Co-continuous phase nanofiber composites

We report on the development of a co-continuous phase composite with a polyacrylonitrile (PAN nanofiber network integrated into an acrylonitrile-butadiene-styrene (ABS) matrix that offers improved mechanical strength. Homogeneous dispersion of nanomaterials in a matrix can be challenging and typically involves mechanical mixing or chemical modification. This work overcomes this obstacle by taking an inverse approach in that a nanoscale network is synthesized then infiltrated with polymer instead of attempting to disperse the nanomaterial in the polymer. This not only enables excellent homogeneity but also allows the nanoscale phase to be continuous throughout the composite. Here, PAN is electrospun to form a random network of nanofibers having diameters of roughly 200 nm, which is then infiltrated with ABS using solution processing. By optimizing the heat treatments and ABS concentrations, the tensile strength and elastic modulus were improved by 208% and 313%, respectively, as compared to the bare PAN nanofibers. Since there has been significant previous research efforts on electrospinning polymers, many different nanofiber and polymer systems can be made into composites using the methodology established in this work. Therefore, this research offers a new route to create a co-continuous composite with the aim to replace some existing fiber reinforced composites.