Varied morphology carbon nanotubes

Abstract

The present invention describes the preparation of carbon nanotubes of varied morphology, catalyst materials for their synthesis. The present invention also describes reactor apparatus and methods of optimizing and controlling process parameters for the manufacture carbon nanotubes with pre-determined morphologies in relatively high purity and in high yields. In particular, the present invention provides methods for the preparation of non-aligned carbon nanotubes with controllable morphologies, catalyst materials and methods for their manufacture.

1 . A material comprising a plurality of non-aligned carbon nanotubes comprising individual tubules having a cylindrical hollow single-walled structure. 
     
     
         2 . The material of  claim 1  wherein the plurality of non-aligned carbon nanotubes are linear unbranched tubules. 
     
     
         3 . The material of  claim 2  wherein the linear unbranched tubules have a hollow cylindrical morphology having at least one graphene layer. 
     
     
         4 . The material of  claim 2  wherein the linear unbranched tubules have a segmentally conical stacked array morphology having at least one graphene layer in each segment. 
     
     
         5 . The material of  claim 1  wherein the plurality of non-aligned carbon nanotubes are substantially comprised of branched tubules having at least one branching node along a tubule axis. 
     
     
         6 . The material of  claim 1  wherein the plurality of non-aligned carbon nanotubes are branched tubules with a Y-junction in at least one branching node. 
     
     
         7 . The material of  claim 6  wherein the angle formed between adjacent branch tubules forming the Y-junction is about 90° to about 240°. 
     
     
         8 . The material of  claim 6  wherein the angle formed between adjacent branch tubules forming the Y-junction is about 120°. 
     
     
         9 . A material comprising a plurality of non-aligned carbon nanotubes comprising individual linear unbranched tubules having a cylindrical hollow multi-walled structure,
 wherein the linear unbranched tubules have a segmentally conical stacked array morphology.   
     
     
         10 . The material of  claim 9  further comprising at least one graphene layer in each segment of the conical stacked array. 
     
     
         11 . A catalyst substrate material comprising:
 a plurality of mesoporous sol-gel particles having substantially uniform pores; and
 a metallic material coated on the plurality of mesoporous sol-gel particles. 
   
     
     
         12 . The catalyst substrate material of  claim 11  wherein the plurality of mesoporous sol-gel particles range from about 10 −3  to about 10 3  microns. 
     
     
         13 . The catalyst substrate material of  claim 11  wherein the plurality of mesoporous sol-gel particles are mesoporous silica, mesoporous alumina or mixtures thereof. 
     
     
         14 . The catalyst substrate material of  claim 11  wherein the metallic material is a transition metal, metal alloy or a combination thereof. 
     
     
         15 . The catalyst substrate material of  claim 11  wherein the metallic material is selected from the group consisting of iron, cobalt, nickel and combinations thereof. 
     
     
         16 . The catalyst substrate material of  claim 11  further comprising at least one non-metallic material. 
     
     
         17 . The catalyst substrate material of  claim 16  wherein the non-metallic material is an organic or inorganic oxide, nitride, sulfide or carbide compound. 
     
     
         18 . The catalyst substrate material of  claim 16  wherein the non-metallic material is an organo-metallic material. 
     
     
         19 . The catalyst substrate material of  claim 18  wherein the organo-metallic material is selected from the group consisting of ferrocene, nickelocene, cobaltocene and mixtures thereof. 
     
     
         20 . The catalyst substrate material of  claim 11  wherein the metallic material is impregnated within the plurality of mesoporous sol-gel particles.