Fused nanostructure material

Abstract

Disclosed herein is a nanostructured material comprising carbon nanotubes fused together to form a three-dimensional structure. Methods of making the nanostructured material are also disclosed. Such methods include a batch type process, as well as multi-step recycling methods or continuous single-step methods. A wide range of articles made from the nanostructured material, including fabrics, ballistic mitigation materials, structural supports, mechanical actuators, heat sink, thermal conductor, and membranes for fluid purification is also disclosed.

1 . A nanostructured material comprising carbon nanotubes fused together to form a three-dimensional structure. 
     
     
         2 . The nanostructured material of  claim 1 , wherein said carbon nanotubes have a scrolled tubular or non-tubular nano-structure of carbon rings. 
     
     
         3 . The nanostructured material of  claim 2 , wherein said carbon nanotubes having a scrolled tubular or non-tubular nano-structure of carbon rings are single-walled, multi-walled, nanoscrolled or combinations thereof. 
     
     
         4 . The nanostructured material of  claim 2 , wherein said carbon nanotubes having a scrolled tubular or non-tubular nano-structure have a morphology chosen from nanohorns, cylinders, nanospirals, dendrites, spider nanotube structures, Y-junction nanotubes, and bamboo morphology. 
     
     
         5 . The nanostructured material of  claim 1 , wherein said carbon nanotubes comprise impregnated, functionalized, irradiated, doped, charged, coated, and bonded to one another or bound with other materials, and combinations thereof. 
     
     
         6 . The nanostructured material of  claim 1 , wherein said three-dimensional structure further comprises at least one material chosen from polymers, ceramics, and metals. 
     
     
         7 . The nanostructured material of  claim 6 , wherein said polymers, ceramics, and metals are in a form chosen from fibers, beads, particles, wires, sheets, foils, and combinations thereof. 
     
     
         8 . The nanostructured material of  claim 6 , wherein said polymers are chosen from single or multi-component polymers. 
     
     
         9 . The nanostructured material of  claim 8 , wherein said single or multi-component polymers are chosen from nylon, polyurethane, acrylic, methacrylic, polycarbonate, epoxy, silicone rubbers, natural rubbers, synthetic rubbers, vulcanized rubbers, polystyrene, aramid, polyethylene, ultra-high-molecular weight polyethylene, high-density polyethylene (HDPE), low-density polyethylene (LDPE), poly(p-fenyl-2,6-benzobisoxazol), polypropylene, polychloroprene, polyimide, polyamide, polyacrylonitrile, polyhydroaminoester, polyester (polyethylene terephthalate), polybutylene terephthalate, poly-paraphylene terephtalamide, polyester ester ketene, viton fluoroelastomer, polytetrafluoroethylene, and polyvinylchloride. 
     
     
         10 . The nanostructured material of  claim 6 , wherein said ceramics are chosen from at least one of the following: boron carbide, boron nitride, boron oxide, boron phosphate, beryllium oxide, spinel, garnet, lanthanum fluoride, calcium fluoride, silicon carbide, carbon and its allotropes, silicon oxide, glass, quartz, aluminum oxide, aluminum nitride, zirconium oxide, zirconium carbide, zirconium boride, zirconium nitrite, hafnium boride, thorium oxide, yttrium oxide, magnesium oxide, phosphorus oxide, cordierite, mullite, silicon nitride, ferrite, sapphire, steatite, titanium carbide, titanium nitride, titanium boride, and combinations thereof. 
     
     
         11 . The nanostructured material of  claim 6 , wherein said metals are chosen from at least one of the following: aluminum, boron, copper, cobalt, gold, platinum, silicon, steel, titanium, rhodium, indium, iron, palladium, germanium, tin, lead, tungsten, niobium, molybdenum, nickel, silver, zirconium, yttrium, and alloys thereof. 
     
     
         12 . The nanostructured material of  claim 6 , wherein at least one of said polymers, ceramics, and metals are grown, deposited, and/or implanted on the surface or in the interior of the carbon nanotubes to form polymer containing particles or layers, ceramic containing particles or layers, metal containing particles or layers, or a combination of any or all of these particles or layers. 
     
     
         13 . The nanostructured material of  claim 12 , wherein said at least one ceramic containing layers or particles comprise boron carbide. 
     
     
         14 . The nanostructured material of  claim 1 , wherein said material comprises 5, 6 and 7-membered carbon rings at the intersection of two or more carbon nanotubes. 
     
     
         15 . The nanostructured material of  claim 1 , wherein said structure has a density ranging from 1 picogram/cm 3  to 20 g/cm 3 . 
     
     
         16 . An article comprising the nanostructured material of  claim 1 . 
     
     
         17 . The article of  claim 16 , which is in the form of a fabric, ballistic material, structural support, mechanical actuator, heat sink, thermal conductor or insulator, or a membrane for fluid purification. 
     
     
         18 . The article of  claim 17 , wherein said thermal insulator comprises a blanket, tent, clothing, or sleeping bag. 
     
     
         19 . A ballistic cloth comprising a nanostructured material comprising carbon nanotubes and at least one material chosen from a polymer, ceramic, and metal fused together to form a three-dimensional structure. 
     
     
         20 - 49 . (canceled) 
     
     
         50 . A multi-step recycling method of making a three-dimensional nanostructure, said method comprising
 (1) growing carbon nanotubes in a reactor;   (2) fusing the grown nanotubes to form a three dimensional nanostructure;   (3) applying a catalyst and growing nanotubes on or within the three-dimensional nanostructure;   (4) repeating (2) to (3) for a time sufficient to achieve a desired thickness or property for said three-dimensional nanostructure.   
     
     
         51 - 58 . (canceled)