Researchers from Applied Sciences Inc., a world leader in advanced materials have demonstrated the ability of Pyrograf III stacked-cup carbon nanotubes to serve as catalyst supports for the air electrode of lithium-air batteries. Preliminary data shows that carbon nanotubes coated with metal oxides are providing reversible behavior for air electrodes to enable the production of secondary lithium-air batteries.

Applied Sciences is exploring this technology under an Army phase I SBIR program aimed at developing the next generation of high energy density rechargeable batteries for use in defense systems.

Project Description

Many defense systems such as silent watch, soldier power, unmanned vehicles, communications equipment, and directed energy weapons require portable power which limits the duration and capability of missions relying upon these systems. The Department of Defense is therefore seeking energy storage devices with higher energy densities to extend mission duration and capability. Of all battery technologies currently available, batteries which rely upon lithium-air chemistry have the highest energy density. However, lithium-air battery performance is limited by issues with the metallic lithium anode and poor performance of the cathode.

Applied Sciences, Inc. proposes to overcome these issues through the use of a positive electrode with a rapid oxygen-exchange catalyst impregnated in a gas-diffusion electrode. The positive electrode catalyst is a transition-metal oxide with high activity for O-O bond cleavage and fast oxygen exchange. Once the proposed cathode is reduced to practive, it is anticipated that the combination of a high capacity anode with the proposed cathode will exceed a specific energy density of 1000 Ah/kg, at relatively low-cost.

Potential Applications

The development of a rechargeable battery with energy densities an order of magnitude higher than existing battery technologies will dramatically increase the mission capability of numerous military systems including silent watch, sensors, soldier power, UAVs and UUVs, surveillance, instrumentation, communication equipment, satellites, and directed energy weapons. Commercial applications for advanced battery technologies include power tools, hybrid and all-electric vehicles.

About Applied Sciences, Inc.
Applied Sciences, Inc. (ASI) is a nationally recognized research and development corporation located in Cedarville, Ohio specializing in advanced materials and their applications. Incorporated in 1984 Applied Sciences has a rich history of development work from a variety of funding sources including NASA, Army, Navy, Air Force, NIST, and EPA, as well as private contracts.

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Researchers from Applied Sciences Inc., a world leader in advanced materials, say carbon nanotubes are ideal materials to pair with nano-sized self-healing capsules in thermoset composites. Applied Sciences is exploring this technology under a NASA Phase I SBIR program targeted at developing self healing composite technology using Pyrograf III carbon nanotubes.

Project Description

Polymer matrix composites offering multiple advantages of lightweight, high strength and stiffness, vibration damping, and corrosion resistance are becoming widely used in aerospace and commercial applications. A primary weakness of structural composites is damage from impact, where resulting micro-cracks can propagate to allow delamination and/or fiber breakage of the composite, resulting in loss of the excellent physical properties for which composites are selected. Incorporation of carbon nanotubes into the polymer matrix, resulting in a significant increase of the composite interphase, has been shown to mitigate micro-crack formation. Carbon nanotube additives in the matrix have also demonstrated improvement in interlaminar mechanical properties, thermal and electrical conductivity, vibration damping, and fire retardancy. A separate promising tool for addressing damage from impact is the emerging class of self healing materials having the ability to heal micro-cracks and restore mechanical and corrosion resistant properties of the composite. In the awarded effort, a combination of these tools will be investigated to determine the feasibility of incorporating self-healing properties, while concurrently producing multifunctional improvements in interlaminar shear strength, modulus, fracture toughness, transport properties, fire retardancy and vibration damping

Potential Applications

Self-healing nano-reinforced composites could be attractive for cryotanks due to carbon nanotubes ability to reinforce the matrix as well as mitigate micro-cracking combined with the capability to repair damage from collisions with debris. In additional, self -healing multi-functional composites could be used for composite fan blades, fan casings or structural components in large-scale structures such as Heavy Lift Vehicle or in-space applications.

Nano-scale self-healing reinforcements could increase the service life and boost physical properties of composites used for aerospace applications and in commercial markets for windmill blades, sporting equipment, automotive, and aerospace structural composites. For example, a reduction in the need to replace windmill blades will result in a lowering of the cost of wind energy and will contribute to the solution of defining economical and renewable energy alternatives for the future.

original article

Pyrograf Products, Inc. has pioneered the development of quality control methodologies for the commercial scale production of stacked-cup carbon nanotubes, also known as carbon nanofiber. The company recently consolidated 15 years of carbon nanotube quality control experience and expertise into a quality management system and was granted ISO 9001:2008 certification.

ISO 9001 provides a suite of proven business and quality management techniques to efficiently and effectively operate a successful business. Pyrograf Products developed its quality management system according to ISO standards over a one year period and then underwent a thorough analysis of its policies and procedures conducted by Eagle Registrations, Inc.

Carbon Nanofiber Reactors

Eagle has a long standing, excellent reputation in the Dayton, OH area and is an ANSI-ASQ National Accreditation Board (ANAB) accredited registrar. Certification through Eagle to ISO 9001:2008 ensures consistent quality and continual improvement of products to provide an added sense of confidence in Pyrograf-III carbon nanofiber.

“ISO certification provides an internationally recognized means for us to communicate Pyrograf’s commitment to quality and continuous improvement to our customers. It is a significant step forward for us and we are very pleased to provide this level of quality assurance in our process and product.” – David Burton, General Manager Pyrograf-III is a patented, highly graphitic, low-cost stacked-cup carbon nanotube with properties approaching the theoretical values of graphite in almost every performance characteristic.

Pyrograf-III stacked-cup carbon nanotubes are a highly pure product with over 99.9% fibrous material and very low metal concentrations. Pyrograf Products, located in Cedarville, OH, was incorporated in 1996 and has since grown to become the world’s leading producer of stacked-cup carbon nanotubes with an annual capacity of 50,000 lbs per year. Pyrograf-III stacked-cup carbon nanotubes are currently being used worldwide to provide unmatched mechanical, electrical, and thermal properties in polymeric composites.

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Products

Learn more about our products. Applied Sciences products have been used to provide unmatched composite performance in metal matrix, carbon matrix, thermoset and thermoplastic composites including record-setting thermal conductivity in carbon-carbon composites with its patented Black Ice™ composite.  If you need materials that are lighter, stronger, more conductive, we can help you push the boundaries.

Contract Research

Learn more about how our contract research services can advance your project. Our Contract Research team offers scientists and engineers with a track record of solving advanced materials problems for government agencies as well as commercial clients. Clients can leverage the expertise of our published PhD scientists for polymer engineering, development of advanced energy devices and development of novel forms of nanomaterials.  ASI’s team is well versed in writing winning grant applications for Department of Energy, Department of Defense, National Institute of Science and Technology, National Science Foundation, NASA, and the US Environmental Protection Agency.

Latest News

Read more about the latest at Applied Sciences. Applied Sciences now offers dispersion analysis using a method developed in part by Applied Sciences, University of Minho in Portugal, and the U.S. Air Force.  Dispersion analysis has been used successfully to analyze and quantify the level of nanomaterials dispersion in pre-dispersions in organic solvents and thermoset resins, thermoplastic compounds, thin films and pre-preg, and finished composites.  This technology allows ASI to help our clients achieve the best possible performance from our nanomaterials.

Pyrograf Products is pleased to announce that the United States Environmental Protection Agency (EPA) has issued a consent order to allow the manufacturing and distribution of Pyrograf-III stacked-cup carbon nanotubes, also known as carbon nanofiber, for commercial applications in the United States.

Pyrograf Products joins the ranks of a select few who have been granted the right to sell carbon nanomaterials for commercial use in the US. Pyrograf Products is the first domestic supplier of carbon nanofiber to be granted a consent order which bodes well for the company to be the supplier of choice for the aerospace, automotive, polymer, and energy storage industries.

Pyrograf Products has been working closely with the EPA over the last several years to comply with local EPA reporting requirements, to participating in the EPA’s voluntary Nanomaterials Stewardship Program, and finally to submitting two Pre-Manufacturing Notices (PMNs) which led to the issuance of the Consent Order. This process exemplifies Pyrograf Products’ long standing commitment to responsible manufacturing and use of it’s products.

The granting of the Consent Order has come just in time for Pyrograf Products to allow several commercial clients to launch new products based on Pyrograf-III carbon nanofiber technology. The company’s General Manager David Burton commented, “We’ve had several customers closely monitoring the status of our Orders so we are very pleased to be able to now provide the regulatory assurance our customers need to launch products. This also gives us the freedom to more actively pursue new applications and to respond more quickly to new opportunities.”

Pyrograf-III is a patented, highly graphitic, low-cost stacked-cup carbon nanotube with properties approaching the theoretical values of graphite in almost every performance characteristic. Pyrograf-III stacked-cup carbon nanotubes are a highly pure product with over 99.9% fibrous material and very low metal concentrations. Pyrograf Products, located in Cedarville, OH, was incorporated in 1996 and has since grown to become the world’s leading producer of stacked-cup carbon nanotubes with an annual capacity of 50,000 lbs per year. Pyrograf-III stacked-cup carbon nanotubes are currently being used worldwide to provide unmatched mechanical, electrical, and thermal properties in polymeric composites.