Systems and methods for formation and harvesting of nanofibrous materials
A system that receives nanomaterials, forms nanofibrous materials therefrom, and collects these nanofibrous materials for subsequent applications. The system is coupled to a chamber that generates nanomaterials, typically carbon nanotubes produced from chemical vapor deposition, and includes a mechanism for spinning the nanotubes into yarns or tows. Alternatively, the system includes a mechanism for forming non-woven sheets from the nanotubes. The system also includes components for collecting the formed nanofibrous materials. Methods for forming and collecting the nanofibrous materials are also provided.
1. A non-woven sheet material comprising:
a first non-woven sheet comprising nanotubes grown at a temperature ranging from 1100° C. to 1300° C. and having an aspect ratio of length to diameter greater than 10,000:1, wherein the nanotubes include a catalytic nanoparticle of ferromagnetic material and are arranged in an intermingled and overlapping fashion with one another;
a second non-woven sheet comprising nanotubes grown at a temperature ranging from 1100° C. to 1300° C. and having an aspect ratio of length to diameter greater than 10,000:1, wherein the nanotubes include a catalytic nanoparticle of ferromagnetic material and are arranged in an intermingled and overlapping fashion with one another, and
a matrix material between the first non-woven sheet and the second non-woven sheet
wherein the matrix material bonds the first and second non-woven sheets together to form a substantially planar body.
2. A sheet as set forth in claim 1 , wherein the planar body can be substantially square or rectangular in shape.
3. A sheet as set forth in claim 1 , wherein the ferromagnetic material includes one of Fe, Co, Ni, an alloy thereof, a combination thereof, or related materials.
4. The non-woven sheet material of claim 1 , wherein the matrix material is selected from Krayton, vinyl ester, PEEK, bispolyamide, bismaleimide, epoxies, polyamide, and combinations therefrom.
5. A non-woven sheet material comprising:
at least a first non-woven sheet comprising nanotubes grown at a temperature ranging from 1100° C. to 1300° C. and having an aspect ratio of length to diameter greater than 10,000:1, wherein the nanotubes include a catalytic nanoparticle of ferromagnetic material and are arranged in an intermingled and overlapping fashion with one another;
at least a second non-woven sheet comprising nanotubes grown at a temperature ranging from 1100° C. to 1300° C. and having an aspect ratio of length to diameter greater than 10,000:1, wherein the nanotubes are arranged in an intermingled
and overlapping fashion with one another,
a matrix material between the first non-woven sheet and the second non-woven sheet; and
a plurality of stacked non-woven sheets comprising nanotubes grown at a temperature ranging from 1100° C. to 1300° C. and having an aspect ratio of length to diameter greater than 10,000:1, wherein the nanotubes include a catalytic nanoparticle of ferromagnetic material and are compacted against one another, wherein each non-woven sheet of nanotubes comprises individual nanotubes intermingled with one another such that the nanotubes overlap and form contact sites both within and between the non-woven sheets of nanotubes; and
bonds, including one of van der Waal's, hydrogen, ionic, or a combination thereof, at (i) the contact sites between adjacent overlapping nanotubes within each stacked non-woven sheet of nanotubes such that the nanotubes within each stacked non-woven sheet are interconnected, and (ii) the contact sites between each consecutive stacked non-woven sheet layer of nanotubes such that each non-woven sheet layer are connected to form a substantially planar body comprising nanotubes with sufficient structural integrity to be handled as a sheet.
6. A sheet as set forth in claim 5 , wherein the planar body can be substantially square or rectangular in shape.
7. A sheet as set forth in claim 5 , wherein the ferromagnetic material includes one of Fe, Co, Ni, an alloy thereof, a combination thereof, or related materials.
8. The non-woven sheet material of claim 5 , wherein the matrix material is selected from Krayton, vinyl ester, PEEK, bispolyamide, bismaleimide, epoxies, polyamide, and combinations therefrom.