Substrate for carbon nanotube growth and method for manufacturing the same

Patent metadata

Field	Value
Publication number	US-9289753-B2
Application number	US-201314095447-A
Country	US
Kind code	B2
Filing date	Dec 3, 2013
Priority date	Dec 4, 2012
Publication date	Mar 22, 2016
Grant date	Mar 22, 2016

Abstract

Provided is a substrate for carbon nanotube growth in which no metal particles as a catalyst aggregates and a method for manufacturing the substrate. A substrate for carbon nanotube growth 1 includes a base plate 2 , a catalyst 3 , a form-defining material layer 4 which allows the catalyst 3 to be dispersed and arranged, and a covering layer 5 which has a metal oxide to cover the catalyst. A method for manufacturing a substrate for carbon nanotube growth 1 includes a step of sputtering on a base plate 2 a metal which forms a catalyst 3 and oxidizing the surface of the metal, a step of sputtering a form-defining material on the base plate 2 , and a step of further sputtering on the form-defining material a metal which forms a catalyst 3 and oxidizing the surface of the metal.

First claim

What is claimed is:

1. A method for manufacturing a substrate for carbon nanotube growth comprising a base plate and a catalyst disposed on the base plate, the method comprising:
a primary metal sputtering step of sputtering on the base plate a first metal which forms the catalyst;
a primary oxidizing step of, after the primary metal sputtering step, oxidizing a surface of the first metal to form a first metal oxide layer on the surface of the first metal;
a form-defining material sputtering step of, after the primary oxidizing step, sputtering on the base plate a form-defining material which defines a form which allows the catalyst to be dispersed and arranged;
a secondary metal sputtering step of, after the form-defining material sputtering step, sputtering on the form-defining material a second metal which forms the catalyst; and
a secondary oxidizing step of, after the secondary metal sputtering step, oxidizing a surface of the catalyst in which the first metal and the second metal is integrated to form a catalyst oxide layer on the surface of the catalyst,
wherein the secondary metal sputtering step causes the form-defining material to reach an area below the first metal, including the first metal oxide layer on the surface of the first metal, thereby being integrated with the base plate.

2. The method for manufacturing a substrate for carbon nanotube growth according to claim 1 , wherein the form-defining material sputtering step, the secondary metal sputtering step, and the secondary oxidizing step are repeated a plurality of times.

3. The method for manufacturing a substrate for carbon nanotube growth according to claim 1 , wherein the first metal and the second metal which form the catalyst consist of a transition metal.

4. The method for manufacturing a substrate for carbon nanotube growth according to claim 1 , wherein the first metal and the second metal which form the catalyst consist of an iron group element.

5. The method for manufacturing a substrate for carbon nanotube growth according to claim 4 , wherein the iron group element is Fe.

6. The method for manufacturing a substrate for carbon nanotube growth according to claim 1 , wherein the base plate consists of MgO (100) single crystal.

7. The method for manufacturing a substrate for carbon nanotube growth according to claim 1 , wherein the form-defining material is the same material as the base plate.

8. The method for manufacturing a substrate for carbon nanotube growth according to claim 1 , wherein the form-defining material is MgO.

9. The method for manufacturing a substrate for carbon nanotube growth according to claim 1 , wherein the secondary oxidizing step prevents the catalyst from aggregating and controls a plane direction of a crystal structure of the catalyst.

10. The method for manufacturing a substrate for carbon nanotube growth according to claim 1 , wherein the form-defining material is sputtered at room temperature, whereas the first metal and the second metal which form the catalyst are sputtered at a temperature greater than room temperature at which the form defining material reaches an area below the first metal, including the first metal oxide layer on the surface of the first metal, thereby being integrated with the base plate.

Assignees

• Honda Motor Co Ltd

Inventors

• Ohashi Toshiyuki
• Tokune Toshio
• Ohta Masahiro
• Kato Ryogo
• Shima Toshiyuki

Classifications

• B01J23/745

  Iron · CPC title

• B01J37/342

  of electric, magnetic or electromagnetic fields, e.g. for magnetic separation · CPC title

• B82Y30/00

  Nanotechnology for materials or surface science, e.g. nanocomposites · CPC title

• C23C14/5853

  Oxidation · CPC title

• B01J37/0244

  Coatings comprising several layers · CPC title