Reactant liquid system for facilitating the production of carbon nanostructures

• US 7,815,886 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:
  US11/931,901
• Publication Number:
  US 20080050303A1
• 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: 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 32/166 in liquid phase
• CPC Class Codes: C01B 32/18 Nanoonions; Nanoscrolls; Nanohorns; Nanocones; Nanowalls
• CPC Class Codes: C01B 32/90 Carbides
• 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 isolating carbon atoms as conditioned carbide anions below a surface of a reactant liquid. The conditioned carbide anions are then enabled to escape from the reactant liquid to a collection area where carbon nanostructures may form. A carbon structure produced in this fashion includes at least one layer made up of hexagonally arranged carbon atoms. Each carbon atom has three covalent bonds to adjoining carbon atoms and one unbound pi electron.

Claims

1. A method including:

(a) introducing a carbon-bearing material into a reactant liquid;

(b) isolating carbon atoms from the carbon-bearing material as conditioned carbide anions located within the reactant liquid;

(c) providing a collection area which contains at least one collection surface;

(d) enabling the conditioned carbide anions to traverse a surface of the reactant liquid and travel into the collection area over the at least one collection surface contained in the collection area;

(e) introducing a material into the collection chamber through a separate collection chamber input as the conditioned carbon anions travel over the collection surface, the separate collection chamber input having an injection end positioned within the collection chamber so that the material introduced into the collection chamber through the separate collection chamber input is directed against the collection surface as the conditioned carbon anions travel over the collection surface; and

(f) removing carbon nanostructures from the collection chamber.

2. The method of claim 1 wherein the reactant liquid is made up of one or more liquid metals.

3. The method of claim 2 wherein the reactant liquid includes predominantly aluminum.

4. The method of claim 3 wherein the reactant liquid is held at a temperature of approximately 900 degrees Celsius.

5. The method of claim 1 wherein the reactant liquid isolates carbon atoms from the carbon-bearing material by chemical reduction, chemical oxidation, or pyrolysis, or by reactions from acids, bases, or salts.

6. The method of claim 1 wherein the material injected into the collection chamber through the separate collection chamber input includes a seed material for the formation of carbon nanostructures.

7. The method of claim 1 wherein the reactant liquid comprises a liquid metal made up predominantly of aluminum and held at a temperature between approximately 650 degrees Celsius and approximately 950 degrees Celsius, and the collection surface is at a temperature no more than fifty (50) degrees Celsius below the temperature of the reactant liquid.

8. The method of claim 1 wherein the carbon-bearing material includes carbon nanostructures.

9. The method of claim 1 wherein the carbon-bearing material includes single carbon bonds exclusively.

10. A method including:

(a) introducing a carbon-bearing material into a reactant liquid;

(b) isolating carbon atoms from the carbon-bearing material as conditioned carbide anions located within the reactant liquid;

(c) enabling the conditioned carbide anions to traverse a surface of the reactant liquid and travel into a collection area adjacent to the reactant liquid;

(d) introducing a seed material into the collection chamber as the conditioned carbon anions travel into the collection chamber, the seed material comprising a material which encourages the assembly of carbon nanostructures from the conditioned carbon atoms in the collection area; and

(e) removing carbon nanostructures from the collection chamber.

11. The method of claim 10 further including providing a collection surface within the collection area.

12. The method of claim 11 wherein the seed material is introduced into the collection chamber through a separate collection chamber input as the conditioned carbon anions travel over the collection surface, the separate collection chamber input having an injection end positioned within the collection chamber so that the seed material is directed against the collection surface as the conditioned carbon anions travel over the collection surface.

13. The method of claim 12 wherein the carbon-bearing material includes single carbon bonds exclusively.

14. The method of claim 11 wherein the reactant liquid comprises a liquid metal made up predominantly of aluminum and held at a temperature between approximately 650 degrees Celsius and approximately 950 degrees Celsius, and the collection surface is at a temperature no more than fifty (50) degrees Celsius below the temperature of the reactant liquid.

15. An apparatus for producing carbon nanostructures, the apparatus including:

(a) a reactant liquid vessel for containing a reactant liquid at a reactant liquid level;

(b) a feed material injector having an outlet end positioned within the reactant liquid vessel at a point below the reactant liquid level;

(c) a collection chamber positioned to receive effluent escaping from the reactant liquid in the reactant liquid vessel;

(d) a collection structure, the collection structure including a collection surface having at least a portion which is spaced apart from side walls of the collection chamber and which resides in the collection chamber at a position above the reactant liquid level; and

(e) a separate collection chamber input having an injection end positioned in the collection chamber so as to direct a material flowing out of the injection end against the collection surface.

16. The apparatus of claim 15 further including a reaction chamber located within the reactant liquid vessel and having an upper surface below the reactant liquid level of the reactant liquid vessel.

17. The apparatus of claim 15 wherein the collection structure is suspended in the collection chamber from a support extending from a top of the collection chamber.