MOLECULAR REBAR® – the Breakthrough Process

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Carbon Nanotubes – Background

In the early 1990’s, carbon nanotube discoveries were praised for their potential to create significant improvements in material science. CNT’s had so much theoretical and broad application potential that they were anointed as a generational change in materials design and performance.  To date, the promise of CNT performance has never materialized. The major impediment was the inability to unbundle CNT’s and separate them into their optimum form – discrete tubes.

Today, all other methods of manufacturing CNT’s – through arc furnaces, laser ablation, or fluid-bed reactors – result in “fuzzy balls,” which are composed of highly entangled CNT’s. These fuzzy balls hinder or prevent the dispersion of the individual tubes which is required to achieve the theoretical optimums proposed by current material science theories. An ideal product would also be functionalized to adhere to the receiving material and be fully dispersed to ensure consistent properties and performance. As expected, the inability to optimize CNT’s resulted in commercially insignificant improvement in the properties of the receiving materials and prevented widespread commercialization of CNT’s.


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Molecular Rebar Design Develops the Breakthrough Process

The patent pending MRD manufacturing method addresses the critical issues presented above. The breakthrough provides a continuous process that results in the production of untangled CNT’s, which we call MOLECULAR REBAR®.

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How It Works
Our patent pending process starts with today’s commercially available, fuzzy-ball laden, but nonperforming CNT’s. Through a set of proprietary operations, the CNT’s are separated into discrete tubes with aspect ratios in the ideal 60-100 range. Then they are dispersed in formulations that maintain the discrete tube composition. The uniform mixture is then made into masterbatches (either solid or liquid), which can be efficiently and safely shipped to customers. Another great advantage of our MOLECULAR REBAR® is that it can be used with existing equipment and processes with little to no investment needed by the end-user.