US4663230A
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US
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Carbon fibrils, method for producing same and compositions containing same
Assignee: Hyperion Catalysis International Inc
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Filing: 1984-12-06
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Granted: 1987-05-05
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Expires: 2004-12-06
Abstract
Abstract This invention concerns an essentially cylindrical discrete carbon fibril characterized by a substantially constant diameter between about 3.5 and about 70 nanometers, e.g. between about 7 and 25 nanometers, length greater than about 102 times the diameter, an outer region of multiple essentially continuous layers of ordered carbon atoms and a distinct inner core region, each of the layers and core disposed substantially concentrically about the cylindrical axis of the fibril. Preferably the entire fibril is substantially free of thermal carbon overcoat. The invention further concerns a plurality of such fibrils. The fibril or plurality of fibrils of this invention may be produced by contacting for an appropriate period of time and at suitable pressure a suitable metal-containing particle with a suitable gaseous, carbon-containing compound, at a temperature between about 850 DEG C. and 1200 DEG C., the ratio on a dry weight basis of carbon-containing compound to metal containing particle being at least about 100:1. The fibrils are useful in composites having a matrix of e.g., an organic polymer, an inorganic polymer or a metal. In one embodiment the fibrils are incorporated into structural materials in a method of reinforcement. In other embodiments the fibrils may be used to enhance the electrical or thermal conductivity of a material, to increase the surface area of an electrode or capacitor plate, to provide a support for a catalyst, or to shield an object from electromagnetic radiation.
Inventors
- 👤 Howard G. Tennent
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 22:00
CPC Classifications
B; B01; B01J; B01J35/00; B01J35/50; B01J35/58; B82; B82Y; B82Y30/00; C; C04; C04B; C04B14/00; C04B14/38; C04B14/386; C04B35/00; C04B35/01; C04B35/10; C04B35/111; C04B35/117; C04B35/16; C04B35/18; C04B35/515; C04B35/56; C04B35/565; C04B35/58; C04B35/583; C04B35/584; C04B35/622; C04B35/62227; C04B35/62272; C04B35/71; C04B35/78; C04B35/80; C04B35/83; C08; C08K; C08K7/00; C08K7/02; C08K7/04; C08K7/06; C22; C22C; C22C32/00; C22C32/0084; D; D01; D01F; D01F11/00; D01F11/10; D01F11/12; D01F11/127; D01F9/00; D01F9/08; D01F9/12; D01F9/127; D01F9/1271; D01F9/1272; D01F9/1273; D01F9/1275; D01F9/1276; D01F9/1277; D01F9/1278; F; F16; F16D; F16D69/00; F16D69/02; F16D69/023; H; H01; H01B; H01B1/00; H01B1/02; H01B1/04; H01B1/14; H01B1/18; B22; B22F; B22F1/00; B22F1/05; B22F1/054; B22F2998/00; B22F2998/10; B22F2999/00; B29; B29K; B29K2307/00; C04B2235/00; C04B2235/02; C04B2235/50; C04B2235/52; C04B2235/5208; C04B2235/5216; C04B2235/524; C04B2235/5248; C04B2235/5264; C04B2235/5284; C04B2235/5288; C04B2235/5296; C22C26/00; Y; Y10; Y10T; Y10T428/00; Y10T428/29; Y10T428/2913; Y10T428/2918; Y10T428/2933; Y10T428/2935; Y10T428/2973; Y10T428/2975; Y10T428/30
Claims Analysis
Total Claims: 60
Claim 1
Independent Claim
63 words
An essentially cylindrical discrete carbon fibril characterized -by a substantially constant diameter between -about 3.5 and about 70 nanometers, length greater than -about 10 2 times the diameter, an outer region of multiple -essentially continuous layers of ordered carbon atoms and -a distinct inner core region, each of the layers and core -disposed substantially concentrically about the cylindrical -axis of the fibril. -
Claim 2
Dependent Claim
63 words
An essentially cylindrical discrete carbon fibril characterized -by a substantially constant diameter between -about 3.5 and about 70 nanometers, length greater than -about 10 2 times the diameter, an outer region of multiple -essentially continuous layers of ordered carbon atoms and -a distinct inner core region, each of the layers and core -disposed substantially concentrically about the cylindrical -axis of the fibril. -
Claim 3
Dependent Claim
11 words
A fibril of claim 1, wherein the core is hollow. -
Claim 4
Dependent Claim
27 words
A fibril of claim 1, wherein the inner core region -comprises carbon atoms which are less ordered than the -ordered carbon atoms of the outer region. -
Claim 5
Dependent Claim
13 words
A fibril of claim 1, wherein the ordered carbon atoms are -graphitic. -
Claim 6
Dependent Claim
18 words
A fibril of claim 1, wherein the length is greater than -about 10 3 times the diameter. -
Claim 7
Dependent Claim
17 words
A fibrile of claim 1, wherein the length is greater than -about 10 4 times the diameter.
Claim 8
Dependent Claim
16 words
A fibril of claim 1, wherein the diameter is between -about 7 and 25 nanometers. -
Claim 9
Dependent Claim
19 words
A fibril of claim 1, wherein the inner core region has -a diameter greater than about 2 nanometers. -
Claim 10
Dependent Claim
65 words
A plurality of essentially discrete carbon fibrils -characterized by a substantially constant diameter between -about 3.5 and about 70 nanometers, length greater than - about 10 2 times the diameter, an outer region of multiple -essentially continuous layers of ordered carbon atoms and -a distinct inner core region, each of the layers and core -disposed substantially concentrically about the cylindrical -axis of the fibrils. -
Claim 11
Dependent Claim
65 words
A plurality of essentially discrete carbon fibrils -characterized by a substantially constant diameter between -about 3.5 and about 70 nanometers, length greater than - about 10 2 times the diameter, an outer region of multiple -essentially continuous layers of ordered carbon atoms and -a distinct inner core region, each of the layers and core -disposed substantially concentrically about the cylindrical -axis of the fibrils. -
Claim 12
Independent Claim
63 words
A method for producing an essentially cylindrical, -carbon fibril which comprises contacting for an appropriate -period of time and at a suitable pressure a suitable -metal-containing -particle with a suitable gaseous, carbon-containing -compound, at a temperature between about 850° C. -and about 1200° C., the ratio on a dry weight basis of -carbon-containing compound to metal-containing particle -being at least about 100:1. -
Claim 13
Independent Claim
63 words
A method for producing an essentially cylindrical, -carbon fibril which comprises contacting for an appropriate -period of time and at a suitable pressure a suitable -metal-containing -particle with a suitable gaseous, carbon-containing -compound, at a temperature between about 850° C. -and about 1200° C., the ratio on a dry weight basis of -carbon-containing compound to metal-containing particle -being at least about 100:1. -
Claim 14
Dependent Claim
34 words
A method according to claim 10, wherein the contacting -of metal-containing particle with carbon-containing compound -is carried out in the presence of a compound capable -of reaction with carbon to produce gaseous products. -
Claim 15
Dependent Claim
25 words
A method according to claim 11, wherein the compound -capable of reacting with carbon is CO 2 , H 2 or H 2 O. -
Claim 16
Dependent Claim
14 words
A method according to claim 10, wherein the carbon-containing -compound is carbon monoxide. -
Claim 17
Dependent Claim
14 words
A method according to claim 10, wherein the carbon-containing -compound is a hydrocarbon. -
Claim 18
Dependent Claim
12 words
A method according to claim 14, wherein the hydrocarbon -contains oxygen. -
Claim 19
Dependent Claim
21 words
A method according to claim 15, wherein the oxygen -containing hydrocarbon is formaldehyde, acetaldehyde, -acetone, methanol, ethanol, or mixtures thereof. -
Claim 20
Dependent Claim
12 words
A method according to claim 14, wherein the hydrocarbon -is aromatic. -
Claim 21
Dependent Claim
23 words
A method according to claim 17, wherein the aromatic -hydrocarbon is benzene, toluene, xylene, cumene, ethylbenzene, -naphthalene, phenanthrene, anthracene or mixtures -thereof. -
Claim 22
Dependent Claim
12 words
A method according to claim 14, wherein the hydrocarbon -is non-aromatic. -
Claim 23
Dependent Claim
22 words
A method according to claim 19, wherein the hydrocarbon -is methane, ethane, propane, ethylene, propylene or acetylene - or mixtures thereof. -
Claim 24
Dependent Claim
28 words
A method according to claim 10, wherein the metal-containing -particle comprises an iron-, cobalt-, or nickel-containing -particle having a diameter between about 3.5 -and about 70 nanometers. -
Claim 25
Dependent Claim
19 words
A method according to claim 10, wherein the metal-containing -particle is supported on a chemically compatible, -refractory support. -
Claim 26
Dependent Claim
12 words
A method according to claim 22, wherein the support is -alumina. -
Claim 27
Dependent Claim
12 words
A method according to claim 22, wherein the support is -carbon. -
Claim 28
Dependent Claim
13 words
A method according to claim 22, wherein the support is -a silicate. -
Claim 29
Dependent Claim
14 words
A method according to claim 25, wherein the silicate is -an aluminum silicate. -
Claim 30
Dependent Claim
73 words
A method according to claim 10, wherein the period of -time is from about 10 seconds to about 180 minutes, the -pressure is from about one-tenth atmosphere to about ten -atmospheres, the metal-containing particle is an -iron-containing particle, the carbon-containing compound -is benzene, the temperature is from about 900° C. to about -1150° C., and the ratio on a dry weight basis of benzene to -iron-containing particle is at least about 1000:1. -
Claim 31
Dependent Claim
42 words
A method according to claim 27, wherein the period of -time is about 180 minutes, the pressure is about one -atmosphere, the carbon-containing compound is benzene in -an approximately 9:1 volume mixture of hydrogen:benzene, -and the temperature is about 900° C. -
Claim 32
Dependent Claim
46 words
A method according to claim 27, wherein the period of -time is from about one to about five minutes, the pressure -is about one atmosphere, the carbon-containing compound is -benzene in an approximately 9:1 volume mixture of hydrogen:benzene, -and the temperature is about 1100° C. -
Claim 33
Dependent Claim
19 words
A method according to claim 27, wherein the -iron-containing particle is supported on a chemically -compatible, refractory support. -
Claim 34
Dependent Claim
15 words
A method according to claim 30, wherein the refractory -support is alumina or carbon. -
Claim 35
Independent Claim
74 words
A method for producing an essentially cylindrical -carbon fibril which comprises contacting for a period of -time from about 10 seconds to about 180 minutes and at a -pressure of from about one-tenth atmosphere to about ten -atmospheres a suitable iron-containing particle with gaseous -benzene at a temperature between about 900° C. and about -1150° C., the ratio on a dry weight basis of benzene to -iron-containing particle being at least about 1000:1. -
Claim 36
Independent Claim
74 words
A method for producing an essentially cylindrical -carbon fibril which comprises contacting for a period of -time from about 10 seconds to about 180 minutes and at a -pressure of from about one-tenth atmosphere to about ten -atmospheres a suitable iron-containing particle with gaseous -benzene at a temperature between about 900° C. and about -1150° C., the ratio on a dry weight basis of benzene to -iron-containing particle being at least about 1000:1. -
Claim 37
Dependent Claim
40 words
A method according to claim 32, wherein the period of -time is about 180 minutes, the pressure is about one -atmosphere, the benzene is in an approximately 9:1 volume -mixture of hydrogen:benzene, and the temperature is about -900° C. -
Claim 38
Dependent Claim
44 words
A method according to claim 32, wherein the period of -time is from about one to about five minutes, the pressure -is about one atmosphere, the benzene is in an approximately -9:1 volume mixture of hydrogen:benzene, and the temperature -is about 1100° C. -
Claim 39
Dependent Claim
19 words
A method according to claim 32, wherein the -iron-containing particle is supported on a chemically -compatible, refractory support. -
Claim 40
Dependent Claim
15 words
A method according to claim 35, wherein the refractory -support is alumina or carbon. -
Claim 41
Independent Claim
67 words
A method for producing an essentially cylindrical -carbon fibril which comprises contacting for an appropriate -period of time and at a suitable pressure a suitable -metal-containing particle with a suitable gaseous, carbon-containing compound, wherein the metal-containing -particle is independently heated to a temperature between -about 850° C. and about 1800° C., the temperature of the -particle being higher than the temperature of the gaseous, -carbon-containing compound. -
Claim 42
Independent Claim
67 words
A method for producing an essentially cylindrical -carbon fibril which comprises contacting for an appropriate -period of time and at a suitable pressure a suitable -metal-containing particle with a suitable gaseous, carbon-containing compound, wherein the metal-containing -particle is independently heated to a temperature between -about 850° C. and about 1800° C., the temperature of the -particle being higher than the temperature of the gaseous, -carbon-containing compound. -
Claim 43
Dependent Claim
15 words
A method according to claim 37, wherein the particle is -heated with electromagnetic radiation. -
Claim 44
Dependent Claim
12 words
A carbon fibril produced according to the method of -claim 10. -
Claim 45
Independent Claim
67 words
A method for producing a substantially uniform plurality - of essentially cylindrical, discrete carbon fibrils -which comprises contacting for an appropriate period of -time and at a suitable pressure, suitable metal-containing -particles with a suitable gaseous carbon-containing compound, at a temperature between about 850° C. and 1200° C., the -ratio on a dry weight basis of carbon-containing compound -to metal-containing particles being at least about 100:1. -
Claim 46
Independent Claim
67 words
A method for producing a substantially uniform plurality - of essentially cylindrical, discrete carbon fibrils -which comprises contacting for an appropriate period of -time and at a suitable pressure, suitable metal-containing -particles with a suitable gaseous carbon-containing compound, at a temperature between about 850° C. and 1200° C., the -ratio on a dry weight basis of carbon-containing compound -to metal-containing particles being at least about 100:1. -
Claim 47
Dependent Claim
23 words
A method of claim 40, wherein each of the fibrils -has a diameter substantially equal to the diameter of each -other fibril. -
Claim 48
Dependent Claim
12 words
A method of claim 40, wherein the metal-containing -particles ae pre-formed. -
Claim 49
Dependent Claim
16 words
A substantially uniform plurality of carbon fibrils -produced according to the method of claim 40. -
Claim 50
Dependent Claim
18 words
A composite which comprises a plurality of carbon -fibrils according to claim 1, 9, 39 or 43. -
Claim 51
Dependent Claim
15 words
A composite according to claim 44 which comprises a -matrix of an organic polymer. -
Claim 52
Dependent Claim
15 words
A composite according to claim 44 which comprises a -matrix of an inorganic polymer. -
Claim 53
Dependent Claim
14 words
A composite according to claim 44 which comprises a -matrix of a metal. -
Claim 54
Dependent Claim
27 words
A method of reinforcing a structural material which -comprises incorporating therein an effective reinforcing -amount of carbon fibrils according to claim 1, 9, 39 or 43. -
Claim 55
Dependent Claim
32 words
A method of enhancing the electrical conductivity of a -material which comprises incorporating therein an effective - electrical conductivity-enhancing amount of carbon -fibrils according to claim 1, 9, 39 or 43. -
Claim 56
Dependent Claim
31 words
A method of enhancing the thermal conductivity of a -material which comprises incorporating therein an effective -thermal conductivity-enhancing amount of carbon fibrils -according to claim 1, 9, 39 or 43. -
Claim 57
Dependent Claim
32 words
A method of increasing the surface area of an electrode -or an electrolytic capacitor plate which comprises attaching -thereto one or more fibrils according to claim 1, 9, 39 -or 43. -
Claim 58
Dependent Claim
23 words
A method of supporting a catalyst which comprises -attaching a catalyst to a fibril according to claim 1, 9, -39 or 43. -
Claim 59
Dependent Claim
14 words
A method according to claim 52, wherein the catalyst is -an electrochemical catalyst. -
Claim 60
Dependent Claim
29 words
A method of shielding an object from electromagnetic -radiation which comprises incorporating therein an effective -shielding amount of carbon fibrils according to -claim 1, 9, 39 or 43. -
References Cited (Backward Citations)
US4397901A
Cited
US4472454A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 1990-05-04 | 1990-11-03 | 1991-05-05 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1994-05-04 | 1994-11-03 | 1995-05-05 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1998-05-04 | 1998-11-03 | 1999-05-05 | $7700.00 | Window Closed / Lapsed |