Method and apparatus for producing carbon nanostructures

• US 7,815,885 B2
• Filed: 10/31/2007
• Issued: 10/19/2010
• Est. Priority Date: 07/09/2004
• Status: Expired due to Fees

• Current Assignee: Clean Technology International Corp.
• Original Assignee: Clean Technology International Corp.
• Inventors: Wagner, Anthony S.
• Primary Examiner(s): Silverman; Stanley S.
• Assistant Examiner(s): MCCRACKEN, DANIEL
• Application Number:
  US11/931,802
• Publication Number:
  US 20090155160A1
• Time in Patent Office: 1,084 Days
• Field of Search: 423/445.B, 423/460, 423/461, 423/DIG.12, 423/447.1, 423/447.3, 110/235, 110/237, 110/243, 977/842, 977/844
• US Class Current: 423/445.00B
• CPC Class Codes: B01J 19/006 Baffles
• CPC Class Codes: B01J 2219/00763 Baffles
• CPC Class Codes: B01J 2219/00768 vertical
• CPC Class Codes: B01J 4/002 Nozzle-type elements nozzle-type reactors B01J19/26
• 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 2202/04 Nanotubes with a specific amount of walls
• CPC Class Codes: C01B 32/166 in liquid phase
• CPC Class Codes: C01B 32/18 Nanoonions; Nanoscrolls; Nanohorns; Nanocones; Nanowalls
• CPC Class Codes: Y10S 977/842 for carbon nanotubes or fullerenes
• 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

Abstract

A method includes liberating carbon atoms from hydrocarbon molecules by reaction with or in a reactant liquid and maintaining the liberated carbon atoms in an excited state. The chemically excited liberated carbon atoms are then enabled to traverse a surface of the reactant liquid and are directed across a collection surface. The collection surface and the conditions at and around the collection surface are maintained so that the liberated carbon atoms in the excited state phase change to a ground state by carbon nanostructure self-assembly.

Claims

1. A method for producing carbon nanostructures, the method including:

(a) placing hydrocarbon molecules in contact with a reactant liquid;

(b) liberating carbon atoms from the hydrocarbon molecules by reaction of the hydrocarbon molecules with the reactant liquid, and placing the liberated carbon atoms in an excited state within the reactant liquid;

(c) enabling the liberated carbon atoms in the excited state to traverse a surface of the reactant liquid to escape into a collection chamber which defines a collection area above the reactant liquid;

(d) maintaining conditions in the collection chamber in which the liberated carbon atoms which have traversed the surface of the reactant liquid phase change to a ground state within the collection chamber to produce carbon nanostructures within the collection chamber; and

(e) removing the carbon nanostructures from the collection chamber.

2. The method of claim 1 further including collecting the carbon nanostructures on a collection surface within the collection chamber as the liberated carbon atoms phase change to the ground state within the collection chamber, and wherein removing the carbon nanostructures from the collection chamber includes:

(a) removing the collection surface from the collection chamber; and

(b) removing carbon nanostructures from the collection surface after the collection surface is removed from the collection chamber.

3. The method of claim 2 further including maintaining the collection surface at a temperature between approximately 600 degrees Celsius to approximately 950 degrees Celsius as the carbon atoms in the excited state traverse the surface of the reactant liquid.

4. The method of claim 2 further including maintaining the collection surface at a temperature no more than approximately fifty (50) degrees Celsius below the temperature of the reactant liquid.

5. The method of claim 2 wherein the collection surface includes a seed material deposited thereon.

6. The method of claim 1 wherein the reactant liquid comprises predominately aluminum at a temperature at or above 650 degrees Celsius.

7. The method of claim 1 wherein the reactant liquid comprises a material that does not react chemically with the hydrocarbon molecules.

8. The method of claim 1 wherein the reactant liquid reacts with the hydrocarbon molecules by a reduction reaction.

9. The method of claim 1 wherein the reactant liquid reacts with the hydrocarbon molecules by an oxidation reaction.

10. The method of claim 1 wherein the reactant liquid is an acid.

11. The method of claim 1 wherein the hydrocarbon molecules do not include double or triple bonded carbon.