Recent advancements in nanocomposite fibers, particularly carbon nanotube (CNT)/polymer hybrids, have revolutionized the textile industry by offering unprecedented mechanical, thermal, and electrical properties. Studies have demonstrated that incorporating 1-5 wt% CNTs into polymer matrices such as polypropylene (PP) or polyethylene terephthalate (PET) can enhance tensile strength by up to 300% and modulus by 200%, while maintaining flexibility. For instance, a PP/CNT composite with 3 wt% CNTs exhibited a tensile strength of 120 MPa compared to 40 MPa for pure PP. These improvements are attributed to the exceptional aspect ratio (~1000) and high surface area (~250 m²/g) of CNTs, which facilitate efficient stress transfer and interfacial bonding with the polymer matrix.
The integration of CNT/polymer fibers into textiles has enabled the development of multifunctional fabrics with enhanced thermal conductivity and flame retardancy. Experimental results show that adding 2 wt% CNTs to nylon increases thermal conductivity from 0.25 W/m·K to 1.2 W/m·K, making it suitable for heat-dissipating applications. Additionally, CNT/polymer composites exhibit self-extinguishing behavior under flame exposure, with a limiting oxygen index (LOI) of 28% compared to 21% for pure polymers. This is due to the formation of a protective char layer and the ability of CNTs to act as thermal barriers. Such properties are critical for protective clothing in high-temperature environments.
Electrically conductive textiles based on CNT/polymer fibers have emerged as a game-changer in wearable electronics and smart textiles. Research has shown that embedding 4 wt% CNTs in polyurethane (PU) fibers achieves an electrical conductivity of 10⁻² S/cm, enabling applications in strain sensing and energy harvesting. For example, a PU/CNT fabric demonstrated a gauge factor of 15 under 10% strain, outperforming traditional metallic sensors. Moreover, these fibers can be woven into fabrics capable of harvesting mechanical energy via piezoelectric effects, generating up to 5 µW/cm² under mechanical deformation.
The scalability and sustainability of CNT/polymer fiber production have been addressed through innovative manufacturing techniques such as melt spinning and electrospinning. Melt spinning of PET/CNT composites at industrial scales has achieved production rates of 500 m/min while maintaining uniform dispersion of CNTs at concentrations up to 5 wt%. Electrospinning, on the other hand, enables the fabrication of nanofibers with diameters as low as 100 nm and surface areas exceeding 50 m²/g, ideal for filtration applications. Recent life cycle assessments indicate that the environmental impact of CNT/polymer fibers can be mitigated by using recycled polymers and optimizing processing conditions.
Future directions in this field focus on leveraging machine learning and advanced characterization techniques to optimize fiber properties and expand applications. Predictive models based on artificial neural networks have achieved over 90% accuracy in forecasting mechanical performance based on CNT concentration and alignment. Furthermore, in situ microscopy techniques such as TEM tomography provide insights into nanoscale interactions between CNTs and polymers, guiding the design of next-generation nanocomposites. These innovations promise to unlock new possibilities in aerospace textiles, biomedical implants, and beyond.
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