Zyvex Continues to Lead CNT Developments

Zyvex Performance Materials is focused on the composites market, which is still one of the most potentially viable sectors of the polymer marketplace. In particular, nanocomposites (carbon nanotube-enhanced composites), are very specific to Zyvex’s innovative products, and nanocomposites are still on track to double in volume annually for the next several years.

Lance Criscuolo, Zyvex President, says that the composites industry is emerging in Ohio and will require state support. “Third Frontier (Ohio Department of Development – ODOD) and other programs have been a huge boost thus far, and such programs need to continue.” One reason why the work begun by the Third Frontier (TFP) is producing noticeable successes is that Ohio has developed a strong supply chain of companies that each take part in the specialized functions required to bring a product from raw material to sellable item. “However, there is a need to capitalize and leverage resources to ensure that Ohio emerges as the national leader in composites and other advanced materials,” says Criscuolo. “In Europe, there is a Composite Park located in France and supported by the French Government that is going to be direct competition for companies in the US.”

The European program is very similar to what Ohio already has in place, namely financial and technical support similar to what PolymerOhio, the Center for Multifunctional Polymer Nanomaterials and Devices (CMPND), and ODOD offer ; the presence of university subsidiaries; networks of similar companies; training programs; and job creation opportunities.

Zyvex has become a role model for how emerging companies in Ohio are optimizing the available technology, funding, and collaboration opportunities to support their growth and advancement. Zyvex started working with nanotechnology and nanomaterials almost a decade ago. They have developed a strong intellectual property basis with 18 patents granted and slightly more than that number moving through the acceptance process. Their Columbus facility has increased to 20 employees and predicts to grow to 55 by 2010. Even better is that their products are winning awards and recognition – Forbes 2005 product of the year, a golf shaft won US Open in 2006; and baseball bats used in the College World Series in 2006 and still produced today.

With some products in production, some in development, and some just emerging from the concept stage, Zyvex is building functionality into nanomaterials-based products. Criscuolo explains that his company’s products depend on molecular and polymer design to incorporate CNTs into nanomaterials with significant mechanical and electrical enhancements. “We can tailor nanomaterials to be adaptable to multiple systems,” Criscuolo explains. “We are using unique and novel, non-covalent, non-damaging functionalization based on patents and protected trade secrets.” “And we have been able to develop compatibility with multiple host matrices and nanomaterials.” CNTs are 100 times stronger than steel at one-sixth the weight, he explains, and they are electrically and thermally conductive. CNTs are also “phobic” to almost everything, so they need to be coerced into resin systems. Criscuolo explains that Zyvex has developed the technology to make CNTs compatible with resins, thus opening the door to many new products and processes.

“Our value is based on our technical approach,” says Criscuolo, “which involves exfoliation of CNTs (which is required to debundle raw tubes), followed by uniform dispersion of nanotubes into matrixes. The technology is dependent on strong adhesive properties, which prevent the CNTs from slipping within the matrix.” “Our Kentera™ technology, which is a dispersing and compatibilizing agent, has enabled Zyvex to lock CNTs into composites and optimize their properties.” CNTs fill the gaps between carbon fibers in composites and effectively increase the load transfer from fiber to fiber. Zyvex has capitalized on this technology with a new product called Arovex, which  is a CN- enhanced, carbon-fiber prepreg with performance improvement of 40 to 50% over the current industry standard products. The Zyvex Epovex™ technology, a novel epoxy, tests out at a 40 percent improvement over conventional epoxy systems used in composites. From its earliest applications as an early applier of CNTs in marine, auto, aviation, and sporting goods, Zyvex is continuing to develop its core capabilities and expand the use of nanomaterials into resins, elastomers, and thermoplastics.

Zyvex recently won a new Research Commercialization Program (RCP) grant from ODOD with networking/supply chain coordination and proposal strategy support from CMPND. The previous RCP grant won by Zyvex has help propel Arovex™ into marine products, and Epovex and Epovex adhesive into wind blades (for power generation) and sporting goods (such as skate boards). Now moving forward is the Zyvex collaboration with PolyOne Corporation and others in their Ohio supply chain to find ways to boost both the conductivity and mechanical properties of materials via nanotechnology. “To date, most innovators in this area have been challenged by the market reality that composite materials that achieve good conductivity tend to lose mechanical properties,” says Criscuolo. “We aim to put both property categories into the “high” category, and are working on such products as a moldable product that has enhanced electromagnetic shielding.” By collaborating with PolyOne, Zyvex hopes to have the first such products released by 2010 for medical and automotive applications.

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Zyvex Performance Materials is one of the first companies to successfully commercialize materials that take advantage of the superior properties of carbon nanotubes and other nanomaterials. With its collaborators – PolyOne, Renegade Materials Corp., APV Engineered Coatings, Hexion Specialty Chemical, Lockheed Martin, the University of Dayton Research Institute, the University of Akron, Shawnee State University, Owens Corning, and PolymerOhio – Zyvex has been researching advanced chemistry to expand its unique Kentera technology for the development, production, and marketing of new materials and products into various markets.

The Center for Multifunctional Polymer Nanomaterials and Devices (CMPND) is a research and commercialization partnership in polymer nanotechnology. This multi-institutional, interdisciplinary organization, centered at The Ohio State University, partners with the University of Dayton, the University of Akron, the University of Toledo, Kent State University, and Wright State University. For more information, cmpnd.org

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