Carbon nanostructures manufactured from catalytic templating nanoparticles
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
C01B-031/00
C01B-031/04
C09C-001/44
C09C-001/46
B01J-021/18
출원번호
UP-0539042
(2006-10-05)
등록번호
US-7718155
(2010-06-10)
발명자
/ 주소
Zhang, Cheng
Fransson, Martin
Liu, Changkun
Zhou, Bing
출원인 / 주소
Headwaters Technology Innovation, LLC
대리인 / 주소
Workman Nydegger
인용정보
피인용 횟수 :
9인용 특허 :
24
초록▼
Methods for manufacturing carbon nanostructures include: 1) forming a plurality of catalytic templating particles using a plurality of dispersing agent molecules; 2) forming an intermediate carbon nanostructure by polymerizing a carbon precursor in the presence of the plurality of templating nanopar
Methods for manufacturing carbon nanostructures include: 1) forming a plurality of catalytic templating particles using a plurality of dispersing agent molecules; 2) forming an intermediate carbon nanostructure by polymerizing a carbon precursor in the presence of the plurality of templating nanoparticles; 3) carbonizing the intermediate carbon nanostructure to form a composite nanostructure; and 4) removing the templating nanoparticles from the composite nanostructure to yield the carbon nanostructures. The carbon nanostructures are well-suited for use as a catalyst support. The carbon nanostructures exhibit high surface area, high porosity, and high graphitization. Carbon nanostructures according to the invention can be used as a substitute for more expensive and likely more fragile carbon nanotubes.
대표청구항▼
We claim: 1. A method for manufacturing carbon nanostructures, comprising: (i) forming a plurality of catalytic templating nanoparticles by: (a) reacting a plurality of precursor catalyst atoms with a plurality of organic dispersing agent molecules to form complexed catalyst atoms; and (b) allowing
We claim: 1. A method for manufacturing carbon nanostructures, comprising: (i) forming a plurality of catalytic templating nanoparticles by: (a) reacting a plurality of precursor catalyst atoms with a plurality of organic dispersing agent molecules to form complexed catalyst atoms; and (b) allowing or causing the complexed catalyst atoms to form the templating nanoparticles; (ii) forming one or more intermediate carbon nanostructures by polymerizing a carbon precursor in the presence of the templating nanoparticles; (iii) carbonizing the intermediate carbon nanostructures to form a plurality of composite nanostructures; and (iv) removing the templating nanoparticles from the composite nanostructures to yield the carbon nanostructures, the carbon nanostructures having a BET specific surface area greater than about 120 m2/g. 2. A method as defined in claim 1, wherein the catalyst atoms comprise at least one of iron, nickel, or cobalt. 3. A method as defined in claim 1, wherein the dispersing agent molecules are capable of bonding with the catalyst atoms and comprise at least one functional group selected from the group consisting of a hydroxyl, a carboxyl, a carbonyl, an amine, an amide, a nitrile, a nitrogen with a free lone pair of electrons, an amino acid, a thiol, a sulfonic acid, a sulfonyl halide, an acyl halide, and combinations thereof. 4. A method as defined in claim 1, wherein the dispersing agent molecules comprise at least one member selected from the group consisting of oxalic acid, malic acid, malonic acid, maleic acid, succinic acid, glycolic acid, lactic acid, glucose, citric acid, pectins, cellulose, ethanolamine, mercaptoethanol, 2-mercaptoacetate, glycine, sulfobenzyl alcohol, sulfobenzoic acid, sulfobenzyl thiol, sulfobenzyl amine, polyacrylates, polyvinylbenzoates, polyvinyl sulfate, polyvinyl sulfonates, polybisphenol carbonates, polybenzimidizoles, polypyridine, sulfonated polyethylene terephthalate, and combinations thereof. 5. A method as defined in claim 1, wherein the carbon precursor comprises a hydrothermally polymerizable organic substrate. 6. A method as defined in claim 5, wherein the hydrothermally polymerizable organic substrate comprises at least one of citric acid, acrylic acid, benzoic acid, acrylic ester, butadiene, styrene, or cinnamic acid. 7. A method as defined in claim 1, wherein the carbon precursor comprises at least one of resorcinol-formaldehyde-gel, phenol resin, melamine-formaldehyde gel, poly(furfuryl alcohol), or poly(acrylonitrile). 8. A method as defined in claim 1, wherein the templating nanoparticles are formed prior to being mixed with the carbon precursor. 9. A method as defined in claim 1, wherein carbonization is carried out at a temperature in a range of about 500° C. to about 2500° C. 10. A method as defined in claim 1, wherein at least a portion of the templating nanoparticles are removed from the composite nanostructure by etching with at least one of an acid or a base. 11. A method as defined in claim 1, further comprising placing metal catalyst particles on the carbon nanostructures. 12. A method as defined in claim 11, wherein the metal catalyst particles comprise at least one noble metal. 13. A method for manufacturing carbon nanostructures comprising: (i) providing a plurality of solid catalytic templating nanoparticles consisting essentially of one or more types of metal catalyst atoms and optionally one or more types of organic dispersing agent molecules; (ii) mixing the solid catalytic templating nanoparticles with a carbon precursor and polymerizing the carbon precursor in the presence of the solid catalytic templating nanoparticles to form a plurality of intermediate carbon nanostructures; (iii) carbonizing the intermediate carbon nanostructures to form a plurality of composite nanostructures; and (iv) removing the templating nanoparticles from the composite nanostructures to yield the carbon nanostructures, the carbon nanostructures having a BET specific surface area greater than about 120 m2/g, the carbon nanostructures being composed of hollow multi-walled sphere-like carbon nanostructures, each multi-walled sphere-like carbon nanostructure being formed from multiple graphitic layers and having a single interior hole defining an interior diameter of the sphere-like carbon nanostructure. 14. A method as defined in claim 13, wherein the metal catalyst atoms comprise at least one of iron, nickel, or cobalt. 15. A method as defined in claim 13, wherein the dispersing agent molecules are capable of bonding with the catalyst atoms and comprise at least one functional group selected from the group consisting of a hydroxyl, a carboxyl, a carbonyl, an amine, an amide, a nitrile, a nitrogen with a free lone pair of electrons, an amino acid, a thiol, a sulfonic acid, a sulfonyl halide, an acyl halide, and combinations thereof. 16. A method as defined in claim 13, wherein the dispersing agent molecules comprise at least one member selected from the group consisting of oxalic acid, malic acid, malonic acid, maleic acid, succinic acid, glycolic acid, lactic acid, glucose, citric acid, pectins, cellulose, ethanolamine, mercaptoethanol, 2-mercaptoacetate, glycine, sulfobenzyl alcohol, sulfobenzoic acid, sulfobenzyl thiol, sulfobenzyl amine, polyacrylates, polyvinylbenzoates, polyvinyl sulfate, polyvinyl sulfonates, polybisphenol carbonates, polybenzimidizoles, polypyridine, sulfonated polyethylene terephthalate, and combinations thereof. 17. A method as defined in claim 13, wherein the carbon precursor comprises a hydrothermally polymerizable organic substrate. 18. A method as defined in claim 17, wherein the hydrothermally polymerizable organic substrate comprises at least one of citric acid, acrylic acid, benzoic acid, acrylic ester, butadiene, styrene or cinnamic acid. 19. A method as defined in claim 13, wherein the carbon precursor comprises at least one of resorcinol-formaldehyde-gel, phenol resin, melamine-formaldehyde gel, poly(furfuryl alcohol), or poly(acrylonitrile). 20. A method as defined in claim 13, wherein carbonization is carried out at a temperature in a range of about 500° C. to about 2500° C. 21. A method as defined in claim 13, further comprising placing metal catalyst particles on the carbon nanostructures. 22. A method as defined in claim 21, wherein the metal catalyst particles comprise at least one noble metal. 23. A method as defined in claim 1, wherein (a) further comprises mixing and reacting a ground state metal comprising the precursor catalyst atoms with the organic dispersing agent molecules to form the complexed catalyst atoms. 24. A method as defined in claim 1, wherein (a) further comprises adding a base to adjust the pH to above 8 and below about 13. 25. A method as defined in claim 13, wherein the solid catalytic templating nanoparticles are provided in an aqueous medium having pH greater than 8 and less than about 13. 26. A method as defined in claim 1, the carbon nanostructures being composed of hollow multi-walled structures, each multi-walled structure being formed from multiple graphitic layers. 27. A method for manufacturing carbon nanostructures, comprising: forming a plurality of catalytic templating nanoparticles by: reacting a plurality of precursor catalyst atoms with a plurality of organic dispersing agent molecules to form complexed catalyst atoms; and allowing or causing the complexed catalyst atoms to form the templating nanoparticles; forming a mixture comprising a carbon precursor and the plurality of catalytic templating nanoparticles, the catalytic templating nanoparticles comprising a catalytic metal, the mixture having a molar ratio of carbon precursor to catalyst metal atoms in a range of about 0.01:1 to about 100:1 causing or allowing the carbon precursor to polymerize in the presence of the templating nanoparticles to form a plurality of intermediate carbon nanostructures; carbonizing the intermediate carbon nanostructures to form a plurality of composite nanostructures; and removing the templating nanoparticles from the composite nanostructures to yield the carbon nanostructures, the carbon nanostructures having a BET specific surface area greater than about 120 m2/g. 28. A method as defined in claim 27, the carbon nanostructures being composed of hollow multi-walled structures, each multi-walled hollow structure being formed from multiple graphitic layers.
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