Aligned Carbon Nanotube Bulk Aggregate, Process for Producing The Same and Uses Thereof

• US 20090272935A1
• Filed: 01/05/2007
• Published: 11/05/2009
• Est. Priority Date: 01/06/2006
• Status: Abandoned Application

• Current Assignee: National Institute of Advanced Industrial Science and Technology (Government of Japan)
• Original Assignee: National Institute of Advanced Industrial Science and Technology (Government of Japan)
• Inventors: Yumura, Motoo, Iijima, Sumio, Hata, Kenji, Futaba, Don N.
• Application Number:
  US12/087,450
• Publication Number:
  US 20090272935A1
• Time in Patent Office: Days
• US Class Current: 252/70
• CPC Class Codes: B01J 20/20 comprising free carbon; comprising carbon obtained by carbonising processes
• CPC Class Codes: B01J 20/205 Carbon nanostructures, e.g. nanotubes, nanohorns, nanocones, nanoballs carbon nanotubes per se C01B32/15
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: B82Y 40/00 Manufacture or treatment of nanostructures
• CPC Class Codes: C01B 2202/02 Single-walled nanotubes
• CPC Class Codes: C01B 2202/04 Nanotubes with a specific amount of walls
• CPC Class Codes: C01B 2202/06 Multi-walled nanotubes
• CPC Class Codes: C01B 2202/08 Aligned nanotubes
• CPC Class Codes: C01B 32/162 characterised by catalysts
• CPC Class Codes: H01G 11/36 Nanostructures, e.g. nanofibres, nanotubes or fullerenes
• CPC Class Codes: H01M 4/587 for inserting or intercalating light metals
• CPC Class Codes: H01M 4/96 Carbon-based electrodes
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/30 Self-sustaining carbon mass or layer with impregnant or other layer

Abstract

An aligned carbon nanotube bulk aggregate of the invention is characterized by consisting of plural carbon nanotubes aligned in a predetermined direction and having a density of 0.2 to 1.5 g/cm³. The carbon nanotube bulk aggregate can be produced by a process of growing carbon nanotubes by chemical vapor deposition (CVD) in the presence of a metal catalyst which comprises growing carbon nanotubes in aligned state in a reaction atmosphere, soaking the obtained carbon nanotubes with a liquid, and then drying the resulting nanotubes. Thus, an aligned carbon nanotube bulk aggregate having a density of 0.2 to 1.5 g/cm³ can be obtained. The invention provides a high density and a high hardness which were not attained in the prior art, and a process for the production of the same.

Claims

1-49. -49. (canceled)

50. An aligned carbon nanotube bulk aggregate in which plural carbon nanotubes are aligned in a predetermined direction and which has a density of from 0.2 to 1.5 g/cm³.

51. The aligned carbon nanotube bulk aggregate as claimed in claim 50, wherein the carbon nanotubes are single-walled carbon nanotubes.

52. The aligned carbon nanotube bulk aggregate as claimed in claim 50, wherein the carbon nanotubes are double-walled carbon nanotubes.

53. The aligned carbon nanotube bulk aggregate as claimed in claim 50, wherein the carbon nanotubes are a mixture of single-walled carbon nanotubes and double-walled or more multi-walled carbon nanotubes.

54. The aligned carbon nanotube bulk aggregate as claimed in claim 50, which has a purity of at least 98 mass %.

55. The aligned carbon nanotube bulk aggregate as claimed in claim 50, which has a specific surface area of from 600 to 2600 m²/g.

56. The aligned carbon nanotube bulk aggregate as claimed in claim 50, which is unopened and which has a specific surface area of from 600 to 1300 m²/g.

57. The aligned carbon nanotube bulk aggregate as claimed in claim 50, which is opened and which has a specific surface area of from 1300 to 2600 m²/g.

58. The aligned carbon nanotube bulk aggregate as claimed in claim 50, which is a mesoporous material having a packing ratio of from 5 to 50%.

59. The aligned carbon nanotube bulk aggregate as claimed in claim 50, which has a mesopore diameter of from 1.0 to 5.0 nm.

60. The aligned carbon nanotube bulk aggregate as claimed in claim 50, which has a Vickers hardness of from 5 to 100 HV.

61. The aligned carbon nanotube bulk aggregate as claimed in claim 50, which is vertically aligned or horizontally aligned on a substrate.

62. The aligned carbon nanotube bulk aggregate as claimed in claim 50, which is aligned on a substrate in the direction oblique to the substrate surface.

63. The aligned carbon nanotube bulk aggregate as claimed in claim 50, which has anisotropy between the alignment direction and the direction vertical thereto, in at least any of optical properties, electric properties, mechanical properties and thermal properties.

64. The aligned carbon nanotube bulk aggregate as claimed in claim 50, wherein the degree of anisotropy between the alignment direction and the direction vertical thereto is at most ⅕

in terms of the ratio of the small value to the large value.

65. The aligned carbon nanotube bulk aggregate as claimed in claim 50, wherein the intensity ratio of any of the (100), (110) and (002) peaks in the alignment direction and in the direction vertical thereto in X-ray diffraction is from ½

to 1/100 in terms of the ratio of the small value to the large value.

66. The aligned carbon nanotube bulk aggregate as claimed in claim 50, wherein the shape of the bulk aggregate is patterned in a predetermined shape.

67. The aligned carbon nanotube bulk aggregate as claimed in claim 66, wherein the shape is a thin film.

68. The aligned carbon nanotube bulk aggregate as claimed in claim 66, wherein the shape is a columnar one having a circular, oval or n-angled cross section (n is an integer of at least 3).

69. The aligned carbon nanotube bulk aggregate as claimed in claim 66, wherein the shape is a block.

70. The aligned carbon nanotube bulk aggregate as claimed in claim 66, wherein the shape is a needle-like one.

87. A heat dissipation material comprising the aligned carbon nanotube bulk aggregate of claim 50.

88. An article provided with the heat dissipation material of claim 87.

89. A heat conductor comprising the aligned carbon nanotube bulk aggregate of claim 50.

90. An article provided with the heat conductor of claim 89.

91. An electric conductor comprising the aligned carbon nanotube bulk aggregate of claim 50.

92. An article provided with the electric conductor of claim 91.

93. An electrode material comprising the aligned carbon nanotube bulk aggregate of claim 50.

94. A cell wherein the electrode comprises the electrode material of claim 93.

95. A capacitor or supercapacitor wherein the electrode material comprises the aligned carbon nanotube bulk aggregate of claim 50.

96. An adsorbent comprising the aligned carbon nanotube bulk aggregate of claim 50.

97. A gas absorbent comprising the aligned carbon nanotube bulk aggregate of claim 50.

98. A flexible electrically conductive heater comprising the aligned carbon nanotube bulk aggregate of claim 50.

71. A process for producing an aligned carbon nanotube bulk aggregate through chemical vapor deposition (CVD) of carbon nanotubes in the presence of a metal catalyst, wherein plural carbon nanotubes are grown, as aligned, in a reaction atmosphere, and then the resulting plural carbon nanotubes are exposed to liquid and dried thereby giving an aligned carbon nanotube bulk aggregate having a density of from 0.2 to 1.5 g/m³.

72. The process for producing an aligned carbon nanotube bulk aggregate as claimed in claim 71, which is for producing an aligned carbon nanotube bulk aggregate where the carbon nanotubes are single-walled carbon nanotubes.

73. The process for producing an aligned carbon nanotube bulk aggregate as claimed in claim 71, which is for producing an aligned carbon nanotube bulk aggregate where the carbon nanotubes are double-walled carbon nanotubes.

74. The process for producing an aligned carbon nanotube bulk aggregate as claimed in claim 71, which is for producing an aligned carbon nanotube bulk aggregate where the carbon nanotubes are a mixture of single-walled carbon nanotubes and double-walled or more multi-walled carbon nanotubes.

75. The process for producing an aligned carbon nanotube bulk aggregate as claimed in claim 71, which is for producing an aligned carbon nanotube bulk aggregate having a purity of at least 98 mass %.

76. The process for producing an aligned carbon nanotube bulk aggregate as claimed in claim 71, which is for producing an aligned carbon nanotube bulk aggregate having a specific surface area of from 600 to 2600 m²/g.

77. The process for producing an aligned carbon nanotube bulk aggregate as claimed in claim 71, which is for producing an aligned carbon nanotube bulk aggregate that is unopened and has a specific surface area of from 600 to 1300 m²/g.

78. The process for producing an aligned carbon nanotube bulk aggregate as claimed in claim 71, which is for producing an aligned carbon nanotube bulk aggregate that is opened and has a specific surface area of from 1300 to 2600 m²/g.

79. The process for producing an aligned carbon nanotube bulk aggregate as claimed in claim 71, which is for producing an aligned carbon nanotube bulk aggregate that has anisotropy between the alignment direction and the direction vertical thereto, in at least any of optical properties, electric properties, mechanical properties and thermal properties.

80. The process for producing an aligned carbon nanotube bulk aggregate as claimed in claim 71, which is for producing an aligned carbon nanotube bulk aggregate of such that the degree of anisotropy between the alignment direction and the direction vertical thereto is at most ⅕

in terms of the ratio of the small value to the large value.

81. The process for producing an aligned carbon nanotube bulk aggregate as claimed in claim 71, which is for producing an aligned carbon nanotube bulk aggregate of such that the intensity ratio of any of the (100), (110) and (002) peaks in the alignment direction and in the direction vertical thereto in X-ray diffraction is from ½

to 1/100 in terms of the ratio of the small value to the large value.

82. The process for producing an aligned carbon nanotube bulk aggregate as claimed in claim 71, which is for producing an aligned carbon nanotube bulk aggregate as patterned in any desired shape.

83. The process for producing an aligned carbon nanotube bulk aggregate as claimed in claim 82, which is for producing an aligned carbon nanotube bulk aggregate having a thin filmy shape.

84. The process for producing an aligned carbon nanotube bulk aggregate as claimed in claim 82, which is for producing an aligned carbon nanotube bulk aggregate having a columnar shape that has a circular, oval or n-angled cross section (n is an integer of at least 3).

85. The process for producing an aligned carbon nanotube bulk aggregate as claimed in claim 82, which is for producing an aligned carbon nanotube bulk aggregate having a block shape.

86. The process for producing an aligned carbon nanotube bulk aggregate as claimed in claim 82, which is for producing an aligned carbon nanotube bulk aggregate having a needle-like shape.