Mechanically strong, thermally stable, and electrically conductive nanocomposite structure and method of fabricating same

Abstract

A nanocomposite structure and method of fabricating same are provided. The nanocomposite structure is a polymer in an extruded shape with carbon nanotubes (CNTs) longitudinally disposed and dispersed in the extruded shape along a dimension thereof. The polymer is characteristically defined as having a viscosity of at least approximately 100,000 poise at a temperature of 200° C.

1 . A nanocomposite structure, comprising: 
 a polymer in an extruded shape, said polymer characteristically defined as having a viscosity of at least approximately 100,000 poise at a temperature of 200° C.; and    a plurality of carbon nanotubes (CNTs) longitudinally disposed and dispersed in said extruded shape along a dimension thereof.    
     
     
         2 . A nanocomposite structure as in  claim 1  wherein said CNTs comprise single-wall CNTs (SWCNTs).  
     
     
         3 . A nanocomposite structure as in  claim 1  wherein said CNTs comprise single-wall CNTs (SWCNTs) having diameters on the order of nanometers.  
     
     
         4 . A nanocomposite structure as in  claim 3  wherein said SWCNTs have a length-to-diameter aspect ratio of at least 100.  
     
     
         5 . A nanocomposite structure as in  claim 1  wherein said CNTs comprise one of a weight percent and volume percent thereof not to exceed approximately 5%.  
     
     
         6 . A nanocomposite structure as in  claim 1  wherein said CNTs comprise single-wall CNTs (SWCNTs) in one of a weight percent and volume percent thereof not to exceed approximately 1%.  
     
     
         7 . A nanocomposite structure as in  claim 1  wherein said extruded shape is a fiber and said dimension is the length of said fiber.  
     
     
         8 . A nanocomposite structure, comprising: 
 a polymer in the form of an extruded fiber, said polymer characteristically defined as having a viscosity of at least approximately 100,000 poise at a temperature of 200° C.; and    a plurality of single-wall carbon nanotubes (SWCNTs) in one of a weight percent and volume percent not to exceed approximately 1% of said nanocomposite structure, said SWCNTs longitudinally disposed and dispersed in said extruded fiber along a length thereof.    
     
     
         9 . A nanocomposite structure as in  claim 8  wherein said CNTs comprise single-wall CNTs (SWCNTs) having diameters on the order of nanometers.  
     
     
         10 . A nanocomposite structure as in  claim 8  wherein said SWCNTs have a length-to-diameter aspect ratio of at least 100.  
     
     
         11 . A method of fabricating a nanocomposite structure, comprising the steps of: 
 providing a polymer characteristically defined as having a viscosity of at least approximately 100,000 poise at a temperature of 200° C.;    mixing carbon nanotubes (CNTs) with said polymer at a temperature of at least 200° C. to form a viscous mixture;    flowing an inert gas through said viscous mixture to purge oxygen therefrom during said step of mixing;    cooling said viscous mixture wherein a solid form of said viscous mixture is generated;    breaking said solid form into pieces not to exceed approximately 0.125 inches in diameter; and    converting said pieces into an extruded shape in which said CNTs are longitudinally aligned along a dimension of said extruded shape.    
     
     
         12 . A method according to  claim 11  wherein said extruded shape is a fiber and said dimension is the length of said fiber.  
     
     
         13 . A method according to  claim 11  wherein said inert gas is selected from the group consisting of argon, helium and nitrogen.  
     
     
         14 . A method according to  claim 11  wherein said step of breaking comprises a step selected from the group of pulverizing said solid form and pelletizing said solid form.  
     
     
         15 . A method according to  claim 11  wherein said step of converting comprises the steps of: 
 collecting said pieces in a storage hopper;    flowing an inert gas through said pieces in the storage hopper to purge oxygen from spaces between said pieces; and    depositing said pieces from the hopper in a temperature-controlled extruder wherein said extruded shape is output therefrom.    
     
     
         16 . A method according to  claim 11  wherein said CNTs comprise one of a weight percent and volume percent thereof not to exceed approximately 5% of said viscous mixture.  
     
     
         17 . A method according to  claim 11  wherein said CNTs comprise single-wall CNTs (SWCNTs) in one of a weight percent and volume percent thereof not to exceed approximately 1% of said viscous mixture.  
     
     
         18 . A method of fabricating a nanocomposite structure, comprising the steps of: 
 providing a polymer characteristically defined as having a viscosity of at least approximately 100,000 poise at a temperature of 200° C.;    mixing carbon nanotubes (CNTs) with said polymer at a temperature of at least 200° C. to form a viscous mixture;    flowing a first inert gas through said viscous mixture to purge oxygen therefrom during said step of mixing;    cooling said viscous mixture wherein a solid form of said viscous mixture is generated;    breaking said solid form into pieces not to exceed approximately 0.125 inches in diameter;    collecting said pieces in a storage hopper;    flowing a second inert gas through said pieces in said storage hopper to purge oxygen from spaces between said pieces; and    depositing said pieces from said hopper in a temperature-controlled extruder that forms an extruded fiber in which said CNTs are longitudinally aligned along the length thereof.    
     
     
         19 . A method according to  claim 18  wherein each of said first inert gas and said second inert gas is selected from the group consisting of argon, helium and nitrogen.  
     
     
         20 . A method according to  claim 18  wherein said step of breaking comprises a step selected from the group of pulverizing said solid form and pelletizing said solid form.  
     
     
         21 . A method according to  claim 18  wherein said CNTs comprise one of a weight percent and volume percent thereof not to exceed approximately 5% of said viscous mixture.  
     
     
         22 . A method according to  claim 18  wherein said CNTs comprise single-wall CNTs (SWCNTs) in one of a weight percent and volume percent thereof not to exceed approximately 1% of said viscous mixture.