Systems and methods of synthesis of extended length nanostructures

Abstract

A system for synthesizing nanostructures using chemical vapor deposition (CVD) is provided. The system includes a housing, a porous substrate within the housing, and on a downstream surface of the substrate, a plurality of catalyst particles from which nanostructures can be synthesized upon interaction with a reaction gas moving through the porous substrate. Electrodes may be provided to generate an electric field to support the nanostructures during growth. A method for synthesizing extended length nanostructures is also provided. The nanostructures are useful as heat conductors, heat sinks, windings for electric motors, solenoid, transformers, for making fabric, protective armor, as well as other applications.

1 - 34 . (canceled)  
     
     
         35 . A substrate for synthesis of nanostructures, the substrate comprising: 
 a porous body having an upstream surface and a downstream surface; and    a plurality of catalyst particles, deposited on the downstream surface of the substrate, and from which nanostructures can be synthesized;    wherein the porous body provides pathways through which a reaction gas can travel across the upstream surface and out the downstream surface to initiate growth of nanostructures from the catalyst particles.    
     
     
         36 . A substrate as set forth in  claim 35 , wherein the body is sufficiently porous so that a pressure difference between the upstream surface and the downstream surface can be substantially low, so as to permit the body to maintain its structural integrity.  
     
     
         37 . A substrate as set forth in  claim 35 , wherein the body is made from a material provided with pore size ranging from about 0.5 nm to about 500 microns.  
     
     
         38 . A substrate as set forth in  claim 35 , wherein the body is made from a material having a void fraction of from about 10 percent to about 95 percent.  
     
     
         39 . A substrate as set forth in  claim 35 , wherein the body is made from a material including carbon foams, glassy carbon, silica, alumina, alumina coated with silica, zirconia, zeolites, sintered titanium, titania, magnesia, yttria, copper, iron, iron nickel, iron cobalt, cobalt, steel, iron carbide, or a combination thereof.  
     
     
         40 . A substrate as set forth in  claim 35 , wherein the substrate is one of foam, channel plate, felt, wool, fibers, cloth, or array of needles.  
     
     
         41 . A substrate as set forth in  claim 35 , wherein the catalyst particles are substantially evenly distributed across the downstream surface of the substrate.  
     
     
         42 . A substrate as set forth in  claim 35 , wherein the catalyst particles are made from a material including iron, nickel, cobalt, iron oxides, nickel oxides, cobalt oxides, metal salts with sulfate, metal salts with sulfamates, acetate, citrate, oxalates, nitrites, nitrates, or a combination thereof.  
     
     
         43 . A substrate as set forth in  claim 35 , wherein the catalyst particles range from about 1 nm to about 50 nm in size.  
     
     
         44 - 97 . (canceled)