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Hyperion Bridge questions
The competencies market for plastics compounded with carbon nanotubes (CNTs) is large. however questions are being asked about fitness and protection.
a short appear at the nanocomposites world may additionally depart the observer with the impact that it''s all talk and little action. The variety of business purposes running with nanoclays which have been made public can probably be numbered on the fingers of one hand.
So this may additionally come as a shock: Hyperion Catalysis (Cambridge, MA), the realm''s leading supplier of multiwall carbon nanotubes (MWNTs), says that roughly 60% of all vehicles in-built the U.S. these days contain its product in gas traces to cease the accumulation of static electrical energy. It says it has done this excellent market position because nanotube-containing compounds simplify construction of the gasoline traces (obviating complex coextrusion) at a value aggressive with other solutions.
These nanotubes—Hyperion''s trade identify is Fibrils—are also found in some compounds used for exterior body materials, enabling them to be electrostatically painted with out affecting the ductility of the thermoplastic. they are additionally common in electronics for such products as challenging disc force trays and wafer carriers, the place their resistance to sloughing places them forward of alternative conductive fillers like carbon black.
Hyperion doesn't establish particular auto products containing fibrils, and sales and advertising supervisor Pat Collins will most effective say the enterprise is talking to all principal suppliers of engineering thermoplastics for fenders. GE Plastics has used Fibrils during the past, nonetheless it is not clear if it still does; in automobile applications, cost is king, and MWNTs aren't inexpensive (over $750/kg, sources say), although addition stages can also be as low as 2%. in the meantime, Hyperion is asking to expand its portfolio (it sells its nanotubes predispersed in compounds and concentrates; it doesn't sell them in their pure form), and it is also trying to promote into extra segments. No bulletins are anticipated earlier than 2005.
"we've on no account viewed a free nanotube"
Collins says in-residence compounding gets around two considerations. First, nano additives are very elaborate to disperse, because of the high stage of Van der Waals forces maintaining them collectively. Hyperion has developed special machine to do its compounding. 2d, shoppers don''t need to be troubled about the health and security issues that are getting increasingly apparent in the nanotechnology world (see accompanying article). "as soon as nanotubes are encapsulated in plastics, they're adequate," says Collins. "which you could sand and grind elements, and also you gained''t liberate individual nanotubes."
What about fitness and safeguard precautions at Hyperion itself? "We go to superb lengths to make certain there is not any publicity all the way through their entire setup. we've by no means seen a free nanotube."
Collins says the business is developing single-wall carbon nanotubes, along with a lot of other organizations. SWNTs have the skills to supply materials with electrical residences orders of magnitude more desirable even than MWNTs, whereas additionally possessing superior mechanical residences (December 2002 MP/MPI). youngsters the rewards may well be high-quality, it may well be a while, youngsters, earlier than the abilities can be actualized. For now, well-nigh all construction is at lab scale, product charges upwards of $500/g, and there are many technical hurdles to be overcome before industrial-scale creation may be common.
growth is being made, notwithstanding. Carbon Nanotechnologies Inc. (Houston, TX) is at present constructing an indication plant with a capacity of about one hundred lb per day (45 kg). company President and CEO Bob Gower expects the unit "to be in the preliminary shake-out mode early all the way through the third quarter. Their plan is also to construct a bigger unit in 2005."
in line with Gower, "CNI has their products at about four hundred places worldwide. a couple of of their consumers point out that they are near commercial purposes, together with testing of products with their customers.
"we now have confidentiality agreements with most of their purchasers and can't discuss specifics," Gower says.
"however the utility areas consist of flat-panel shows, electronics, electrostatic dissipation, electromagnetic defensive, excessive-electricity composites and fibers, and fuel cells."
Single-walled tubes in construction
The U.ok.''s first commercial manufacturing manner for prime-purity SWNTs was commissioned earlier this yr by way of efficiency chemical substances enterprise Thomas Swan & Co. Ltd. (Consett, England). "the provision of commercially produced carbon nanotubes of a constant best and at an purchasable price is anticipated to liberate the capabilities for a wide range of industrial functions," says the business. it is going to sell Elicarb nanotubes for round $350/g. "The enterprise is now in a position to provide kilogram orders from inventory however are reserving judgment on ability except they have run the plant for a month or in an effort to collect accurate and meaningful records," observed a consultant in late April.
In February, Carbon Nanotechnolo- gies introduced the concern of a patent it says "is crucial to the building of real-world functions of nanotechnology." It describes linking carbon nanotubes to each different and to other species and substrates, "vastly bettering the abilities of carbon nanotubes and broadly increasing their range of conclusion uses." Richard Smalley, whose Nobel Prize-profitable technology is licensed solely to CNI, is quoted through the company as saying "it is tricky to think about carbon nanotechnology applications which aren't better with the aid of this enabling patented expertise." it can "dramatically increase" physical homes for a brand new type of nanocomposite items and fibers.
In April, Zyvex Corp. (Richardson, TX) introduced the primary two products in its NanoSolve line of additives in response to nanotubes, for polyurethanes. One is in keeping with SWNTs, the other on MWNTs, which it sources externally. The enterprise says the additives boost the host fabric''s conductivity and mechanical electricity. Electrical conductivity can also be boosted by way of 10 orders of magnitude. Zyvex envisages applications in printers, auto ingredients, heat pipes, flooring, and other areas. in the works are components for different plastics, together with epoxies, polycarbonate, polystyrene, and a exclusive cloth for the U.S. militia.
Zyvex has developed surface remedy technology it says enables fantastic dispersion of CNTs in various solvents (together with water), as well as improving the interplay between CNTs and the host matrix. A multifunctional "bridge" between the CNT sidewalls and the host fabric consists of two predominant components. One component adheres to the nanotube; the other has the functionality to stick to the host. Mark Banash, senior engineer for nanomaterials, says that Zyvex ''Kentera'' technology gives ranges of adhesion between polymer and nanotube far higher than the cohesive forces between the nanotubes themselves. He additionally says that bonding is particularly resistant to thermal cycling.
Zyvex is additionally working on a two-12 months NASA contract to build what it says should be a prototype of the area''s hardest material in collaboration with the Nano Tech Institute at the institution of Texas at Dallas. NASA wants the brand new materials to help Strengthen
spacecraft, car launch, and space station performance.
"It''s not a higher kind of carbon black"
Banash reckons the market can sustain the excessive costs nanotubes command. "I even have became down pretty massive avid gamers within the plastics market because they notion this would be a carbon black substitute. It''s not a commodity chemical. Single-walled tubes are $500 a gram in some circumstances. but we're aiming for individuals who're early adopters of the technology; they want a aggressive knowledge and they need it now. we're talking about whatever thing it truly is used at a really low loading, a quarter of a percent in some cases, via weight. you probably have a $20/lb resin and also you are speaking about including $2 to the fee of that, you will definitely get an important leap in efficiency—people can soak up that." PM
Is that a brick wall in front of the complete new ball video game?
First, the good news, from the government summary of a brand new document through the Freedonia community detailing the marketplace for nanocomposites:
"The U.S. marketplace for nanocomposites is expected to raise to 345 million kilos [158,000 tonnes] with the aid of 2008 and strategy eleven billion kilos [5 million tonnes] with the aid of 2020, with a worth of $37 billion. by way of that time, nanocomposites are expected to have in part supplanted ordinary reinforced plastics in construction applications...motor car components...customer items corresponding to appliances and sporting items; in packaging materials...in digital components and different equipment; and in high efficiency applications similar to spacecraft and military device."
Now the dangerous information, this time from a fresh report in the Washington put up:
"reviews have also shown that nanoparticles can act as poisons within the ambiance and accumulate in animal organs. And the primary two studies of the health results of engineered nanoparticles, published in January, have documented lung hurt more extreme and unusually distinctive than that caused by means of conventional toxic dusts...Some in California are trying to dam development of a nanotech factory, noting that no govt agency has developed safeguard guidelines for nano items. Others want a global moratorium on the field until the risks are improved understood."
It is not stretching the imagination too a ways to envisage the nanotechnology industry running into the same brick wall as Monsanto and others did with their genetically modified (GM) vegetation. And while main lights within the nano world like Mark Ratner (the creator of Nanotechnology: a mild Introduction to the subsequent huge issue) agree with that instructions had been discovered from the GM debacle; nano-particle producers argue that their products are protected once they are in compounds; and governments all over the world are pumping tens of millions of dollars into nanotechnology programs; political sensitivity to "What if?" eventualities can not rule out restrictions being applied to at least some areas of nanotechnology development.
Bob Gower, president and CEO of CNI, cites a study by using the U.S. govt''s countrywide Institute for Occupational safety and health (NIOSH), which visited the business''s facility. "They concluded that, under regular coping with situations, there have been very low respirable-size concentrations developed. They concluded that this changed into as a result of single-wall carbon nanotubes do not exist as individual molecules under general circumstances, but instead exist as significant ropes containing 1,000,000 or greater individual nanotubes." Gower also cites reviews "the place toxicological have an impact on become examined absolutely become independent from the capability to get respirable-size portions into the air. In those situations, nanotubes were injected at once into mice or rats, and abnormalities resulted. [The author] indicated that lots of the effect may additionally have been as a result the injection system and of dose level."
Dai Hayward, GM at Thomas Swan & Co. Ltd., says:
"we are making each effort to Strengthen
safe and valuable strategies of the usage of carbon nanotubes and are working with others to outline how the benefits of carbon nanotubes may also be developed in a secure manner...The expertise and market is in the early levels of construction.
"meanwhile, U.ok. and European legislations regulate the way new materials are developed via a suitable activity of the precautionary precept. The law at present states that carbon nanotubes are nonhazardous and similar in nature to different forms of pure carbon equivalent to graphite and carbon black. although, they appreciate the want for the entire nature of carbon nanotubes to be evaluated and for the entire hazards to be totally understood...
"there is a large difference from the GM debate in that nanomaterials present a number actual, quantifiable challenges for their protected use and dealing with, which can be understood and addressed in a great deal the equal method as all different materials. The development of GM is influenced by way of biological and herbal influences which can be probably more random, unpredictable and fewer smartly understood."
Peter Mapleston [email protected]
Zyvex recently announced the implementation of a provide chain certification software for carbon nanotube suppliers. "setting up a raw material regular and keeping excellent assurance to meet that regular is the important thing to the commercialization of carbon nanotubes and carbon nanotube-primarily based substances," says Zyvex President Thomas A. Cellucci. in keeping with Mark Banash, "Our analytical procedure objectively assesses a given CNT manufacturer''s underlying expertise and construction scalability. It additionally considers the enterprise structure of the enterprise, its skill to elevate capital, and its long-time period commitment to the marketplace." Zyvex became expecting to certify essential suppliers of multiwall and single-wall carbon nanotubes by way of June. Banash says he reckons that whereas there are "three to four dozen" businesses in the world making nanotubes, there are doubtless no more than six in a position to continuously making a high quality product.
meanwhile, Dutch firm Mo6 B.V. (Helmond) has developed MoSIx-6 as an alternative to carbon nanotubes. "one of the largest challenges in nanotechnology is the synthesis of pure, monodispersed nanotubes or nanowires with identical constitution and, ideally, tuneable genuine
or practical houses," says Dragan Mihailovic, chief scientist of Mo6, "but the prototype cloth—carbon nanotubes—stops short of satisfying this aim, partly because it is complicated to synthesize CNTs in a way that produces identical nanotubes in bulk.
One-dimensional "molybdenum cluster polymers" are referred to to surpass most of the synthesis-related shortcomings of carbon nanotubes, while their practical homes, equivalent to mechanical power, electrical conductivity, and box emission traits, are very corresponding to carbon nanotubes. Pricing is—stay up for it—€2000 to €4000/g, "with extent discounts." PM
Made in Japan?
"a few businesses have potential for commercial portions of MWNTs in Japan, but two components are limiting market penetration of nanocomposites there— satisfactory considerations and huge utility patent insurance held by Hyperion." That''s the view from Toru Kawasaki, President of Kawasaki Techno research, Osaka.
He says it is important that CNTs are of uniform measurement to enable uniform dispersion all through the resin matrix, however here is proving elaborate to achieve. He provides that talents users are delay by means of the prospect of criminal action from Hyperion if they use carbon nanotube-primarily based composites in commercial applications.
One japanese supplier is Nikkiso Co. (Tokyo), with annual skill estimated at between 20 and 40 tonnes. Kawasaki says Nikkiso claims prior submission of patents covering CNT software, and is fighting Hyperion within the U.S. courts. Nikkiso has misplaced courtroom situations twice, and is attractive for the second time.
Hyperion''s application patents cover using CNTs of diameters lower than 80 nm, a important dimension beneath which conductive properties are maximized, says Kawasaki.
"the rest above this and the merits over common carbon fibers are minimal," he says. Suppliers equivalent to Showa Denko (Tokyo; forty tonnes/year capacity) and Nikkiso at present most effective offer CNTs with diameters of eighty nm or more. Showa Denko, as an instance, offers the VGCF (Vapor Grown Carbon Fiber) electrically/thermally conductive fabric to be used in resins.
jap buying and selling homes have invested heavily in CNTs with little to reveal yet [for the reasons stated above]. The XNRI community at Mitsui & Co. (Tokyo) has a facility at Akishima, close Tokyo, rated at one hundred twenty-tonnes/12 months, but output is known to be very low.
Sumitomo Corp. (Osaka) is one other buying and selling house with huge CNT capacity (150 tonnes/yr). It recently licensed patents from NEC. It also signed an unique advertising and distribution agreement for CNI''s SWNTs in Japan and South Korea, and has taken a fiscal stake in CNI. Stephen Moore