Industrial Production Methods for Ultra-High-Strength Fibers based on Double-Walled Carbon Nanotubes

This project will complete development of a viable, cost-effective industrial production technique for producing ultrastrong, flexible and tough carbon fibers composed of double-walled carbon nanotubes (DWNTs) and of a small amount of a polymer, based on a continuous manufacturing process. This will be done by refining MERs innovative technology for the efficient continuous production of unique forms of DWNT yarns directly from aerosol generated in the floating catalyst CVD reactor and by applying mechanical, chemical, thermal and e-beam irradiation treatments of these yarns containing a polymer matrix acquired in the CVD process or added in the post-CVD processing, to ultimately enhance the load transfer between the nanotubes in the optimally twisted and stretched fibers, which are composed of very long and defect-free nanotubes. The DWNT fibers currently revealing the record breaking strength and toughness will be subjected to these post synthesis or on-line treatments to optimally crosslink the polymer matrix and graft it to the nanotube surface, so as to achieve the resulting fiber strength well above that of high performance commercial fibers with concomitant improvement in modulus and toughness, while providing an acceptable level of flexibility for further use in advanced textiles manufacture and other important structural applications.