Methods for forming composite armor plates using ordered nanotube fabrics

Abstract

A method for arranging nanotube elements within nanotube fabric layers and films is disclosed. A directional force is applied over a nanotube fabric layer to render the fabric layer into an ordered network of nanotube elements. That is, a network of nanotube elements drawn together along their sidewalls and substantially oriented in a uniform direction. In some embodiments this directional force is applied by rolling a cylindrical element over the fabric layer. In other embodiments this directional force is applied by passing a rubbing material over the surface of a nanotube fabric layer. In other embodiments this directional force is applied by running a polishing material over the nanotube fabric layer for a predetermined time. Exemplary rolling, rubbing, and polishing apparatuses are also disclosed.

What is claimed is: 
     
         1 . A method for forming composite armor plate, comprising:
 providing a first material layer;   depositing a first plurality of nanotube elements over said first material layer, to obtain a first unordered nanotube fabric, wherein said first unordered nanotube fabric is substantially dry, fully formed, and fixed;   translating a directional force across said first unordered nanotube fabric to render said first unordered nanotube fabric into a first ordered nanotube fabric layer;   providing a second material layer over said first ordered nanotube fabric;   depositing a second plurality of nanotube elements over said second material layer, to obtain a second unordered nanotube fabric, wherein said second unordered nanotube fabric is substantially dry, fully formed, and fixed; and   translating a directional force across said second unordered nanotube fabric to render said second unordered nanotube fabric into a second ordered nanotube fabric layer.   
     
     
         2 . The method of  claim 1  wherein at least one of said first material layer and said second material layer are rigid. 
     
     
         3 . The method of  claim 1  wherein said first material layer, said first ordered nanotube fabric layer, said second material layer, and said second ordered nanotube fabric layer are flexible. 
     
     
         4 . The method of  claim 1  wherein said first material layer and said second material layer are comprised of a material selected from the list consisting of steel, steel alloy, metallic alloy, fabric, ballistic fabric, ceramic plates, shaped ceramic particles suspended in a matrix, and mixtures thereof. 
     
     
         5 . The method of  claim 1  wherein said first plurality of nanotube elements within said first ordered nanotube fabric layer are oriented in a first direction and said second plurality of nanotube elements within said second ordered nanotube fabric layer are oriented in a second direction. 
     
     
         6 . The method of  claim 5  wherein said first direction is different from said second direction. 
     
     
         7 . The method of  claim 5  wherein said first direction and said second direction are substantially orthogonal with respect to each other. 
     
     
         8 . The method of  claim 5  wherein said first direction and said second direction are the same. 
     
     
         9 . The method of  claim 1  wherein said at least one of said first ordered nanotube fabric layer and said second ordered nanotube fabric layer further comprises a matrix material. 
     
     
         10 . The method of  claim 9  wherein said matrix material comprises at least one of surfactants, cross-linking agents, polymers, dopants, photoactive particles, ceramic fibers, ceramic particles, metallic fibers, metallic particles, ballistic fiber, and nanoscopic particles. 
     
     
         11 . The method of  claim 1  further comprising repeating the steps of providing, depositing, and translating to provide a first preselected number of additional material layers and a second preselected number of ordered nanotube fabric layers. 
     
     
         12 . The method of  claim 11  wherein at least one of said first preselected number of additional material layers are rigid. 
     
     
         13 . The method of  claim 11  wherein said first preselected number of additional material layers and said second preselected number of additional ordered nanotube fabric layer are flexible. 
     
     
         14 . The method of  claim 11  wherein said first preselected number of additional material layers are comprised of a material selected from the list consisting of steel, steel alloy, metallic alloy, fabric, ballistic fabric, ceramic plates, shaped ceramic particles suspended in a matrix, and mixtures thereof. 
     
     
         15 . The method of  claim 11  wherein said second preselected number is greater than one. 
     
     
         16 . The method of  claim 15  wherein nanotube elements within at least one of said additional ordered nanotube fabric layers are oriented in a different direction with respect to nanotube elements within another of said additional ordered nanotube fabric layers. 
     
     
         17 . The method of  claim 15  wherein nanotube elements within at least one of said additional ordered nanotube fabric layers are oriented orthogonally to nanotube elements within another of said additional ordered nanotube fabric layers. 
     
     
         18 . The method of  claim 11  wherein said at least one of said second preselected number of additional ordered nanotube fabric layers further comprises a matrix material. 
     
     
         19 . The method of  claim 18  wherein said matrix material comprises at least one of surfactants, cross-linking agents, polymers, dopants, photoactive particles, ceramic fibers, ceramic particles, metallic fibers, metallic particles, ballistic fiber, and nanoscopic particles. 
     
     
         20 . The method of  claim 1  wherein said first plurality of nanotube elements and said second plurality of nanotube elements are carbon nanotubes.