Abstract: The present disclosure is directed to a method and apparatus for continuous production of composites of carbon nanotubes and electrode active material from decoupled sources. Composites thusly produced may be used as self-standing electrodes without binder or collector. Moreover, the method of the present disclosure may allow more cost-efficient production while simultaneously affording control over nanotube loading and composite thickness.

Abstract: The present disclosure is directed to a method and apparatus for continuous production of composites of carbon nanotubes and electrode active material from decoupled sources. Composites thusly produced may be used as self-standing electrodes without binder or collector. Moreover, the method of the present disclosure may allow more cost-efficient production while simultaneously affording control over nanotube loading and composite thickness.

Abstract: The present disclosure relates to a method of making a composite product that may be used as a flexible electrode. An aerosolized mixture of nanotubes and an electrode active material is collected on a porous substrate, such as a filter, until it reaches a desired thickness. The resulting self-standing electrode may then be removed from the porous substrate and may operate as a battery electrode.

Abstract: Methods of making single walled carbon nanotubes (SWNTs) including a single step for preparing a homogeneous dispersion of SWNTs in a battery electrode powder. The method may comprise providing a reactor in fluid communication with a mixer, wherein an aerosol containing SWNTs is transmitted from the reactor directly to the mixer containing a battery electrode powder.

Abstract: A method of producing a composite product is provided. The method includes providing a fluidized bed of metal oxide particles in a fluidized bed reactor, providing a catalyst or catalyst precursor in the fluidized bed reactor, providing a carbon source in the fluidized bed reactor for growing carbon nanotubes, growing carbon nanotubes in a carbon nanotube growth zone of the fluidized bed reactor, and collecting a composite product comprising metal oxide particles and carbon nanotubes.