Carbon Nanoparticle Polymer Matrix Composite Fabricated Using Electromagnetic Irradiation

Abstract

A method for fabricating carbon nanoparticle polymer matrix composites includes the steps of: providing a nanoparticle mixture that includes carbon nanoparticles (CNPs), mixing the nanoparticle mixture and a plastic substrate into a homogenous (CNP)/polymer mixture having an interconnected network of carbon nanoparticles (CNPs); and irradiating the (CNP)/polymer mixture with electromagnetic radiation controlled to form a polymer composite and uniformly consolidate and/or interfacially bond the carbon nanoparticles (CNPs) into the polymer matrix.

What is claimed is: 
     
         1 . A carbon nanoparticle polymer matrix composite comprising:
 a polymer matrix comprising a plurality of polymer particles comprising a polymer having a selected composition and a particle size of less than 500 μm; and   a plurality of interconnected electromagnetically irradiated carbon nanoparticles (CNPs) interfacially bonded to the polymer matrix with a consolidated morphology, the carbon nanoparticles (CNPs) forming an interconnected electrical network of carbon nanoparticles (CNPs) integrated into the polymer matrix on a micron scale,   the carbon nanoparticles (CNPs) having a concentration of at least 7.5 wt % in the polymer matrix composite,   the polymer matrix composite configured as a masterbatch.   
     
     
         2 . The carbon nanoparticle polymer matrix composite of  claim 1  wherein the carbon nanoparticles (CNPs) comprise particles selected from the group consisting of carbon nanotubes (CNTs), carbon nanofibers (CNFs), graphene, carbon black, amorphous carbon and mixtures of these materials. 
     
     
         3 . The carbon nanoparticle polymer matrix composite of  claim 1  wherein the polymer comprises a thermoplastic polymer, or a thermoset polymer. 
     
     
         4 . The carbon nanoparticle polymer matrix composite of  claim 1  wherein the polymer matrix includes a non-carbon nano- or micro-material (NMM). 
     
     
         5 . The carbon nanoparticle polymer matrix composite of  claim 1  wherein the carbon nanoparticles (CNPs) include halloysite nanoparticles. 
     
     
         6 . The carbon nanoparticle polymer matrix composite of  claim 1  wherein the polymer matrix comprises an electromagnetically irradiated remelt. 
     
     
         7 . A carbon nanoparticle polymer matrix composite comprising:
 a polymer matrix comprising a plurality of polymer particles comprising a polymer having a selected composition and a particle size of less than 500 μm; and   a plurality of interconnected electromagnetically irradiated carbon nanoparticles (CNPs) and halloysite nanoparticles interfacially bonded to the polymer matrix with a consolidated morphology, the carbon nanoparticles (CNPs) forming an interconnected electrical network of carbon nanoparticles (CNPs) integrated into the polymer matrix on a micron scale,   the carbon nanoparticles (CNPs) having a concentration of from 0.3 wt % to 80 wt % in the polymer matrix composite.   
     
     
         8 . The carbon nanoparticle polymer matrix composite of  claim 7  wherein the carbon nanoparticles (CNPs) comprise particles selected from the group consisting of carbon nanotubes (CNTs), carbon nanofibers (CNFs), graphene, carbon black, amorphous carbon and mixtures of these materials. 
     
     
         9 . The carbon nanoparticle polymer matrix composite of  claim 7  wherein the polymer comprises a thermoplastic polymer, or a thermoset polymer. 
     
     
         10 . The carbon nanoparticle polymer matrix composite of  claim 7  wherein the polymer matrix includes a non-carbon nano- or micro-material (NMMs). 
     
     
         11 . The carbon nanoparticle polymer matrix composite of  claim 7  wherein the polymer matrix composite comprises a masterbatch. 
     
     
         12 . The carbon nanoparticle polymer matrix composite of  claim 7  wherein the polymer matrix comprises an electromagnetically irradiated remelt.