JP2012518076A - カーボン・ナノチューブを繊維上に含んで構成された複合材料 - Google Patents
カーボン・ナノチューブを繊維上に含んで構成された複合材料 Download PDFInfo
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Abstract
【選択図】図1
Description
本願は、2009年11月23日出願の米国仮特許出願第61/263,807号、及び2009年2月17日出願の米国仮特許出願第61/153,143号に基づいて優先権を主張するものであり、これらは参照により本明細書に組み込まれる。
適用なし。
当該技術分野で知られている標準的なCNT合成反応器は横断面が円形である。これには、例えば、歴史的理由(研究所では円筒状の反応器がよく用いられる)及び利便性(流体力学は円筒状の反応器にモデル化すると容易であり、また、加熱器システムは円管チューブ(石英など)に容易に対応する)、並びに製造の容易性などの多くの理由がある。本願発明は、従来の円筒形状から脱却して、矩形横断面を有するCNT合成反応器を提供する。脱却の理由は以下の通りである。1.反応器により処理される多数の繊維材料は、例えば、形状が薄いテープやシート状など相対的に平面的であるので、円形横断面では反応器の容積を効率的に使用していない。この非効率性は、円筒状のCNT合成反応器にとって、例えば、以下のa)ないしc)など、いくつかの欠点となる。a)十分なシステムパージの維持;反応器の容積が増大すれば、同レベルのガスパージを維持するためにガス流量の増大が必要になる。これは、開放環境におけるCNTsの大量生産には非効率なシステムとなる。b)炭素原料ガス流の増大;前記a)のように、不活性ガス流を相対的に増大させると、炭素原料ガス流を増大させる必要がある。12Kの炭素繊維トウは、矩形横断面を有する合成反応器の全容積に対して2000分の1の容積であることを考慮されたい。同等の円筒状の成長反応器(すなわち、矩形横断面の反応器と同様に平坦化された繊維材料を収容するための幅を有する円筒状の反応器)では、繊維材料は、チャンバー容積の17,500分の1の容積である。CVDなどのガス蒸着処理(gas deposition processes)は、通常、圧力及び温度だけで制御されるが、容積は蒸着の効率に顕著な影響を与える。矩形反応器の場合、それでもなお過剰な容積が存在する。この過剰容積は無用の反応を促進してしまうが、円筒状反応器は、その容積が約8倍もある。このように競合する反応が発生する機会が増加することにより、所望の反応が有効に生じるには、円筒状反応器チャンバーでは遅くなってしまう。このようなCNT成長の減速は連続処理の開発には問題となる。矩形反応器の構成には、矩形チャンバーの高さが低いことを利用することで、反応器の容積が低減され、これにより容積比を改善して反応をより効率的にできるという1つの利点がある。本願発明のある実施形態において、矩形合成反応器の全容積は、合成反応器を通過中の繊維材料の全容積に対して約3000倍にしかすぎない。またある実施形態では、矩形合成反応器の全容積は、合成反応器を通過中の繊維材料の全容積に対して約4000倍にしかすぎない。また更なる実施形態では、矩形合成反応器の全容積は、合成反応器を通過中の繊維材料の全容積に対して約10,000倍未満である。加えて、円筒状反応器を使用した場合、矩形横断面を有する反応器と比較すると、同じ流量比をもたらすためには、より大量の炭素原料が必要である点に注目されたい。当然のことながら、実施形態の中には、合成反応器が、矩形ではないが比較的矩形に類似する多角形状で表される横断面を有し、円形横断面を有する反応器に対して反応器の容積を同様に低減するものがある。c)問題のある温度分布;相対的に小径の反応器が用いられた場合、チャンバー中心からその壁面までの温度勾配はごく僅かである。しかし、例えば、工業規模の生産に用いられるなど、サイズが増大した場合、温度勾配は増加する。このような温度勾配により、繊維材料基材の全域で製品品質がばらつくことになる(すなわち、製品品質が半径位置の関数として変化する)。この問題は、矩形横断面を有する反応器を用いた場合に殆ど回避される。特に、平面状基材が用いられた場合、反応器の高さを、基材の上方向のスケールサイズとして一定に維持できる。反応器の頂部及び底部間の温度勾配は基本的にごく僅かであるため、生じる熱的な問題や製品品質のばらつきは回避される。2.ガス導入:当該技術分野では、通常、管状炉が使用されるが、一般的なCNT合成反応器は、ガスを一端に導入し、それを反応器に通して他端から引き出す。本明細書に開示された実施形態の中には、ガスが、反応器の中心、又は対象とする成長ゾーン内において、反応器の両側面、又は、反応器の天板及び底板の、いずれかを介して、対称的に導入されるものがある。これにより、流入する原料ガスがシステムの最も高温の部分(CNT成長が最も活発な場所)に連続的に補充されるので、全体のCNT成長速度が向上する。このような一定のガス補充は、矩形のCNT反応器により示される成長速度の向上にとって重要な側面である。
比較的低温のパージゾーンを備えるチャンバーが矩形合成反応器の両端に従属する。出願人は、高温ガスが外部環境(すなわち、反応器の外部)と接触すると、繊維材料の分解が増加すると断定した。低温パージゾーンは、内部システム及び外部環境間の緩衝となるものを提供する。当該技術分野で知られている標準的なCNT合成反応器の構成では、通常、基材を慎重に(かつ緩やかに)冷却することが必要とされる。本矩形CNT成長反応器の出口における低温パージゾーンは、連続的なインライン処理で必要とされるような短時間の冷却を実現する。
ある実施形態において、金属製、特にステンレス鋼製のホットウォール型反応器が使用される。このことは、金属、特にステンレス鋼は炭素が析出(すなわち、すす及び副生成物の形成)しやすいため、常識に反するように考えられる。従って、大部分のCNT反応器の構造には、炭素の析出が少なく、また、石英が洗浄しやすく、試料の観察が容易であることから、石英反応器が使用されている。しかしながら、出願人は、ステンレス鋼上におけるすす及び炭素析出物の増加は、より着実で高速に、より効率的に、かつ、より安定的にCNTを成長させるということに気付いた。理論に拘束されるものではないが、大気の影響と連動して、反応器内で生じるCVD処理では拡散が制限されることを示している。すなわち、触媒に「過度に供給される(overfed)」、つまり、過量の炭素が(反応器が不完全真空下で作動している場合よりも)その相対的に高い分圧により反応器システム内で得られる。結果として、開放型システム(特に清浄なもの)では、過量の炭素が触媒粒子に付着してCNTsの合成能力を低下させる。ある実施形態において、反応器が、金属製の反応器ウォールにすすが析出して「汚れて(dirty)」いる場合に、矩形反応器を意図的に作動する。炭素が反応器のウォール上の単分子層に一度析出すると、炭素は、それ自体を覆って容易に析出する。利用可能な炭素には、この機構により「回収される(withdrawn)」ものがあるので、残りの炭素原料(ラジカル型)が、触媒を被毒させない速度で触媒と反応する。既存のシステムが「清浄に」作動しても、連続処理のために開放状態であれば、成長速度が低下してCNTsの生産量はかなり小さくなる。
本明細書に開示されたCNT合成反応器において、触媒低減及びCNT成長のいずれもが反応器内で生じる。低減工程は、個別の工程として実施されると、連続処理に用いるものとして十分タイムリーに行われなくなるため、これは重要である。当該技術分野において知られている標準的な処理において、低減工程の実施には、通常1〜12時間かかる。本願発明によれば、両工程は1つの反応器内で生じるが、これは、少なくとも1つには、円筒状反応器を用いる当該技術分野では標準的となっている反応器の端部ではなく、中心部に炭素原料ガスが導入されることによるものである。低減処理は、繊維が加熱ゾーンに入ったときに行われる;この時点までに、ガスには、触媒と反応して(水素ラジカルの相互作用により)酸化還元を引き起こす前にウォールと反応して冷える時間がある。低減が生じるのは、この移行領域である。システム内で最も高温の等温ゾーンでCNTの成長は起こり、反応器の中心近傍におけるガス入口の近位で最速の成長速度が生じる。
Claims (33)
- カーボン・ナノチューブが浸出した繊維を、マトリックス材に分散した状態で複数含んで構成される複合材料の組成物であって、
前記組成物中の前記カーボン・ナノチューブの量が、前記複合材料の約0.1重量%から約60重量%の範囲である複合材料の組成物。 - 前記組成物中の前記カーボン・ナノチューブの量が、前記複合材料の約10重量%から約60重量%の範囲である請求項1に記載の複合材料の組成物。
- 前記組成物中の前記カーボン・ナノチューブの量が、前記複合材料の約15重量%から約60重量%の範囲である請求項1に記載の複合材料の組成物。
- 前記組成物中の前記カーボン・ナノチューブの量が、前記複合材料の約20重量%から約60重量%の範囲である請求項1に記載の複合材料の組成物。
- 前記組成物中の前記カーボン・ナノチューブの量が、前記複合材料の約25重量%から約60重量%の範囲である請求項1に記載の複合材料の組成物。
- 前記組成物中の前記カーボン・ナノチューブの量が、前記複合材料の約10重量%から約50重量%の範囲である請求項1に記載の複合材料の組成物。
- 前記組成物中の前記カーボン・ナノチューブの量が、前記複合材料の約20重量%から約40重量%の範囲である請求項1に記載の複合材料の組成物。
- 前記組成物中の前記カーボン・ナノチューブの量が、前記複合材料の約5重量%から約10重量%の範囲である請求項1に記載の複合材料の組成物。
- 前記組成物中の前記カーボン・ナノチューブの量が、前記複合材料の約10重量%から約20重量%の範囲である請求項1に記載の複合材料の組成物。
- 前記組成物中の前記カーボン・ナノチューブの量が、前記複合材料の約20重量%から約30重量%の範囲である請求項1に記載の複合材料の組成物。
- 前記組成物中の前記カーボン・ナノチューブの量が、前記複合材料の約30重量%から約40重量%の範囲である請求項1に記載の複合材料の組成物。
- 前記組成物中の前記カーボン・ナノチューブの量が、前記複合材料の約40重量%から約50重量%の範囲である請求項1に記載の複合材料の組成物。
- 前記組成物中の前記カーボン・ナノチューブの量が、前記複合材料の約50重量%から約60重量%の範囲である請求項1に記載の複合材料の組成物。
- 前記組成物中の前記カーボン・ナノチューブの量が、前記複合材料の約40重量%から約60重量%の範囲である請求項1に記載の複合材料の組成物。
- 前記組成物中の前記カーボン・ナノチューブの量が、前記複合材料の約10重量%である請求項1に記載の複合材料の組成物。
- 前記組成物中の前記カーボン・ナノチューブの量が、前記複合材料の約15重量%である請求項1に記載の複合材料の組成物。
- 前記組成物中の前記カーボン・ナノチューブの量が、前記複合材料の約20重量%である請求項1に記載の複合材料の組成物。
- 前記組成物中の前記カーボン・ナノチューブの量が、前記複合材料の約25重量%である請求項1に記載の複合材料の組成物。
- 前記組成物中の前記カーボン・ナノチューブの量が、前記複合材料の約30重量%である請求項1に記載の複合材料の組成物。
- 前記組成物中の前記カーボン・ナノチューブの量が、前記複合材料の約35重量%である請求項1に記載の複合材料の組成物。
- 前記カーボン・ナノチューブが浸出した繊維が、繊維トウを含んで構成された請求項1に記載の複合材料の組成物。
- 前記カーボン・ナノチューブが浸出した繊維が、複数のロービングを含んで構成された請求項1に記載の複合材料の組成物。
- 前記カーボン・ナノチューブが浸出した繊維が、織物を含んで構成された請求項1に記載の複合材料の組成物。
- 前記カーボン・ナノチューブが浸出した繊維が、前記マトリックス材全体にわたって均一に分布する請求項1に記載の複合材料の組成物。
- 前記カーボン・ナノチューブが浸出した繊維の前記カーボン・ナノチューブには、前記マトリックス材の一部の全域にわたって濃度勾配が存在する請求項1に記載の複合材料の組成物。
- 前記カーボン・ナノチューブが浸出した繊維が、前記複合材料の構造体の略表面付近にのみ分布する請求項1に記載の複合材料の組成物。
- 前記カーボン・ナノチューブが浸出した繊維に浸出した前記カーボン・ナノチューブが、一定のパターンで配向される請求項1に記載の複合材料。
- 前記浸出したカーボン・ナノチューブが、前記繊維の軸の周囲に放射状に配設される請求項1に記載の複合材料。
- 前記浸出したカーボン・ナノチューブが、前記繊維の軸に平行に配設される請求項1に記載の複合材料。
- 前記カーボン・ナノチューブの長さが、前記複合材料の構造体内の少なくとも2つの部位で異なる請求項1に記載の複合材料。
- 前記カーボン・ナノチューブの密度が、前記複合材料の構造体の少なくとも2つの部位で異なる請求項1に記載の複合材料。
- 前記カーボン・ナノチューブの配列が、前記複合材料の構造体の少なくとも2つの部位で異なる請求項1に記載の複合材料。
- 前記カーボン・ナノチューブのうち、長さ、密度及び配列の任意の組み合わせが、前記複合材料の構造体の少なくとも2つの部位で異なる請求項1に記載の複合材料。
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US26380709P | 2009-11-23 | 2009-11-23 | |
US61/263,807 | 2009-11-23 | ||
PCT/US2010/024490 WO2010144161A2 (en) | 2009-02-17 | 2010-02-17 | Composites comprising carbon nanotubes on fiber |
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EP (1) | EP2398955B8 (ja) |
JP (1) | JP5577356B2 (ja) |
KR (1) | KR20110125220A (ja) |
CN (1) | CN102317200B (ja) |
AU (1) | AU2010259234B2 (ja) |
BR (1) | BRPI1007300A2 (ja) |
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