Spherical carbon nanostructure and method for producing spherical carbon nanostructures

• US 7,901,653 B2
• Filed: 10/31/2007
• Issued: 03/08/2011
• 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:
  US11/932,558
• Publication Number:
  US 20080056980A1
• Time in Patent Office: 1,224 Days
• Field of Search: 423/445.B, 423/460, 423/461, 423/DIG.12, 423/447.1, 423/447.3, 110/235, 110/237, 977/243, 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 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 for producing carbon nanostructures according to the invention includes injecting acetylene gas into a reactant liquid. The injected acetylene molecules are then maintained in contact with the reactant liquid for a period of time sufficient to break the carbon-hydrogen bonds in at least some of the acetylene molecules, and place the liberated carbon ions in an excited state. This preferred method further includes enabling the liberated carbon ions in the excited state to traverse a surface of the reactant liquid and enter a collection area. Collection surfaces are provided in the collection area to collect carbon nanostructures.

Claims

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

(a) placing acetylene molecules within a volume of reactant liquid for a period of time sufficient to liberate carbon ions in an excited state;

(b) enabling the liberated carbon ions in the excited state to traverse a surface of the reactant liquid and enter a collection area; and

(c) removing spherical carbon nanostructures from the collection area.

2. The method of claim 1 further including producing an acetylene and inert gas mixture, and injecting the acetylene and inert gas mixture into the reactant liquid to place acetylene molecules within the volume of reactant liquid.

3. The method of claim 2 further including enabling the inert gas to vent from the collection area together with hydrogen liberated from the acetylene.

4. The method of claim 1 further including adding heat to the collection area with a heater element.

5. The method of claim 1 wherein the reactant liquid includes substantially pure liquid aluminum at approximately 1650°

F., at least one collection surface is maintained in the collection area at approximately 1350°

F. to 1620°

F. as carbon ions enter the collection area, and metal catalysts are absent from the at least one collection surface.

6. The method of claim 1 further including maintaining one or more collection surfaces in the collection area at approximately 100°

F. to 590°

F. as carbon ions enter the collection area.

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

(a) injecting acetylene into a reactant liquid comprising substantially pure liquid aluminum which is maintained at a temperature sufficient to liberate carbon ions in an excited state from the acetylene, the carbon ions in the excited state comprising two bonded carbon atoms;

(b) enabling carbon from the injected acetylene to traverse a surface of the reactant liquid and enter a collection area;

(c) providing one or more collection surfaces in the collection area to collect carbon nanostructures; and

(d) removing at least one of the one or more collection surfaces from the collection area and removing spherical carbon nanostructures collected on the at least one collection surface.

8. The method of claim 7 wherein the acetylene is injected into the reactant liquid at a depth of approximately sixteen inches or more below the surface of the reactant liquid.

9. The method of claim 7 wherein providing one or more collection surfaces in the collection area includes positioning one or more horizontal plates in the collection area.

10. The method of claim 7 wherein providing one or more collection surfaces in the collection area includes positioning one or more vertical plates the collection area.

11. The method of claim 7 further including heating the one or more of the collection surfaces to a temperature of approximately 1350°

F. to 1620°

F. while carbon ions in the excited state enter the collection area.

12. The method of claim 11 wherein the one or more collection surfaces each comprise a surface of a substrate that is substantially free of metal catalysts.

13. The method of claim 7 further including maintaining the one or more collection surfaces at approximately 100°

F. to 590°

F. while carbon ions in the excited state enter the collection area.

14. The method of claim 7 wherein the acetylene is injected together with argon gas.

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

(a) placing acetylene in contact with a reactant liquid including liquid aluminum at a sufficient temperature to liberate carbon ions from the acetylene and place the liberated carbon atoms in an excited state, the carbon ions comprising two bonded carbon atoms;

(b) enabling the carbon ions from the reaction of acetylene with the reactant liquid to escape from the reactant liquid and enter a collection area; and

(c) removing spherical carbon nanostructures from the collection area.

16. The method of claim 15 further including controlling the temperature of collection surfaces in the collection area by applying heat to the collection surfaces with a heater element.

17. The method of claim 16 wherein the temperature of the collection surfaces is maintained from approximately 1350°

F. to 1620°

F., and metal catalysts are absent from the collection surfaces.

18. The method of claim 16 wherein the temperature of the collection surfaces is maintained from approximately 100°

F. to 590°

F.