SBIR Phase I: Achieving Breakthrough Properties for Carbon Nanotube Yarn via Base Flow Chemical Vapor Deposition and Industrial Spinning

This Small Businesses Innovation Research (SBIR) Phase I project aims to synthesize ultra-long carbon nanotubes (CNT) and spin them into the yarns to achieve breakthrough properties of CNT yarns. The approach is to develop a base flow chemical vapor deposition (CVD) reactor, new porous substrates patterned using laser drilling and nano-imprint lithography, and separate gas flows to keep the catalyst alive. This technology will allow control of nanotube morphology which is not achievable using current semi-conductor processing technologies. The broader/commercial impacts of this project will be the potential to break the length record of long and aligned single-wall carbon nanotubes (SWCNT). Long CNT reduces the number of end junctions and the twist angle in yarns. This will make it possible to develop ultra-strong, lightweight and electrically conductive yarns which may have commercial applications in aerospace, apparel, composite and various segments of the medical industry.