Infiltration of highly aligned carbon nanotube arrays with molten polystyrene

Highly aligned carbon nanotube/polystyrene (HACNT/PS) composites were prepared conveniently via polymer impregnation of aligned arrays, avoiding conventional solution or melt processes that involve high-shear blending. Detailed scanning electron microscopy (SEM), X-Ray diffraction (XRD) and differential scanning calorimetry (DSC) studies show that the alignment of the multi-wall nanotubes is retained after polymer impregnation. A range of key parameters were investigated, including the amount of molten polymer required for complete infiltration, the maximum mass fraction of CNTs in dense composites, and the effect of CNTs on the glass transition temperature (Tg) of the polymer. This approach may be adapted to the fabrication of large scale, highly anisotropic, thin or multilayer CNT composites using other molten polymers.

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► General method to produce aligned CNT/thermoplastic composites by melt-infiltration.
► High loadings of aligned CNTs can be translated into larger multilayer composites.
► CNT loading fraction influences the resulting Tg due to the large interfacial area.