Microporous Nanocomposite Multifunctional Carbon Fiber Composites
Abstract
Approved for Public Release: One of the longest-standing engineering challenges is the problem of wasted material mass. In aerospace structures, one large source of wasted mass arises from structural specialization, with each component providing only a single func tionality. It is for this reason that multifunctional structures are so desirable, as they can satisfy several performance requireme nts with the same mass. One of the most ubiquitous existing lightweighting strategies, especially in the development of unmanned dro nes, is the replacement of structural metallic components with carbon fiber (CF) composites. This composite approach already leverag es the functional toughness and chemical barrier properties of matrix resins with the uniaxial stiffness of CF to make moldable comp onents that possess the best features of each material. Here, a new class of resin materials is proposed, microporous nanocomposite emulsion thermosets (MiNETs), as a matrix material for vacuum molded CF composites. MiNETs are bi- or tri-continuous composites of ( 1) a non-volatile oil, (2) a particle or particle blend, and (3) a polymeric resin formed by microphase separation of these three ma terials groups together with (4) a surfactant after high shear mixing. The high loading of particles prevents the formation of a con ventional emulsion, leaving the continuous networks at a length scale commensurate to the particles employed in the synthesis from t he nanometer to micrometer scale. Critically, there are no designer chemistries required for the formulation beyond what can be read ily sourced as large-scale commercial resins, modifiers, and fillers. The major advantage of MiNET materials is that they can be pro cessed in the same way as any conventional resin, but with the added extraordinary properties intrinsic to the nanomaterials that co mpose them. In addition, on removal of the porogenic oil, MiNETs possess open porosity at tunable length scales that can be infiltra ted with selected working fluids to achieve desired function. In total, the function of MiNETs can be tuned in four distinct ways: ( 1) the composition of the particle(s), (2) the selection of the filler fluid, (3) the selection of the resin, and (4) the selection of the surfactant. Due to the viscosity of MiNET materials and through use of a common resin backbone, multiple functionalities can be present on the same component, allowing for the spatial selection of particulate function. Using these materials in combination w ith CF composites will allow for the selection of desired multifunctionality. This proposal investigates opportunities in three of t hese possible functional additions: (i) anti-icing/anti-fouling functionalities, (ii) electromagnetic interference (EMI) shielding, and (iii) energy storage. Each target functionality requires co-optimization of the mechanical properties of the resulting composite along with the target additional functionality. This process necessitates new fundamental understanding of each component of the Mi NET blend along with their interaction with each other and with the CF. The net result will be a new platform for incorporating thes e and other multifunctionalities in future aerospace structures.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Aug 20, 2021
- Source ID
- N000142112605
Entities
People
- Jonathan P Singer
Organizations
- Office of Naval Research
- Rutgers University
- United States Navy