Materials for Thermal Protection and Methods of Manufacturing Same

1 . A thermal protection material comprising:

a non-woven sheet of nanotubes;

a substrate material adjacent to the non-woven sheet; and

an adhesive material positioned between the non-woven sheet and the substrate material.

2 . A material as set forth in claim 1 , wherein the non-woven nanotube sheet has a density ranging from at least about 0.1 mg/cm2 to over 5 mg/cm 2 .

3 . A material as set forth in claim 1 , wherein the non-woven nanotube sheet has a nominal strength ranging from about 10K to about 20K psi.

4 . A material as set forth in claim 1 , wherein the non-woven nanotube sheet a tensile strength over 40 MPa.

5 . A material as set forth in claim 1 , wherein the substrate material includes one of Nomex®, aluminum foil, structural aluminum component, stainless steel, Incontel, titanium, or any other type of textile, metal, or substrate for which thermal protection is desired.

6 . A material as set forth in claim 1 , wherein the adhesive material includes a glassy carbon precursor material.

7 . A material as set forth in claim 1 , wherein the adhesive material can form a char, rather than melts or destructively bums in the presence of relatively high heat.

8 . A material as set forth in claim 1 , wherein the adhesive material includes one of PVA, furfuryl alcohol, or RESOL® resin.

9 . A material as set forth in claim 1 , wherein the material can withstand heat up to about 500° C. without substantially burning.

10 . A material as set forth in claim 1 , further including a coating that can enhance strength and oxidation resistance.

11 . A material as set forth in claim 10 , wherein the coating includes one of Polyureamethylvinylsilazane, Polycarbosilane, or a similar compound.

12 . A material as set forth in claim 10 , wherein the material can withstand heat over 1000° C. or more without substantially burning.

13 . A material as set forth in claim 10 , wherein the material has an increased strength of from about 30 MPa to over about 300 MPa.

14 . A method of manufacturing a thermal protection material, the method comprising:

providing a non-woven sheet of nanotubes;

bonding a substrate material to the non-woven sheet with an adhesive material positioned between the non-woven sheet and the substrate material; and

pyrolyzing the non-woven nanotube sheet and the substrate material in an inert atmosphere to form a thin glassy carbon bonding layer therebetween.

15 . A method of claim 14 , wherein, in the step of bonding, the adhesive material includes a glassy carbon precursor.

16 . A method of claim 15 , wherein, in the step of bonding, the glassy carbon precursor is one of Resol resin, malic acid catalyzed furfuryl alcohol, or PVA.

17 . A method of claim 14 , wherein the step of pyrolyzing includes carrying out in an inert atmosphere or in a vacuum.

18 . A method of claim 14 , further including coating the material with one of Polyureamethylvinylsilazane, Polycarbosilane, or a similar compound that can enhance strength and oxidation resistance.

19 . A method of claim 18 , wherein the step of coating includes dissolving the Polyureamethylvinylsilazane in acetone solutions in concentrations ranging from about 1% to about 20%.

20 . A method of claim 18 , further including hot pressing the coated material at an elevated temperature ranging from about 50° C. to about 300° C.

21 . A method of claim 20 , wherein the step of hot pressing includes exposing the coated material to a pressure ranging from about 1,000 psi to about 20,000 psi.

22 . A thermal protection material comprising:

a first layer having a first non-woven sheet of nanotubes, a substrate material adjacent to the first non-woven sheet, and an adhesive material positioned between the first non-woven sheet and the substrate material; and

a second layer adjacent the first layer, the second layer having a second non-woven sheet of nanotubes, a substrate material adjacent to the second non-woven sheet, an adhesive material positioned between the second non-woven sheet and the substrate material, and a coating that can enhance strength and oxidation resistance in the second layer.

23 . A material as set forth in claim 22 , wherein the substrate material includes one of Nomex®, aluminum foil, structural aluminum component, stainless steel, Incontel, titanium, or any other type of textile, metal, or substrate for which thermal protection is desired.

24 . A thermal transfer material comprising a non-woven sheet of nanotubes designed to be placed between a heat source and a heat dissipation source, so as to serve to transfer heat from the heat source to the heat dissipation source.

25 . A material as set forth in claim 24 , wherein the heat transfer capability of the non-woven nanotube sheet occurs in a lateral direction.

26 . A material as set forth in claim 25 , wherein the heat transfer capability of the non-woven nanotube sheet occurs in a transverse direction within a plane of the sheet.

27 . A material as set forth in claim 25 , further including a substrate bonded to the non-woven sheet of nanotubes.

28 . A apparatus for forming a nanofibrous non-woven sheet, the apparatus comprising:

a housing having an inlet through which a flow of synthesized nanotubes can enter into the apparatus;

an assembly situated substantially parallel to the flow of synthesized nanotubes for collecting the nanotubes entering through the inlet;

a moving surface positioned about the assembly onto which synthesized nanotubes can be substantially continuously deposited, so as to form a non-woven sheet; and

an outlet for removing the non-woven sheet of nanotubes from housing.

29 . An apparatus as set forth in claim 28 , wherein the housing is substantially airtight to minimize airborne release of nanotubes and related particulates from within the housing.

30 . An apparatus as set forth in claim 28 , wherein the assembly includes an ability to substantially transverse to the flow of the nanotubes across the inlet in order to generate a sheet relatively wider than the flow of nanotubes.

31 . An apparatus as set forth in claim 28 , wherein the assembly includes sliding arms, so that the assembly can be pulled from housing through the outlet for ease of removal of the non-woven sheet of nanotubes.

32 . An apparatus as set forth in claim 28 , wherein the moving surface is a belt disposed about opposing rotating elements on the assembly.

33 . An apparatus as set forth in claim 28 , wherein the moving surface includes a material capable of attracting the nanotubes thereonto.