Nanoscale
Materials Make for Large-Scale Applications
Consumer/Home/Recreation
Originating Technology/ NASA Contribution
Since its dawning days, NASA has been at the forefront
of developing and improving materials for aerospace
applications. In particular, NASA requires dramatic
advancements in material properties to enhance the
performance, robustness, and reliability of its launch
vehicles, spacecraft, and the International Space Station.
Such advancements over the years include noise-abatement
materials, fire-resistant fibers, heat-absorbing insulation,
and light-but-strong moldable composites.
In 1991, a new carbon fiber called a carbon nanotube
was discovered and fully substantiated by a Japanese
electron microscopist. Its dramatic strength and low
density (20 times the tensile strength and one-sixth
the density of steel) were turning the heads of materials
scientists and engineers all around the world, including
those who developed equipment for NASA.
While NASA did not invent the carbon nanotube, it is
working to advance the fibrous material for widespread,
low-cost application in sending humans beyond low-Earth
orbit, well into the outer reaches of the universe.
Carbon nanotubes have the potential to reduce spacecraft
weight by 50 percent or more, by replacing the heavier
copper wires currently used, according to NASA scientists.
Furthermore, NASA researchers have reported a new method
for producing integrated circuits using carbon nanotubes
instead of copper for interconnects. This technology
has the capability to extend the life of the silicon
chip industry by 10 years.
Because of this growing interest in carbon nanotubes
and their perpetual possibilities, NASA has funded
both internal and external research in this field.
Partnership
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With assistance from NASA, Zyvex Corporation built extremely strong and light hierarchical carbon nanotube-composite materials. |
In 2001, Zyvex Corporation, of Richardson, Texas, developed a revolutionary method of changing carbon nanotube chemistry without harming the molecular structure that gives the carbon nanotubes their remarkable properties. In February 2003, Johnson Space Center recognized the promise of this technology and began working with Zyvex through a Phase I Small
Business Innovation Research (SBIR) contract to develop
the rational engineering of carbon nanotube surface
chemistry.
In the Phase I program, Zyvex not only demonstrated
the ability to make high-concentration solutions
of carbon nanotubes in organic solvents, but also
demonstrated the ability to achieve excellent dispersion
of the carbon nanotubes in polymers such as epoxy.
These successes led to a Phase II SBIR contract with
Johnson in January 2004, to build extremely strong
and light hierarchical carbon nanotube-composite
materials for NASA applications.
Even though the partnership between Zyvex and NASA
is still in its early stages, these modified carbon
nanotubes are on the fast track for establishing
new classes of materials that will meet the Space
Agency’s needs as it produces new, safer, and more
cost-effective spacecraft. The Phase II contract
with Johnson is still in progress and a new Phase
I SBIR contract with Marshall Space Flight Center
to develop carbon nanotube-reinforced radiation shielding
is also underway.
Product Outcome
The introduction of a new material into commercial
applications is usually a 5- to 10-year process.
With the active support of NASA, a rigorous New Product
Development Process, and a commitment to speed of
execution, Zyvex took less than 3 years to go from
invention to commercialization.
Shortly after conceiving and demonstrating a new
way to functionalize carbon nanotubes, Zyvex filed
initial patents and implemented its New Product Development
Process for the carbon nanotube polymer composites.
Based on the successful results of the Phase
I Johnson SBIR contract, Zyvex started offering solubilized
carbon nanotubes on its Web site in September 2003.
Exactly a year later—in the midst of the Phase II
SBIR work—Easton Sports, Inc., announced the use
of Zyvex carbon nanotube technology in its new line
of bicycle parts.
Van Nuys, California-based Easton Sports has
an 82-year history of leading its market by developing
new materials to achieve enhanced performance in
sporting goods. The company’s bicycle division has
incorporated the Zyvex technology, commercially known
as NanoSolve, in its 2005 line of bicycle components,
including handlebars.
Robert Folaron, Zyvex’s director of product development,
noted, “The Easton-Zyvex partnership offers an oppotunity
for two leaders to rapidly develop a carbon nanotube-enhanced
composite and quickly adopt it into a product line.”
John Harrington, vice president of Easton Sports’s
bicycle division, agreed, saying, “We saw a large
increase in the strength and toughness of the composite
when the nanotubes were properly functionalized.
With that achievement, we were able to create lighter
and stronger bicycle components.”
Easton Sports again looked to Zyvex and its NanoSolve
technology in February of this year, to take hockey
and baseball equipment to the next level.
The revolutionary Easton Synergy SL composite hockey
stick increases stick strength while reducing weight.
It is lighter (420 grams) and stronger than
its Synergy predecessor, and has a new blade design
that yields “unmatched performance,” according to
Easton Sports.
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The manipulation of materials
on a molecular scale is leading to lighter-but-stronger
hockey sticks. Pictured here is Easton Sports, Inc.’s
Synergy SL product, featuring Zyvex Corporation’s
NanoSolve technology. |
“We view the incorporation of carbon nanotubes into
our sticks as a critical step in further developing
the world’s best hockey sticks,” said Ned Goldsmith,
vice president of Easton Sports’s hockey division.
“The Synergy SL is the first stick to utilize carbon
nanotube’s stronger and more durable material design.
Keeping with our tradition of putting Easton sticks
in the hands of the world’s best players, Peter Forsberg
has already adopted this new design while playing
in Sweden for Modo,” he added. Forsberg is also a
member of the National Hockey League’s Philadelphia
Flyers franchise.
Easton Sports is touting its NanoSolve-reinforced
Stealth baseball bat as the “best bat in the game
today.” The NanoSolve technology enhances the company’s
Opti-Flex composite handle technology, providing
maximum handle flex, up to 3 times greater than aluminum
bats. Additionally, NanoSolve provides better responsiveness
and more “kick” through the hitting zone.
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The addition of carbon nanotube technology, made possible by NanoSolve materials and exclusive to Easton Sports, Inc., strengthens composite structures in baseball bats to provide improved handle designs with optimized flex, responsiveness, and more “kick” through the hitting zone, for maximum performance. Pictured here is the Easton Stealth Sc900 |
Zyvex recently partnered with
several other major corporations to introduce NanoSolve
in multiple markets. These businesses include Boston
Scientific Corporation; IBM Corporation; Honeywell
International, Inc.; Nantero, Inc.; Fiat; and DuPont.
The success realized to date is just the beginning
for Zyvex, as it is committed to continuing the development
of NanoSolve for both commercial and government applications.
Based on the company’s preliminary commercial analysis
for market segments, it estimates that the potential
niche markets for its composites will be modest in
the beginning years, but its growth will reach $400
million to $800 million, 10 years after commercialization.
Zyvex acknowledges that the market for advanced composites
is competitive; but, since its goal is to develop
composite materials with strength superior to any
material produced today, it believes it will be in
a unique position to
partner with companies that manufacture carbon and
composite fibers.
According to Thomas A. Cellucci, Zyvex president,
the company’s ongoing relationship with NASA is especially
important: “We are extremely pleased to be working
with NASA. A large portion of our success in nanomaterials
is due to their involvement.”
The Federal Aviation Administration will be
referencing the Johnson SBIR Phase II contract, according
to Zyvex, in a congressional report that highlights
the future benefits of carbon nanotubes. Zyvex also
has monetary and hands-on support from the Defense
Advanced Research Projects Agency to develop high-strength
materials.
NanoSolve™ is a trademark of Zyvex Corporation.
Sc900™ is a trademark of Easton Sports, Inc.
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