SINGLE WALL CARBON NANOTUBES (SWCNT) Redefining materials Reinventing technologies. SOLUTIONS in Elastomers
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1 SINGLE WALL CARBON NANOTUBES (SWCNT) Redefining materials Reinventing technologies SOLUTIONS in Elastomers
2 OUTLINE 1 Brief introduction about OCSiAl 2 Single Wall Carbon Nanotubes (SWCNT) 3 SWCNT Masterbatches for Elastomers 4 SWCNT Development Expanded Offerings for Elastomers 5 Questions
3 ABOUT OCSiAl 2009 Founded to develop scalable synthesis of single wall carbon nanotubes (SWCNT) 2014 Began large scale industrial sampling 2013 Awarded patent for scalable SWCNT production Launched Graphetron V1.0 nanotube reactor 10 T/Y capacity 2016 ~260 people, 30 Ph.D. Product lines for elastomers, plastics, composites, coatings, batteries
4 OCSiAl PRODUCTION FACILITY GRAPHETRON 1.0 SWCNT REACTOR 4,200 m 2 FACILITY 10 T/YEAR 90% OF GLOBAL SWCNT PRODUCTION
5 2016 FACTS & FIGURES TUBALL MATRIX superconcentrates launched First Nanoaugmented Materials Industry Summit GRAPHETRON 50 construction started to bring 50 metric tons production of TUBALL annually 4 metric tons of TUBALL produced 222 customers from 29 countries 1034 active prospects sales force present in 13 countries 256 employees
6 SWCNT THE FIRST SCALABLE PRODUCTION PROCESS Production capacity, kg/y 3,000, ton/y 800,000 Х800 50,000 Х50 10,000 1, kg/y Х years
7 SWCNT PROTOTYPING CENTER 150 items of equipment 6 key technologies 200 tons/year capacity support
8 WHAT ARE SWCNT.. SINGLE WALL CARBON NANOTUBES
9 SWCNT FIRST UNIVERSAL ADDITIVE Electrochemical Power sources Ceramics Concrete Glass Copper Sensors Semiconductors Rubber materials Plastics Aluminum Composites Paints Adhesives
10 SWCNT EXCEPTIONAL PROPERTIES OPTIMAL ADDITIVE FOR CONDUCTIVITY Current carrying while 5 times lighter than copper THERMAL STABILITY up to 1000 C LARGE SURFACE AREA 1 g = 2 basketball courts STRONGER THAN STEEL 100 times VERY HIGH ASPECT RATIO up to 5000 L/D 1 G = 5,000,000 KM length of line 1 nanotube thick
11 SWCNT TECHNICAL DATA SHEET SPECIFICATION UNIT OF MEASURE VALUE METHOD OF EVALUATION CARBON CONTENT wt. % >85 TGA, EDX CNT CONTENT wt. % 75 TEM, TGA NUMBER OF LAYERS CNT unit 1-2 TEM OUTER MEAN DIAMETER CNT nm 1.8±0.4 RAMAN, TEM LENGTH OF CNT μm >5 AFM METAL IMPURITIES wt. % <15 EDX, TGA
12 SINGLE WALL CARBON NANOTUBES / OCSIAL.COM EXPLOSIVE GROWTH IN THE NUMBER OF PATENTS FOR CNT APPLICATIONS
13 SWCNT COMMERCIALIZATION CHALLENGES lack of scalable production difficult to directly add to materials nanomaterial safety concerns CHALLENGE #1 CHALLENGE #2 CHALLENGE #3
14 SOLUTIONS
15 OCSIALDEVELOPED DISPERSION TECHNOLOGIES FOR SWCNT MASTERBATCH TECHNOLOGIES SUSPENSIONS MATRIX CONCENTRATES RUBBER PLAST COMP COAT INK BATT
16 SWCNTs DISPERSION POWER Concentration of particles ~0.1% A B C 1 0,5mm 0 0 0,5mm ,5mm MICROPARTICLES CARBON NANOFIBERS SINGLE WALL CARBON NANOTUBES SWCNT FORMS ITS OWN CONDUCTIVE 3D NETWORK AT ULTRA LOW CONCENTRATIONS
17 SWCNT ADDITIVE IN ELASTOMERS ULTRA LOW CONCENTRATIONS CARBON BLACK 20-40% METAL FILLERS 15-35% CARBON FIBERS 3 12% Multi-Wall Carbon Nanotubes (MWCNT) 1-6% SWCNT ADDITIVE % FORMS ITS OWN CONDUCTIVE 3D NETWORK AT ULTRA LOW CONCENTRATIONS IN ELASTOMERS
18 CARBON FIBERS, MWCNT, SWCNT SWCNTs have significantly smaller diameter (1-2nm) Low number of structural defects, high conductivity, high mechanicals No agglomerates and tangling typical for MWCNTs, due to their synthesis TUBALL VAPOR GROWN CARBON FIBERS MWCNT Minimal catalyst particles as-produced 1 µm Note scale 1 µm 1 µm Nominal bundling of SWCNT s 50 nm 20 nm 200 nm
19 MWCNT VS SWCNT CHANGES POLYMER PROPERTIES UNFAVORABLY MWCNT synthesized In fluidized bed reactor SWCNT produced by OCSiAl SINGLE WALL CARBON NANOTUBES DELIVER IMPROVEMENTS AT 10 TO 1000 TIMES LOWER CONCENTRATIONS THAN MWCNT AND OTHER NANO ADDITIVES
20 SOLUTIONS FOR SILICONES
21 END USE CHALLENGE, CONDUCTIVE ELASTOMERS
22 TECHNOLOGY APPROACH A SWCNT MASTERBATCHES FOR SILICONE For anti-static, static dissipative and conductive applications Extremely low loadings of SWCNT that preserve properties Retain mechanical properties including softness Maintain rheology of the uncured compound Standard processing and mixing equipment Enable colored ESD compounds Volume resistivity Retain properties Color enabling Low loading level Ω сm Elasticity & rheology Colored ESD compounds <0.5 wt.% of filler
23 MASTERBATCHES FOR SILICONES Option 1 Carrier: polydimethylsiloxaneoil LSR, and RTV silicones Option 2 Carrier: vinyl-terminated polydimethylsiloxane LSR, RTV and HCR silicones
24 CONDUCTIVE SILICONES VIA SWCNT MASTERBATCH PRIOR APPROACH RESULTS WITH SWCNT MASTERBATCH Specific resistivity level Ω*cm Ω*cm Concentration of conductive filler 30-70% % Negative impact on mechanical properties Yes No Possibilityto mix at clean facilities No Yes Color No Yes 0.2% SWCNT
25 SWCNT MASTERBATCH RTV ELECTRICAL RESISTANCE Ω cm 0.02% SWCNT 0.05% SWCNT 0.4% SWCNT * Tested in two component RTV, dilution in part A. Measurements conducted according to ASTM D257 standard.
26 SWCNT MASTERBATCH HCR ELECTRICAL RESISTANCE Ω cm 0.2% SWCNT * Tested in HCR (Shore 60). Measurements conducted according to ASTM D257 standard.
27 MASTERBATCH AT 3% (SWCNT 0.3%) PHYSICAL PROPERTIES OF HCR WITH Ω cm Tensile strength, Mpa Ultimate elongation, % Hardness Shore A, pts. HCR (Base) 0.3% SWCNT 50% Carbon Black
28 SOLUTIONS FOR OTHER RUBBER TYPES
29
30 TECHNOLOGY APPROACH B MASTERBATCH FOR RUBBER COMPOUNDING FEATURES: Concentrate carrier Low aromatic oil-plasticizer Low concentration in final compounds, 0.1 to 0.3 phrtypical Improved mechanical properties Better wet grip & abrasion resistance Lightweighting(formulation & design) Lower rolling resistance Reduced heat build up Strong increase of electrical conductivity TUBALL MATRIX Loading 5 10 wt.%
31 HOW IT WORKS IN RUBBER SWCNT forms its own spatial network that intertwines withinthe compound TUBALL (SWCNT) Carbon black Rubber macromolecule
32 INDEPENDENT LAB VALIDATION: NATURAL RUBBER-BASED +2% COMPOUND (CB N990) +3% Tensile Strength, MPa +9% -2% -6% Compression set, % -15% TUBALL SWCNT Concentration 0% 0.05% -5% -17% -18% +2% +11% +24% 0.2% 0.5% Abrasion loss, мм3 Shore A Hardness, pts.
33 INDEPENDENT LAB VALIDATION: NATURAL RUBBER-BASED COMPOUND -1% (CB N990) -7% -14% +10% +50% +140% Ultimate elongation, % M 100, MPa TUBALL SWCNT Concentration 0% 0.05% 0.2% 0.5% +5% +48% +126% +2% +41% +113% M 200, MPa +47% M 300, MPa
34 TIRE PERFORMANCE: CURRENT SPACE Performance trade-offs due to limits reached with silica Higher Abrasion Resistance Higher Energy Efficiency Higher Grip Energy efficiency Electrical conductivity Stiffness Energy efficiency Electrical conductivity Stiffness Energy efficiency Electrical conductivity Stiffness Wet grip Abrasion resistance Wet grip Abrasion resistance Wet grip Abrasion resistance Reference compounds
35 TIRE PERFORMANCE: NEW SPACE With TUBALL : strong expansion of performance space Manufacturer Recipe #1 0.2% TUBALL in compound Manufacturer Recipe #2 0.1% TUBALL in compound Manufacturer Recipe #3 0.1% TUBALL in compound Energy efficiency (TanD 60 C) Electrical Conductivity Stiffness Energy efficiency (TanD 60 C) Electrical Conductivity Stiffness Energy efficiency (TanD 60 C) Electrical Conductivity Stiffness Wet Grip (TanD 0 C) Abrasion resistance Wet Grip (TanD 0 C) Abrasion resistance Wet Grip (TanD 0 C) Abrasion resistance Reference compounds
36 TIRE PERFORMANCE SUMMARY TUBALL data from OCSiAl customer trials. Silica data from NHTSA Feb report Dynamic Mechanical Properties of Passenger and Light Truck Tire Treads.
37 SOLUTIONS FOR LATEX
38 TUBALL RUBBER SWCNT MASTERBATCHES FOR LATEX No powder: suspensions for all types of latexes Minimal changes to production technology and formulation Ready to use as produced Retains color
39 NEW STANDARD FOR ESD GLOVES EN 16350:2014 Contact resistance < 1.0x10 8 Ω/sq Vertical leakage resistance < 1.0x10 8 Ω*cm 23 C(±1 C) 25% (±5%) Gloves in the market do not fully comply with the new standard.
40 ESD GLOVES WITH TUBALL RUBBER NATURAL & NITRILE LATEXES NATURAL LATEX FILM 0.03% 10 5 Ohm*m STRENGTH OF MEDIUM MODULUS (L) NATURAL LATEX WITH 0.03%TUBALL +21% +30% +19% NITRILE LATEX FILM 0.05% LINER NITRILE GLOVE 0.06% 0% 10 6 Ohm*m 10 6 Ohm*m *Glove made by industrial partner with 0.05% TUBALL TM M100, MPa M300, MPa Tensile strength, MPa No CNT 0.03% CNT CL60, Medium Modulus, pre-vulcanized. CNT dispersion stabilized by CMC surfactant. EB, %
41 DEVELOPMENT EXPANDING TECHNOLOGY
42 NBR (HNBR) RUBBER O-RING COMPOUND Introduced technology for adding of TUBALL TM based suspension to industrial process of rubber polymer production Q1 & Q Collaboration with large rubber polymer manufacturer. Industrial sampling commenced Q Customer samples of NBR with 0.05% TUBALL TM NBR-based O-ring with TUBALL
43 TUBALL IN RUBBER POLYMERS INTRODUCTION IN RUBBER IN SITU FAVORABLE CHANGE IN POLYMER PROPERTIES Nitrile-butadiene rubber Nitrile-butadiene rubber with 0.05% TUBALL TM
44 INTRODUCED TUBALL INTO RUBBER: IN SITU: NBR-BASED COMPOUND (CB N330) +12% Tear resistance No changes Ultimate elongation Tensile strength Hardness +43% Modulus 300% +29% resistance to repeated deformation
45 NBR (HNBR) RUBBER O-RING COMPOUND +10% property retention after heat aging +20% reduced property loss after rapid gas decompression + 33 C temperature before degradation of material (thermal resistance )
46 OCSiAlCONTACTS OCSiAl LLC OCSiAl Europe Sarl OCSiAl.ru LLC OCSiAl ASIA PACIFIC 500 S Front St, Suite 860, Columbus, OH Luxembourg: L-3364, Leudelange, 1, rue de la Poudrerie, Grand Duchy of Luxembourg , Russia, Moscow Kalanchevskaya str., 2 bld , Russia, Novosibirsk, Inzhenernaya str., Hong Kong: Suite , Queen s Road Central Hong Kong China: #2004, 20th Floor, Block B, DachongBusiness Centre, No. 9678, Shennan Road, Nanshan District, Shenzhen, Guangdong, China QUESTIONS? Korea: Republic of Korea, Incheon, Incheon Technopark12, Gaetbeol-ro, Yeonsu-gu,Pilot Plant Bldg., Office
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