Entangled single-wall carbon nanotube solid material and methods for making same

• US 6,899,945 B2
• Filed: 03/19/2003
• Issued: 05/31/2005
• Est. Priority Date: 03/19/2002
• Status: Expired due to Fees

• Current Assignee: Rice University
• Original Assignee: Rice University
• Inventors: Smalley, Richard E., Sivarajan, Ramesh
• Primary Examiner(s): Buttner, David J.
• Assistant Examiner(s): KEEHAN, CHRISTOPHER M
• Application Number:
  US10/391,988
• Publication Number:
  US 20030211028A1
• Time in Patent Office: 804 Days
• Field of Search: 428/314.2, 428/315.9, 428/314.8, 428/319.3, 428/319.1, 428/220, 423/445.B, 423/445.R, 2/25
• US Class Current: 428/314.8
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: D01F 9/127 by thermal decomposition of hydrocarbon gases or vapours or other carbon-containing compounds in the form of gas or vapour, e.g. carbon monoxide, alcohols
• CPC Class Codes: Y10S 977/75 Single-walled
• CPC Class Codes: Y10T 428/249975 Void shape specified [e.g., crushed, flat, round, etc.]
• CPC Class Codes: Y10T 428/249977 Specified thickness of void-containing component [absolute or relative], numerical cell dimension or density
• CPC Class Codes: Y10T 428/24998 Composite has more than two layers
• CPC Class Codes: Y10T 428/24999 Inorganic
• CPC Class Codes: Y10T 428/249991 Synthetic resin or natural rubbers

Abstract

Buckyrock is a three-dimensional, solid block material comprising an entangled network of single-wall carbon nanotubes (SWNT), wherein the block comprises greater than 75 wt % SWNT. SWNT buckyrock is mechanically strong, tough and impact resistant. The single-wall carbon nanotubes in buckyrock form are present in a random network of individual single-wall carbon nanotubes, SWNT “ropes” and combinations thereof. The random network of the SWNT or SWNT ropes can be held in place by non-covalent “cross-links” between the nanotubes at nanotube contact points. In one embodiment, SWNT buckyrock is made by forming a SWNT-water slurry, slowly removing water from the slurry which results in a SWNT-water paste, and allowing the paste to dry very slowly, such that the SWNT network of the SWNT-water paste is preserved during solvent evaporation. Buckyrock can be used in applications, such as ballistic protection systems, involving light-weight material with mechanical strength, toughness and impact resistance.

Claims

1. A method for making a macroscopic, three-dimensional single-wall carbon nanotube solid block material, comprising:

a) forming a paste comprising single-wall carbon nanotubes and a liquid; and

b) removing the liquid from the paste to form a macroscopic three-dimensional solid block of entangled single-wall carbon nanotubes, wherein each dimension is at least about 1 mm and wherein the block material comprises at least about 75 wt % single-wall carbon nanotubes.

2. The method of claim 1, wherein the solid block material comprises at least about 85 wt % single-wall carbon nanotubes.

3. The method of claim 1, wherein the solid block material comprises at least about 90 wt % single-wall carbon nanotubes.

4. The method of claim 1, wherein the solid block material comprises at least about 95 wt % single-wall carbon nanotubes.

5. The method of claim 1, wherein the solid block material consists essentially of single-wall carbon nanotubes.

6. The method of claim 1, wherein the single-wall carbon nanotubes are in a form selected from the group consisting of ropes of single-wall carbon nanotubes, individual single-wall carbon nanotubes and a combination thereof.

7. The method of claim 1, further comprising purifying the single-wall carbon nanotubes.

8. The method of claim 1, wherein the liquid is selected from the group consisting of water, hydrocarbon, oxygenated hydrocarbon, aromatic compounds, and combinations thereof.

9. The method of claim 1, wherein the paste is formed from a slurry of the single-wall carbon nanotubes and the liquid.

10. The method of claim 1, wherein the liquid is water.

11. The method of claim 1, wherein the single-wall carbon nanotubes are derivatized by a method selected from the group consisting of side-wall derivatization, end-derivatization, and a combination thereof.

12. A macroscopic, three-dimensional solid block material comprising single-wall carbon nanotubes, wherein the solid block material comprises at least about 75 wt % entangled single-wall carbon nanotubes and wherein each dimension is at least about 1 mm.

13. The material of claim 12, wherein the solid block material comprises at least about 85 wt % single wall carbon nanotubes.

14. The material of claim 12, wherein the solid block material comprises at least about 90 wt % single-wall carbon nanotubes.

15. The material of claim 12, wherein the solid block material comprises at least about 95 wt % single-wall carbon nanotubes.

16. The material of claim 12, wherein the single-wall carbon nanotubes are in a form selected from the group consisting of ropes of single-wall carbon nanotubes, individual single-wall carbon nanotubes and a combination thereof.

17. An armor comprising the material of claim 12, wherein the armor is capable of absorbing kinetic energy of a projectile.

18. The armor of claim 17, wherein armor is vehicle armor.

19. The armor of claim 17, wherein the armor is body armor.

20. A microelectromechanical system comprising a platform structure, wherein the platform structure comprises the material of claim 12.

21. A structure comprising:

(a) a macroscopic, three-dimensional solid block material, wherein the solid block material comprises at least about 75 wt % entangled single-wall carbon nanotubes and wherein each dimension is at least about 1 mm;

(b) a first heterostructure layer;

(c) a second heterostructure layer, wherein the solid block material is dispersed between the first heterostructure layer and the second heterostructure layer.

22. The structure of claim 21, wherein the first heterostructure layer comprises a first substance selected from the group consisting of polymers, glass, metals, alloys, silicon, non-metals, and combinations thereof.

23. The structure of claim 22, wherein the first heterostructure layer and the second heterostructure layer are the same substance.

24. The structure of claim 22, wherein the second heterostructure layer comprises a second substance, selected from the group consisting of polymers, glass, metals, alloys, silicon, non-metals, and combinations thereof, and the first heterostructure layer and the second hetero structure layer are different substances.