Condensed phase conversion and growth of nanorods instead of from vapor

• US 6,923,946 B2
• Filed: 11/28/2001
• Issued: 08/02/2005
• Est. Priority Date: 11/26/1999
• Status: Expired due to Fees

• Current Assignee: UT-Battelle LLC
• Original Assignee: UT-Battelle LLC
• Inventors: Seals, Roland D., Geohegan, David B., Puretzky, Alex A., Fan, Xudong
• Primary Examiner(s): Cole, Elizabeth M.
• Application Number:
  US09/997,600
• Publication Number:
  US 20020179564A1
• Time in Patent Office: 1,343 Days
• Field of Search: 423/447.3, 423/445.B, 423/447.2
• US Class Current: 423/447.1
• 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 2202/06 Multi-walled nanotubes
• CPC Class Codes: C01B 32/162 characterised by catalysts
• CPC Class Codes: C01B 32/18 Nanoonions; Nanoscrolls; Nanohorns; Nanocones; Nanowalls
• CPC Class Codes: C01B 33/02 Silicon forming single crystals or homogeneous polycrystalline material with defined structure C30B
• CPC Class Codes: Y10S 977/842 for carbon nanotubes or fullerenes
• CPC Class Codes: Y10S 977/843 Gas phase catalytic growth, i.e. chemical vapor deposition
• CPC Class Codes: Y10S 977/844 Growth by vaporization or dissociation of carbon source using a high-energy heat source, e.g. electric arc, laser, plasma, e-beam
• CPC Class Codes: Y10T 428/24992 Density or compression of components
• CPC Class Codes: Y10T 442/60 Nonwoven fabric [i.e., nonwoven strand or fiber material]
• CPC Class Codes: Y10T 442/614 Strand or fiber material specified as having microdimensions [i.e., microfiber]

Abstract

Compositions, systems and methods are described for condensed phase conversion and growth of nanorods and other materials. A method includes providing a condensed phase matrix material; and activating the condensed phase matrix material to produce a plurality of nanorods by condensed phase conversion and growth from the condensed chase matrix material instead of from vacor. The compositions are very strong. The compositions and methods provide advantages because they allow (1) formation rates of nanostructures necessary for reasonable production rates, and (2) the near net shaped production of component structures.

Claims

1. A method, comprising:

depositing a condensed phase matrix material;

activating said condensed phase matrix material to produce a plurality of nanorods by condensed phase conversion and growth from the condensed phase matrix material instead of from vapors;

acquiring data from said plurality of nanorods during activating; and

changing operational parameters of activating using acquired spectroscopic data to optimize said plurality of nanorods,

wherein said condensed phase matrix material includes at least one member selected from the group consisting of carbon, silicon, silicon carbide, germanium, and gallium arsenide and said plurality of nanorods include at least one member selected from the group consisting of carbon, silicon, silicon carbide, germanium, boron nitride and gallium arsenide.

2. The method of claim 1, wherein said condensed phase matrix material is deposited by condensing a gaseous phase source of condensed phase matrix material.

4. The method of claim 1, further comprising providing a plurality of catalyst particles, wherein activating said condensed phase matrix material includes activating said plurality of catalyst particles to produce a plurality of nanorods by condensed phase conversion growth.

5. The method of claim 1, wherein said condensed phase matrix material is prepared by at least one technique selected from the group consisting of laser ablation, thermal spray, electric arc, plasma arc, infrared vaporization, microwave vaporization, mechanical grinding, mechanical fracture, explosive vaporization, ion sputtering, electron beam etching.

6. The method of claim 1, wherein said condensed phase matrix material includes a plurality of solid phase templates and activating said condensed phase matrix material includes activating said plurality of solid phase templates to grow said plurality of nanorods by condensed phase conversion growth from said solid phase templates.

7. The method of claim 6, wherein said plurality of solid phase templates include nanorods.

8. The method of claim 6, wherein said solid phase templates include single wall nanotubes.

9. The method of claim 8, wherein said single wall nanotubes are produced by condensed phase conversion growth and activating said plurality of solid phase templates includes reactivating said single wall nanotubes.

10. The method of claim 7, wherein activating said plurality of solid phase templates includes reactivating said plurality of nanorods.

11. The method of claim 1, wherein said condensed phase matrix material is provided in a pattern of a substrate.

12. The method of claim 11, further comprising providing at least one catalyst particle on said pattern, wherein activating said condensed phase matrix material, includes activating said at least one catalyst particle to transform said condensed phase matrix material into at least one nanorod by condensed phase conversion growth.

13. The method of claim 1, wherein said condensed phase matrix material is provided in a mold space.

14. The method of claim 1, wherein said plurality of nanorods include at least one substantially cylindrical nanostructure selected from the group consisting of nanowires, multi-wall nanotubes and single-wall nanotubes.

15. The method of claim 1, said plurality of nanorods are interrelated to define a substantially random distribution of intersection angles between the plurality of nanorods.

16. The method of claim 1, wherein said plurality of nanorods are interwoven.

17. The method of claim 1, wherein condensed phase conversion and growth includes solid-state conversion and growth.

18. The method of claim 1, wherein activating takes place after depositing.

19. The method of claim 1, further comprising placing said plurality of nanorods in contact with a condensed phase feedstock material and annealing to continue growth of the plurality of nanorods.

3. A method, comprising:

depositing a condensed phase matrix material;

activating said condensed phase matrix material to produce a plurality of nanorods by condensed phase conversion and growth from the condensed phase matrix material instead of from vapors;

acquiring data from said plurality of nanorods during activating; and

changing operational parameters of activating using acquired spectroscopic data to optimize said plurality of nanorods,

wherein said condensed phase matrix material includes at least one member selected from the group consisting of carbon, silicon, silicon carbide, germanium, and gallium arsenide and said plurality of nanorods include at least one member selected from the group consisting of carbon, silicon, silicon carbide, germanium, boron nitride and gallium arsenide and

wherein said condensed phase matrix material includes amorphous carbon particles with an average diameter of from approximately 1 nm to approximately 100 nm.

20. The method of claim 3, wherein said plurality of nanorods are interrelated to define a substantially random distribution of intersection angles between the plurality of nanorods.

21. The method of claim 3, wherein said plurality of nanorods are interwoven.

22. The method of claim 3, further comprising placing said plurality of nanorods in contact with a condensed phase feedstock material and annealing to continue growth of the plurality of nanorods.

23. The method of claim 3, wherein condensed phase conversion and growth includes solid-state conversion and growth.

24. The method of claim 3, wherein activating takes place after depositing.