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Cincinnati, OH, United States

Chan E.M.,General Nano, LLC
CAMX 2015 - Composites and Advanced Materials Expo

Over a decade ago, the National Nanotechnology Initiative was authorized by President Clinton at Caltech in 2000. A good deal of science and fundamentals were ascertained in this period at the nanoscale. Practitioners and investors have benefited with scientific insight. In recent years, nanomaterials are being described from a manufacturing or a macro perspective. In this presentation, General Nano will highlight our modular, continuous and flexible processes to deliver vertically aligned CNT rollstock and nonwoven rollstock at high volume throughput to afford systems level evaluation and applications. In early 2014, General Nano was awarded a Commercial Readiness Program by the Air Force to scale uniquely long and pure MWCNTs. To accelerate time to commercialization and to minimize capital expenditure, a strategy chosen and executed by General Nano were to decouple the rollstock manufacturing into three unit operations. A patent pending, liquid catalyst on continuous substrate was developed to replace an electron beam deposition process with similar quality (1 - 3 mm heights, G/D ∼1.0), significant throughput increase and cost reduction. The second unit operation is CNT synthesis. Precision chemical vapor deposition used for semiconductor fabrication is the norm. Our development team demonstrated growth on a moving belt using the liquid catalyst system. The kinetics was quantified to scale toward 10 - 100 kg/day. Lastly, rollstock manufacturing is a reengineered but standard roll-to-roll process. A provisional patent has also been filed. This process is foundational to tailorable electrical properties. Finally, application evaluations from aerospace to industrial durables will be presented. Copyright 2015. Used by CAMX - The Composites and Advanced Materials Expo with permission. Source

General Nano, LLC | Date: 2012-02-01

A method using of electrostatic spraying or dispersing processes and techniques for depositing a particulate material onto the outside surfaces of carbon nanotubes (CNTs) and CNT elongates consisting of the CNTs. The particulate material can include either or both particles and droplets, and the material can be an element, compound or composition, including polymers and thermoplastics. The particulate material is dispersed and induced with a static charge, while the CNT elongate is grounded.

Agency: Department of Defense | Branch: Air Force | Program: SBIR | Phase: Phase I | Award Amount: 99.77K | Year: 2011

Carbon Nanotube (CNT) technology has become a promising replacement for traditional copper, aluminum, and metallic based EMI shielding in power and data transmission cables. CNT materials offer the potential for significant weight reduction and improved mechanical performance. The proposed work plan encompasses a team that spans the entire cable and nanomaterial supply chain. Each team member will apply their individual core competencies to address the stated objective, which is to determine which type of cable(s) will be able to benefit from integrating nanomaterials. Specifically, the team will 1) integrate its proprietary CNT threads, ribbons, yarns and other derivative materials; 2) perform analysis and modeling, and 3) a technical and commercial feasibility assessment. BENEFIT: It is anticipated that the work performed in the proposed technical plan will result in identifying cables (e.g. data and/or power) that will benefit from replacing bulky metal-based EMI shielding with General Nano proprietary Carbon Nanotube (CNT) technology. By replacing incumbent metal-based materials with nanomaterials, significant weight reduction and improved mechanical performance will be achieved. Weight reduction yields major cost savings and improved mechanical performance yields improved form factor capabilities and durabilities.

Agency: Department of Defense | Branch: Navy | Program: STTR | Phase: Phase I | Award Amount: 100.00K | Year: 2011

Success growing long carbon nanotube arrays rests on the preparation of the catalytic substrate. Current best practices use a sputtering, oxidization, evaporation and annealing process to form catalyst particles. This natural self-assembly method is not the best approach. It creates substrates with too many variations, causing nanotubes to grow at different rates, lengths, and diameters, and causing defects and preventing nanotube arrays from achieving their growth potential. Proposed is a new nanomanufacturing approach - Substrate Engineering. In this approach, the catalytic substrate is designed to produce carbon nanotube arrays with a desired morphology. Van der Waals force engineering is used to optimize the geometry of catalyst wells. Chirality control will be attempted by matching catalyst well size to the diameter of armchair nanotubes. Novel techniques will be used to fabricate the substrate. Nanoimprint lithography will pattern the alumina buffer layer on the substrate with catalyst wells the same size throughout the substrate. Laser drilled holes in thin substrates will enable a new base flow chemical vapor deposition method to be used in conjunction with the patterned catalyst. Combinatorial studies using different mold patterns will determine the diameter, depth, and spacing of wells that produce long, high-quality nanotube arrays. It is anticipate that nanotube arrays produced from engineered substrates will permit advanced devices with the energy and power to outperform incumbent materials.

Agency: Department of Defense | Branch: Air Force | Program: SBIR | Phase: Phase II | Award Amount: 1.17M | Year: 2014

ABSTRACT: General Nano is partnering with Top 3 prime to develop next generation composite systems for air vehicles. The core technology involves integrating lightweight, conductive CNT non-woven sheet materials into aerospace qualified prepreg. The program builds from initial Air Force SBIR investment in long Carbon Nanotube development and manufacturing. BENEFIT: Reduce parasitic weight and enable magnitudes of order improvement in electrical and thermal conductivity while also reducing manufacturing costs by reducing scrap. Air vehicles will get increased range, longer time on station, increased payload capacity, longer product lifetimes, and reduces manufacturing costs.

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