Bulk synthesis of carbon nanotubes from metallic and ethynyl compounds

Abstract

A process of making carbon nanotubes comprising the steps of: providing a precursor composition comprising at least one metallic compound and at least one organic compound; wherein the organic compound is selected from the group consisting of an ethynyl compound, a metal-ethynyl complex, and combinations thereof; wherein the precursor composition is a liquid or solid at room temperature; and heating the precursor composition under conditions effective to produce carbon nanotubes. A carbon nanotube composition comprising carbon nanotubes and a metal component selected from the group consisting of metal nanoparticles and elemental metal; wherein the carbon nanotube composition is rigid.

We claim:  
     
         1 . A process of making carbon nanotubes comprising the steps of: 
 providing a precursor composition comprising at least one metallic compound and at least one organic compound; 
 wherein the organic compound is selected from the group consisting of an ethynyl compound, a metal-ethynyl complex, and combinations thereof;  
 wherein the precursor composition is a liquid or solid at room temperature; and  
   heating the precursor composition under conditions effective to produce carbon nanotubes.    
     
     
         2 . The process of  claim 1 , wherein the metallic compound and the organic compound are the same compound.  
     
     
         3 . The process of  claim 1 , wherein the metal in the metallic compound is selected from the group consisting of a transition metal, iron, cobalt, nickel, ruthenium, osmium, molybdenum, tungsten, yttrium, lutetium, boron, copper, manganese, silicon, chromium, zinc, palladium, silver, platinum, tin, tellurium, bismuth, germanium, antimony, aluminum, indium, sulfur, selenium, cadmium, gadolinium, hafnium, magnesium, titanium, lanthanum, cerium, praseodymium, neodymium, terbium, dysprosium, holmium, erbium, and combinations thereof.  
     
     
         4 . The process of  claim 1 , wherein more than one metal is present in the precursor composition.  
     
     
         5 . The process of  claim 1 , wherein the metallic compound is selected from the group consisting of a metallocenyl compound, a metal salt, a metal-ethynyl complex, and combinations thereof.  
     
     
         6 . The process of  claim 5 , wherein the metallocenyl compound is selected from the group consisting of a ferrocenyl compound, a metallocenylethynyl compound, 1,4-bis(ferrocenyl)butadiyne, metallocenylethynylaromatic compound, 1,3-bis(ferrocenylethynyl)benzene, 1,4-bis(ferrocenylethynyl)benzene, 1-(ferrocenylethynyl)-3-(phenylethynyl)benzene, 1-(ferrocenylethynyl)-4-(phenylethynyl)benzene, 1,3,5-tris(ferrocenylethynyl)benzene, a metallocenylethynyl phosphine metal salt, bis(ferrocenylethynyl)-bis(triphenylphosphine)nickel, bis(ferrocenylethynyl)-bis(triethylphosphine)palladium, bis(ferrocenylethynyl)-bis(triethylphosphine)platinum, and combinations thereof.  
     
     
         7 . The process of  claim 5 , wherein the metal salt is selected from the group consisting of a metal carbonyl salt, nonacarbonyl diiron, octacarbonyl dicobalt, dodecacarbonyl triruthenium, hexacarbonyl tungsten, a phosphine metal salt, bis(triphenylphosphine)nickel, bis(triethylphosphine)palladium, bis(triethylphosphine)platinum, dicarbonyl bis(triphenylphosphine)nickel, palladium (II) acetylacetonate, manganese (III)-2,4-pentanedionate, cyclopentadienyl tungsten tricarbonyl dimer, and combinations thereof.  
     
     
         8 . The process of  claim 1 , wherein the metal-ethynyl complex is selected from the group consisting of a metal carbonyl-ethynyl complex, hexacarbonyl dicobalt complex of 1,2,4,5-tetrakis(phenylethynyl)benzene, hexacarbonyl diiron complex of 1,2,4,5-tetrakis(phenylethynyl)benzene, nonacarbonyl triruthenium complex of 1,2,4,5-tetrakis(phenylethynyl)benzene, a metal carbonyl-metallocenylethynyl containing complex, hexacarbonyl dicobalt complex of 1,4-bis(ferrocenyl)butadiyne, hexacarbonyl dicobalt complex of l-(ferrocenylethynyl)-4-(phenylethynyl)benzene, hexacarbonyl dicobalt complex of 1-(ferrocenylethynyl)-3-(phenylethynyl)benzene, and combinations thereof.  
     
     
         9 . The process of  claim 1 , wherein the ethynyl compound is selected from the group consisting of an ethynylaromatic compound, 1,2,3-tris(phenylethynyl)benzene, 1,2,4-tris(phenylethynyl)benzene, 1,3,5-tris(phenylethynyl)benzene, 1,2,3,4-tetrakis(phenylethynyl)benzene, 1,2,3,5-tetrakis(phenylethynyl)benzene, 1,2,4,5-tetrakis(phenylethynyl)benzene, 1,2,3,4,5-pentakis(phenylethynyl)benzene, 1,2,3,4,5,6-hexakis(phenylethynyl)benzene, and combinations thereof.  
     
     
         10 . The process of  claim 1 , wherein at least one of the compounds is an aromatic compound.  
     
     
         11 . The process of  claim 1 , wherein the metal content of the precursor composition is less than about 1% by weight.  
     
     
         12 . The process of  claim 1 , wherein the heating step comprises heating the precursor composition under nitrogen to a temperature of at least about 500° C.  
     
     
         13 . The product made by the process of  claim 1 .  
     
     
         14 . The process of  claim 1 , wherein the compounds are combined by a method selected from the group consisting of mechanical mixing, solvent mixing, and partial complexation.  
     
     
         15 . A process of making carbon nanotubes comprising the steps of: 
 providing a precursor composition comprising a polymer and a metallic component; 
 wherein the polymer has crosslinked ethynyl groups;  
 wherein the metallic component is bonded to the polymer, combined with the polymer, or combinations thereof; and  
   heating the precursor composition under conditions effective to produce carbon nanotubes.    
     
     
         16 . The process of  claim 15 , wherein the metallic component is selected from the group consisting of a metallocenyl group, a metal-ethynyl complex group, a metal salt, metal nanoparticles, elemental metal, and combinations thereof  
     
     
         17 . The process of  claim 16 , wherein the metallocenyl group is ferrocenyl.  
     
     
         18 . The process of  claim 16 , wherein the metal-ethynyl complex group is selected from the group consisting of hexacarbonyl dicobalt-ethynyl complex group, hexacarbonyl diiron-ethynyl complex group, nonacarbonyl triruthenium-ethynyl complex group, and combinations thereof.  
     
     
         19 . The process of  claim 16 , wherein the metal salt is selected from the group consisting of a metal carbonyl salt, nonacarbonyl diiron, octacarbonyl dicobalt, dodecacarbonyl triruthenium, hexacarbonyl tungsten, a phosphine metal salt, bis(triphenylphosphine)nickel, bis(triethylphosphine)palladium, bis(triethylphosphine)platinum, dicarbonyl bis(triphenylphosphine)nickel, palladium (II) acetylacetonate, manganese (III)-2,4-pentanedionate, cyclopentadienyl tungsten tricarbonyl dimer, and combinations thereof.  
     
     
         20 . The process of  claim 15 , wherein the heating step comprises heating the precursor composition under nitrogen to a temperature of at least about 500° C.  
     
     
         21 . The product made by the process of  claim 15 .  
     
     
         22 . A carbon nanotube composition comprising carbon nanotubes and a metal component selected from the group consisting of metal nanoparticles, elemental metal, and combinations thereof; 
 wherein the carbon nanotube composition is rigid.    
     
     
         23 . The carbon nanotube composition of  claim 22 , wherein the carbon nanotube composition is made by a process comprising the steps of: 
 providing a precursor composition comprising at least one metallic compound and at least one organic compound; 
 wherein the organic compound is selected from the group consisting of an ethynyl compound, a metal-ethynyl complex, and combinations thereof;  
 wherein the precursor composition is a liquid or solid at room temperature; and  
   heating the precursor composition under conditions effective to produce carbon nanotubes.    
     
     
         24 . The carbon nanotube composition of  claim 23 , wherein the metallic compound is selected from the group consisting of a metallocenyl compound, a metal salt, a metal-ethynyl complex, and combinations thereof.  
     
     
         25 . The carbon nanotube composition of  claim 22 , wherein the carbon nanotube composition is made by a process comprising the steps of: 
 providing a precursor composition comprising a polymer and a metallic component; 
 wherein the polymer has crosslinked ethynyl groups;  
 wherein the metallic component is bonded to the polymer, combined with the polymer, or both; and  
   heating the precursor composition under conditions effective to produce carbon nanotubes.    
     
     
         26 . The carbon nanotube composition of  claim 25 , wherein the metallic component is selected from the group consisting of a metallocenyl group, a metal-ethynyl complex group, a metal salt, metal nanoparticles, elemental metal, and combinations thereof.  
     
     
         27 . The carbon nanotube composition of  claim 22 , wherein the metal content of the carbon nanotube composition is less than about 1%.  
     
     
         28 . The carbon nanotube composition of  claim 22  further comprising carbon nanoparticles.  
     
     
         29 . A magnetic semiconductor comprising the carbon nanotube composition of  claim 22 .  
     
     
         30 . A superconductor comprising the carbon nanotube composition of  claim 22 .  
     
     
         31 . A fiber comprising the carbon nanotube composition of  claim 22 .  
     
     
         32 . A shaped article comprising the carbon nanotube composition of  claim 22 .  
     
     
         33 . A powder made by grinding the carbon nanotube composition of  claim 22 .  
     
     
         34 . A film comprising the carbon nanotube composition of  claim 22 .  
     
     
         35 . The film of  claim 34 , wherein the film comprises a plurality of layers containing different concentrations of carbon nanotubes.  
     
     
         36 . A composite comprising the carbon nanotube composition of  claim 22 .  
     
     
         37 . A drug delivery system comprising the carbon nanotube composition of  claim 22 .  
     
     
         38 . A lubricant comprising the carbon nanotube composition of  claim 22 .  
     
     
         39 . A microelectronic device comprising the carbon nanotube composition of  claim 22 .  
     
     
         40 . An electrode comprising the carbon nanotube composition of  claim 22 .  
     
     
         41 . A fuel cell electrode comprising the carbon nanotube composition of  claim 22 .  
     
     
         42 . A ferrofluid comprising the carbon nanotube composition of  claim 22 , wherein carbon nanotube composition is ground to a powder.  
     
     
         43 . A battery comprising the electrode of  claim 22 .  
     
     
         44 . A magnetic component comprising the carbon nanotube composition of  claim 22 .  
     
     
         45 . An electrical component comprising the carbon nanotube composition of  claim 22 .  
     
     
         46 . The electrical component of  claim 45 , wherein the electrical component is a fiber.  
     
     
         47 . A sensor comprising the carbon nanotube composition of  claim 22 .  
     
     
         48 . A photovoltaic device comprising the carbon nanotube composition of  claim 22.