Carbon nanotube foam and method of making and using thereof

Abstract

A method of making a carbon nanotube structure includes providing an array of substantially aligned carbon nanotubes, wetting the array with a liquid, and evaporating the liquid to form the carbon nanotube structure having a pattern in the carbon nanotube array. The structure is preferably a carbon nanotube foam.

1 . A bundle of carbon nanotubes aligned in a same direction, wherein a base of the bundle has a width that is less than a top of the bundle. 
     
     
         2 . The bundle of  claim 1 , wherein:
 the base of the bundle is located in contact with a first surface of a substrate which promotes growth of carbon nanotubes in a first direction normal to the first substrate;   the nanotubes in the bundle are aligned and extend in the first direction; and   the top of the bundle is located above the base of the bundle.   
     
     
         3 . The bundle of  claim 1 , wherein the base of the bundle is removed from a growth substrate. 
     
     
         4 . The bundle of  claim 1 , wherein the bundle comprises a circular or oval bundle having a smaller base diameter than a corresponding top diameter. 
     
     
         5 . The bundle of  claim 1 , wherein the bundle comprises a polygonal or a substantially two dimensional bundle. 
     
     
         6 . A method of making a carbon nanotube structure, comprising:
 providing an array of substantially aligned carbon nanotubes;   wetting the array with a liquid; and   evaporating the liquid to form the carbon nanotube structure having a pattern in the carbon nanotube array.   
     
     
         7 . The method of  claim 6 , wherein the step of providing the array of substantially aligned carbon nanotubes comprises growing multiwalled carbon nanotubes on a surface of a substrate by chemical vapor deposition in a direction substantially normal to the substrate surface. 
     
     
         8 . The method of  claim 6 , wherein the step of wetting the array with a liquid comprises wetting the array with at least one of water, acetone, toluene, dimethylformahide, tetrahydrofuran and methanol. 
     
     
         9 . The method of  claim 8 , where the liquid comprises water. 
     
     
         10 . The method of  claim 6 , wherein the carbon nanotube structure comprises a carbon nanotube foam formed on a substrate. 
     
     
         11 . The method of  claim 10 , wherein the carbon nanotube foam comprises a cellular film containing an open cellular structure pattern. 
     
     
         12 . The method of  claim 6 , wherein the step of providing the array of substantially aligned carbon nanotubes comprises growing multiwalled carbon nanotubes on a template pattern on surface of a substrate by chemical vapor deposition in a direction substantially normal to the substrate surface to form a patterned array of carbon nanotubes. 
     
     
         13 . The method of  claim 12 , wherein the step of evaporating the liquid forms a plurality of different predetermined cellular patterns. 
     
     
         14 . The method of  claim 12 , wherein:
 the patterned array of carbon nanotubes comprises bundle of carbon nanotubes aligned perpendicular to the template pattern; and   the step of evaporating the liquid forms a bundle of carbon nanotubes which has a width that is less than a top.   
     
     
         15 . The method of  claim 6 , further comprising removing the carbon nanotube structure from the substrate. 
     
     
         16 . The method of  claim 10 , further comprising incorporating the carbon nanotube foam into a composite material containing a non-carbon nanotube material. 
     
     
         17 . The method of  claim 16 , further comprising incorporating a polymer material into the carbon nanotube foam to form the composite material. 
     
     
         18 . The method of  claim 16 , further comprising growing a metal or ceramic foam on the carbon nanotube foam using the carbon nanotube foam as a template. 
     
     
         19 . The method of  claim 10 , wherein the carbon nanotube foam is incorporated into at least one of a flexible membrane, a filter, a shock absorbing material, an acoustic damping material, a matrix as a reinforcing material, a fabric, an electrochemical storage device electrode and a cell growth matrix.