US Patent 8628747 Carbon nanotube structures formed on large free floating substrates

Carbon nanotube structures are formed by providing metal composite particles including a catalyst metal and a non-catalyst metal, where the catalyst metal catalyzes the decomposition of a hydrocarbon compound and the formation of carbon nanotube structures on surfaces of the particles. The metal composite particles are combined with the hydrocarbon compound in a heated environment so as to form carbon nanotube structures on the surfaces of the metal composite particles. The metal composite particles can be include iron and aluminum at varying amounts. The carbon nanotubes formed on the metal particles can remain on the metal particles or, alternatively, be removed from the metal particles for use in different applications.