Methods for manufacturing carbon nanotube (CNT) hybrid sheet and yarn by gas phase assembly, and CNT-hybrid materials

A gas-phase method for the production of carbon nanotube (CNT)-hybrid yarn and sheets using a pyrolytic reactor tube comprising an inlet port, an inlet zone, a furnace zone, an exit zone, and an exit port, the method comprising:

• delivering an atomized fuel flow to the furnace zone at a point proximate the inlet port at a fuel flow rate, said fuel flow comprising a carrier gas and at least one source of carbon;
• delivering a particle flow to the furnace zone at a point in the inlet zone at or beyond the delivery point of the fuel flow at a particle flow rate, said particle flow comprising carrier gas and at least one particle selected from ceramic, polymer, metal, a carbon source, and combinations thereof;
• independently controlling the fuel flow rate and the particle flow rate to achieve a production time sufficient to continuously form a CNT-hybrid sock at a furnace zone temperature of between 1200° C. and 1600° C.;
• and
• collecting the emerging CNT-hybrid sock in a harvest box;
• wherein the collected CNT-hybrid sock comprises carbon nanotube bundles integrated with the injected particles.