Process for the production of nanostructured carbon materials

• US 9,365,426 B2
• Filed: 07/22/2013
• Issued: 06/14/2016
• Est. Priority Date: 07/30/2012
• Status: Expired due to Fees

• Current Assignee: Scnte, LLC
• Original Assignee: Scnte, LLC
• Inventors: Riehl, Bill L., Riehl, Bonnie D., Riehl, Lee R., Riehl, Jim R., Johnson, Jay M.
• Primary Examiner(s): HENDRICKSON, STUART L
• Application Number:
  US13/947,767
• Publication Number:
  US 20140030184A1
• Time in Patent Office: 1,058 Days
• US Class Current: 1/1
• 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 32/05 Preparation or purification of carbon not covered by groups C01B32/15, C01B32/20, C01B32/25, C01B32/30
• CPC Class Codes: C01B 32/164 involving continuous processes
• CPC Class Codes: D01F 9/127 by thermal decomposition of hydrocarbon gases or vapours or other carbon-containing compounds in the form of gas or vapour, e.g. carbon monoxide, alcohols

Abstract

A process for producing a nanostructured carbon material including the steps of providing a metal or metalloid carbide substrate and reacting the carbide substrate with a reactive gas to form the nanostructured carbon material, the reactive gas and the carbide substrate being added during the reacting step.

Claims

1. A process for producing a nanostructured carbon material comprising the steps of:

providing a metal or metalloid carbide substrate;

reacting said carbide substrate with a carbon oxide to form said nanostructured carbon material, said carbide substrate being added during said reaction.

2. The process of claim 1 wherein said carbide substrate comprises silicon carbide.

3. The process of claim 2 wherein said silicon carbide is in crystalline form.

4. The process of claim 3 wherein said crystalline form is polycrystalline form.

5. The process of claim 1 wherein said carbide substrate is modified with a dopant.

6. The process of claim 5 wherein said dopant is nitrogen.

7. The process of claim 1 wherein said providing step comprises:

providing a carbon-containing precursor; and

decomposing said carbon-containing precursor in the presence of a metal or metalloid to form said carbide substrate.

8. The process of claim 7 wherein said carbon-containing precursor is a textile.

9. The process of claim 7 wherein said carbon-containing precursor comprises at least one of cellulose, cotton, hemp, wool and organic polymer.

10. The process of claim 7 wherein said carbon-containing precursor comprises a silylation chemical.

11. The process of claim 7 wherein said carbon-containing precursor comprises at least one of a silicon-containing polymer and a vapor.

12. The process of claim 1 wherein said reacting step comprises continuously passing said carbide substrate through a reactor.

13. The process of claim 1 wherein said reacting step is performed at a temperature ranging from about 1000°

C. to about 2200°

C.

14. The process of claim 1 wherein said reacting step occurs in a reactor, and wherein said carbon oxide is formed in situ in said reactor.

15. The process of claim 1 wherein said nanostructured carbon material is a yarn or fabric.

16. A process for producing a nanostructured carbon textile comprising the steps of:

providing a carbon-containing precursor, wherein said carbon-containing precursor is in textile form;

decomposing said carbon-containing precursor in the presence of a metal or metalloid to form a carbide textile substrate; and

reacting said carbide textile substrate with a reactive gas comprising carbon oxide to form said nanostructured carbon textile.

17. The process of claim 16 wherein said reacting step occurs in a reactor, and wherein said carbide textile substrate is continuously fed to said reactor.

18. The process of claim 16 wherein said carbon-containing precursor has a first shape, and wherein said nanostructured carbon textile has a second shape, said second shape being substantially similar to said first shape.

19. A process for producing a nanostructured carbon material comprising the steps of:

providing a metal or metalloid carbide substrate;

reacting said carbide substrate with a reactive gas to form said nanostructured carbon material, wherein said nanostructured carbon material is a yarn or fabric, said reactive gas and said carbide substrate being added during said reaction.

20. The process of claim 19 wherein said providing step comprises:

providing a carbon-containing precursor, wherein said carbon-containing precursor is a textile; and

decomposing said carbon-containing precursor in the presence of a metal or metalloid to form said carbide substrate.