OPPORTUNITY

Nanocomposites have been used commercially since Toyota introduced the first polymer/clay nanocomposite auto parts in the 1980s. The demand for lightweight automotive parts has given an edge to polymer nanocomposites due to its high strength and lightweight properties. The use of polymer nanocomposites enabled automotive parts reduction in lightweight vehicles, improved engine efficiency, reduction in CO2 emissions and superior performance. The automotive industry can benefit from polymer nanocomposites in several applications such as powertrain, suspension and breaking systems, exhaust systems and catalytic converters, lubrication, tires and body parts. The advantage of nanocomposites over conventional composites is that their mechanical, electrical, thermal, barrier and chemical properties such as increased tensile strength, improved heat deflection temperature, flame retardancy, etc. Recently, advances in the ability to characterize, produce and manipulate nanometer-scale materials have led to their increased use as fillers in new types of nanocomposites. Manufacturers now mix nanoparticulate metals, oxides and other materials with polymers and other matrix materials to optimize the composite’s properties with respect to color/transparency, conductivity, flame retardancy, barrier properties, magnetic properties and anti-corrosive properties, as well as tensile strength, modulus and heat distortion temperature. These composites offer users significantly enhanced properties compared to conventional composite and non-composite materials. Global consumption of nanocomposites has increased significantly since 2014, reaching 261,779 metric tons (MT). Nanocomposite consumption is growing rapidly, and is expected to reach close to 733,220 MT, or $5.3 billion in value terms, by 2021. This raise is compounded at an annual growth (CAGR) rate of 26.7%.

BREAKTHROUGH IN POROUS NANOCOMPOSITES

Researchers at the University of South Alabama have developed a new composite material. This composite consists of (1) a plurality of very long/continuous fibers (e.g. microfibers), (2) z-aligned nanofibers stitched and mechanically interlocked with said long fibers, (3) small amount of matrix (e.g. resin) to secure the nanofibers and the long fibers at the contact locations, but not saturate the composite, and (4) significant porosity formed inside said composite (i.e. the space excluding the long fibers and nanofibers is majorly not occupied by the matrix). Due to the mechanical interlock of the nanofibers with the long fibers, full matrix saturation, which is typically required for traditional composites, traditional nanocomposites, or alike, is not necessary in this novel porous super composite.

COMPETITIVE ADVANTAGES

•  Improved strength-to-weight ratio

•  Z-aligned nanofibers provide increased sheer strength

•  Full matrix saturation not necessary

•  Lighter than conventional composite materials

•  Porous nature permits filling with other functional components

INTELLECTUAL PROPERTY STATUS

Patent filed