A method for preparing a cable formed of carbon nanotubes, comprising decomposing at least one carbon precursor compound and at least one precursor compound of a catalyst on a porous substrate (43), in which method continuously:a first gas stream comprising a precursor of a catalyst is brought into contact with a porous substrate (43);a second gas stream comprising at least one carbon precursor is brought into contact with said porous substrate (43);said porous substrate (43) is heated to a temperature leading to the deposition of catalyst particles and the catalytic growth of a carbon nanotube bundle, and preferably between 500 C. and 1000 C.

A method for preparing a cable formed of carbon nanotubes, comprising decomposing at least one carbon precursor compound and at least one precursor compound of a catalyst on a porous substrate (43), in which method continuously:a first gas stream comprising a precursor of a catalyst is brought into contact with a porous substrate (43);a second gas stream comprising at least one carbon precursor is brought into contact with said porous substrate (43);said porous substrate (43) is heated to a temperature leading to the deposition of catalyst particles and the catalytic growth of a carbon nanotube bundle, and preferably between 500 C. and 1000 C.

The present invention provides a process for preparing a yarn, which comprises introducing a raw material that comprises a carbon source and a catalyst into a reaction chamber having a heating means, converting the carbon source into a plurality of carbon nanotubes in a heating part of the reaction chamber with thermal energy supplied by the heating means, and growing the plurality of carbon nanotubes in the vertical direction to form a yarn by the interactions among the carbon nanotubes.

The present invention provides methods for uniform growth of nanostructures such as nanotubes (e.g., carbon nanotubes) on the surface of a substrate, wherein the long axes of the nanostructures may be substantially aligned. The nanostructures may be further processed for use in various applications, such as composite materials. For example, a set of aligned nanostructures may be formed and transferred, either in bulk or to another surface, to another material to enhance the properties of the material. In some cases, the nanostructures may enhance the mechanical properties of a material, for example, providing mechanical reinforcement at an interface between two materials or plies. In some cases, the nanostructures may enhance thermal and/or electronic properties of a material. The present invention also provides systems and methods for growth of nanostructures, including batch processes and continuous processes.

The present invention provides methods for uniform growth of nanostructures such as nanotubes (e.g., carbon nanotubes) on the surface of a substrate, wherein the long axes of the nanostructures may be substantially aligned. The nanostructures may be further processed for use in various applications, such as composite materials. For example, a set of aligned nanostructures may be formed and transferred, either in bulk or to another surface, to another material to enhance the properties of the material. In some cases, the nanostructures may enhance the mechanical properties of a material, for example, providing mechanical reinforcement at an interface between two materials or plies. In some cases, the nanostructures may enhance thermal and/or electronic properties of a material. The present invention also provides systems and methods for growth of nanostructures, including batch processes and continuous processes.

An apparatus for growing carbon nanostructures (CNSs) on a substrate can include at least two CNS growth zones with at least one intermediate zone disposed therebetween and a substrate inlet before the CNS growth zones sized to allow a spoolable length substrate to pass therethrough.

An apparatus for growing carbon nanostructures (CNSs) on a substrate can include at least two CNS growth zones with at least one intermediate zone disposed therebetween and a substrate inlet before the CNS growth zones sized to allow a spoolable length substrate to pass therethrough.

A system for hydrocarbon decomposition comprising a reactor volume, a mechanism to distribute the liquid catalyst as a liquid mist, a distributor to distribute a hydrocarbon reactant, a heat source, a separator to separate the solid product from the liquid catalyst, a re-circulation path and mechanism to re-circulate the liquid catalyst, and an outlet for at least one gaseous product. A system to distribute a liquid to an enclosed volume as a mist has a plurality of orifices designed to break the liquid into a mist. A method to decompose a hydrocarbon reactant includes generating a mist of a liquid catalyst, heating the reactor volume, introducing a hydrocarbon reactant into the reactor volume to produce a solid product and a gaseous product, separating the solid product from the liquid catalyst, removing the solid and gaseous products from the reactor volume, and recirculating the liquid catalyst to the reactor volume.

Systems and methods for pyrolysis using an induction source of energy. A system can include: a reaction chamber, the reaction chamber having a cylindrical shape, the reaction chamber containing a catalyst; a fluidization plate connected to a first end of the reaction chamber; a gas input receiver connected to the fluidization plate; and a mechanism connected to a second end of the reaction chamber, wherein, during operation of the system: hydrocarbon gas is received at the gas input receiver; the input gas is forced through the fluidization plate; the fluidized gas mixes with the catalyst, resulting in at least one catalyzed molecule; the at least one catalyzed molecule undergo pyrolysis, resulting in at least two cracked elements; and the at least two cracked elements are removed from the system via the at least one output mechanism.

The present invention provides methods for uniform growth of nanostructures such as nanotubes (e.g., carbon nanotubes) on the surface of a substrate, wherein the long axes of the nanostructures may be substantially aligned. The nanostructures may be further processed for use in various applications, such as composite materials. For example, a set of aligned nanostructures may be formed and transferred, either in bulk or to another surface, to another material to enhance the properties of the material. In some cases, the nanostructures may enhance the mechanical properties of a material, for example, providing mechanical reinforcement at an interface between two materials or plies. In some cases, the nanostructures may enhance thermal and/or electronic properties of a material. The present invention also provides systems and methods for growth of nanostructures, including batch processes and continuous processes.