Dispersion of Carbon Nanotubes in Polymers

Carbon nanotubes (CNTs) show promise for multifunctional materials for a range of applications due to their outstanding combination of mechanical, electrical and thermal properties. However, these promising mechanical properties have not translated well to CNT nanocomposites fabricated by conventional methods due to the weak load transfer between tubes or tube bundles. In this invention, the carbon nanotube forms such as sheets and yarns were modified by in-situ polymerization with polyaniline, a -conjugated conductive polymer. The resulting CNT nanocomposites were subsequently post-processed to improve mechanical properties by hot pressing and carbonization. A significant improvement of mechanical properties of the polyaniline/carbon nanotube nanocomposites was achieved through a combination of stretching, polymerization, hot pressing, and carbonization.

The new composite developed by NASA incorporates PGS and CNTs to enhance its thermal conductivity while preserving the mechanical properties of the underlying carbon fiber polymer composite. NASA has also improved the composite manufacturing process to ensure better thermal conductivity not only on the surface, but also through the thickness of the material. This was achieved by adding perforations that enable the additives to spread through the composite. The process for developing this innovative, highly thermally conductive hybrid carbon fiber polymer composite involves several steps. Firstly, a CNT-doped polymer resin is prepared to improve the matrix's thermal conductivity, which is then infused into a carbon fiber fabric. Secondly, PGS is treated to enhance its mechanical interface with the composite. Thirdly, perforation is done on the pyrolytic graphite sheet to improve the thermal conductivity through the thickness of the material by allowing CNT-doped resin to flow and better interlaminar mechanical strength. Finally, the layup of PGS and CNT-CF polymer is optimized. Initial testing of the composite has shown significant increases in thermal conductivity compared to typical carbon fiber composites, with a more than tenfold increase. The composite also has higher thermal conductivity than aluminum alloys, with more than twice the thermal conductivity of the Aluminum 6061 typically used in the aerospace industry. For this new material, NASA has completed a proof-of-concept demonstration and work continues to use the material in a heat exchanger system and further characterize the properties including longevity and radiation impact analysis.

In Glenn's technique, SWCNTs are dispersed in a suitable solvent, such as N-methyl pyrollidinone, and the resulting suspension is saturated with oxygen gas. A singlet oxygen sensitizer is added and the resulting mixture is irradiated under a continuous flow of oxygen for many hours. The resulting oxidized tubes are recovered by filtering the suspension, washing them, and then drying them in a vacuum oven. Singlet oxygen is a highly reactive species and is known to add to a variety of aromatic carbons. Singlet oxygen is prepared by irradiating an oxygen saturated solution with ultraviolet light in the presence of a sensitizer. This method may also be suitable for use in oxidation of multi-wall carbon nanotubes and graphenes. This is an early-stage technology requiring additional development. Glenn welcomes co-development opportunities.

NASA's new material is a toughened triaxial braid made from ductile carbon nanotube (CNT) yarn hybridized with carbon fiber, which is ultimately used as reinforcement material to make toughened polymer matrix composites. The CNT yarn component of the reinforcement is solely responsible for adding toughness, while the processes used to optimize the fiber braiding parameters and tensile properties of the carbon fiber-CNT yarn hybrid tow material determine the overall improvement in tensile strength for resin impregnated fiber tows. Bundles of continuous carbon nanotube yarns are combined with a similar format of carbon fiber, yielding an easily scalable process. Advantages of the material include reduced cost by eliminating use of toughening agents, increased ability to conform to highly complex geometries, greater environmental stability compared to aramid fiber reinforcements such as Kevlar, and possibly decreased density. Many hybrid reinforcements exhibit interfacial compatibility issues, which could lead to premature failure via crack propagation at the polymer matrix interface. In contrast, chemical similarities between the CNT yarn and carbon fiber constituents impart NASA's hybrid reinforcement material with excellent interfacial compatibility. Potential applications include aerospace components, composite pressure vessels, wind turbine blades, automotive components, prosthetics, sporting equipment, construction reinforcement material, and other use-cases where strength-to-weight ratio is of utmost importance.

Various aerospace and terrestrial applications require lightweight materials with very high mechanical properties. Carbon nanotubes and graphene sheets have been found to be such materials. In addition, they have been found to have excellent electrical and thermal transport properties. However, retaining the excellent nanoscale properties, particularly mechanical and thermal transport, in bulk materials has proven to be challenging. In order for the nanotubes to be used in applications, they must be spun into yarn(s), sheet(s), and other macroscopic forms introducing relatively weak tube-to-tube and inter-bundle bonds. Also, the nanotubes tend to be entangled, and they therefore do not all contribute in load bearing. Weak coupling at tube and bundle interfaces also leads to mechanical and thermal transport that are much lower than would be expected from the nanoscale carbon nanotube or graphene properties. This invention is for consolidated carbon nanotube or graphene yarns and woven sheets via the formation of a carbon binder formed from the dehydration of sucrose. The resulting materials are lightweight and possess a high specific modulus and/or strength on the macro-scale. Sucrose is relatively inexpensive and readily available, leading to a cost-effective route for achieving bulk nanotube/graphene based multifunctional material formats.