Mark R. Haase

In this paper, we present the results of a study related to fabrication of polymer-aligned carbon nanotube (CNT) composites made with different thermoplastic polymers. These composites have been manufactured by employing a simple two-step process using the internal resistive heating approach. The resulting composites have shown improved tensile strength, load, and elastic modulus compared to pristine CNT sheets. Poly (methyl methacrylate) (PMMA)-CNT, Ultem^TM-CNT and thermoplastic polyurethane (TPU)-CNT composites showed an increase in tensile strength by as much as 41%, 77% and 86% respectively over pristine CNT sheets. The improvement in tensile strength is the result of a good adhesion achieved between the aligned CNTs and polymer as observed with transmission electron microscopy (TEM) and scanning electron microscopy (SEM).

Individual Carbon Nanotubes (CNTs) have a great mechanical strength that needs to be transferred into macroscopic fiber assemblies. One approach to improve the mechanical strength of the CNT assemblies is by creating covalent bonding among their individual CNT building blocks. Chemical cross-linking of multiwall CNTs (MWCNTs) within the fiber has significantly improved the strength of MWCNT thread. Results reported in this work show that the cross-linked thread had a tensile strength six times greater than the strength of its control counterpart, a pristine MWCNT thread (1192 MPa and 194 MPa, respectively). Additionally, electrical conductivity changes were observed, revealing 2123.40 S·cm⁻¹ for cross-linked thread, and 3984.26 S·cm⁻¹ for pristine CNT thread. Characterization suggests that the obtained high tensile strength is due to the cross-linking reaction of amine groups from ethylenediamine plasma-functionalized CNT with the epoxy groups of the cross-linking agent, 4,4-methylenebis(N,N-diglycidylaniline).

Carbon nanotubes (CNTs) are considered the most promising candidates to replace Cu and Al in a large number of electrical, mechanical and thermal applications. Although most CNT industrial applications require macro and micro size CNT fiber assemblies, several techniques to make conducting CNT fibers, threads, yarns and ropes have been reported to this day, and improvement of their electrical and mechanical conductivity continues. Some electrical applications of these CNT conducting fibers require an insulating layer for electrical insulation and protection against mechanical tearing. Ideally, a flexible insulator such as hydrogenated nitrile butadiene rubber (HNBR) on the CNT fiber can allow fabrication of CNT coils that can be assembled into lightweight, corrosion resistant electrical motors and transformers. HNBR is a largely used commercial polymer that unlike other cable-coating polymers such as polyvinyl chloride (PVC), it provides unique continuous and uniform coating on the CNT fibers. The polymer coated/insulated CNT fibers have a 26.54 μm average diameter—which is approximately four times the diameter of a red blood cell—is produced by a simple dip-coating process. Our results confirm that HNBR in solution creates a few microns uniform insulation and mechanical protection over a CNT fiber that is used as the electrically conducting core.