SBIR-STTR Award

This project is to address the feasibility of manufacturing carbon nanotube (CNT) fiber that can replace copper wire for electrical power applications in the Air Force. The proposed work will focus on three critical aspects for fiber production that we believe are unique, and that will allow mass production of high quality electrical fiber. The approaches we selected to attack this scientific and technological challenge are: (1) synthesis of large area, cm long multi-wall carbon nanotubes (MWCNT) using our novel composite catalysts for which a US patent is pending; (2) spinning long MWCNT into fiber based on existing and widely available industrial spinning technology which is only possible by using cm long nanotubes; and (3) post treatment of the produced CNT fibers for improved electrical conductivity. In practice, MWCNT and hence electrical fiber will always contain defects. A post treatment step integrated within the spinning procedure and based on thermal and plasma annealing is chosen to heal defects and improve the strength and conductivity of the fiber. Electrical fiber after such treatment is expected to be highly electrically conductive, and also flexible, bendable, fatigue resistant, and load bearing for multifunctional applications. All these fiber properties will be vigorously characterized.

Keywords:
Carbon Nanotubes, Super Long Cnt Arrays, Synthesis, Spinning, Manufacturing Of Electrical Cnt Fibers, Post Treatment, Electrical Properties, Electric Power Application.

The objectives of the Phase II project are to optimize nanotube fabrication techniques, scale up production of long carbon nanotubes, spin the nanotubes into electrical fiber that is stronger and lighter than copper wire, and form carbon electronic components that can be integrated into electrical power system applications. Three unique technologies are being developed that will allow mass production of high quality electrical fiber and components: (i) synthesis of centimeters long double wall carbon nanotubes called Black CottonTM using a revolutionary approach consisting of a composite catalyst, a nozzle substrate, and a specially designed nanofurnace; (ii) post treatment to heal defects and improve the properties of Black Cotton; and (iii) spinning Black Cotton into fiber using existing and widely available industrial cotton spinning technology which is only possible using long nanotubes. Our vision for the Phase II project is not just to show that one company can scale up production of electrical fiber, but, more preferably, to start a whole new industry where any company can purchase a commercial nanofurnace, license the technology to grow Black Cotton, and begin producing electrical fiber and components using two-thousand year old cotton spinning technology.

Benefits:
Carbon nanotube spun fiber will provide many benefits including strengthening the defense of the United States, improving the US economy, increasing transportation safety, opening up exploration of space, and providing new electronic materials for nanomedicine.

Keywords:
Long Carbon Nanotubes, Black Cotton, Electrical Fiber And Components, Composite Catalyst, Industrial Cotton Spinning