Carbon nanotube (cnt) extrusion methods and cnt wire and composites

Abstract

A method of manufacturing a carbon nanotube (CNT) extrusion. The method includes providing a carbon source, and extruding the CNT extrusion through an extrusion die. The extruded CNT extrusions can be spun into fibers, strands or the like in order to produce a final product. The carbon source can be mixed with a liquid prior to being extruded.

1 . A method for manufacture of a carbon nanotube (CNT) extrusion comprising:
 providing a carbon source;   extruding the carbon source through an extrusion die;   spinning the extruded CNT to form a product.   
     
     
         2 . A method according to  claim 1  wherein the final manufactured product is selected from the group comprising a wire, a string, a rope, a cable, a yarn, a twine, a fabric, a filament, a plurality of filaments, a fiber, a plurality of fibers, a strand, a plurality of strands, or combinations thereof of two or more of said products. 
     
     
         3 . The method according to  claim 1  further comprising providing an extrusion die comprising at least one die member having a plurality of through-holes in fluid communication with the carbon source. 
     
     
         4 . The method according to  claim 3  further comprising providing a plurality of template tubes connected at one end to said extrusion die and coaxial with the through-holes. 
     
     
         5 . The method according to  claim 4  further comprising providing an oscillating mechanism operatively associated with the free end of each plurality of template tubes. 
     
     
         6 . The method according to  claim 5  further comprising the step of axially oscillating the free end of each of said plurality of template tubes. 
     
     
         7 . The method according to  claim 5  wherein said oscillating mechanism comprises an alternating electric field or magnetic field applied to said template tubes. 
     
     
         8 . The method according to  claim 7  further comprising the step of synchronizing the frequency of said electric field or magnetic field with the formation rate of the CNT extrusion within said template tubes. 
     
     
         9 . The method according to  claim 4  wherein said template tubes comprise of at least one of the following group of materials: silicon carbide, boron carbide, cobalt, nickel, iron, or carbon. 
     
     
         10 . The method according to  claim 4  further comprising the step of providing the template tubes with a diameter greater than the CNT extrusion which is being manufactured. 
     
     
         11 . The method according to  claim 1  further comprising the step of including a catalyst working with said carbon source. 
     
     
         12 . The method according to  claim 11  further comprising the step of connecting at least one template tube to said extrusion die and introducing said carbon source into said template tube. 
     
     
         13 . The method according to  claim 12  further comprising the step of repeatedly axially oscillating the at least one template tube at a frequency corresponding to a formation rate of the CNT structure. 
     
     
         14 . The method according to  claim 1  wherein said extrusion die comprises a stationary first plate and a movable second plate. 
     
     
         15 . The method according to  claim 14  further comprising providing at least one template tube extending between said first plate and said second plate. 
     
     
         16 . The method according to  claim 15  further comprising the step of oscillating said second plate to alternatively axially compress and stretch said at least one template tube. 
     
     
         17 . The method according to  claim 15  wherein the oscillation rate is synchronized with a formation rate of the CNT extrusion within said at least one template tube. 
     
     
         18 . The method according to  claim 1  wherein the carbon source comprises a carbon vapor. 
     
     
         19 . The method according to  claim 1  wherein the extrusion die contains a plurality of through holes and a plurality of CNT extrusions are formed. 
     
     
         20 . The method according to  claim 19  wherein at least two of said plurality of CNT extrusions are subjected to said spinning step and are formed into the manufactured product. 
     
     
         21 . The method according to  claim 20  wherein said manufactured product is selected from the group comprising a wire, a string, a rope, a cable, a yarn, a twine, a fabric, a filament, a plurality of filaments, a fiber, a plurality of fibers, a strand, a plurality of strands, or combinations thereof of two or more of said products. 
     
     
         22 . The method according to  claim 1  wherein said carbon source is formed by a chemical vapor deposition (CVD) process. 
     
     
         23 . The method according to  claim 22  further comprising the use of a catalyst in the CVD process. 
     
     
         24 . The method according to  claim 1  further comprising extruding a plurality of strands of CNT extrusion from said extrusion die. 
     
     
         25 . The method according to  claim 24  when said plurality of strands are spun by said spinning step into a final manufactured product. 
     
     
         26 . The method according to  claim 25  wherein said manufactured product is selected from the group comprising a wire, a string, a rope, a cable, a yarn, a twine, a fabric, a filament, a plurality of filaments, a fiber, a plurality of fibers, a strand, a plurality of strands, or combinations thereof of two or more of said products. 
     
     
         27 . The method according to  claim 24  wherein at least two of said strands are formed in substantial axial alignment with the flow of CNT extrusion. 
     
     
         28 . The method according to  claim 24  wherein said plurality of strands are formed in substantial axial alignment with each other. 
     
     
         29 . The method for manufacture of a carbon nanotube (CNT) extrusion comprising:
 providing a carbon source; and   extruding the carbon source through an extrusion die;   wherein CNT extrusions are formed.   
     
     
         30 . The method according to  claim 29  further comprising the step of spinning the extruded CNT extrusions to form a product. 
     
     
         31 . The method according to  claim 29  wherein the final manufactured product is selected from the group comprising a wire, a string, a rope, a cable, a yarn, a twine, a fabric, a filament, a plurality of filaments, a fiber, a plurality of fibers, a strand, a plurality of strands, or combinations thereof of two or more of said products. 
     
     
         32 . The method according to  claim 29  further comprising providing an extrusion die comprising at least one die member having a plurality of through-holes in fluid communication with the carbon source. 
     
     
         33 . The method according to  claim 29  further comprising the step of including the carbon source in a liquid prior to extrusion. 
     
     
         34 . The method according to  claim 29  further comprising extruding a plurality of strands of CNT extrusion from said extrusion die. 
     
     
         35 . The method according to  claim 34  when said plurality of strands are spun by said spinning step into a final manufactured product. 
     
     
         36 . The method according to  claim 35  wherein said manufactured product is selected from the group comprising a wire, a string, a rope, a cable, a yarn, a twine, a fabric, a filament, a plurality of filaments, a fiber, a plurality of fibers, a strand, a plurality of strands, or combinations thereof of two or more of said products.