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A novel method for the continuous dispersion of carbon nanofibers (CNFs) in a polymer matrix for manufacturing high performance nanocomposites was developed using an ultrasonically assisted single screw extrusion process. The effect of ultrasound on die pressure, electrical and thermal conductivity, rheological, morphological and mechanical properties of polyetherimide (PEI) filled with 1 to 20 wt.% CNFs was studied. A reduction in the die pressure and percolation threshold of CNF/PEI nanocomposites with a permanent increase in the viscosity and a permanent decrease in tan δ was achieved through ultrasonic treatment. Morphological studies of the treated nanocomposites revealed their improved homogeneity leading to an increase of the Young's modulus and electrical and thermal conductivity.

Ultrasound Assisted Single Screw Extrusion Process for Dispersion of Carbon Nanofibers in Polymers