A method of forming a composite material includes disposing dried plant material, nanoparticles, and a supercritical fluid in a vessel. A cellular structure of the dried plant material expands when disposed in the supercritical fluid and the nanoparticles migrate into and are embedded within the expanded cellular structure of the disposed dried plant material. The disposed dried plant fibers with embedded nanoparticles are removed from the vessel and mixed with a polymer to form a polymer-nanoparticle mixture. A chemical additive can be added to the supercritical fluid and the chemical additive can remove at least one of hemicellulose, lignin and pectins from the dried plant material.

In an embodiment the dielectric layer comprises a fluoropolymer, a plurality of boron nitride particles, a plurality of titanium dioxide particles, a plurality of silica particles; and a reinforcing layer. The dielectric layer can comprise at least one of 20 to 45 volume percent of the fluoropolymer, 15 to 35 volume percent of the plurality of boron nitride particles, 1 to 32 volume percent of the plurality of titanium dioxide particles, 10 to 35 volume percent of the plurality of silica particles, and 5 to 15 volume percent of the reinforcing layer; wherein the volume percent values are based on a total volume of the dielectric layer.

A water-resistant composition 20 includes a graphene material 22 forming a matrix with a resin 23. The matrix can include reinforcing fibres such as glass fibres. The composition can include the graphene material 22, a polyester resin 23 and glass fibre reinforcement. Multiple forms of the composite can be provided in layers, such as a barrier layer containing the graphene material 22 in a resin 23 and a second layer containing reinforcing material. A cosmetic coloured gel coat can be applied to the composition and a clear gel coat applied over the cosmetic coating. The graphene material can include graphene platelets 22 dispersed within the resin. The graphene material can provide up to 5% by weight (% wt) of the composite, preferably up to 2% wt of the composite, more preferably between 1% wt and 2.5% wt of the composite and yet more preferably 2% wt of the composite. The composition can be applied to a boat hull, a pipe, a swimming pool, a spa or a tank, or a surface subject to prolonged contact with or submersion in water.

A composite formulation for use in lightweight molded components includes an untreated low density filler, such as glass bubbles, a solvated polymer mixture, and polymer paste. In one embodiment the solvated polymer mixture is used to treat the low density filler to form a treated low density filler. The solvated polymer mixture many include a thermoplastic resin or a reactive resin and an additive package. The additive package may include a dispersing agent and a silane carrier composition.

A method for fabricating carbon nanoparticle polymer matrix composites includes the steps of: providing a nanoparticle mixture that includes carbon nanoparticles (CNPs), mixing the nanoparticle mixture and a plastic substrate into a homogenous (CNP)/polymer mixture having an interconnected network of carbon nanoparticles (CNPs); and irradiating the (CNP)/polymer mixture with electromagnetic radiation controlled to form a polymer composite and uniformly consolidate and/or interfacially bond the carbon nanoparticles (CNPs) into the polymer matrix.

The present invention includes the efficient dispersion and high loading of fillers in a thermoplastic polymer matrix. In a first general embodiment, the present invention includes a method wherein fillers are first synthesized and dispersed in a liquid monomer. The liquid monomer is then polymerized to a solid. The nanofillers may be silver nanoparticle/nanowire fillers. Ethylene glycol may serve as a solvent, reducing agent as well as precursor monomer for polymerization. In a second general embodiment, the present invention includes a method wherein fillers may be separately synthesized (or obtained commercially) and then added and dispersed in a liquid monomer. The liquid monomer is then polymerized to a solid. In a third general embodiment, a composite is synthesized using interfacial polycondensation. This is accomplished by aggressive mixing of two solvents during the reaction. The aggressive mixing forms microdroplets (i.e., emulsion) and hence dramatically increases the interface area thereby to a much faster polymerization rate.

A carbon nanotube-elastomer composite material according to the present invention is produced by dispersing a carbon nanotube in an elastomer, including a carbon nanotube having a diameter of 20 nm or less, the number of layers of 10 or less, the carbon nanotube being contained in an amount of 0.1 to 20 parts by weight inclusive relative to the total weight of the carbon nanotube and the elastomer, and a continuous network having a Va/V.sub.0 value of 0.5 or more is formed in the elastomer wherein V.sub.0 represents the initial volume of the composite material and Va represents the volume of the structure formed from the remaining carbon nanotubes when the composite material is maintained at a temperature of 400° C. or higher for 6 hours while introducing nitrogen, the elastomer is thermally decomposed and the remaining carbon nanotubes form a structure.

A bore tool can include a component that includes a longitudinal axis and a perimeter surface disposed at one or more radii from the longitudinal axis; and an elastomeric component disposed about the perimeter surface where the elastomeric component includes an elastomeric material that includes carbon-based nanoplatelets.

A method for making a carbon nanotube composite structure includes providing a polymer substrate having a first surface and a second surface opposite to the first surface. A first carbon nanotube layer including a plurality of carbon nanotubes is placed on the first surface to form a preformed structure, wherein the carbon nanotube layer and the polymer substrate are stacked with each other. The preformed structure is scanned with a laser according to a predetermined pattern. The treated preformed structure includes a first part and a second part. The first part is scanned by the laser, and the second part is not scanned by the laser. The first part includes a plurality of first carbon nanotubes, and the second part includes a plurality of second carbon nanotubes. The plurality of second carbon nanotubes is removed.

Materials including support layers and fiber-free compositions are disclosed, as well as related articles and methods for making the materials. The fiber-free compositions are formed from a precursor composition that includes a nitrile butadiene rubber, a nanoclay and a cure package including a sulfur-based curing agent. The fiber-free compositions may have a substantially reduced weight and compressive modulus in comparison to conventional rubber. Thus, the fiber-free compositions may provide improved ballistic properties in addition to reduced density and thickness. Precursor compositions for forming the insulative composition may have good flow characteristics. The fiber-free compositions may be used in a variety of applications, such as personnel body armor, ground vehicle armor and aircraft armor systems.