Apparatuses and Methods for Large-Scale Production of Hybrid Fibers Containing Carbon Nanostructures and Related Materials

Abstract

An apparatus for growing carbon nanostructures (CNSs) on a substrate can include at least two CNS growth zones with at least one intermediate zone disposed therebetween and a substrate inlet before the CNS growth zones sized to allow a spoolable length substrate to pass therethrough.

1 - 33 . (canceled) 
     
     
         34 . A method for growing carbon nanostructures (CNSs), the method comprising:
 transporting at least a portion of a spoolable length substrate along a substrate path that comprises at least two CNS growth zones and at least one intermediate zone disposed therebetween;   heating at least the CNS growth zones; and   passing a feed gas through at least the CNS growth zones.   
     
     
         35 . The method of  claim 34 , wherein at least one intermediate zone is at a lower temperature than the at least two CNS growth zones. 
     
     
         36 . The method of  claim 34 , wherein at least one intermediate zone comprises at least one feed gas inlet. 
     
     
         37 . The method of  claim 34 , wherein at least one CNS growth zone or at least one intermediate zone further comprises a magnetic field, an electric field, a hot filament, and any combination thereof. 
     
     
         38 . The method of  claim 34 , wherein transporting at least a portion of the spoolable length substrate along the substrate path takes place at a linespeed of about 1.5 to about 50 m/min. 
     
     
         39 . The method of  claim 34 , wherein at least a portion of the spoolable length substrate comprises a catalyst prior to passing through the at least two CNS growth zones. 
     
     
         40 . The method of  claim 34  further comprising:
 growing a plurality of CNSs on at least a portion of the substrate. 
 
     
     
         41 . The method of  claim 34  further comprising:
 heating the feed gas prior to passing the feed gas through at least one CNS growth zone. 
 
     
     
         42 . The method of  claim 34  further comprising:
 transporting at least a portion of at least one additional spoolable length substrate along at least one additional substrate path that comprises at least two CNS growth zones and at least one intermediate zone disposed therebetween.