Composite material processing routinely uses continuous and/or woven fiber systems as reinforcement. This STTR project will develop continuous micron-size fibers made of single-walled carbon nanotubes aligned within a polymer binder. These fibers can be manipulated, layed up, processed in tows, wound, and even woven using current manufacturing expertise. Nanotubes are expected to have tremendous properties (strength, stiffness, thermal and electrical conductivity, etc.) and to be of practical use when well aligned. This project will produce nanotubes in a configuration that will realize such expectations. The proposers have already produced prototype fibers of micron size using vapor grown carbon mulitwall tubes mixed with a polymer. The prototypes demonstrate an easy way of delivering nanotubes which easily can be chemically and physically manipulated. The focus of this project will be to optimize the single-wall nanotube continuous fiber for improved strength so that polymer nanocomposites can be subsequently developed based on these new fibers. The goal of the over-all product development (Past Phase I-II) is to produce a range of nanotube continuous fibers that optimize structural, electronic and thermal properties. Potential Commercial Application(s) The exemplary properties of carbon nanotubes are well known but utility in materials science has been limited due to the minimal knowledgebase at nanoscale manipulation. The deliverables of this proposal will have a direct market inlet into advanced composites manufacturing and their products, with a US market estimated at 10 billion USD. In addition, NCFs will contribute to unique products in thermal and electrical management composites.
