Carbon nanotube production process and carbon nanotube production apparatus

• US 8,784,562 B2
• Filed: 04/08/2010
• Issued: 07/22/2014
• Est. Priority Date: 04/09/2009
• Status: Expired due to Fees

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Ito, Naoki, Murata, Shigeaki, Nagasaka, Keisuke, Kawai, Hiroyuki, Imanishi, Masahiro, Nakazawa, Satoshi
• Primary Examiner(s): Lund, Jeffrie R
• Assistant Examiner(s): Antolin, Stanislav
• Application Number:
  US13/263,405
• Publication Number:
  US 20120045572A1
• Time in Patent Office: 1,566 Days
• Field of Search: None
• US Class Current: 118/715
• 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 2203/0277 containing a catalytic decomposition step
• CPC Class Codes: C01B 2203/041 In-situ membrane purification during hydrogen production
• CPC Class Codes: C01B 2203/0811 by combustion of fuel
• CPC Class Codes: C01B 2203/1058 Nickel catalysts
• CPC Class Codes: C01B 2203/1064 Platinum group metal catalysts
• CPC Class Codes: C01B 2203/107 Platinum catalysts
• CPC Class Codes: C01B 3/22 by decomposition of gaseous or liquid organic compounds C01B3/0005 takes precedence ; coking liquid carbonaceous materials C10B55/00
• CPC Class Codes: C01B 3/26 using catalysts
• CPC Class Codes: C01B 3/503 characterised by the membrane
• CPC Class Codes: C01B 32/162 characterised by catalysts

Abstract

A substrate 10 that selectively allows hydrogen to permeate therethrough is formed with a catalyst thin layer 20 on a first side 11 thereof and is heated in a furnace tube 110, which functions as a reactor, of a heating furnace 100 while a raw material gas to the catalyst thin layer 20 is fed. Hydrogen produced on the first side 11 of the substrate 10 as a result of the formation of carbon nanotubes 5 is separated from the raw material gas and is allowed to permeate to a second side 12 thereof.

Claims

1. A carbon nanotube production apparatus by a chemical vapor deposition method, comprising:

a reactor that accommodates a substrate;

the substrate comprising a first side and a second side;

a first hydrogen permeable electrode layer provided on the first side;

a second hydrogen permeable electrode layer provided on the second side;

a polymer electrolyte layer having proton conductivity interposed between the first and second hydrogen permeable electrode layers; and

a catalyst that promotes a forming reaction of a carbon nanotube supported on the first side, the substrate having the first hydrogen permeable electrode layer interposed between the catalyst and the polymer electrolyte layer, the substrate being configured to allow hydrogen to permeate therethrough from the first side to the second side;

a raw material gas feeding section that feeds a raw material gas that contains carbon atoms and hydrogen atoms to the first side;

an oxidizing gas supply section the supplies an oxygen-containing gas to the second side and is configured to subject the hydrogen that is produced by the forming reaction of the carbon nanotube on the first side and has permeated from the first side to the second side to an electrochemical reaction with the oxidizing gas so that the hydrogen that is produced by the forming reaction of the carbon nanotube;

a heater section that is configured to heat the reactor; and

a heater power source section that is an electrical power source for the heater section, electrically connected between the first and second hydrogen permeable electrode layers configured to collect an electrical power that is generated by the electrochemical reaction to supply part of an electrical power that is supplied to the heater power source section.

2. The production apparatus according to claim 1, further comprising a raw material gas inducing member that induces the raw material gas to the first side of the substrate, wherein the raw material gas inducing member has an outer peripheral side wall that surrounds a catalytic region in the first side on which the catalyst is supported such that the raw material gas is induced to the catalytic region, and

the outer peripheral side wall is provided with a discharge hole through which an unreacted raw material gas is discharged to outside, the unreacted raw material gas being a portion of the raw material gas that has been induced to the catalytic region but that has not undergone the forming reaction of the carbon nanotube.

3. The production apparatus according to claim 1, wherein the substrate is configured to allow hydrogen to selectively permeate therethrough, and the hydrogen that is produced on the first side is selectively permeated to the second side, to be removed from the first side.

4. The production apparatus according to claim 1, wherein the permeated hydrogen is in the form of protons.