Carbon nanotube mass production: principles and processes

Our society requires new materials for a sustainable future, and carbon nanotubes (CNTs) are among the most important advanced materials. This Review describes the state-of-the-art of CNT synthesis, with a focus on their mass-production in industry. At the nanoscale, the production of CNTs involves the self-assembly of carbon atoms into a one-dimensional tubular structure. We describe how this synthesis can be achieved on the macroscopic scale in processes akin to the continuous tonne-scale mass production of chemical products in the modern chemical industry. Our overview includes discussions on processing methods for high-purity CNTs, and the handling of heat and mass transfer problems. Manufacturing strategies for agglomerated and aligned single-/multiwalled CNTs are used as examples of the engineering science of CNT production, which includes an understanding of their growth mechanism, agglomeration mechanism, reactor design, and process intensification. We aim to provide guidelines for the production and commercialization of CNTs. Although CNTs can now be produced on the tonne scale, knowledge of the growth mechanism at the atomic scale, the relationship between CNT structure and application, and scale-up of the production of CNTs with specific chirality are still inadequate. A multidisciplinary approach is a prerequisite for the sustainable development of the CNT industry.

Toughening of epoxy matrices with reduced single-walled carbon nanotubes

Reduced single-walled carbon nanotubes (r-SWCNT) are shown to react readily at room temperature under inert atmosphere conditions with epoxide moieties, such as those in triglycidyl p-amino phenol (TGAP), to produce a soft covalently bonded interface around the SWCNT. The soft interface is compatible with the SWCNT-free cross-linked cured matrix and acts as a toughener for the composite. Incorporation of 0.2 wt % r-SWCNT enhances the ultimate tensile strength, toughness and fracture toughness by 32, 118, and 40%, respectively, without change in modulus. A toughening rate (dK(IC)/dwt(f)) of 200 MPa m(0.5) is obtained. The toughening mechanism is elucidated through dynamic mechanical analyses, Raman spectroscopy and imaging, and stress-strain curve analyses. The method is scalable and applicable to epoxy resins and systems used commercially.