Preparation and performance study of carbon nanotube/polyphenylene sulfidecomposite materials based on floating catalytic chemical vapor deposition and continuous dusting powder

Abstract Carbon nanotubes (CNTs) are commonly used to enhance composite performance due to their exceptional properties. However, existing preparation methods suffer from complexity, poor interfacial bonding, and inadequate CNT dispersion. To address these issues, a new method for CNT composite preparation using floating catalytic chemical vapor deposition (FCCVD) is proposed in this study. Here, polyphenylene sulfide (PPS) powder is uniformly spread onto the continuously formed CNT network using a vibrator to prepare a CNT/PPS composite film. Subsequently, multilayer composite films are hot‐pressed into molds to produce CNT/PPS composites. The study investigates the mechanical, electrical, and thermal properties of these composites. Due to the preserved 3D CNT conductive network and strong interfacial bonding between PPS and CNTs bundles, the CNT/PPS composite demonstrates excellent electrical conductivity, mechanical strength, and electrothermal performance. This method offers a simple, effective, environmentally friendly, and promising approach for producing high‐performance CNT composite materials. Highlights A novel method for the fabrication of CNT/PPS composites. 3D conductive network enables composites to obtain high conductivity at low CNT content. The prepared CNT/PPS composites have excellent electrical, mechanical, and electrothermal properties.