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

This proposal seeks to develop a viable, cost-effective industrial technique for production of ultrastrong, flexible and tough carbon fibers composed of double-walled carbon nanotubes (DWNTs) combined with a small amount of polymer matrix, based on a continuous process for manufacturing these fibers. MER"s innovative technology for the efficient production of uniquely thin and highly twisted DWNT yarns directly from an aerogel generated in a floating catalyst CVD reactorwill be combined with electron irradiation treatments by our STTR partner Northwestern University. Such treatments cause crosslinking that will enhance the load transfer in these optimally twisted and stretched fibers, which are composed of very long, clean and defect-free nanotubes. These DWNT fibers currently demonstrate record breaking strength and toughness even without irradiation treatment. Post synthesis e-beam treatment can modify the polymer matrix, its interaction with the nanotube surface and the density of covalent crosslinks to significantly enhance the strength and toughness of the resulting fiber, while retaining an acceptable level of flexibility that will allow various industrial applications.