JP2014501026A - カーボンナノチューブ浸出繊維を含む電気装置とその製造方法 - Google Patents
カーボンナノチューブ浸出繊維を含む電気装置とその製造方法 Download PDFInfo
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Images
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- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G11/00—Hybrid capacitors, i.e. capacitors having different positive and negative electrodes; Electric double-layer [EDL] capacitors; Processes for the manufacture thereof or of parts thereof
- H01G11/22—Electrodes
- H01G11/30—Electrodes characterised by their material
- H01G11/32—Carbon-based
- H01G11/34—Carbon-based characterised by carbonisation or activation of carbon
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- H—ELECTRICITY
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- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
- H01G11/00—Hybrid capacitors, i.e. capacitors having different positive and negative electrodes; Electric double-layer [EDL] capacitors; Processes for the manufacture thereof or of parts thereof
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- B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
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- H01G11/00—Hybrid capacitors, i.e. capacitors having different positive and negative electrodes; Electric double-layer [EDL] capacitors; Processes for the manufacture thereof or of parts thereof
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- H01G11/00—Hybrid capacitors, i.e. capacitors having different positive and negative electrodes; Electric double-layer [EDL] capacitors; Processes for the manufacture thereof or of parts thereof
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
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Abstract
【選択図】図3
Description
本願は、2010年6月15日出願の米国仮特許出願第61/355,097号に基づき、合衆国法典第35巻(35 U.S.C.)第119条に従って優先権を主張するものであり、参照により全内容が本明細書に組み込まれる。
適用なし。
また、キラリティに加えてカーボンナノチューブの直径は、その電気伝導性と熱伝導性に関する性質にも影響を与える。カーボンナノチューブの合成において、カーボンナノチューブの直径は、一定サイズの触媒ナノ粒子を用いることにより制御可能である。カーボンナノチューブの直径は、通常、ほぼその形成に触媒作用を及ぼす触媒ナノ粒子の直径である。このため、カーボンナノチューブの性質は、例えば、カーボンナノチューブの合成に用いられる触媒ナノ粒子のサイズを調整することで、ある面ではさらに制御される。限定しない例として、直径約1nmの触媒ナノ粒子は、繊維材料に単層カーボンナノチューブを浸出させるために用いられる。より大きな触媒ナノ粒子は、主に、多層カーボンナノチューブを生成するために用いられるが、これは、その複数のナノチューブ層、あるいは、単層及び多層カーボンナノチューブの混合であるため、より大きな直径を有する。多層カーボンナノチューブは、通常、単層カーボンナノチューブより複雑な伝導性プロファイル(conductivity profile)を有する。何故なら、壁間反応が個々のナノチューブ層間に生じて電流を不均一に再配分することがあるからである。対照的に、単層カーボンナノチューブでは、異なる部分にまたがる電流に変化がない。
図2では、基板200周囲の連続繊維201の隣接巻線間に隙間をあけて示したが、図示された隙間は、図の明確化の目的のためのものであることが理解できる。当業者には明らかであるように、連続繊維201の隣接巻線を基板200周囲に可能な限り隙間なく配することによって、単位面積当たりで、より多数のカーボンナノチューブを得ることができ、それによって、連続繊維の単位重量当りで、より高い電極層表面積、及び、より高いエネルギー密度が得られる。しかしながら、連続繊維201の隣接巻線間隔は、本実施形態の電気装置の電気特性を変化させるために(例えば、所定サイズのスーパーキャパシタにおいて、所望の静電容量を提供するために)、必要に応じて変動可能である点に注目されたい。
本実施形態においては排除されていないが、通常の場合、連続繊維の単位重量当りでより小さな表面積を有する電極層を作るときに、連続繊維201の隣接巻線どうしが重なり合うことはほぼない。電解質が各連続繊維及びそこに浸出したカーボンナノチューブの表面に十分に近づくことが可能であれば、より高次の連続繊維構造(higher order continuous fiber structures)(例えば、繊維トウ、繊維リボン、繊維テープ及び/又は類似の物)の場合、各連続繊維間における若干の接触は許されるという点に留意されたい。
当該技術分野で既知の標準的なカーボンナノチューブ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になり、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。本開示は、従来の円筒形状を変えて、矩形横断面を有するカーボンナノチューブ合成反応器を提供する。変更の理由は以下の通りである。
比較的低温のパージゾーンを提供するチャンバーは、矩形合成反応器の両端から延びる。出願人は、仮に高温ガスが外部環境(すなわち、反応器の外部)と接触(mix)すると、繊維材料の劣化(degradation)が増加することを究明した。低温パージゾーンは、内部システムと外部環境間の緩衝となる。当該技術分野で既知のカーボンナノチューブ合成反応器の構成では、通常、基材を慎重に(かつ緩やかに)冷却することが求められる。本願の矩形カーボンナノチューブ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に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、金属製ホットウォール型(hot-walled)反応器(例えば、ステンレス鋼)が用いられる。この種類の反応器の使用は、金属、特にステンレス鋼が炭素の付着(すなわち、すす及び副生成物の形成)を受けやすいために、常識に反するようにも考えられる。したがって、大部分のカーボンナノチューブ合成反応器は、炭素の付着が殆どないため、また、石英は洗浄しやすく試料の観察を容易にするため、石英製である。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付着物が増加することにより、より着実、より効率的、より高速、かつ、より安定的なカーボンナノチューブ成長がもたらされること、を発見した。理論に拘束されるものではないが、大気圧運転(atmospheric operation)と連動して、反応器内で起こるCVDプロセスでは拡散が制限されることが示されている。すなわち、カーボンナノチューブ形成触媒に「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運転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、開放システム(特に清浄な(clean)もの)では、過量の炭素がカーボンナノチューブ形成触媒の粒子に付着して、カーボンナノチューブの合成能力を低下させる。ある実施形態において、反応器に「汚れが付いて(dirty)」いる、すなわち、金属反応器壁にすすが付着している状態の場合に、矩形反応器を意図的に運転する。炭素が反応器壁上の単分子層に付着すると、炭素は、それ自体を覆って付着しやすくなる。得られる炭素の中には、この機構により「回収される(withdrawn)」ものがあるので、ラジカルの形で残っている炭素原料が、カーボンナノチューブ形成触媒を被毒させない速度でこの触媒と反応する。既存のシステムでは「清浄に(cleanly)」運転するが、連続処理のために開放状態であれば、減速した成長速度で、はるかに低い収率でしかカーボンナノチューブを生産できない。
本明細書に開示されたカーボンナノチューブ合成反応器において、触媒還元及びカーボンナノチューブ成長のいずれもが反応器内で起こる。還元工程が個別の工程として実施されると、連続プロセスに用いるものとして十分タイムリーに行えなくなるため、このことは重要である。当該技術分野において既知の標準的なプロセスにおいて、還元工程の実施には、通常1〜12時間かかる。本開示によれば、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、炭素含有原料ガスを導入するのが、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、中心部であることに起因する。還元プロセスは、繊維が加熱ゾーンに入ったときに行われる。この時点に至るまでに、ガスには、触媒を(水素ラジカルの相互作用を介して)還元する前に反応器壁と反応して冷える時間があるということである。還元が起こるのは、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カーボンナノチューブの成長は起こり、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 (52)
- 複数の積層された電極層を含んで構成され、
各電極層はカーボンナノチューブが浸出した連続繊維を含んで構成される、電気装置。 - 各電極層はほぼ平面的である、請求項1に記載の電気装置。
- 各電極層は電気伝導性の基板を更に含んで構成され、前記基板上に前記連続繊維が配置される、請求項1に記載の電気装置。
- 前記連続繊維は各基板の周囲に等角的に巻回される、請求項3に記載の電気装置。
- 各基板の周囲に巻回される前記連続繊維の隣接巻線間の重なり合いはほぼない、請求項4に記載の電気装置。
- 各電極層と接触する電解質と、
各電極層間に配置される隔離材料の層と、
を更に含んで構成され、
前記隔離材料は、前記電解質のイオンに対して透過性である、請求項1に記載の電気装置。 - 隣接電極層は逆帯電され、1つおきの電極層は互いに電気的に接続されている、請求項6に記載の電気装置。
- 第1電極端子及び第2電極端子を含んで構成され、
前記第1電極端子は第1電荷を有する1つおきの電極層に電気的に接続されており、前記第2電極端子は第2電荷を有する1つおきの電極層に電気的に接続されている、請求項6に記載の電気装置。 - 前記電極層を収容する外側ケーシングを更に含んで構成される、請求項8に記載の電気装置。
- 前記電気装置はスーパーキャパシタを含んで構成される、請求項6に記載の電気装置。
- 前記スーパーキャパシタは、連続繊維のグラム当りで、少なくとも約1Farad/gramの静電容量を有する、請求項10に記載の電気装置。
- 前記電解質は、無機電解質を含んで構成される、請求項6に記載の電気装置。
- 前記電解質は、有機電解質を含んで構成される、請求項6に記載の電気装置。
- 前記連続繊維は、繊維トウ、繊維テープ、繊維リボン及びそれらの組合せからなる群より選択される繊維形態を含んで構成される、請求項1に記載の電気装置。
- 前記連続繊維は、カーボンナノチューブが浸出する前は電気伝導性である、請求項1に記載の電気装置。
- 前記連続繊維は、連続金属繊維を含んで構成される、請求項15に記載の電気装置。
- 前記連続繊維は、連続炭素繊維を含んで構成される、請求項15に記載の電気装置。
- 前記浸出したカーボンナノチューブは、前記連続繊維の表面に対してほぼ垂直である、請求項1に記載の電気装置。
- 前記連続繊維は、前記浸出したカーボンナノチューブの少なくとも一部に付着したコーティングを更に含んで構成される、請求項1に記載の電気装置。
- 前記コーティングは、導電性高分子、主族金属化合物、遷移金属化合物及びそれらの組合せからなる群より選択される材料を含んで構成される、請求項19に記載の電気装置。
- 前記コーティングは、ポリピロール、MnO2、RuO2及びそれらの組合せからなる群より選択される材料を含んで構成される、請求項19に記載の電気装置。
- 複数の積層された電極層を含んで構成され、
各電極層は、電気伝導性の基板と、カーボンナノチューブが浸出し、そして前記電気伝導性の基板の周囲に配置された連続繊維とを含んで構成され、
前記連続繊維は、前記浸出したカーボンナノチューブの少なくとも一部に付着するコーティングを更に含んで構成される、電気装置。 - 前記コーティングは、導電性高分子、主族金属化合物、遷移金属化合物及びそれらの組合せからなる群より選択される材料を含んで構成される、請求項22に記載の電気装置。
- 前記コーティングは、ポリピロール、MnO2、RuO2及びそれらの組合せからなる群より選択される材料を含んで構成される、請求項22に記載の電気装置。
- 各電極層と接触する電解質と、
各電極層間に配置される隔離材料の層と、
を更に含んで構成され、
前記隔離材料は前記電解質のイオンに対して透過性である、請求項22に記載の電気装置。 - 前記電気装置はスーパーキャパシタを含んで構成される、請求項25に記載の電気装置。
- 前記コーティングは、前記スーパーキャパシタの静電容量を、前記コーティングがない同等のスーパーキャパシタと比べて、少なくとも約10倍増加させる、請求項26に記載の電気装置。
- 前記スーパーキャパシタは、連続繊維のグラム当りで、少なくとも約10Farad/gramの静電容量を有する、請求項26に記載の電気装置。
- 隣接電極層は逆帯電され、1つおきの電極層は互いに電気的に接続されている、請求項25に記載の電気装置。
- 前記連続繊維は、繊維トウ、繊維テープ、繊維リボン及びそれらの組合せからなる群より選択される繊維形態を含んで構成される、請求項22に記載の電気装置。
- 前記連続繊維は、カーボンナノチューブが浸出する前は電気伝導性である、請求項22に記載の電気装置。
- 前記連続繊維は、連続金属繊維を含んで構成される、請求項31に記載の電気装置。
- 前記連続繊維は、連続炭素繊維を含んで構成される、請求項31に記載の電気装置。
- 前記浸出したカーボンナノチューブは、前記連続繊維の表面に対してほぼ垂直である、請求項22に記載の電気装置。
- 電気装置を形成する方法であって、
カーボンナノチューブが浸出した連続繊維を電気伝導性の基板の周囲に配置することによって、電極層を形成することと、
複数の前記電極層を互いに対向して積層させることと、
を含んで構成され、
各電極層は、隔離材料の層によって分離される、方法。 - 各電極層を電解質にさらすことを更に含んで構成される、請求項35に記載の方法。
- 前記隔離材料は、前記電解質のイオンに対して透過性である、請求項36に記載の方法。
- 前記浸出したカーボンナノチューブ上にコーティングを付着させることを更に含んで構成される、請求項35に記載の方法。
- 前記コーティングは、導電性高分子、主族金属化合物、遷移金属化合物及びそれらの組合せからなる群より選択される材料を含んで構成される、請求項38に記載の方法。
- 前記コーティングは、ポリピロール、MnO2、RuO2及びそれらの組合せからなる群より選択される材料を含んで構成される、請求項38に記載の方法。
- 前記コーティングは、前記連続繊維を前記基板の周囲に配置する前に、前記浸出したカーボンナノチューブ上に付着される、請求項38に記載の方法。
- 前記コーティングは、前記連続繊維を前記基板の周囲に配置した後に、前記浸出したカーボンナノチューブ上に付着される、請求項38に記載の方法。
- 前記コーティングは、化学蒸着、物理蒸着、電着、電気めっき、無電解めっき、浸漬、スプレー及びそれらの組合せからなる群より選択される技術によって、前記浸出したカーボンナノチューブ上に付着される、請求項38に記載の方法。
- 前記連続繊維は、カーボンナノチューブが浸出する前は電気伝導性であり、前記連続繊維は、連続金属繊維、連続炭素繊維及びそれらの組合せからなる群より選択される、請求項35に記載の方法。
- 前記連続繊維は、繊維トウ、繊維テープ、繊維リボン及びそれらの組合せからなる群より選択される繊維形態を含んで構成される、請求項35に記載の方法。
- 積層後に、前記複数の電極層を一緒に圧縮することを更に含んで構成される、請求項35に記載の方法。
- 複数の積層された電極層を含んで構成され、
少なくとも一つの電極層は、カーボンナノチューブが浸出した連続繊維を含んで構成される、電気装置。 - カーボンナノチューブが浸出した連続繊維を含んで構成される少なくとも1つの電極層は、電気伝導性の基板を更に含んで構成され、前記基板上に前記連続繊維が配置される、請求項47に記載の電気装置。
- 各電極層と接触する電解質と、
各電極層間に配置される隔離材料の層と、
を更に含んで構成され、
前記隔離材料は、前記電解質のイオンに対して透過性である、請求項47に記載の電気装置。 - 前記連続繊維は、前記浸出したカーボンナノチューブの少なくとも一部に付着するコーティングを更に含んで構成され、
前記コーティングは、導電性高分子、主族金属化合物、遷移金属化合物及びそれらの組合せからなる群より選択される材料を含んで構成される、請求項47に記載の電気装置。 - 前記コーティングは、ポリピロール、MnO2、RuO2及びそれらの組合せからなる群より選択される材料を含んで構成される、請求項50に記載の電気装置。
- 前記積層された電極層の少なくともいくつかは、カーボンナノチューブを欠く、請求項47に記載の電気装置。
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WO2011159477A1 (en) | 2011-12-22 |
US20110304964A1 (en) | 2011-12-15 |
KR101896041B1 (ko) | 2018-10-24 |
EP2583291A1 (en) | 2013-04-24 |
CN103003902A (zh) | 2013-03-27 |
BR112012029004A2 (pt) | 2016-07-26 |
CA2798740A1 (en) | 2011-12-22 |
US8780526B2 (en) | 2014-07-15 |
ZA201208288B (en) | 2013-07-31 |
KR20130100239A (ko) | 2013-09-10 |
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