Potential release of carbon nanotubes from their composites during grinding

Quantitative assessment of nano-plastic aerosol particles emitted during machining of carbon fiber reinforced plastic

Focusing on the relatively unexplored presence of micro- and nano-plastic aerosol particles, this study quantitatively assessed the emission of nano-plastic particles during the machining of carbon fiber reinforced plastic (CFRP) in the working environment. Measurements of aerosol particles smaller than 1 µm in size were performed by aerosol mass spectrometry. The findings revealed that concentrations of carbonous aerosol particles (organic aerosol and refractory black carbon (rBC)) were higher during working hours than during non-working hours. Positive matrix factorization identified CFRP particles as a significant source, contributing an average of approximately 30% of concentration of carbonous aerosol particles during working hours. This source apportionment was corroborated by the presence of bisphenol A and F fragments, principal components of the epoxy resins used in CFRP, and was corroborated by similarities to the carbon cluster ion distribution observed in rBC during CFRP pipe-cutting operations. Further, the particle size distribution suggested the existence of plastic aerosol particles smaller than 100 nm. This study established the method to quantitatively distinguish nano-plastic aerosol particles from other aerosol particles in high temporal resolution and these techniques are useful for accurately assessing exposure to nano-plastic aerosol particles in working environments.

Key Role of the Dispersion of Carbon Nanotubes (CNTs) within Epoxy Networks on their Ability to Release

Carbon nanotube (CNT)-reinforced nanocomposites represent a unique opportunity in terms of designing advanced materials with mechanical reinforcement and improvements in the electrical and thermal conductivities. However, the toxic effects of these composites on human health have been studied, and very soon, some regulations on CNTs and on composites based on CNTs will be enacted. That is why the release of CNTs during the nanocomposite lifecycle must be controlled. As the releasing depends on the interfacial strength that is stronger between CNTs and polymers compared to CNTs in a CNT agglomerate, two dispersion states—one poorly dispersed versus another well dispersed—are generated and finely described. So, the main aim of this study is to check if the CNT dispersion state has an influence on the CNT releasing potential in the nanocomposite. To well tailor and characterize the CNT dispersion state in the polymer matrix, electronic microscopies (SEM and TEM) and also rheological analysis are carried out to identify whether CNTs are isolated, in bundles, or in agglomerates. When the dispersion state is known and controlled, its influence on the polymerization kinetic and on mechanical properties is discussed. It appears clearly that in the case of a good dispersion state, strong interfaces are generated, linking the isolated nanotubes with the polymer, whereas the CNT cohesion in an agglomerate seems much more weak, and it does not provide any improvement to the polymer matrix. Raman spectroscopy is relevant to analyze the interfacial properties and allows the relationship with the releasing ability of nanocomposites; i.e., CNTs poorly dispersed in the matrix are more readily released when compared to well-dispersed nanocomposites. The tribological tests confirm from released particles granulometry and observations that a CNT dispersion state sufficiently achieved in the nanocomposite avoids single CNT releasing under those solicitations.

Quantitative evaluation of carbon nanomaterial releases during electric heating wire cutting and sawing machine cutting of expanded polystyrene-based composites using thermal carbon analysis

Field measurements were conducted at a facility where expanded polystyrene-based carbon nanomaterial composites, namely, carbon nanotube and carbon black composites, were cut with an electric heating wire cutter or a circular sawing machine. The aerosol particles released during the cutting of the composites were measured using real-time aerosol monitoring, gravimetric analysis, thermal carbon analysis, and scanning electron microscopic observations. This study had two major goals: (1) to quantitatively evaluate the concentrations of airborne carbon nanomaterials during the cutting of their composites; (2) to evaluate the capability of thermal carbon analysis to quantify airborne carbon nanomaterials in the presence of expanded polystyrene-derived particles. The results of thermal carbon analysis showed that the concentrations of elemental carbon (an indicator of carbon nanomaterials) for all the respirable dust samples in both cutting processes were less than the limit of detection (∼2 µg/m³), which is nearly equivalent to or lower than the occupational exposure limits for carbon nanotubes (1 to 50 µg/m³). For total dust, which includes particles larger than respirable size, although the elemental carbon concentrations during heating wire cutting were low (<3 µg/m³), those during sawing machine cutting were up to 58 µg/m³. In scanning electron microscopic observations, micron-sized particles composed of or including carbon nanotubes were detected only in aerosol particles collected during the sawing machine cutting. Therefore, heating wire cutting is considered preferable. This study demonstrated that thermal carbon analysis can quantify airborne carbon nanomaterials in the presence of expanded polystyrene-derived particles.

Nano-object Release During Machining of Polymer-Based Nanocomposites Depends on Process Factors and the Type of Nanofiller

We tested the nanomaterial release from composites during two different mechanical treatment processes, automated drilling and manual sawing. Polyurethane (PU) polymer discs (1-cm thickness and 11-cm diameter) were created using different nanomaterial fillers: multiwall carbon nanotubes (MWCNT), carbon black (CB), silicon dioxide (SiO2), and an unfilled PU control. Drilling generated far more submicron range particles than sawing. In the drilling experiments, none of the tested nanofillers showed a significant influence on particle number concentrations or sizes, except for the PU/MWCNT samples, from which larger particles were released than from control samples. Higher drilling speed and larger drill bit size were associated with higher particle counts. Differences between composites were observed during sawing: PU/CB released higher number concentrations of micro-sized particles compared to reference samples. When sawing PU/SiO2 more nanoparticle agglomerates were observed. Furthermore, polymer fumes were released during sawing experiments, which was attributed to the process heat. For both drilling and sawing, the majority of the aerosolized particles were polymer matrix materials containing nanofillers (or protruding from their surface), as evidenced by electron microscopic analysis. Results suggest that: (i) processes associated with higher energy inputs are more likely to result in higher particle release in terms of number concentration; (ii) nanofillers may alter release processes; and (iii) other types of released particles, in particular polymer fumes from high-temperature processes, must also be considered in occupational exposure and risk assessments.

Exposures to nanoparticles and fibers during injection molding and recycling of carbon nanotube reinforced polycarbonate composites

In this study, the characteristics of airborne particles generated during injection molding and grinding processes of carbon nanotube reinforced polycarbonate composites (CNT-PC) were investigated. Particle number concentration, size distribution, and morphology of particles emitted from the processes were determined using real-time particle sizers and transmission electron microscopy. The air samples near the operator's breathing zone were collected on filters and analyzed using scanning electron microscope for particle morphology and respirable fiber count. Processing and grinding during recycling of CNT-PC released airborne nanoparticles (NPs) with a geometric mean (GM) particle concentration from 4.7 × 10³ to 1.7 × 10⁶ particles/cm³. The ratios of the GM particle concentration measured during the injection molding process with exhaust ventilation relative to background were up to 1.3 (loading), 1.9 (melting), and 1.4 (molding), and 101.4 for grinding process without exhaust ventilation, suggesting substantial NP exposures during these processes. The estimated mass concentration was in the range of 1.6-95.2 μg/m³. Diverse particle morphologies, including NPs, NP agglomerates, particles with embedded or protruding CNTs and fibers, were observed. No free CNTs were found during any of the investigated processes. The breathing zone respirable fiber concentration during the grinding process ranged from non-detectable to 0.13 fiber/cm³. No evidence was found that the emissions were affected by the number of recycling cycles. Institution of exposure controls is recommended during these processes to limit exposures to airborne NPs and CNT-containing fibers.

Review on the Processing and Properties of Polymer Nanocomposites and Nanocoatings and Their Applications in the Packaging, Automotive and Solar Energy Fields

For the last decades, nanocomposites materials have been widely studied in the scientific literature as they provide substantial properties enhancements, even at low nanoparticles content. Their performance depends on a number of parameters but the nanoparticles dispersion and distribution state remains the key challenge in order to obtain the full nanocomposites' potential in terms of, e.g., flame retardance, mechanical, barrier and thermal properties, etc., that would allow extending their use in the industry. While the amount of existing research and indeed review papers regarding the formulation of nanocomposites is already significant, after listing the most common applications, this review focuses more in-depth on the properties and materials of relevance in three target sectors: packaging, solar energy and automotive. In terms of advances in the processing of nanocomposites, this review discusses various enhancement technologies such as the use of ultrasounds for in-process nanoparticles dispersion. In the case of nanocoatings, it describes the different conventionally used processes as well as nanoparticles deposition by electro-hydrodynamic processing. All in all, this review gives the basics both in terms of composition and of processing aspects to reach optimal properties for using nanocomposites in the selected applications. As an outlook, up-to-date nanosafety issues are discussed.

Transformation of the released asbestos, carbon fibers and carbon nanotubes from composite materials and the changes of their potential health impacts

Composite materials with fibrous reinforcement often provide superior mechanical, thermal, electrical and optical properties than the matrix. Asbestos, carbon fibers and carbon nanotubes (CNTs) have been widely used in composites with profound impacts not only on technology and economy but also on human health and environment. A large number of studies have been dedicated to the release of fibrous particles from composites. Here we focus on the transformation of the fibrous fillers after their release, especially the change of the properties essential for the health impacts. Asbestos fibers exist in a large number of products and the end-of-the-life treatment of asbestos-containing materials poses potential risks. Thermal treatment can transform asbestos to non-hazardous phase which provides opportunities of safe disposal of asbestos-containing materials by incineration, but challenges still exist. Carbon fibers with diameters in the range of 5–10 μm are not considered to be respirable, however, during the release process from composites, the carbon fibers may be split along the fiber axis, generating smaller and respirable fibers. CNTs may be exposed on the surface of the composites or released as free standing fibers, which have lengths shorter than the original ones. CNTs have high thermal stability and may be exposed after thermal treatment of the composites and still keep their structural integrity. Due to the transformation of the fibrous fillers during the release process, their toxicity may be significantly different from the virgin fibers, which should be taken into account in the risk assessment of fiber-containing composites.

The Life Cycle of Engineered Nanoparticles

The first years in the twenty-first century have meant the inclusion of nanotechnology in most industrial sectors, from very specific sensors to construction materials. The increasing use of nanomaterials in consumer products has raised concerns about their potential risks for workers, consumers and the environment. In a comprehensive risk assessment or life cycle assessment, a life cycle schema is the starting point necessary to build up the exposure scenarios and study the processes and mechanisms driving to safety concerns. This book chapter describes the processes that usually occur at all the stages of the life cycle of the nano-enabled product, from the nanomaterial synthesis to the end-of-life of the products. Furthermore, release studies reported in literature related to these processes are briefly discussed.

Human exposure to carbon-based fibrous nanomaterials: A review

In an emerging field of nanotechnologies, assessment of exposure to carbon nanotubes (CNT) and carbon nanofibers (CNF) is an integral component of occupational and environmental epidemiology, risk assessment and management, as well as regulatory actions. The current state of knowledge on exposure to carbon-based fibrous nanomaterials among workers, consumers and general population was studied in frame of the International Agency for Research on Cancer (IARC) Monographs-Volume 111 "Some Nanomaterials and Some Fibres". Completeness and reliability of available exposure data for use in epidemiology and risk assessment were assessed. Occupational exposure to CNT/CNF may be of concern at all stages of the material life-cycle from research through manufacture to use and disposal. Consumer and environmental exposures are only estimated by modeled data. The available information of the final steps of the life-cycle of these materials remains incomplete so far regarding amounts of handled materials and levels of exposure. The quality and amount of information available on the uses and applications of CNT/CNF should be improved to enable quantitative assessment of human exposure to these materials. For that, coordinated effort in producing surveys and exposure inventories based on harmonized strategy of material test, exposure measurement and reporting results is strongly encouraged.

Characterization of Potential Exposures to Nanoparticles and Fibers during Manufacturing and Recycling of Carbon Nanotube Reinforced Polypropylene Composites

Carbon nanotube (CNT) polymer composites are widely used as raw materials in multiple industries because of their excellent properties. This expansion, however, is accompanied by realistic concerns over potential release of CNTs and associated nanoparticles during the manufacturing, recycling, use, and disposal of CNT composite products. Such data continue to be limited, especially with regards to post-processing of CNT-enabled products, recycling and handling of nanowaste, and end-of-life disposal. This study investigated for the first time airborne nanoparticle and fibers exposures during injection molding and recycling of CNT polypropylene composites (CNT-PP) relative to that of PP. Exposure characterization focused on source emissions during loading, melting, molding, grinding, and recycling of scrap material over 20 cycles and included real-time characterization of total particle number concentration and size distribution, nanoparticle and fiber morphology, and fiber concentrations near the operator. Total airborne nanoparticle concentration emitted during loading, melting, molding, and grinding of CNT-PP had geometric mean ranging from 1.2 × 10(3) to 4.3 × 10(5) particles cm(-3), with the highest exposures being up to 2.9 and 300.7 times above the background for injection molding and grinding, respectively. Most of these emissions were similar to PP synthesis. Melting and molding of CNT-PP and PP produced exclusively nanoparticles. Grinding of CNT-PP but not PP generated larger particles with encapsulated CNTs, particles with CNT extrusions, and respirable fiber (up to 0.2 fibers cm(-3)). No free CNTs were found in any of the processes. The number of recycling runs had no significant impact on exposures. Further research into the chemical composition of the emitted nanoparticles is warranted. In the meanwhile, exposure controls should be instituted during processing and recycling of CNT-PP.

Aerosol Emission Monitoring and Assessment of Potential Exposure to Multi-walled Carbon Nanotubes in the Manufacture of Polymer Nanocomposites

Recent animal studies have shown that carbon nanotubes (CNTs) may pose a significant health risk to those exposed in the workplace. To further understand this potential risk, effort must be taken to measure the occupational exposure to CNTs. Results from an assessment of potential exposure to multi-walled carbon nanotubes (MWCNTs) conducted at an industrial facility where polymer nanocomposites were manufactured by an extrusion process are presented. Exposure to MWCNTs was quantified by the thermal-optical analysis for elemental carbon (EC) of respirable dust collected by personal sampling. All personal respirable samples collected (n = 8) had estimated 8-h time weighted average (TWA) EC concentrations below the limit of detection for the analysis which was about one-half of the recommended exposure limit for CNTs, 1 µg EC/m(3) as an 8-h TWA respirable mass concentration. Potential exposure sources were identified and characterized by direct-reading instruments and area sampling. Area samples analyzed for EC yielded quantifiable mass concentrations inside an enclosure where unbound MWCNTs were handled and near a pelletizer where nanocomposite was cut, while those analyzed by electron microscopy detected the presence of MWCNTs at six locations throughout the facility. Through size selective area sampling it was identified that the airborne MWCNTs present in the workplace were in the form of large agglomerates. This was confirmed by electron microscopy where most of the MWCNT structures observed were in the form of micrometer-sized ropey agglomerates. However, a small fraction of single, free MWCNTs was also observed. It was found that the high number concentrations of nanoparticles, ~200000 particles/cm(3), present in the manufacturing facility were likely attributable to polymer fumes produced in the extrusion process.

Formulation effects on the release of silica dioxide nanoparticles from paint debris to water

Waterborne paints with integrated nanoparticles have been recently introduced into the market as nanoparticles offer improved or novel functionalities to paints. However, the release of nanoparticles during the life cycle of nano-enhanced paint has only been studied to a very limited extent. The paint composition could determine in what quantities and forms the nanoparticles are released. In this work, paint formulations containing the same amount of silicon dioxide (SiO2) nanoparticles but differing in the pigment volume concentration (PVC) and in amount and type of binder and pigment, were studied through leaching test to investigate the influence of these parameters on release of Si from paint. The results indicate greater release of Si, about 1.7 wt.% of the SiO2 nanoparticles in the paint, for paint formulated with higher PVC value (63%), suggesting that the PVC is a crucial factor for release of SiO2 nanoparticles from paints. This hypothesis was also based on the fact that agglomerates of SiO2 nanoparticles were only found in leachates from paint with higher PVC. A paint sample with the higher amount of binder and less calcite filler exhibited a lower release of Si among the paints with a low PVC value (35%), and no SiO2 particles were detected in leachates collected from this paint. This could be due to the fact that a high portion of binder forms a suitable matrix to hold the SiO2 ENPs in paint. The paint sample in which the amount of calcite was partially substituted with TiO2 pigment did not show an important reduction on Si release. Our work suggests that paint debris containing SiO2 nanoparticles may release a limited amount of Si into the environment, and that by adjusting the properties of the binder in combination with common pigments it is possible to reduce the release of SiO2 nanoparticles.