Method for forming an array of single-wall carbon nanotubes and compositions thereof

A method for forming a macroscopic molecular array of tubular carbon molecules, said method comprising the steps of:

• (a) providing at least about 106 tubular carbon molecules of substantially similar length in the range of 50 to 500 nm;
• (b) introducing a linking moiety onto at least one end of said tubular carbon molecules;
• (c) providing a substrate coated with a material to which said linking moiety will attach;
• and
• (d) contacting said tubular carbon molecules containing a linking moiety with said substrate.

A method for forming a macroscopic molecular array of tubular carbon molecules, said method comprising the steps of:

• (a) providing a nanoscale array of microwells on a substrate;
• (b) depositing a metal catalyst in each of said microwells;
• and
• (c) directing a stream of hydrocarbon or CO feedstock gas at said substrate under conditions that effect growth of single-wall carbon nanotubes from each microwell.

A method for forming a macroscopic molecular array of tubular carbon molecules, said method comprising the steps of:

• (a) providing surface containing purified but entangled and relatively endless single-wall carbon nanotube material;
• (b) subjecting said surface to oxidizing conditions sufficient to cause short lengths of broken nanotubes to protrude up from said surface;
• and
• (c) applying an electric field to said surface to cause said nanotubes protruding from said surface to align in an orientation generally perpendicular to said surface and coalesce into an array by van der Waals interaction forces.

A method for continuously growing macroscopic carbon fiber comprising at least about 106 single-wall nanotubes in generally parallel orientation, said method comprising the steps of:

• (a) providing a macroscopic molecular array of at least about 106 tubular carbon molecules in generally parallel orientation and having substantially similar lengths in the range of from about 50 to about 500 nanometers;
• (b) removing the hemispheric fullerene cap from the upper ends of the tubular carbon molecules in said array;
• contacting said upper ends of the tubular carbon molecules in said array with at least one catalytic metal;
• (d) supplying a gaseous source of carbon to the end of said array while applying localized energy to the end of said array to heat said end to a temperature in the range of about 500° C. to about 1300° C.;
• and
• (e) continuously recovering the growing carbon fiber.

A tubular carbon molecule having the following structure:

• 4
• where
• 5
• is a substantially defect-free cylindrical graphene sheet (optionally doped with noncarbon atoms) having from about 102 to 106 carbon atoms;
• where
• 6
• is a hemispheric fullerene cap having at least six pentagons and the remainder hexagons;
• n is a number from 0 to 30, and
• R, R1, R2, R3, R4 , and R5 each may be independently selected from the group consisting of hydrogen;
• alkyl, acyl, aryl, aralkyl, halogen;
• substituted or unsubstituted thiol;
• unsubstituted or substituted, amino;
• hydroxy, and OR′ wherein R′ is selected from the group consisting of hydrogen, alkyl, acyl, aryl aralkyl, unsubstituted or substituted amino;
• substituted or unsubstituted thiol;
• and halogen;
• and a linear or cyclic carbon chain optionally interrupted with one or more heteroatom, and optionally substituted with one or more ═O, or ═S, hydroxy, an aminoalkyl group, an amino acid, or a peptide of 2-8 amino acids.

An apparatus for forming a continuous macroscopic carbon fiber from a macroscopic molecular template array comprising at least about 106 single-wall carbon nanotubes having a catalytic metal deposited on the open ends of said nanotubes, said apparatus comprising:

• (a) means for locally heating only said open ends of said nanotubes in said template array in a growth and annealing zone to a temperature in the range of about 500° C. to about 1300° C.;
• (b) means for supplying a carbon-containing feedstock gas to the growth and annealing zone immediately adjacent said heated open ends of said nanotubes in said template array;
• and
• (c) means for continuously removing growing carbon fiber from said growth and annealing zone while maintaining the growing open end of said fiber in said growth and annealing zone.

A method for producing a composite material containing carbon nanotube material comprising:

• (a) preparing a matrix material precursor;
• (b) combining a carbon nanotube material with said matrix material precursor;
• and
• (c) forming said composite material,

A method of producing a composite material containing carbon nanotube material comprising:

• (a) preparing an assembly of a fibrous material;
• (b) adding said carbon nanotube material to said fibrous material;
• and
• (c) adding a matrix material precursor to said carbon nanotube material and said fibrous material.