SBIR Phase II: Advanced Polymer Matrix Composites Based on Nanofiber Fused Microfiber Architecture

这个小型企业创新研究(SBIR)第二阶段项目将开发和表征一种使用连续纳米纤维熔融-超细纤维(NF2-M)增强技术的新型聚合物基复合材料。在这一专利方法中，碳纳米纤维以连续的方式直接从连续长丝的表面(以丝束的形式引入)在连续的、容易缩放的过程中生长。与传统方法不同，传统方法需要在非常低的加入量和可疑的分散度下将纳米碳纤维引入基质树脂中，这种方法产生连续的三维增强网络，使用标准制造技术很容易将其并入复合材料中，包括纤维缠绕和预浸料湿法铺设工艺。不需要额外的或修改的复合材料制造步骤。这项技术具有巨大的商业应用潜力。该项目的广泛/商业影响有三个方面：1)为材料科学研究中的新技术奠定基础；2)利用基本发现开发和设计使能材料，以满足当前和未来工业日益增长的需求；以及3)提供一种低成本、商业可用的高性能碳纤维增强技术，有可能改变复合材料行业的面貌。到2011年，全球增强碳纤维的市场预测为每年约122亿美元，该项目的方法可以利用众多现有市场，如体育用品、电子产品、消费品、商业航空航天和汽车行业。

This Small Business Innovation Research (SBIR) Phase II project will develop and characterize a novel class of polymer matrix composite materials using a continuous NanoFiber Fused-Microfiber (Nf2-M) reinforcement technology. This patented approach, carbon nanofibers are grown in a continuous manner directly from the surface of continuous filaments (introduced in tow form) in a continuous, easily scaled process. Unlike traditional approaches which involve difficult mixing operations to introduce carbon nanofibers into the matrix resin at very low loading levels and with questionable dispersion, this approach produces continuous three-dimensional reinforcement networks which are easily incorporated into composites using standard fabrication techniques, including filament winding and prepreg wet lay-up processes. No additional or modified composite fabrication steps are needed. This technology has enormous potential for a multitude of commercial applications. The broader/commercial impact of this project are threefold: 1) providing a foundation for a new technology in materials science research; 2) utilizing the fundamental findings to develop and engineer enabling materials to meet growing needs in industry for current and future applications; and 3) providing a low cost, commercially available, high performance carbon fiber reinforcement technology that has the potential to change the face of the composite materials industry. Global market forecast for reinforcing carbon fibers is ~$12.2 billion annually by 2011, and the approach of this project can take advantage of the multitude of existing markets, such as sporting goods, electronics, consumer products, commercial aerospace and automotive industries.