Mineral fillers, metals, and fibers have been added to thermoplastics and thermosets for decades to form composites. Compared to neat resins, these composites have a number of improved properties including tensile strength, heat distortion temperature, and modulus. Thus for structural applications, composites have become very popular and are sold in billion-pound quantities. These filled thermoplastics are even sold in larger volumes than neat thermoplastics. Furthermore, the volume of fillers sold is roughly equal to the volume of thermoplastic resin sold. More recently, advances in synthetic techniques and the ability to characterize materials readily on an atomic scale has led to interest in nanometer-sized materials. These nanometer-sized grains, fibers, and plates have dramatically increased surface area compared to their conventionally sized counterparts. Polymer nanocomposites (thermoplastics and thermosets) combine these two concepts of increased surface area and synergies between fillers and matrices.
According to a soon-to-be-released updated report from Business Communications Company, Inc, RP-234 Polymer Nanocomposites: Nanoparticles, Nanoclays and Nanotubes, the total worldwide market for polymer nanocomposites reached 24.5 million pounds valued at $90.8 million in 2003. This market is expected to grow at an AAGR (average annual growth rate) of 18.4% to reach $211.1 million by 2008.
Polymer nanocomposites have been making a large splash in the media and in many industries of late. Given all the interest in these materials, it is surprising to discover that it is difficult to find them in actual use. Most of the successes of nanocomposites have actually been rather low profile, but they have stealthily been making an impact on modern life. Nearly every car produced in the U.S. since the late 1990s contains some carbon nanotubes blended into a nylon to protect against static electricity in the fuel system. Computer read/write heads are protected using ESD polymers, which contain nanotubes as well. In Europe, some buildings contain flame retardant polymers with nanoclays mixed in, while Japanese automakers continue to use nanoclay-filled polymers for engine parts. Perhaps the most visible nanocomposite application involves GM's recent announcement that its 2004 Chevrolet Impala will have the first major exterior application of a nanoclay-filled TPO.
Current volumes of thermoplastic and thermoset nanocomposites produced are roughly equal. By 2008, thermoplastics will constitute 77% of the volume market. The dollar value of thermoplastics is larger, because these are higher valued added goods and are used in high dollar niche applications. Over the next five years, some of the long-touted applications of thermoplastic nanocomposites may come to fruition, which would lead to dramatic growth in these markets -- in both dollars and volumes. Even if these new applications run into unexpected difficulties, these products will continue to expand into their existing markets at a strong rate of growth, exceeding 20% in some cases.
While thermoset applications of nanocomposites are less diverse than thermoplastic applications, there have already been some successes with these materials. Thermoset nanocomposites are currently being used in prefinished wood flooring found in many residential homes. Nanocomposite thermosets will rise at an AAGR of 9.9% from $20 million in 2003 to $32 million in 2008.
