Carbon-containing metal catalyst particles for carbon nanotube synthesis and method of producing the same, catalyst carrier support, and method of producing carbon nanotubes

Patent metadata

Field	Value
Publication number	US-10357765-B2
Application number	US-201314409499-A
Country	US
Kind code	B2
Filing date	Jun 20, 2013
Priority date	Jun 22, 2012
Publication date	Jul 23, 2019
Grant date	Jul 23, 2019

Abstract

The present invention relates to metal catalyst particles for carbon nanotube synthesis, comprising carbon-containing regions on their surfaces.

First claim

The invention claimed is:

1. A catalyst-carrying support comprising a support and carbon-containing metal catalyst particles for carbon nanotube synthesis carried on the support,
wherein the carbon-containing metal catalyst particles for carbon nanotube synthesis comprise carbon-containing regions on their surfaces, and
wherein a density of the carbon-containing metal catalyst particles for carbon nanotube synthesis on the support is more than one particle/100 nm 2 under a measurement condition of being observed within a 200 nm ×200 nm scanning region on the support by an atomic force microscope.

2. The catalyst-carrying support according to claim 1 , wherein the carbon-containing metal catalyst particles for carbon nanotube synthesis contain at least one metal selected from the group consisting of Fe, Co, and Ni.

3. The catalyst-carrying support according to claim 1 , wherein the carbon-containing metal catalyst particles for carbon nanotube synthesis contain Fe.

4. The catalyst-carrying support according to claim 1 , wherein the carbon-containing metal catalyst particles for carbon nanotube synthesis are obtained by flowing a carbon-containing compound gas without an unsaturated bond onto a heated raw material substance to form the carbon-containing regions on surfaces of the raw material substance.

5. The catalyst-carrying support according to claim 4 , wherein the carbon-containing compound gas without an unsaturated bond is a saturated hydrocarbon gas.

6. The catalyst-carrying support according to claim 5 , wherein the saturated hydrocarbon gas is methane.

7. A method of producing the catalyst-carrying support according to claim 1 , comprising:
a step of adhering a raw material substance to the support, and
a carbon-containing region forming step of heating the raw material substance and flowing a carbon-containing compound gas without an unsaturated bond onto the heated raw material substance to form the carbon-containing regions on surfaces of the raw material substance.

8. The method of producing the catalyst-carrying support according to claim 7 , wherein the carbon-containing compound gas without an unsaturated bond is a saturated hydrocarbon gas.

9. The method of producing the catalyst-carrying support according to claim 8 , wherein the saturated hydrocarbon gas is methane.

10. A method of producing carbon nanotubes, comprising a carbon nanotube synthesizing step of flowing a raw material gas onto the heated catalyst-carrying support according to claim 1 to synthesize carbon nanotubes.

11. A method of producing carbon nanotubes, comprising:
a carbon nanotube synthesizing step of flowing a raw material gas containing acetylene onto a heated catalyst-carrying support, wherein the catalyst-carrying support comprises a support and carbon-containing metal catalyst particles for carbon nanotube synthesis carried on the support, the carbon-containing metal catalyst particles for carbon nanotube synthesis comprise carbon-containing regions on their surfaces, and a density of the carbon-containing metal catalyst particles for carbon nanotube synthesis on the support is one or more particles/100 nm 2 under a measurement condition of being observed within a 200 nm×200 nm scanning region on the support by an atomic force microscope; and
during the carbon nanotube synthesizing step, flowing methane onto the carbon-containing metal catalyst particles for carbon nanotube synthesis.

12. The method of producing carbon nanotubes according to claim 11 , wherein the density of the carbon-containing metal catalyst particles for carbon nanotube synthesis on the support is more than one particle/100 nm 2 .

Assignees

• Univ Tokyo
• Hitachi Chemical Co Ltd

Inventors

• Noda Suguru
• Chen Zhongming
• Kim Dong Young
• Ueda Shunsuke
• Haba Eisuke

Classifications

• B01J21/18

  Carbon · CPC title

• B01J23/74

  Iron group metals · CPC title

• B01J37/084

  Decomposition of carbon-containing compounds into carbon · CPC title

• C01B32/05

  Preparation or purification of carbon not covered by groups C01B32/15, C01B32/20, C01B32/25, C01B32/30 · CPC title

• C01B32/162

  characterised by catalysts · CPC title