors with solid metal wires. An electrical generator, a large generator in a power plant, or an AC generator with an MCW can weigh significantly less than the same using solid copper wire. Transformers that incorporate large coils of wire can weigh less using an MCW. Transmitters, antennas, and inductors are other illustrative examples of devices that include an MCW. Storage of energy by the MCW on power lines, vehicles, machines, and devices can reduce or eliminate the need for additional power carriers to carry power to or from an external storage battery.

In some aspects, an apparatus is disclosed herein that includes one or more MCW coils, each coil including an MCW that is twisted in the shape of a coil, spiral, or helix. Each coil can provide electromagnetic induction / generation while providing battery and / or storage capabilities. An MCW coil can provide or store electrical energy and conduct electrical energy.

In some aspects, the MCW disclosed herein may comprise two or more flexible electrodes, each flexible electrode comprising a carbon nanotube composite yarn, the carbon nanotube composite yarn comprising carbon nanotubes and secondary particles, and optionally comprising one or more separator membranes. In some aspects, the one or more separator membranes may include a different separator membrane provided between the two or more flexible electrodes. As used herein, the term “different separator membrane” refers to a separator membrane as described herein that is not in direct contact with the two or more flexible electrodes. Additionally or alternatively, each flexible electrode can independently comprise an outer layer of a separator membrane. In some examples, the outer layer of the separator membrane (s) can eliminate the need for additional separator membranes placed between electrodes. The MCW may further include an electrolyte positioned between each of the two or more flexible electrodes.

In some aspects, the two or more flexible electrodes can be wrapped around one another in a twisted configuration. It is known in the prior art that twisting two wires around one another significantly reduces the electromagnetic interference (also called radio frequency, RF, interference in the RF spectral range) in the wires. In some aspects, winding or twisting the two or more flexible electrodes about one another can reduce or eliminate electromagnetic interference in the two or more flexible electrodes from AC power (in the outer conductive layer) or from environmental sources. Optionally, the two or more flexible electrodes may be in a parallel or quasi-parallel configuration, or may not be in contact with each other. A flexible insulator layer surrounding the two or more flexible electrodes, the optional separator membrane (s), and the electrolyte may contain the two or more flexible electrodes and the electrolyte within the MCW, thereby providing a battery within the MCW. A flexible conductive layer, for example a metal layer, can surround the flexible insulating layer, the thickness of the flexible conductive layer varying as a function of the frequency of an alternating current carried by the flexible conductive layer. The flexible electrodes inside the MCW are self-standing flexible electrodes due to the carbon nanotubes they contain. As used herein, the term "self-standing electrode" refers to an electrode that is capable of functioning without one or more components that are provided as a structural support. It should be noted that in some aspects, any carbon nanotube composite yarn as described herein can be a self-standing electrode.

Methods of making the self-standing flexible electrodes are disclosed herein. A carbon nanotube composite yarn can be made by growing floating carbon nanotubes, continuously removing sheets of the floating carbon nanotubes to provide a mat of the carbon nanotubes, and in parallel depositing secondary particles on at least a portion of the mat of carbon nanotubes to form a carbon nanotube composite mat and compressing the carbon nanotube composite mat to provide a carbon nanotube composite yarn.

The method may include growing suspended carbon nanotubes in a reactor. As used herein, the term "nanotube" refers to a tube that has at least one dimension in the nanometer range; i.e., at least one dimension between about 0.6 and 100 nm. For example, a nanotube may comprise a tube that has a diameter in the nanometer range. In some aspects, the nanotubes according to the present disclosure can be selected from the group consisting of single-walled carbon nanotubes (SWNTs), multi-walled carbon nanotubes (MWNTs), and combinations thereof.

The floating carbon nanotubes can be grown in a reactor such as a chemical vapor deposition (CVD) reactor. For example shows 1A an exemplary reactor 11 which can be used in accordance with aspects of the present disclosure. As in 1A shown can the reactor 11 at least a first inlet 12th in fluid communication with a carbon source chamber 13th comprise, wherein the carbon source chamber 13th is configured to provide a carbon source, such as a carbon source gas.

Examples of carbon sources include, but are not limited to, one or more carbonaceous gases, one or more hydrocarbon solvents, and mixtures thereof. Specific examples include, but are not limited to, gases and / or solvents containing and / or consisting of a hydrocarbon, an alcohol, an ester, a ketone, an aromatic, an aldehyde, and a combination thereof. For example, the carbon source can be selected from xylene, toluene, propane, butane, butene, ethylene, ethanol, carbon monoxide, butadiene, pentane, pentene, methane, ethane, acetylene, carbon dioxide, naphthalene, hexane, cyclohexane, benzene, methanol, propanol, Propylene, commercial fuel gases (such as liquefied petroleum gas, natural gas, and the like), and combinations thereof.

The carbon source chamber 13th can also be set up to provide a catalyst and / or a catalyst precursor, such as a catalyst and / or a catalyst precursor vapor. As used herein, the term “catalyst” refers to a component that provokes or accelerates a chemical reaction, for example the synthesis of nanotubes. Examples of catalysts useful in accordance with the present disclosure include, but are not limited to, transition metals, lanthanide metals, actinide metals, and combinations thereof. For example, the catalyst can be a transition metal such as chromium (Cr), molybdenum (Mo), tungsten (W), iron (Fe), cobalt (Co), nickel (Ni), ruthenium (Ru), rhodium (Rh), Palladium (Pd), Osmium (Os), Iridium (Ir), Copper (Cu), Silver (Ag), Gold (Au), Cadmium (Cd), Scandium (Sc), Yttrium (Y), Lanthanum (La), Platinum (Pt) and / or combinations thereof. The catalyst can be a supported catalyst or an unsupported catalyst. In some aspects, a combination of two or more metals, for example a mixture of iron, nickel and cobalt, can be used. In one example, the mixture may include a 50:50 mixture (by weight) of nickel and cobalt. The catalyst can comprise a pure metal, a metal oxide, a metal carbide, a nitrate salt of a metal, other compounds containing one or more of the metals described herein, and / or a combination thereof.

As used herein, the term "catalyst precursor" refers to a component that can be converted into an active catalyst. Examples of catalyst precursors include, but are not limited to, transition metal salts such as a nitrate, acetate, citrate, chloride, fluoride, bromide, iodide, and / or hydrates thereof, and combinations thereof. For example, the catalyst precursor can be a metallocene, a metal acetylacetonate, a metal phthalocyanine, a metal porphyrin, a metal salt, an organometallic compound, a metal sulfate, a metal hydroxide, a metal carbonate, or a combination thereof. For example, the catalyst precursor may be ferrocene, nickelocene, cobaltocene, Molybdenocen, ruthenocene, iron acetylacetonate, nickel acetylacetonate, cobalt acetylacetonate, molybdenum acetylacetonate, ruthenium acetylacetonate, iron phthalocyanine, nickel phthalocyanine, Kobaltporphthalocyanin, iron porphyrin, nickel porphyrin, Kobaltporphyrin, an iron salt, a nickel salt, cobalt salt, molybdenum salt, ruthenium salt or be a combination of these. The catalyst precursor can comprise a soluble salt, such as Fe (NO ₃ ) ₃ , Ni (NO ₃ ) _2, or Co (NO ₃ ) ₂ , which is dissolved in a liquid such as water. The catalyst precursor can reach an intermediate catalyst state in the catalyst particle growth zone of the reactor and then be converted to an active catalyst when exposed to the nanostructure growth conditions in the nanostructure growth zone of the reactor. For example, the catalyst precursor can be a transition metal salt which is converted to a transition metal oxide in the catalyst particle growth zone and then converted to active catalytic nanoparticles in the nanostructure growth zone.

It should be noted that while 1A a carbon source chamber 13th Figure 8 shows which contains both a carbon source and a catalyst and / or a catalyst precursor, the carbon source chamber 13th via the first admission 12th in fluid communication with the reactor 11 is, the carbon source and the catalyst and / or the catalyst precursor can be provided in separate chambers, optionally via separate inlets in fluid communication with the reactor 11 .

The carbon source and the catalyst and / or the catalyst precursor can be supplied to the reactor via a carrier gas, such as an inert carrier gas. For example shows 1A the carbon source and the catalyst and / or the catalyst precursor which the reactor 11 be supplied via a helium (He) gas. Examples of inert gases that are suitable in accordance with the present disclosure include, but are not limited to, gases that include helium (He), radon (Rd), neon (Ne), argon (Ar), xenon (Xe), nitrogen ( N), and combinations thereof.

As in 1A shown can the reactor 11 with a second inlet 14th be provided. The second inlet 14th may be in fluid communication with, for example, a hydrogen gas source, which may be provided to provide higher growth yield and / or to control SWNT vs. MWNT production. Hydrogen gas can additionally or alternatively via a third inlet 15th which is in fluid communication with a carbon source chamber passage 16 is the carbon source chamber passage 16 is configured to provide fluid communication between the carbon source chamber 13th and the first inlet 12th provide. In the reactor 11 can floating carbon nanotubes 17th grown as in 1A shown. As used herein, the term "floating" refers to a state of being suspended, for example suspended in a gas or liquid. As in 1A shown, the floating carbon nanotubes 17th float in the inert gas as described herein. The temperature of the reactor 11 can be using one or more heat sources 18a and 18b be maintained and / or varied. In an illustrative example, the heat sources 18a and 18b individually or collectively comprise an oven or a lamp. The one or more heat sources 18a and 18b can be near the reactor 11 are located and can control the temperature of the reactor 11 hold at a temperature which is suitable for reducing the catalyst precursor into an active catalyst and / or for the synthesis and / or formation of carbon nanotubes. In some aspects, the one or more heat sources 18a and 18b the temperature of the reactor 11 at a temperature between about 300 and 1800 ° C, optionally between about 450 and 1600 ° C.

The method may include providing a structure that includes, but is not limited to, a mat of the carbon nanotubes, which is alternatively referred to herein as a “web”. As used herein, the term “mat” or “web” refers to an entangled or bundled mass, such as an entangled, uncompacted mass, formed by the floating carbon nanotubes downstream of the nanotube growth zone. The mat of carbon nanotubes can be provided, for example, in and / or on the reactor and / or by continuously pulling the floating carbon nanotubes out of the reactor. For example shows 1A an example of floating carbon nanotubes 17th which are in a nanotube growth zone of the reactor 11 getting produced. A mat made of carbon nanotubes 110 can then be in the reactor 11 form downstream of the nanotube growth zone. The mat made of carbon nanotubes 110 can get on the inner walls of the reactor 11 and / or along the edges of the outlet 19th of the reactor 11 deposit. The mat made of carbon nanotubes 110 can via a high flow rate of the carrier gas and / or the hydrogen gas, as described herein, through the outlet 19th from the reactor 11 to be pulled. 2 shows an SEM image of a pure carbon nanotube mat, for example a mat made of carbon nanotubes 110 , as in 1A shown. 3 shows a photograph of a mat made of pure carbon nanotubes, for example a mat made of carbon nanotubes 110 , as in 1A shown.

The method may include depositing a secondary material on at least a portion of the carbon nanotubes to provide a carbon nanotube composite yarn. In some aspects, the method may include depositing a secondary material on at least a portion of the mat of carbon nanotubes to provide a carbon nanotube composite mat, followed by a densification step wherein the carbon nanotube composite mat is densified to provide a carbon nanotube composite yarn. The method may include a simultaneous deposition and densification step wherein the secondary material is deposited on at least a portion of the carbon nanotube mat while the carbon nanotube mat is simultaneously densified to provide a composite carbon nanotube yarn. In some aspects, the deposition and / or densification steps can be continuous steps that run parallel to continuously pulling the mat of carbon nanotubes from the reactor as described herein.

As used herein, the term “secondary material” refers to a material that comprises at least one material that differs from the carbon nanotube mat. Examples of materials suitable as secondary materials in accordance with the present disclosure include, but are not limited to, electrode active material (s), metals, metal oxides, lithium metal oxides, lithium iron phosphate, ceramics, carbon-based materials, and combinations thereof. Examples of carbon-based materials include, but are not limited to, graphite particles, graphite and graphene flakes, hard carbon, and combinations thereof.

In an illustrative example, the carbon-based material is an electrode active material for use in an electrode of a battery. Active electrode materials can be metal oxides. Examples of metal oxides include, but are not limited to, any metal oxide that can be used as an electrode active material in an electrode. In an illustrative example, the metal oxide is a material for use in the cathode of a battery. Non-limiting examples of metal oxides include those comprising Ni, Mn, Co, Al, Mg, Ti, or any mixtures thereof. The metal oxide can be lithiated. In an illustrative example, the metal oxide is lithium-nickel-manganese-cobalt oxide (LiNiMnCoO ₂ ), Li (Ni, Mn, Co) O ₂ , Li-Ni-Mn-Co-O, or (LiNi _x Mn _y Co _z O ₂ , x + y + z = 1). The metal oxide can be represented by Li-Me-O. Metals in lithium metal oxides according to the present disclosure can include, but are not limited to, one or more alkali metals, alkaline earth metals, transition metals, aluminum, or post transition metals and hydrates thereof. In some aspects, the electrode active material is selected from graphite, hard carbon, metal oxides, lithium metal oxides, and lithium iron phosphate. In some aspects, the electrode active material for the anode may be a carbon-based material as described herein including, but not limited to, graphite particles, graphite flakes, graphene flakes, hard carbon, and combinations thereof. The electrode active material can be any solid metal oxide powder that can be aerosolized. The metal oxide powders can have a particle size which is defined in a range between approximately 1 nanometer and approximately 100 micrometers. In one non-limiting example, the metal oxide particles have an average particle size of about 1 nanometer to about 10 nanometers.

According to some aspects, flexible self-standing electrodes for anode and cathode based on carbon nanotube composite yarn are formed by introducing graphite flakes or Li-Me-O particles, respectively, into CNT yarn. The thread-like electrodes can optionally be twisted together and an electrolyte can be added, followed by covering with a polymer-based insulator material. A layer of copper (or other metal) of a desired thickness can be deposited on the surface of a thread-like battery. The surface layer of the resulting cable, or MCW, serves as a typical conductor for alternating current (e.g. for a vehicle electric motor), while the "core" of the cable can provide the energy as a battery ( 6B) . The thickness of the deposited Cu layer can be varied depending on the frequency of an alternating current used. The terms cable and MCW are used interchangeably herein to refer to various embodiments of multifunctional conductive wire. The term cable does not limit the MCW disclosed herein to an insulator layer or an outer conductive metal layer, since the MCW disclosed herein can have more than one insulator layer and more than one conductive metal or current carrier layer in various embodiments.

"Alkali metals" are metals from Group I of the Periodic Table of the Elements, such as lithium, sodium, potassium, rubidium, cesium or francium.

“Alkaline earth metals” are metals from group II of the periodic table of the elements, such as beryllium, magnesium, calcium, strontium, barium or radium.

"Transition metals" are metals in the d-block of the periodic table of the elements, including the lanthanide and actinide series. Transition metals include, but are not limited to, scandium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, yttrium, zirconium, niobium, molybdenum, technetium, ruthenium, rhodium, palladium, silver, cadmium, lanthanum, Cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium, hafnium, tantalum, tungsten, rhenium, osmium, iridium, platinum, gold, mercury, actinium, thorium Protactinium, Uranium, Neptunium, Plutonium, Americium, Curium, Berkelium, Californium, Einsteinium, Fermium, Mendelevium, Nobelium and Lawrencium.

"Post-transition metals" include, but are not limited to, gallium, indium, tin, thallium, lead, bismuth, or polonium.

The term “electrode” refers to an electrical conductor in which ions and electrons are exchanged with an electrolyte and an external circuit. “Positive electrode” and “cathode” are used synonymously in this description and refer to the electrode with the higher electrode potential in an electrochemical cell (ie, higher than the negative electrode). “Negative electrode” and “anode” are used synonymously in this description and refer to the electrode with the lower electrode potential in an electrochemical cell (ie, lower than the positive electrode). Cathodic reduction refers to a gain of an electron (s) of a chemical species and anodic oxidation refers to a loss of an electron (s) of a chemical species.

In some aspects, the secondary material may be provided as secondary particles deposited on at least a portion of the carbon nanotube mat. In some aspects, the particles can have a particle size from about 1 nanometer to about 100 micrometers, optionally from about 1 nanometer to about 10 nanometers. 1A shows a secondary particle chamber 111 which secondary particles 112 as described herein. The secondary particle chamber 111 can have at least one outlet 113 near the outlet 19th of the reactor 11 include. In this way, the mat made of carbon nanotubes 110 showing the reactor 11 over the outlet 19th leaves, secondary particles 112 get abandoned. While 1A only one secondary particle chamber 111 12, two, three, or more secondary particle chambers may be provided, each of the plurality of secondary particle chambers including the same type or a different type of secondary particles from at least one other of the plurality of secondary particle chambers.

The secondary particle chamber 111 and the delivery mechanism are not limited. As an example and not by way of limitation, the secondary particle chamber 111 include one or more of belt conveyors, gravimetric conveyors, pneumatic conveyors, vacuum conveyors, screw conveyors, vibratory conveyors, volumetric conveyors, and valves.

In some aspects, the secondary particles can be provided via one or more carriers. Examples of carriers include any substance known in the art which is designed to supply secondary particles to a substrate (for example a mat of carbon nanotubes), as described herein, without damaging the carbon nanotubes and / or the secondary particles. Examples of suitable carriers include gas carriers, liquid carriers, and combinations thereof. Exemplary gas carriers include, but are not limited to, Ar, He, N ₂ , dry air, and combinations thereof. Exemplary liquid carriers include, but are not limited to, water, acetone, ethanol, and combinations thereof. In some aspects, the one or more carriers may contain the secondary particles 112 in the secondary particle chamber 111 be provided as in 1A shown. Alternatively or additionally, one or more additional carrier chambers (not shown) can be provided so that the carrier and the secondary particles are in contact before they are deposited on the mat of carbon nanotubes. It should also be noted that a carrier can be excluded from the method described herein so that the secondary particles are deposited, for example as a powder, on at least a portion of the mat of carbon nanotubes.

1A shows a carbon nanotube composite mat 114 which contain at least a section of secondary particles 112 includes. 4th shows an SEM image of a carbon nanotube composite mat, for example a carbon nanotube composite mat 114 , as in 1A shown comprising carbon nanotubes and a metal oxide powder. In some aspects, the carbon nanotube composite mat may comprise 90% (w / w) or less carbon nanotubes, optionally 80% (w / w) w / w or less, optionally 70% (w / w) w / w or less, optionally 60% ( w / w) w / w or less, optionally 50% (w / w) w / w or less, optionally 40% (w / w) w / w or less, optionally 30% (w / w) w / w or less, optionally 20% (w / w) w / w or less, optionally 10% (w / w) w / w or less, optionally 9% (w / w) w / w or less, optionally 8% (w / w) w / w or less, optionally 7% (w / w) w / w or less, optionally 6% (w / w) w / w or less, optionally 5% (w / w) w / w or less, optional 4% (w / w) w / w or less, optional 3% (w / w) w / w or less, optional 2% (w / w) w / w or less and optionally 1% (w / w) w / w or less. According to some aspects, the carbon nanotube composite mat may comprise 10% (w / w) or more secondary particles, optionally 20% (w / w) or more secondary particles, optionally 30% (w / w) or more secondary particles, optionally 40% (w / w) or more secondary particles, optionally 50% (w / w) or more secondary particles, optionally 60% (w / w) or more secondary particles, optionally 70% (w / w) or more secondary particles, optionally 80% (w / w) or more Secondary particles, optionally 90% (w / w) or more Secondary particles, optionally 91% (w / w) or more, optionally 92% (w / w) or more, optionally 93% (w / w) or more, optionally 94% (w / w) or more, optionally 95% (w / w) or more, optionally 96% (w / w) or more, optionally 97% (w / w) or more, optionally 98% (w / w) or more and optionally 99% (w / w) or more. In some aspects, the carbon nanotube composite mat can comprise from 0.1% to 4% (w / w) carbon nanotubes and the remainder secondary particles and optionally one or more additives. Optionally, the carbon nanotube composite mat 0 , 2% to 3% (w / w) carbon nanotubes and the remainder comprise secondary particles and optionally one or more additives. Optionally, the carbon nanotube composite mat can comprise from 0.75% to 2% (w / w) carbon nanotubes and the remainder secondary particles and optionally one or more additives. Additives and / or dopants can be present in an amount of 0 to 5% (w / w) for each area. In one non-limiting example, the carbon nanotube composite mat consists essentially of the carbon nanotubes and the secondary particles. In one non-limiting example, the composite carbon nanotube mat consists of the carbon nanotubes and the secondary particles.

The method may include densifying the carbon nanotube composite mat to provide a carbon nanotube composite yarn as described herein. For example, the carbon nanotube composite mat can be exposed to a liquid bath and / or a roller press and / or a spindle and / or a cylindrical tube and / or a conduit, such as by spinning, drawing and / or passing the carbon nanotube composite mat through or around the liquid bath and / or or the roller press and / or the spindle and / or the cylindrical tube and / or the line. In this way, the carbon nanotube composite mat 114 be compressed, for example, to make a carbon nanotube composite yarn 115 as in 1A shown.

As in 1A shown, the carbon nanotube composite yarn 115 further processed, for example by spinning the carbon nanotube composite yarn 115 around a coil 116 . Alternatively or additionally, the further processing step (s) can comprise removing excess secondary material from the carbon nanotube composite mat and / or the carbon nanotube composite yarn, for example by shaking. One or more of the further processing steps can take place before and / or after the compression step (s) described herein.

1B shows two exemplary densification steps as described herein. In particular shows 1B floating carbon nanotubes 17th which in a reactor 11 have been grown, for example, a mat made of carbon nanotubes 110 how to provide in relation to 1A described. 1 B also shows a secondary particle chamber 111 which secondary particles 112 contains, as in relation to 1A described. 1B further shows two exemplary densification steps including a spin densification step 117 and a liquid bath densification step 118 . In particular, a spin compression step 117 a spinning of a carbon nanotube composite mat 114 (Carbon nanotube composite mat 114 comprising at least a portion of secondary particles 112 as described herein) through or around a roller press and / or a spindle, around a carbon nanotube composite yarn 115 as described herein, similar to that in 1A shown example.

1B also shows a liquid bath densification step 118 which instead of or in addition to the spin densification step 117 can be carried out. As in 1B shown, the liquid bath densification step 118 exposing a carbon nanotube composite mat 114 as described herein, a liquid bath 119 comprise, which comprises a solvent. In some aspects, the solvent can be any solvent known in the art that is configured to densify a mat of carbon nanotubes as described herein. Exemplary solvents include, but are not limited to, water, acetone, ethanol, and combinations thereof. It should be noted that exposing the carbon nanotube composite mat 114 the liquid bath 119 comprising the solvent, a carbon nanotube composite yarn 115 can provide, as in 1B shown, which can be further processed as described herein, for example by spinning the carbon nanotube composite yarn 115 around a coil 116 hereabouts. The further processing step (s) can be selected in such a way that at least part of the solvent which is on the carbon nanotube composite yarn 115 after it sticks to the liquid bath 119 has been exposed, made of the carbon nanotube composite yarn 115 evaporated.

The method may include a simultaneous deposition and densification step, as described herein, wherein the secondary material is deposited on at least a portion of the carbon nanotube mat while the carbon nanotube mat is simultaneously or approximately simultaneously densified to provide a composite carbon nanotube yarn. For example, as described herein, the carrier can be configured to simultaneously carry the Secondary particles to be deposited on the mat made of carbon nanotubes and to compact the mat made of carbon nanotubes. A non-limiting example of such a step includes the use of a solvent as described herein, the solvent being used as a carrier to deposit the secondary particles on the mat of carbon nanotubes as described herein. The solvent can simultaneously densify the mat of carbon nanotubes, as described herein (e.g. as in relation to the in 1B liquid bath densification step shown 118 described) to provide a carbon nanotube composite yarn. It should be noted that the simultaneous deposition and densification step can be performed instead of or in addition to one or more other steps as described herein, comprising one or more additional deposition steps, one or more additional densification steps, one or more additional simultaneous deposition and densification steps Densification steps, one or more additional processing steps, and combinations thereof, each additional step being performed individually before or after the simultaneous deposition and densification step.

The entire process for manufacturing the carbon nanotube composite yarn can be a continuous process. For example, the carbon source can be the reactor 11 continuously fed, so that the carbon nanotube mat continuously to the secondary particle chamber 111 can be supplied for continuous deposition of the secondary particles, and the resulting composite structure can be continuously processed to form the carbon nanotube composite yarn. It should be noted, however, that one or more stages can be carried out separately in a continuous, batch or semi-batch operation. For example, individual segments of carbon nanotube mats of the secondary particle chamber 111 are fed to deposit the particles thereon. The resulting composite structure may undergo additional processing to evenly distribute the particles across the carbon nanotube mat.

After different degrees of compression, the carbon nanotube composite yarn is a self-standing flexible electrode and the carbon nanotube composite yarn can optionally be covered externally with a separator membrane. As a self-standing flexible electrode, the carbon nanotube composite yarn can comprise carbon nanotubes, as described herein, with secondary particles deposited thereon, as described herein. The carbon nanotube yarn may be an electrode (such as an electrode for a battery), an electrode for a multifunctional conductive wire, a super capacitor, a solar cell, a thermoelectric material, a sensor, an actuator, an element of an electronic device, a compound, or an E. -Textile, depending on the compression, dopants, secondary particles and various conditions that are used during or after the production of the carbon nanotube composite yarn.

The self-standing flexible electrodes can in some cases (e.g. when using a liquid electrolyte) lie within a cable with at least two electrodes and optionally one or more separator membranes between the at least two electrodes, at least one of the electrodes comprising a carbon nanotube composite yarn, such as disclosed herein. In some aspects, at least two of the electrodes each comprise a carbon nanotube composite yarn as disclosed herein. The cable can further comprise an electrolyte, an insulator layer and a conductive layer.

5A FIG. 10 shows an exemplary cable or MCW in accordance with aspects of the present disclosure. In particular shows 5A a cable with a first electrode 51 (e.g. an anode) and a second electrode 52 (e.g., a cathode), each of the first and second electrodes individually comprising a carbon nanotube composite yarn, as disclosed herein. For example, the first electrode 51 comprise a carbon nanotube composite yarn, wherein the secondary material comprises graphite flakes, and the second electrode 52 may comprise a carbon nanotube composite yarn, wherein the secondary material comprises Li-Me-O particles.

In some aspects, the cable or MCW can be the first electrode 51 and the second electrode 52 in a coaxial configuration, i.e., with an axis of the first electrode 51 and an axis of the second electrode 52 are parallel or quasi-parallel, as in 5A shown. It should be noted that, in this example, “quasi-parallel” refers to a relationship between the axes such that the axes extend in the same direction and do not overlap each other. In some aspects, the cable or MCW can be the first electrode 51 and the second electrode 52 in a twisted configuration. It should be noted that a “twisted configuration” can refer to a configuration where the first electrode 51 and the second electrode 52 are wrapped around each other.

In some aspects, the first electrode 51 and the second electrode 52 be separated from each other by a separator membrane (e.g. a Nafion membrane). For example shows 5A an enlarged view 56 the first electrode 51 comprising a carbon nanotube composite yarn as described herein. The first electrode 51 can from a separator membrane 57 be surrounded as described herein. The second electrode 52 may have a similar configuration. It is It should be noted that in some cases neither the first nor the second electrode may be surrounded by a separator membrane, one of the first and second electrodes may be surrounded by a separator membrane, or both the first and second electrodes may be surrounded by a separator membrane can be surrounded. In some aspects, the first electrode is 51 and the second electrode 52 not in direct contact with each other.

The MCW or cable may further comprise an electrolyte (e.g., a liquid, gel, solid, or a combination thereof) 53, which is essentially the first electrode 51 and the second electrode 51 surrounds an insulator layer 54 which is essentially the electrolyte 53 surrounds, and a conductive layer 55 which is essentially the insulator layer 54 surrounds.

5B FIG. 11 shows an exemplary cross-sectional schematic of an MCW, including a first electrode, in accordance with aspects of the present disclosure 51 , a second electrode 52 and an insulator layer 54 which is essentially an electrolyte 53 surrounds (in this example a liquid electrolyte) as described herein. In this example are the first electrode 51 and the second electrode 52 of separator membranes 57a respectively. 57b surrounded as described herein.

5C FIG. 10 shows another exemplary cross-sectional schematic of an MCW in accordance with aspects of the present disclosure. Similar to 5B shows 5c a first electrode 51 , a second electrode 52 and an insulator layer 54 which is essentially an electrolyte 53 (in this example a liquid electrolyte) as described herein. In this example there is only the second electrode 52 from a separator membrane 57b surrounded as described herein. It should be noted that in some examples, only the first electrode may be 51 is surrounded by a separator membrane (in 5C Not shown).

5D FIG. 10 shows another exemplary cross-sectional schematic of an MCW in accordance with aspects of the present disclosure. Similar to that 5B and 5C shows 5D a first electrode 51 , a second electrode 52 and an insulator layer 54 which is essentially an electrolyte 53 (in this example a liquid electrolyte) as described herein. In this example, neither may be the first electrode 51 the second electrode 52 from a separator membrane 57 surround. In this example, an individual separator membrane 501 between the first electrode 51 and the second electrode 52 be provided.

5E FIG. 10 shows another exemplary cross-sectional schematic of an MCW in accordance with aspects of the present disclosure. Similar to that 5B-5D shows 5E a first electrode 51 , a second electrode 52 and an insulator layer 54 which is essentially an electrolyte 53 surrounds as described herein. In this example, the electrolyte 53 be a solid and / or a gel electrolyte and therefore separator membranes may not be required.

Materials suitable for the electrolyte include, but are not limited to, mixtures of alkyl carbonates (e.g., ethylene carbonate (EC), dimethyl (DMC), diethyl (DEC), and ethyl methyl carbonates (EMC)) and LiPF ₆ as the electrolyte solution as well as gel and solid electrolytes.

Materials suitable for the insulator layer include, but are not limited to, non-conductive materials such as polymer-based materials. Exemplary non-conductive polymer-based materials include plastics such as polyethylene.

Suitable materials for the conductive layer include, but are not limited to, materials capable of conducting alternating current, such as copper, nickel, aluminum, and alloys thereof. In one example, the conductive layer comprises 55 Copper. In some aspects, the thickness of the conductive layer can be 55 can be selected based on the frequency of the alternating current used. For example, alternating current at 60 Hz in copper has a skin depth of about 7 to 8.5 mm. For higher frequency alternating current, the thickness of the conductive layer can be thinner without adding a resistor. In some aspects, an intended current (amperage) can also determine a thickness of the conductive layer. In some aspects, the thickness of the conductive layer can be between about 1 mm to about 10 mm. However, the thickness of the conductive layer is not limited. An insulator layer can be applied over the conductive layer and further conductive layers can be applied over this insulator layer. For example, an electromagnetic shielding layer (or RF shielding layer) can be applied over the entire MCW, and this shielding layer can be covered with an insulator.

The depth to which alternating current penetrates a conductor can be defined by a skin depth, which can be described as the depth at which the current is reduced to 37% of its surface area. The skin depth decreases with frequency. At low frequencies, where the skin depth is greater than the wire diameter, the skin effect is negligible and the current distribution and resistance are virtually the same as with DC. As the frequency increases and the skin depth becomes smaller than the wire diameter, the skin effect becomes significant, the current increasingly concentrates near the surface, and the resistance per unit length of the wire increases above its DC value. Non-limiting examples of skin depth in copper wire at different frequencies are: At 60 Hz, the skin depth of copper wire is about 0.3 inches (7.6 mm); at 60 kHz the skin depth of the copper wire is about 0.01 inches ( 0 , 25 mm); at 6 MHz the skin depth of the copper wire is about 0.001 in. ( 25th µm). Round conductors, such as wire or cable, that are more than a few skin depths in thickness do not conduct much current near their axis, so the metal located in the central part of the wire is not used effectively.

It should be noted that the cable or MCW according to the present disclosure, for example as shown in FIGS 5A-5D can function as both a conductor for alternating current (e.g. for use in an electric vehicle engine) and a battery. In particular, at least the first electrode, the second electrode and the electrolyte can together provide energy, while the conductive layer can transmit electrical current. The MCW disclosed herein can be used for direct current and can optionally switch from alternating current to direct current, direct current to alternating current, and can be used for any range of alternating current frequencies. In some aspects, the one or more conductive layers may include insulated conductors such that a conductive layer has multiple conductors therein. The MCW can have an additional MCW in any layer surrounding the MCW.

As in 5A As shown, the self-standing flexible electrodes can have one or more conductive battery tongues 58 which may provide an area for electrically connecting or securing the electrode to an external component or device. The conductive battery tongues can be used to connect an electrode to the conductive metal layer or the current carrying layer of an MCW. The conductive battery tongues can be attached to or embedded in the flexible self-standing electrodes in any way. The conductive battery tongues are not current collectors, for example a metal substrate for the electrode, which tends to peel off and break. The self-standing flexible electrodes disclosed herein can be free of current collectors and free of binders. In some aspects, the battery tab may include a different material at or near the attachment area on the flexible self-standing electrode and a different material external to or extending from the MCW. Battery tabs may be attached to the electrodes in accordance with aspects of the present disclosure, either on protrusions that extend from the main body of the respective electrode and do not overlap the other electrode; or on the main body of the respective electrode at cutouts of a separator membrane and the opposite electrode. In some aspects, battery tongues are embedded in the electrodes. Suitable battery tongue materials and fastening methods include those known to those of ordinary skill in the art. In some aspects, the conductive battery tabs can include copper or lead for the anode. In some aspects, the conductive battery tabs may include aluminum or lead for the cathode. In some aspects, the battery tongues may comprise a metal at or near an attachment to the electrode and another metal extending away from the electrode, for example a stretchable and flexible spring metal as a stretchable and flexible battery tongue attachment. In some aspects, they are flexible or inflexible battery tab fasteners 59 attached to the conductive battery tongues. The battery tongue fasteners 59 can be attached to the battery tabs by any means known in the art 58 be attached, for example by soldering, welding, pressing or interlocking components. The battery tongue fasteners 59 can be used to connect the electrodes to any external components, objects, or devices. The battery tongues 58 or battery tongue fasteners 59 can be used to connect the electrodes to one or more conductive layers or current carriers in the MCW. For example, the battery tabs or battery tab fasteners may be connected to a component that is used to convert direct current to alternating current, and may also be connected to a conductive layer. The battery tongues 58 or battery tongue fasteners 59 may be at one or more exposed ends of the MCW, or at any location along the MCW. In some aspects, a length of an MCW can include multiple battery tongues 58 or battery tongue fasteners 59 include.

Any electrical device or object may include the MCW as described herein, including, for example, an electric vehicle engine. Conventional electric vehicle motors, such as the one in 6A shown electric motor 61 generally require external batteries 62A and 62B to generate a torque via induced electromagnetic fields. As in 6A shown, can such Electric motors generally have copper coils 63 which transmit electric current which generates a magnetic field and / or which accumulate electric current which is induced by an external magnetic field. In some aspects, an MCW can replace solid copper wires in the copper coils 63 be used; the MCW may have an outer square or rectangular shape to improve nesting in a winding of a coil in an electrical device.

6B Figure 13 shows an illustrative aspect of the present disclosure, particularly an electric vehicle engine 601 . As in 6B shown can be an electric vehicle engine 601 one or more MCW coils 602 instead of one or more of the copper coils 63 which are generally provided in conventional electric vehicle engines (such as in 6A shown). The one or more MCW coils 602 may include an MCW coil having a configuration such as that shown in relation to FIG 5A is described. The MCW coil can have two electrodes 603 in a twisted configuration, an electrolyte 604 , an insulator layer 605 , a conductive layer 606 and a battery tongue attachment 59 include, as in relation to 5A described. In some aspects, the MCW coils 602 be configured to transmit electrical power as well as the electric vehicle engine 601 partially or fully supplied with energy, which reduces or eliminates the need for an external battery (for example in 6A external batteries shown 62A and 62B) . The in 6B shown electric motor 61 FIG. 10 is a non-limiting example and may represent a solenoid, a generator, an alternator, and a transformer, all of which include an MCW in accordance with various aspects of the present disclosure.

In one example, the electric vehicle motor according to the present disclosure may include a stator having one or more stator coils and a rotor. In some aspects, at least a portion of the one or more stator coils may include an MCW coil as described herein. Additionally or alternatively, the rotor may comprise one or more rotor coils, wherein at least a portion of the one or more rotor coils comprises an MCW coil, as described herein. The electric vehicle motor may further include, for example, a commutator that is provided in electrical communication with the one or more rotor coils and a brush that contacts the commutator.

A non-limiting example of an electric vehicle engine useful in accordance with the present disclosure is described in U.S. Patent Publication No. 2019/068033 A1, the disclosure of which is incorporated herein in its entirety. It should be noted that the motor described in US Patent Publication No. 2019/068033 A1 may include one or more MCW coils of the present disclosure in addition to the coils described therein. For example, a permanent magnet of the stator can be formed or replaced by a stator coil that includes an MCW coil that serves as a permanent magnet. Additionally or alternatively, one or more of the coils described in US Patent Publication No. 2019/068033 A1 can be replaced by one or more MCW coils in accordance with the present disclosure.

The present disclosure is also directed to methods of using the carbon nanotube composite yarns made according to the methods described herein. For example, a method may include making an article or device as described herein comprising the carbon nanotube composite yarns. For example, the method may include weaving the carbon nanotube composite yarns to provide an e-textile. The method may include manufacturing an MCW or a cable as described herein. For example, the method may include providing a first electrode (e.g., an anode) and a second electrode (e.g., a cathode) in an optionally twisted configuration and separated by one or more separator membranes and / or an electrolyte, wherein each of the first and second electrodes individually comprises a carbon nanotube composite yarn as disclosed herein. The method can further include providing an electrolyte surrounding the first and second electrodes, providing an insulator layer surrounding the electrolyte, and providing a conductive layer surrounding the insulator layer.

In some aspects, a method of making an MCW may include: providing a first flexible electrode comprising a first carbon nanotube composite yarn containing carbon nanotubes and a first secondary material (e.g., first secondary particles); Providing a second flexible electrode which comprises a second carbon nanotube composite yarn which contains carbon nanotubes and a second secondary material (e.g. second secondary particles); optionally surrounding the first flexible electrode with a first separator membrane; optionally surrounding the second flexible electrode with a second separator membrane; Surrounding the first and second flexible electrodes with a Electrolytes; Surrounding the electrolyte with a flexible insulator layer; and at least partially surrounding the flexible insulator layer with a flexible conductive layer.

It should be noted that the steps described herein are not limited to any order. In the case of a liquid electrolyte, for example, the method of making the MCW may include providing a first flexible electrode and a second flexible electrode in a configuration as described herein (e.g., in a parallel, quasi-parallel, or twisted configuration), wherein the first flexible electrode and the second flexible electrode are provided with a first separator membrane and a second separator membrane, respectively, and / or an individual separator membrane is provided between the first flexible electrode and the second flexible electrode, as described herein. The method may further include providing the first and second flexible electrodes in an insulator layer, as described herein, and then surrounding the first and second flexible electrodes with an electrolyte, as described herein. In this example, a flexible conductive layer can be provided before, during, or after any step described herein.

In another example, in the case of a solid or gel electrolyte, the method of making the MCW may include providing the electrolyte in conjunction with (e.g., on a surface of and / or immersed in) a first flexible electrode and a second flexible electrode wherein the first flexible electrode and / or the second flexible electrode are provided independently with or without a first separator membrane and a second separator membrane, respectively. It should be noted that the first separator membrane and / or the second separator membrane can be provided independently of one another before, during and / or after the electrolyte is provided, or that the first separator membrane and / or the second separator membrane can be removed. The method may further include subsequently providing the first electrode and the second electrode in a configuration as described herein (e.g. in a parallel, quasi-parallel, or twisted configuration). In this example, the first and second electrodes can be provided in an insulator layer before, during, or after they are provided in their final configuration. Additionally, in this example, a flexible conductive layer can be provided before, during, or after any step described herein.

In some aspects, providing a flexible conductive layer as described herein can be performed using any technique suitable in accordance with the present disclosure. For example, the flexible conductive layer can be provided using an electrodeposition technique, an electroplating technique, or a combination thereof. As an example and not by way of limitation, the flexible conductive layer may be provided using an electroplating technique that includes providing an electrical current that causes dissolved metal ions to adhere to a surface, for example the surface of an insulator layer, as described herein. As another non-limiting example, the flexible conductive layer may be provided as a preformed structure (e.g., a preformed elongated hollow body, such as a tube) in which a first flexible electrode, a second flexible electrode, a first Separator membrane, a second separator membrane, an electrolyte and / or a flexible insulator layer can be provided as described herein.

Methods of assembling an article or device comprising a multifunctional conductive wire (MCW) are disclosed herein. For example, attaching an MCW to one or more electrical components of a device can assemble a device comprising an MCW, wherein the MCW can provide current carrying capacity concurrently with providing or storing energy for a device. Winding an MCW into a coil, optionally a metal core coil, and attaching the coil to a component can assemble a device or article comprising an MCW. According to some aspects, a device or an article comprising an MCW can be assembled by attaching an MCW as a power carrier and an energy source and / or an energy store for a component of a device or an article.

A device or article comprising an MCW may use an MCW with a specific thickness of a conductive layer. In some aspects, the thickness of a conductive layer can be determined according to the AC frequency in a device. With direct current, the resistance of a solid metal conductor depends on its cross-sectional area; a conductor with a larger area has less resistance for a given length. At high frequencies, alternating current does not penetrate deep into conductors due to eddy currents induced in the material; it tends to flow near the surface, known as the skin effect. Because less of the cross-sectional area of the wire is used, the resistance of the wire is greater than that of direct current. The higher the frequency of the current, the more the depth to which the current penetrates is less and the current is conducted in an increasingly smaller cross-sectional area along the surface, so that the AC resistance of the wire increases with frequency.

This detailed description uses examples to illustrate the disclosure, including the preferred aspects and variations, and to enable any person skilled in the art to practice the disclosed aspects, including making and using any devices or systems and performing any included methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. Aspects from the various described embodiments, as well as other known equivalents for each of these aspects, can be mixed and matched by one of ordinary skill in the art to construct additional embodiments and techniques in accordance with the principles of this application.

In some aspects, various electrical devices may include an MCW to make an electrical device more efficient, for example with a greater energy-to-weight ratio, with energy storage capability without an external battery, or with energy provided by the MCW. While the aspects described herein have been described in conjunction with the exemplary aspects outlined above, various alternatives, modifications, variations, improvements, and / or substantial equivalents, whether known or presently unforeseen, may become apparent to those of ordinary skill in the art. Accordingly, the exemplary aspects set forth above are intended to be illustrative, not restrictive. Various changes can be made without departing from the spirit and scope of the disclosure. Therefore, the disclosure is intended to embrace all known or later developed alternatives, modifications, variations, improvements and / or substantial equivalents.

Any reference to an element in the singular is not intended to mean “only one”, unless specifically stated, but rather “one or more”. All structural and functional equivalents to the elements of the various aspects described in this disclosure that are known to those skilled in the art or later become known are expressly incorporated herein by reference. Furthermore, nothing disclosed here is intended to be devoted to the public.

Further, the word “example” is used herein to mean “serving as an example, instance, or illustration”. Any aspect described herein as an “example” is not necessarily to be construed as preferred or advantageous over other aspects. Unless otherwise specified, the term “some” refers to one or more. Combinations such as “at least one of A, B or C”, “at least one of A, B and C” and “A, B, C or any combination thereof” include any combination of A, B, and / or C and may a multiple of A, a multiple of B, or a multiple of C. In particular, combinations such as “at least one of A, B or C”, “at least one of A, B and C” and “A, B, C or any combination thereof” can only be A, only B, only C, A and B , A and C, B and C, or A and B and C, any such combination including one or more elements of A, B or C.

As used herein, the terms "about" and "approximately" are defined to mean close to as understood by one of ordinary skill in the art. In one non-limiting embodiment, the terms “about” and “approximately” are defined to mean within 10%, preferably within 5%, more preferably within 1%, and most preferably within 0.5%.

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

• US 62/813516 [0001]
• US 16/446389 [0001]
• US 16/805565 [0001]

Non-patent literature cited

• June 19, 2019, entitled "Composite Yarn and Method of Making a Carbon Nanotube Composite Yarn" [0001]
• February 28, 2020, entitled “Multifunctional Conductive Wire and Method of Making” [0001]

Claims (25)

An electrical device comprising: a multifunctional conductive wire, the multifunctional conductive wire comprising: an elongated hollow body comprising a conductive material; a first electrode comprising a first carbon nanotube composite yarn comprising carbon nanotubes and a first secondary material; a second electrode comprising a second carbon nanotube composite yarn comprising carbon nanotubes and a second secondary material, wherein the multifunctional conductive wire is operable to carry electricity and provide energy and / or store energy for the electrical device. Electrical device according to Claim 1 wherein the multifunctional conductive wire further comprises an electrolyte surrounding the first and second electrodes. Electrical device according to Claim 2 wherein the multifunctional conductive wire comprises a flexible insulator layer surrounding the electrolyte, and wherein the conductive material comprises a flexible conductive layer which at least partially surrounds the flexible insulator layer. Electrical device according to Claim 3 wherein the multifunctional conductive wire further comprises an outer flexible insulator layer surrounding the flexible conductive layer. Electrical device according to Claim 1 wherein the multifunctional conductive wire further comprises: one or more conductive battery tabs attached to the first electrode and / or the second electrode, and one or more respective battery tab attachments attached to the one or more conductive battery tabs. Electrical device according to Claim 1 wherein at least one of the first electrode and the second electrode is surrounded by a separator membrane, and wherein the first electrode and the second electrode are wrapped around each other in a twisted configuration. Electrical device according to Claim 1 wherein at least a portion of the multifunctional conductive wire is in a turn of one or more coils, each coil comprising a portion of the multifunctional conductive wire that is twisted in the shape of a spiral or helix. Electrical device according to Claim 7 wherein the portion of the multifunctional conductive wire in the winding of one or more coils has an outer square or rectangular shape, the outer square or rectangular shape being operable to nest the multifunctional conductive wire in the winding of one or more coils. Electrical device according to Claim 7 , wherein the winding of one or more coils surrounds a metal core. Electrical device according to Claim 3 wherein the flexible conductive layer has a thickness of about 1 micrometer to about 10 millimeters. Electrical device according to Claim 1 wherein the electrical device is selected from the group consisting of an electric motor, a solenoid, a generator, an alternator, and a transformer. Electrical device according to Claim 1 wherein the conductive material comprises a flexible conductive layer comprising copper. Electrical device according to Claim 6 wherein the first separator membrane and the second separator membrane are not in contact with each other. A method of making an electrical device comprising a multifunctional conductive wire, the method comprising: Providing a multifunctional conductive wire; Connecting the multifunctional conductive wire to an electrical device such that the multifunctional conductive wire is operable to carry current and provide energy and / or store energy for the electrical device. Procedure according to Claim 14 , further comprising winding at least a portion of the multifunctional wire in a turn of one or more coils, each coil comprising a portion of the multifunctional conductive wire twisted in the shape of a spiral or a helix. Procedure according to Claim 14 wherein providing the multifunctional conductive wire comprises: providing a first electrode comprising a first carbon nanotube composite yarn comprising carbon nanotubes and a first secondary material; and providing a second electrode comprising a second carbon nanotube composite yarn which comprises carbon nanotubes and a second secondary material. Procedure according to Claim 16 wherein providing the multifunctional conductive wire further comprises: surrounding the first and second electrodes with an electrolyte; Surrounding the electrolyte with a flexible insulator layer; at least partially surrounding the flexible insulator layer with a flexible conductive layer and surrounding the flexible conductive layer with an outer flexible insulator layer. Procedure according to Claim 17 wherein providing the multifunctional conductive wire further comprises: attaching one or more conductive battery tabs to the first electrode and / or the second electrode; and attaching one or more respective battery tab fasteners to one or more of the conductive battery tabs. Procedure according to Claim 16 wherein providing the multifunctional conductive wire further comprises: surrounding at least one of the first electrode and the second electrode with a separator membrane; and winding the first electrode and the second electrode around each other in a twisted configuration. Procedure according to Claim 16 wherein providing the first electrode comprises: growing suspended carbon nanotubes in a reactor; Removing the floating carbon nanotubes from the reactor to provide a mat of carbon nanotubes; Depositing secondary particles comprising the first secondary material on at least a portion of the mat of carbon nanotubes to provide a carbon nanotube composite mat; and compacting the carbon nanotube composite mat to provide a carbon nanotube composite yarn. Electric motor, comprising: a rotor comprising one or more rotor coils; and a stator comprising one or more stator coils; wherein at least a portion of the one or more stator coils comprises a conductive wire; and wherein the conductive wire comprises: an elongated hollow body; a first flexible electrode positioned in the hollow body and comprising a first composite yarn comprising carbon nanotubes and a first secondary material; a second flexible electrode positioned in the hollow body and comprising a second composite yarn comprising carbon nanotubes and a second secondary material. Electric motor after Claim 21 wherein the conductive wire further comprises an electrolyte surrounding the first and second electrodes. Electric motor after Claim 22 wherein the conductive wire further comprises a flexible insulator layer surrounding the electrolyte, and wherein the conductive material comprises a flexible conductive layer which at least partially surrounds the flexible insulator layer. Electric motor after Claim 23 wherein the conductive wire further comprises an outer flexible insulator layer surrounding the flexible conductive layer. Electric motor after Claim 21 , further comprising a commutator in electrical communication with the one or more rotor coils and a brush that contacts the commutator.

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