Zyvex Performance Materials revolutionary new boat utilizing next generation carbon nanotube-enhanced prepreg composite materials weighs four times less and gets five times better fuel mileage compared to a similar sized fiber glass boat.
The 540SE is a technology demonstrator built entirely out of ZPM’s Arovex prepreg. The use of Arovex allows for a boat that is dramatically lighter, uses less fuel, and produces lower emissions.
Image Credit: Zyvex
Comparison | |
540SE Built with Arovex | Typical Fiberglass Boat |
10,000 pounds | 40,000 pounds |
520 hp | 1,600 hp |
15 gallons/hour @ 35MPH | 85 gallons/hour @ 35 MPH |
330 pounds CO2 emissions per hour | 1,865 pounds CO2 emissions per hour |
ZPM’s carbon nanotube functionalization technology increases the mechanical properties of fibers in prepregs. The increased mechanical properties reduce the weight of the structural requirements for a boat hull. Arovex is a 250°F cure, carbon nanotube strengthened prepreg system suitable for numerous composites applications.
Polymer composites offer several advantages compared to metals and ceramics in that polymer composites are lightweight, have high specific stiffness and strength, are easy to manufacture, have tailorable properties for different applications and have a low coefficient of thermal expansion.
Such polymer composites, however, have disadvantages compared to metals and ceramics. For instance, while polymer composites can be used as structural materials to absorb loads and stresses they do not possess any additional functionality such as electrical or thermal conductivity
Such polymer composites, however, have disadvantages compared to metals and ceramics. For instance, while polymer composites can be used as structural materials to absorb loads and stresses they do not possess any additional functionality such as electrical or thermal conductivity
Zyvex Performance Materials, LLC (Columbus, Oh) in U.S. Patent Application 20100009165 provides insight into their method for making multifunctional nanomaterial-containing composites that overcome polymer composite shortcomings. The nanomaterial containing composites haven additional and enhanced physical properties including tensile strength, tensile modulus, impact resistance, compression strength, high electrical conductivity, and high thermal conductivity. These are the type of materials used in the Arovex.
According to inventors Pritesh Patel, Jian Chen and Gobinath Balasubramaniyam the methods of nincorporation of nanomaterials into such composites is accomplished in one of two manners: 1) in a solution of dispersed nanomaterials for coating onto a substrate; and 2) by dispersing nanomaterials in a matrix material, such as epoxy, applied to a single substrate layer or sandwiched between adjacent layers in a multiple layer composite. The methods permit loading of carbon nanotubes and other nanomaterials in polymers in proportions as high as 30% of weight.
According to /Zyvex methods, a high loading of nanomaterials may be incorporated into the composites without any deterioration in processing or handling properties.
FIG. 2 is a schematic view of a three roll mill apparatus for improving the dispersion of carbon nanotubes in resin.
FIG. 3 is a scanning electron microscopy image of carbon nanotubes coated onto polyethylene fabric.
All the composites perform better in tensile modulus compared with the ultra high molecular weight polyethylene sheets. This is believed to be due to the oriented crystals in the composites (fibers).
FIG. 7 is a scanning electron microscopy image of raw nanotubes
FIG. 7 is a scanning electron microscopy image of raw nanotubes
The tensile modulus of the carbon nanotube composite and the radiated neat composite is higher than the unradiated neat composite. This shows the stiffening properties of carbon nanotubes and radiation.
FIG. 8 is a scanning electron microscopy image of polyphenyleneethynylene (PPE) dispersed nanotubes
The tensile modulus of the radiated neat composite increased by 61% compared to the unradiated neat composite. This is believed to be due to the cross-linking of the polyethylene and epoxy interface. The radiation is believed to oxidize the hydrogen atoms of the polyethylene to groups that are more hydrophilic which leads to better bonding with the epoxy at their interface.
By adding the carbon nanotubes to the composite (unradiated neat composite vs. unradiated carbon nanotube composite) the tensile modulus increased by 36%.
By adding the carbon nanotubes to the composite (unradiated neat composite vs. unradiated carbon nanotube composite) the tensile modulus increased by 36%.
One possible reason may be that the addition of carbon nanotubes acts as an effective reinforcement as shown in FIG. 9. Also, if the carbon nanotube composites are radiated, the tensile modulus does not change as much compared to the unradiated carbon nanotube composites.
FIG. 9 shows scanning electron microscopy images showing nanotubes bridging a crack under stress
FIG. 9 shows scanning electron microscopy images showing nanotubes bridging a crack under stress
The mixing and compounding method may be used with multi-wall carbon nanotubes, multi-wall boron nitride nanotubes, single-wall carbon nanotubes, single-wall boron nitride nanotubes, carbon nanoparticles, boron nitride nanoparticles, carbon nanofibers, boron nitride nanofibers, carbon nanoropes, boron nitride nanoropes, carbon nanoribbons, boron nitride nanoribbons, carbon nanofibrils, boron nitride nanofibrils, carbon nanoneedles, boron nitride nanoneedles, carbon nanosheets, boron nitride nanosheets, carbon nanorods, boron nitride nanorods, carbon nanohoms, boron nitride nanohoms, carbon nanocones, boron nitride nanocones, carbon nanoscrolls, boron nitride nanoscrolls, graphite nanoplatelets, nanodots, fullerene materials and combinations
