Carbon nanotube buckypaper to improve fire retardancy of high-temperature/high-performance polymer composites.

Mixed single-walled and multi-walled carbon nanotube membrane (buckypaper) was incorporated onto the surface of polyimide/carbon fibre composites via a compression moulding process. Flammability was investigated by cone calorimeter tests under an external radiant heat flux of 50 kW m(-2). The burning residue was analysed with scanning electron microscopy and thermogravimetric analysis. The buckypaper survived the burning test and decreased the peak heat release rate by 40%, reduced the total heat release by 26%, produced 82% less smoke release and resulted in 33% less mass loss. The directly mixed carbon nanotubes (5 wt% multi-walled carbon nanotubes) yielded 38% less peak heat release rate, only 3.7% less total heat release, 28% more smoke release and no change in mass loss. Compared to direct mixing of carbon nanotubes into the resin, the use of buckypaper is more efficient in fire retardancy improvement; it yielded further delay of ignition, lower heat release rate, further reduced heat release, lower mass loss and less smoke release. The buckypaper worked as an excellent physical barrier, obstructing the flow of heat and oxygen to the inner polymer resin. The as-prepared buckypaper greatly improved the fire retardancy of polyimide matrix carbon fibre composites.