Methods for manufacturing carbon nanotube (CNT) hybrid sheet and yarn by gas phase assembly, and CNT-hybrid materials

1. A gas-phase method for the production of carbon nanotube (CNT)-hybrid yarn and sheets using a pyrolytic reactor tube comprising an inlet port, an inlet zone, a furnace zone, an exit zone, and an exit port, the method comprising:

delivering an atomized fuel flow to the furnace zone at a point proximate the inlet port at a fuel flow rate, said fuel flow comprising a carrier gas and at least one source of carbon;

delivering a particle flow to the furnace zone at a point in the inlet zone at or beyond the delivery point of the fuel flow at a particle flow rate, said particle flow comprising carrier gas and at least one particle selected from ceramic, polymer, metal, a carbon source, and combinations thereof;

independently controlling the fuel flow rate and the particle flow rate to achieve a production time sufficient to continuously form a CNT-hybrid sock at a furnace zone temperature of between 1200° C. and 1600° C.;

and

collecting the emerging CNT-hybrid sock in a harvest box;

wherein the collected CNT-hybrid sock comprises carbon nanotube bundles integrated with the injected particles.

2. The method according to claim 1 , wherein the furnace zone temperature is maintained at about 1400° C. across the production time.

3. The method according to claim 1 , further comprising twisting the emerging CNT-hybrid sock into yarn or rolling the emerging CNT-hybrid sock into sheets.

4. The method according to claim 3 , wherein the twisting and/or rolling is accompanied by one or more of water densification and electric charging.

5. The method according to claim 4 , wherein the emerging CNT-hybrid sock is wound onto a rolling drum partially submerged in a water bath.

6. The method according to claim 5 , wherein the CNT-hybrid sock is rolled with a backing sheet, tape or fiber.

7. The method according to claim 6 , wherein the backing sheet comprises

polytetrafluoroethylene.

8. The method according to claim 1 , wherein the fuel flow and/or the particle flow comprises at least one catalyst.

9. The method according to claim 8 , wherein the catalyst comprises ferrocene.

10. The method according to claim 8 , wherein the fuel flow further comprises thiophene.

11. The method according to claim 8 , wherein the fuel flow further comprises xylene.

12. The method according to claim 1 , wherein the fuel flow carbon source comprises a C 1-6 hydrocarbon, optionally as an alcohol.

13. The method according to claim 1 , wherein the fuel flow comprises a carbon source and the particle flow comprises particles selected from the group consisting of Li, Na, K, Mg, Ca, Ba, Ti, Zr, Nb, Cr, Ni, Pd, Cu, Al, Ag-coated Cu, Si, granulated activated carbon, granulated activated carbon and ferrocene, powder CNT, boron nitride nanotubes, C-60, nitinol, Cu—Ni alloy, Fe, and gaseous C 13 .

14. The method according to claim 1 , wherein the particles comprise a nanopowder.

15. The method according to claim 14 , wherein the particles comprise a functional group selected from the group consisting of —OH, —COOH, —CHO, —X (F, Cl, Br, I), N 2 , epoxide, and a combination of two or more thereof.

16. The method according to claim 1 , wherein the carrier gas comprises Argon.

17. The method according to claim 1 , wherein there is no independent fuel flow and particles comprising a high aspect ratio carbon are injected from a particle injector.

18. The method according to claim 17 , wherein the high aspect ratio carbon particles are selected from the group consisting of carbon nanotubes, carbon nanofibers, carbon microfibers, and C-60.

19. The method according to claim 18 , wherein one or more non-carbon particles are mixed with the high aspect ratio carbon particles in a particle injector, or delivered into the reactor inlet by different particle injectors.

20. The method according to claim 1 , wherein to achieve continuous product the fuel flow rate is adjusted to between 10 ml/hr and 60 ml/hr, and the particle delivery rate is roughly adjusted to between 1 g/hr and 100 g/hr for a 2 inch outer diameter reactor tube.

21. The method according to claim 1 , wherein hydrogen exhaust gas generated in the furnace is vented through one or more openings in the exit port to a hood at least partially surrounding the exit port, and through a conduit in communication with a first bubbler located exterior to the harvest box.

22. The method according to claim 21 , wherein hydrogen gas present in the harvest box is vented via a conduit from the harvest box to a second bubbler situated exterior to the harvest box.

23. The method according to claim 1 , further comprising delivering a dilution gas flow into the harvest box at a dilution gas flow rate of from about 2 SLM to about 15 SLM.

24. The method according to claim 1 wherein hydrogen exhaust gas generated in the furnace is vented through one or more openings in the exit port to a hood at least partially surrounding the exit port, and through a conduit in communication with a first bubbler located exterior to the harvest box, hydrogen gas present in the harvest box is vented via a conduit from the harvest box to a second bubbler situated exterior to the harvest box, said first bubbler at a pressure of about 0.5 inches of water, said second bubbler at a pressure of about 1.0 inches of water and further comprising a dilution gas flow into the harvest box at a dilution gas flow rate of from about 2 SLM to about 15 SLM.

25. The method according to claim 1 , wherein delivering a particle flow comprises injecting particles via at least one particle injector selected from the group consisting of a flow type injector, a venturi eductor, and combinations thereof, wherein prior to delivering the particle flow, the particles are mixed with the carrier gas in the at least one injector.

26. The method according to claim 25 , wherein particles are delivered from at least two different particle injectors, each particle injector comprising a different particle.

27. The method according to claim 1 , wherein delivering an atomized fuel flow and delivering a particle flow are effectuated via a dual injection device comprising a first nozzle and a second nozzle that meet at a merged injection outlet, the first nozzle providing carrier gas and particles at a first flow rate, the second nozzle providing fuel at a second flow rate via a positive displacement pump, whereby the first flow rate and the second flow rate are independently controlled.

28. The method according to claim 27 , wherein the positive displacement pump comprises a syringe.

29. The method of claim 27 , wherein a voltage between about −20 kV and +3 kV is applied to the duel injection device during a production time.

30. The method according to claim 1 , further comprising applying an electromagnetic field to the reactor during the production time.

31. A carbon nanotube (CNT)-NP hybrid material having NPs integrated into the material at a nanoscale level, wherein the CNT-NP hybrid material is formed from a continuous CNT-NP hybrid sock.

32. A filter comprising a CNT-NP hybrid material having NPs integrated into the material at a nanoscale, the filter comprising a porosity defined by pore size and pore density, the CNT-NP hybrid material comprising CNT bundles integrated with one or more of the NPs, the NPs being selected from granulated activated carbon and iron, wherein the CNT-NP hybrid material is formed from a continuous CNT-NP hybrid sock.

33. The filter according to claim 32 , wherein the filter pore size and density are uniform.

34. The CNT-NP hybrid material according to claim 31 comprising a CNT-Cu wire.

35. The CNT-NP hybrid material according to claim 31 comprising CNT-Al sheet.

36. The CNT-NP hybrid material according to claim 31 comprising CNT-(Ag-coated-Cu) sheet.

37. The CNT-NP hybrid material according to claim 31 comprising CNT-Si sheet.

38. The CNT-NP hybrid material according to claim 31 comprising a magnetic CNT-Fe material.

39. The CNT-NP hybrid material according to claim 31 comprising CNT-nitinol sheet.

40. The CNT-NP hybrid material according to claim 31 comprising CNT-Y—X, wherein Y is selected from carbon nanofiber (CNF) and carbon microfiber (CMF), and X is selected from the group consisting of Li, Na, K, Mg, Ca, Ba, Ti, Zr, Nb, Cr, Ni, Pd, Cu, Al, Ag-coated Cu, Si, granulated activated carbon, granulated activated carbon and ferrocene, powder CNT, boron nitride nanotubes, C-60, nitinol, Cu—Ni alloy, Fe, and gaseous C 13 .

41. The CNT-NP hybrid material according to claim 31 comprising a CNT-X material, wherein X is selected from the group consisting of Li, Na, K, Mg, Ca, Ba, Ti, Zr, Nb, Cr, Ni, Pd, Cu, Al, Ag-coated Cu, Si, granulated activated carbon, granulated activated carbon and ferrocene, powder CNT, boron nitride nanotubes, C-60, nitinol, Cu—Ni alloy, Fe, gaseous C 13 , rubidium, cesium, and francium.

42. The CNT-NP hybrid material according to claim 41 , wherein X is selected from the group consisting of lithium, sodium, potassium, rubidium, cesium, francium, and a combination of two or more thereof, and, prior to removal from the harvest box, the CNT-X material is coated with a dielectric coating.

43. The CNT-NP hybrid material according to claim 31 , wherein the CNT-NP hybrid material comprises a plurality of nano-voids between adjacent CNT, at least one of the plurality of nano-voids containing at least one NP.