Polymer matrix composites with nano-scale reinforcements

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.

What is claimed is: 
     
       1. A composite material, comprising:
 a matrix material selected from the group consisting of epoxies and polyesters; and 
 a reinforcement material comprising at least one of nanoparticles selected from the group consisting of TiO 2 , ZnO, SiC, Y 2 O 3 , C and carbon nanotubes having at least one dimension of about 100 nm or less dispersed within the matrix material, wherein the reinforcement is present in a concentration between approximately 0.01% and 0.4% on the basis of the weight of the composite material so as to improve at least one of strength and toughness of the composite. 
 
     
     
       2. A nanomaterial-reinforced nail polish comprising the composite material of  claim 1 , wherein the reinforcement material is present in a concentration between approximately 0.2 to 0.4 wt %. 
     
     
       3. The composite material of  claim 1 , wherein the reinforcement material is present in a concentration between approximately 0.1% to 0.4% on the basis of weight of the composite material. 
     
     
       4. The composite material of  claim 1 , wherein the matrix material comprises an epoxy and the reinforcement material comprises SiC. 
     
     
       5. The composite material of  claim 4 , wherein the SiC reinforcement material is provided in a concentration between about 0.2% and 0.4% on the basis of the weight of the composite material. 
     
     
       6. The composite material of  claim 1 , wherein the matrix material comprises a polyester resin and the reinforcement material comprises TiO 2 . 
     
     
       7. The composite material of  claim 6 , wherein the TiO 2  reinforcement material is provided in a concentration of about 0.2% on the basis of the weight of the composite material. 
     
     
       8. The composite material of  claim 1 , wherein the reinforcement material comprises carbon nanotubes in a concentration of about 0.01% to 0.1% on the basis of the weight of the composite material. 
     
     
       9. The composite material of  claim 1 , wherein the matrix comprises a high temperature epoxy based on diglycidyl ether of bisphenol A and alkylglycidyl ether, a ceramic based on a pre-ceramic polymer, or polyester. 
     
     
       10. The composite material of  claim 1 , wherein the reinforcement causes an increase in ultimate strength of the composite of about 10% or more compared to an unreinforced matrix. 
     
     
       11. The composite material of  claim 1 , wherein the reinforcement causes an increase in strain to failure of the composite of about 50% or more compared to an unreinforced matrix. 
     
     
       12. The composite material of  claim 1 , wherein the reinforcement causes an increase in G IC  of about two-fold or more compared to an unreinforced matrix. 
     
     
       13. The composite material of  claim 1 , wherein the reinforcement causes an increase in K IC  of about 20% or more compared to an unreinforced matrix. 
     
     
       14. The composite material of  claim 1 , wherein the matrix material comprises a nail polish and the reinforcement material comprises TiO 2 . 
     
     
       15. The composite material of  claim 14 , wherein the TiO 2  reinforcement material is provided in a concentration of about 0.2% on the basis of the weight of the composite material. 
     
     
       16. The nail polish of  claim 2 , wherein color of the nail polish is substantially unchanged by the presence of the reinforcement material. 
     
     
       17. A bulk nanocomposite, comprising:
 a body having at least one cross-sectional dimension of at least about 3.2 mm, the body comprising:   a matrix material selected from the group consisting of epoxies and polyesters; and   a reinforcement material having at least one dimension of about 100 nm or less dispersed within the matrix material, said reinforcement material comprising at least one of nanoparticles selected from TiO 2 , ZnO, SiC, Y 2 O 3 , C and carbon nanotubes;   wherein the reinforcement material is present in a concentration between approximately 0.01% and 0.4% on the basis of the weight of the bulk nanocomposite so as to improve at least one of strength and toughness of the bulk nanocomposite.   
     
     
       18. The bulk nanocomposite of claim 17, wherein the reinforcement material comprises nanoparticles homogeneously distributed in the matrix material.  
     
     
       19. The bulk nanocomposite of claim 17, wherein the nanoparticles comprise TiO 2 .  
     
     
       20. The bulk nanocomposite of claim 17, wherein the nanoparticles comprise ZnO.  
     
     
       21. The bulk nanocomposite of claim 17, wherein the nanoparticles comprise SiC.  
     
     
       22. The bulk nanocomposite of claim 17, wherein the nanoparticles comprise Y 2 O 3 .  
     
     
       23. The bulk nanocomposite of claim 17, wherein the nanoparticles comprise C.  
     
     
       24. The bulk nanocomposite of claim 17, wherein the nanoparticles comprise carbon nanotubes.  
     
     
       25. The bulk nanocomposite of claim 24, wherein the carbon nanotubes are characterized as being separated into single units from aggregates and clusters within the matrix material.  
     
     
       26. The bulk nanocomposite of claim 17, wherein the reinforcement material is present in a concentration between approximately 0.01% and 0.1% on the basis of the weight of the bulk nanocomposite.  
     
     
       27. The bulk nanocomposite of claim 17, wherein the reinforcement material is present in a concentration between approximately 0.02% and 0.1% on the basis of the weight of the bulk nanocomposite.  
     
     
       28. A bulk nanocomposite, comprising:
 a body having at least one cross-sectional dimension of at least 3.2 mm; the body comprising;   a polymer matrix material, and   carbon elemental nanoparticle reinforcements homogenously dispersed in the matrix material, the elemental nanoparticle reinforcements having at least one dimension of about 100 nm or less dispersed within the matrix material, wherein the elemental nanoparticle reinforcements are present in a concentration between approximately 0.01% to 0.4% on the basis of the weight of the bulk nanocomposite so as to improve at least one of strength and toughness of the matrix material.    
     
     
       29. The bulk nanocomposite of claim 17, wherein the material matrix comprises epoxy.  
     
     
       30. The bulk nanocomposite of claim 29, wherein the material matrix comprises a high temperature epoxy based on diglycidyl ether of bisphenol A and alkylglycidyl ether.  
     
     
       31. The bulk nanocomposite of claim 29, wherein the nanoparticles comprise TiO 2 .  
     
     
       32. The bulk nanocomposite of claim 29, wherein the nanoparticles comprise ZnO.  
     
     
       33. The bulk nanocomposite of claim 29, wherein the nanoparticles comprise SiC.  
     
     
       34. The bulk nanocomposite of claim 29, wherein the nanoparticles comprise Y 2 O 3 .  
     
     
       35. The bulk nanocomposite of claim 29, wherein the nanoparticles comprise C.  
     
     
       36. The bulk nanocomposite of claim 35, wherein the nanoparticles comprise carbon nanotubes.  
     
     
       37. The bulk nanocomposite of claim 36, wherein the nanoparticles comprise single walled carbon nanotubes.  
     
     
       38. The bulk nanocomposite of claim 36, wherein the nanoparticles comprise multiple walled carbon nanotubes.  
     
     
       39. The bulk nanocomposite of claim 29, wherein the carbon nanotubes are characterized as being separated into single units from aggregates and clusters within matrix material.  
     
     
       40. The bulk nanocomposite of claim 29, wherein the reinforcement material is present in a concentration between approximately 0.01% and 0.1% on the basis of the weight of the bulk nanocomposite.  
     
     
       41. The bulk nanocomposite of claim 29, wherein the reinforcement material is present in a concentration between approximately 0.02% and 0.1% on the basis of the weight of the bulk nanocomposite.  
     
     
       42. The bulk nanocomposite of claim 28, wherein the elemental nanoparticle reinforcements comprising carbon comprise a one-atom-thick layer of graphite.  
     
     
       43. The bulk nanocomposite of claim 17, wherein the material matrix comprises a polyester.  
     
     
       44. The bulk nanocomposite of claim 43, wherein the material matrix comprises a polyester that is curable at room temperature.  
     
     
       45. The bulk nanocomposite of claim 43, wherein the nanoparticles comprise TiO 2 .  
     
     
       46. The bulk nanocomposite of claim 43, wherein the nanoparticles comprise ZnO.  
     
     
       47. The bulk nanocomposite of claim 43, wherein the nanoparticles comprise SiC.  
     
     
       48. The bulk nanocomposite of claim 43, wherein the nanoparticles comprise Y 2 O 3 .  
     
     
       49. The bulk nanocomposite of claim 43, wherein the nanoparticles comprise C.  
     
     
       50. The bulk nanocomposite of claim 49, wherein the nanoparticles comprise carbon nanotubes.  
     
     
       51. The bulk nanocomposite of claim 50, wherein the carbon nanotubes comprise single walled carbon nanotubes.  
     
     
       52. The bulk nanocomposite of claim 50, wherein the carbon nanotubes comprise multiple walled carbon nanotubes.  
     
     
       53. The bulk nanocomposite of claim 43, wherein the carbon nanotubes are characterized as being separated into single units from aggregates and clusters within matrix material.  
     
     
       54. The bulk nanocomposite of claim 43, wherein the reinforcement material is present in a concentration between approximately 0.01% and 0.1% on the basis of the weight of the bulk nanocomposite.  
     
     
       55. The bulk nanocomposite of claim 43, wherein the reinforcement material is present in a concentration between approximately 0.02% and 0.1% on the basis of the weight of the bulk nanocomposite.  
     
     
       56. The bulk nanocomposite of claim 43, wherein the reinforcement material comprises elemental nanoparticles.  
     
     
       57. The composite material of claim 43, wherein the SiC reinforcement material is provided in a concentration between about 0.2% and 0.4% on the basis of the weight of the composite material.  
     
     
       58. The composite material of claim 17, wherein the matrix material comprises an epoxy and the reinforcement material comprises C.  
     
     
       59. The composite material of claim 17, wherein the matrix material comprises a polyester resin and the reinforcement material comprises TiO 2 .  
     
     
       60. The composite material of claim 59, wherein the TiO 2  reinforcement material is provided in a concentration of about 0.2% on the basis of the weight of the composite material.  
     
     
       61. The composite material of claim 17, wherein the reinforcement material comprises carbon nanotubes in a concentration of about 0.01% to 0.1% on the basis of the weight of the composite material.  
     
     
       62. The composite material of claim 17, wherein the reinforcement causes an increase in ultimate strength of the composite of about 10% or more compared to an unreinforced matrix.  
     
     
       63. The composite material of claim 17, wherein the reinforcement causes an increase in strain to failure of the composite of about 50% or more compared to an unreinforced matrix.  
     
     
       64. The composite material of claim 17, wherein the reinforcement causes an increase in G IC  of about two-fold or more compared to an unreinforced matrix.  
     
     
       65. The composite material of claim 17, wherein the reinforcement causes an increase in K IC  of about 20% or more compared to an unreinforced matrix.  
     
     
       66. The composite material of claim 17, wherein the reinforcement causes an increase in G IC  of about two-fold or more compared to an unreinforced matrix and the reinforcement causes an increase in K IC  of about 20% or more compared to an unreinforced matrix.  
     
     
       67. The composite material of claim 66, wherein the reinforcement comprises TiO 2  in a concentration of about 0.2% on the basis of the weight of the composite material.  
     
     
       68. A bulk nanocomposite, comprising:
 an epoxy matrix material based on diglycidyl ether of bisphenol A and alkylglycidyl ether, and   SiC nanoparticles homogenously dispersed in the epoxy matrix material, the SiC nanoparticles having at least one dimension of about 100 nm or less dispersed within the epoxy matrix material, wherein the SiC nanoparticles are present in a concentration between approximately 0.01% and 0.4% on the basis of the weight of the bulk nanocomposite so as to improve at least one of strength and toughness of the epoxy matrix material.    
     
     
       69. A bulk nanocomposite, comprising:
 a body having at least one cross-sectional dimension of at least 3.2 mm, the body comprising:   a polyester matrix material, and   TiO 2  nanoparticles homogenously dispersed in the polyester matrix material, the TiO 2  nanoparticles having at least one dimension of about 100 nm or less dispersed within the polyester matrix material wherein the TiO 2  nanoparticles are present in a concentration between approximately 0.01% and 0.4% on the basis of the weight of the bulk nanocomposite so as to improve at least one of strength and toughness of the polyester matrix material.    
     
     
       70. The bulk nanocomposite of claim 42, wherein the one-atom-thick layer of graphite comprises carbon nanotubes.  
     
     
       71. The bulk nanocomposite of claim 70, wherein the carbon nanotubes comprise SWNTs.  
     
     
       72. The bulk nanocomposite of claim 70, wherein the carbon nanotubes comprise MWNTs.  
     
     
       73. The bulk nanocomposite of claim 28, wherein the matrix material is selected from the group consisting of epoxies and polyesters.  
     
     
       74. The bulk nanocomposite of claim 73, wherein the matrix material is an epoxy.  
     
     
       75. The bulk nanocomposite of claim 74, wherein the epoxy is based on diglycidyl ether of bisphenol A and alkylglycidyl ether.  
     
     
       76. The bulk nanocomposite of claim 73, wherein the matrix material is a polyester.