Abstract: Methods and apparatuses for continuous, large scale, commercially viable production of nanoforests. A roll-to-roll process passes a flexible substrate, including fibers and fabrics, through a furnace. Precursors are introduced in a growth zone in which a vertical or horizontal nanoforest of nanotubes or nanowires is grown on the substrate. Sensors and actuators with feedback control are provided for parameters such as substrate speed, substrate tension, furnace temperature, precursor flow rate, nanoforest thickness, and nanoforest. The furnace is preferably enclosed for environmental and safety purposes. The feed roll and take-up roll are disposed in housings can be attached to the furnace via airlocks, which enables rapid loading and unloading of the rolls using techniques well known in the industry while maintaining furnace conditions.

Abstract: A reinforcement for increasing the strength and toughness and other properties in both transverse and in-piano directions for a composite material, and methods of manufacture therefor. The reinforcement has a layer of a nanoforest of vertical nanotubes or nanowires and a layer of horizontal nanotubes or nanowires. The reinforcement can be made by rolling a vertical nanoforest to produce a collapsed layer of horizontal nanofubes or nanowires, then growing a vertical nanoforest on the collapsed layer. The reinforcement can be grown directly on fibers which are used to reinforce the composite material, or alternatively Interleaved with layers of those fibers before the composite part is cured. The reinforcement and manufacturing method are compatible with almost any composite material in any shape, including epoxy, polymer, or ceramic matrix composites, or any manufacturing method, including prepreg, wet-layup and matrix film stacking.

Abstract: A method of making a ceramic matrix composite (CMC) part such as armor, in which a mixture, including a preceramic polymer, particles such as ceramic microparticles and/or nanoparticles, and organic compounds such as a surfactant and a solvent, are mixed to form a paste and printed or molded. The part is then cured and densified by polymer infiltration and pyrolysis (PIP) using the preceramic polymer with a varying amount and size of ceramic particles and different temperatures in some of the cycles. The CMC can contain silicon carbide, boron carbide, boron suboxide, alumina, or any other ceramic. The process is compatible with sacrificial materials, enabling the creation of parts with hollow portions or overhangs. The mixture preferably has a high loading of particles, for example between 70 wt % and 90 wt % of the mixture, in order to minimize shrinkage. Curing and pyrolyzing the part can be performed by microwaving.

Abstract: A lightweight cargo container and methods of use, assembly, and repair are disclosed herein. Individual panels, frame components, base, and joints may be customized with composite materials to further improve strength-to-weight ratio. Some embodiments provide for a simplified manufacturing and assembly of cargo container, through standardization, while improving cost, time-to-produce, durability, and strength-to-weight ratios. The embodiments described herein provide a significant weight savings for all cargo containers, modern present-day composite containers included.

Abstract: A three-dimensional composite reinforcement, a three-dimensionally reinforced multifunctional nanocomposite, and methods of manufacture of each are disclosed. The three dimensional reinforcement comprises a two dimensional fiber cloth upon which carbon nanotubes have been grown, approximately perpendicular to the plane of the fiber cloth. The nanocomposite comprises the three-dimensional reinforcement and a surrounding matrix material. Examples illustrate improvements in the through-thickness mechanical, thermal, and electrical properties of the nanocomposite, in addition to substantial improvements in geometrical stability upon temperature changes and vibrational damping, compared to baseline composites reinforced with the two-dimensional fiber cloth alone.

Abstract: Embodiments of the present invention provide polymer matrix nanocomposites reinforced with nano-scale materials such as nanoparticles and carbon nanotubes and methods of fabricating. The nanomaterials are provided within relatively low weight fractions, for example in the range of approximately 0.01 to about 0.4% by weight and distributed within the matrix by a magnetic mixing procedure to provide substantially uniform reinforcement of the nanocomposites. Advantageously, these nanocomposites provide significantly enhanced tensile strength, strain to failure, and fracture toughness over corresponding neat matrices.

Abstract: Embodiments of the present invention provide polymer matrix nanocomposites reinforced with nano-scale materials such as nanoparticles and carbon nanotubes and methods of fabricating. The nanomaterials are provided within relatively low weight fractions, for example in the range of approximately 0.01 to about 0.4% by weight and distributed within the matrix by a magnetic mixing procedure to provide substantially uniform reinforcement of the nanocomposites. Advantageously, these nanocomposites provide significantly enhanced tensile strength, strain to failure, and fracture toughness over corresponding neat matrices.

Abstract: Embodiments of the present invention provide polymer matrix nanocomposites reinforced with nano-scale materials such as nanoparticles and carbon nanotubes and methods of fabricating. The nanomaterials are provided within relatively low weight fractions, for example in the range of approximately 0.01 to about 0.4% by weight and distributed within the matrix by a magnetic mixing procedure to provide substantially uniform reinforcement of the nanocomposites. Advantageously, these nanocomposites provide significantly enhanced tensile strength, strain to failure, and fracture toughness over corresponding neat matrices.

Abstract: A brush includes a microscale handle and nanostructure bristles, such as carbon nanotube bristles, located on at least one portion of the handle.

Abstract: Embodiments of the present invention provide polymer matrix nanocomposites reinforced with nano-scale materials such as nanoparticles and carbon nanotubes and methods of fabricating. The nanomaterials are provided within relatively low weight fractions, for example in the range of approximately 0.01 to about 0.4% by weight and distributed within the matrix by a magnetic mixing procedure to provide substantially uniform reinforcement of the nanocomposites. Advantageously, these nanocomposites provide significantly enhanced tensile strength, strain to failure, and fracture toughness over corresponding neat matrices.