Process and apparatus for producing composite material that includes carbon nanotubes
First Claim
1. A process for producing a composite material having carbon nanotubes present on a surface of a base material using an apparatus that comprises:
- a hollow body defining an elongated chamber that is configured to have a gas flow through it and is heatable, wherein the hollow body is rotatable about a major axis and is inclined such that an upstream side on one end of the hollow body in the direction of the major axis is higher than a downstream side of the hollow body on the other end,an introduction site configured to input the base material into the chamber,a supply site configured to input a carbon source vapor into the chamber, the introduction site and the supply site being arranged so that contact between the base material and the carbon source vapor occurs in a reaction zone disposed in at least one upstream portion of the elongated chamber in the direction of the major axis, anda plurality of ribs disposed on at least one inner peripheral wall of the hollow body at least within a portion of the elongated chamber adjacent to the reaction zone,wherein the process comprises;
inputting the base material, which already has a catalyst disposed on its surface, into the chamber of the hollow body via the introduction site;
supplying the carbon source vapor, which is comprised of a carbon source capable of forming the carbon nanotubes on the base material, via the supply site, andmoving the base material from the upstream side to the downstream side by rotating the hollow body about the major axis, wherein base material disposed on the at least one inner peripheral wall is caught on the ribs and is lifted up and then is dropped such that the base material and the carbon source vapor make contact in the reaction zone.
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Accused Products
Abstract
A process and an apparatus for producing a composite material utilize a rotatable hollow body that is inclined with an upstream side being higher than a downstream side. A reaction zone is defined within an elongated chamber in the hollow body. Protrusions inwardly extend from an inner peripheral wall of the hollow body adjacent to the reaction zone. Base material is input into the chamber via a base material introduction port and a carbon source vapor is input into the chamber via a carbon source supply port. A heater heats the reaction zone to a temperature at which carbon nanotubes form on the base material from the carbon source vapor. The protrusions catch base material disposed on the inner peripheral wall of the hollow body when the hollow body rotates and then drop the base material through the reaction zone so that the base material contacts the carbon source vapor.
21 Citations
24 Claims
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1. A process for producing a composite material having carbon nanotubes present on a surface of a base material using an apparatus that comprises:
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a hollow body defining an elongated chamber that is configured to have a gas flow through it and is heatable, wherein the hollow body is rotatable about a major axis and is inclined such that an upstream side on one end of the hollow body in the direction of the major axis is higher than a downstream side of the hollow body on the other end, an introduction site configured to input the base material into the chamber, a supply site configured to input a carbon source vapor into the chamber, the introduction site and the supply site being arranged so that contact between the base material and the carbon source vapor occurs in a reaction zone disposed in at least one upstream portion of the elongated chamber in the direction of the major axis, and a plurality of ribs disposed on at least one inner peripheral wall of the hollow body at least within a portion of the elongated chamber adjacent to the reaction zone, wherein the process comprises; inputting the base material, which already has a catalyst disposed on its surface, into the chamber of the hollow body via the introduction site; supplying the carbon source vapor, which is comprised of a carbon source capable of forming the carbon nanotubes on the base material, via the supply site, and moving the base material from the upstream side to the downstream side by rotating the hollow body about the major axis, wherein base material disposed on the at least one inner peripheral wall is caught on the ribs and is lifted up and then is dropped such that the base material and the carbon source vapor make contact in the reaction zone. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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16. A process for producing a composite material having carbon nanotubes present on a surface of a base material, the base material having a catalyst on a surface, the process comprising:
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providing an apparatus that includes a hollow body defining an elongated chamber configured to have a gas flow therethrough and being heatable, the hollow body being mounted for rotation about a major axis and being inclined, the apparatus including an introduction site configured for inputting the base material into the chamber and a supply site configured for inputting a carbon source vapor into the chamber, the introduction site and the supply site being arranged so that contact between the base material and the carbon source vapor occurs in a reaction zone, and the apparatus having a plurality of ribs disposed on at least one inner peripheral wall of the hollow body at least within a portion of the elongated chamber adjacent to the reaction zone, inputting the base material into the chamber of the hollow body via the introduction site; supplying the carbon source vapor via the supply site, and rotating the hollow body about the major axis to move the base material along the inclined hollow body, to lift the base material on the ribs and to drop the base material from the ribs such that the base material and the carbon source vapor make contact in the reaction zone.
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17. An apparatus capable of producing a composite material having carbon nanotubes present on a surface of a base material, comprising:
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a hollow body rotatable about a major axis and disposed such that the major axis is inclined with an upstream side of the hollow body on one end of the major axis being higher than a downstream side of the hollow body on the other end, an elongated chamber comprising a reaction zone defined within the hollow body over at least one longitudinal section of the elongated chamber along the major axis, a plurality of ribs disposed on at least one inner peripheral wall of the hollow body in at least a portion of the elongated chamber that is adjacent to the reaction zone, an input device configured to input the base material into the chamber via a base material introduction port, a carbon source vapor supply device configured to supply a carbon source vapor into the chamber via a carbon source supply port, and a heater configured to heat at least the reaction zone to a temperature at which carbon nanotubes form from the carbon source vapor, wherein the ribs are configured to catch base material disposed on the inner peripheral wall of the hollow body when the hollow body rotates and then drop the base material through the reaction zone so that the base material contacts the carbon source vapor. - View Dependent Claims (18, 19, 20, 21, 22, 23, 24)
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Specification