US2003149163A1PendingUtilityA1

Catalyst system for producing carbon fibrils

33
Priority: Mar 31, 1999Filed: Dec 16, 2002Published: Aug 7, 2003
Est. expiryMar 31, 2019(expired)· nominal 20-yr term from priority
Inventors:Xiao-Dong SunNavjot SinghLionel M. Levinson
Y10S977/774B01J 19/0046B01J 2219/00635B01J 2219/00707B01J 2219/00605B01J 23/866Y10S977/742B01J 2219/00659C40B 60/14C40B 40/18B01J 2219/00376B01J 2219/0043B01J 23/83B82Y 30/00B01J 2219/00745Y10S977/89B01J 2219/00585B01J 23/80Y10S977/775B01J 23/8878B01J 2219/00747B01J 23/72C40B 30/08B01J 23/864B01J 37/347C08K 7/06G01N 31/10B01J 2219/00612Y10S977/896D01F 9/127Y10S977/881B01J 2219/00369B01J 2219/00695
33
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Claims

Abstract

A catalyst system and method for making carbon fibrils is provided which comprises a catalytic amount of an inorganic catalyst comprising nickel and one of the following substances selected from the group consisting of chromium; chromium and iron; chromium and molybdenum; chromium, molybdenum, and iron; aluminum; yttrium and iron; yttrium, iron and aluminum; zinc; copper; yttrium; yttrium and chromium; and yttrium, chromium and zinc. In a further aspect of the invention, a catalyst system and method is provided for making carbon fibrils which comprises a catalytic amount of an inorganic catalyst comprising cobalt and one of the following substances selected from the group consisting of chromium; aluminum; zinc; copper; copper and zinc; copper, zinc, and chromium; copper and iron; copper, iron, and aluminum; copper and nickel; and yttrium, nickel and copper.

Claims

exact text as granted — not AI-modified
What is claimed is:  
     
         1 . A catalyst system for making carbon fibrils, the system comprising a catalytic amount of an inorganic catalyst comprising nickel and one of the following substances selected from the group consisting of chromium; chromium and iron; chromium and molybdenum; chromium, molybdenum, and iron; aluminum; yttrium and iron; yttrium, iron and aluminum; zinc; copper; yttrium; yttrium and chromium; and yttrium, chromium and zinc.  
     
     
         2 . The system of  claim 1 , wherein the inorganic catalyst comprises nickel and chromium.  
     
     
         3 . The system of  claim 2 , wherein the inorganic catalyst further comprises iron.  
     
     
         4 . The system of  claim 2 , wherein the inorganic catalyst further comprises molybdenum.  
     
     
         5 . The system of  claim 4 , wherein the inorganic catalyst further comprises iron.  
     
     
         6 . The system of  claim 2 , wherein the inorganic catalyst further comprises yttrium.  
     
     
         7 . The system of  claim 6 , wherein the inorganic catalyst further comprises zinc.  
     
     
         8 . The system of  claim 1 , wherein the inorganic catalyst comprises nickel and aluminum.  
     
     
         9 . The system of  claim 1 , wherein the inorganic catalyst comprises nickel and yttrium.  
     
     
         10 . The system of  claim 9 , wherein the inorganic catalyst further comprises iron.  
     
     
         11 . The system of  claim 10 , wherein the inorganic catalyst further comprises aluminum.  
     
     
         12 . The system of  claim 1 , wherein the inorganic catalyst comprises nickel and zinc.  
     
     
         13 . The system of  claim 1 , wherein the inorganic catalyst comprises nickel and copper.  
     
     
         14 . The system of  claim 1 , wherein the inorganic catalyst is substantially free of iron.  
     
     
         15 . A catalyst system for making carbon fibrils, the system comprising a catalytic amount of an inorganic catalyst comprising cobalt and one of the following substances selected from the group consisting of chromium; aluminum; zinc; copper; copper and zinc; copper, zinc, and chromium; copper and iron; copper, iron, and aluminum; copper and nickel; and yttrium, nickel and copper.  
     
     
         16 . The system of  claim 15 , wherein the inorganic catalyst comprises cobalt and chromium.  
     
     
         17 . The system of  claim 15 , wherein the inorganic catalyst comprises cobalt and aluminum.  
     
     
         18 . The system of  claim 15 , wherein the inorganic catalyst comprises cobalt and copper.  
     
     
         19 . The system of  claim 18 , wherein the inorganic catalyst further comprises zinc.  
     
     
         20 . The system of  claim 19 , wherein the inorganic catalyst further comprises chromium.  
     
     
         21 . The system of  claim 18 , wherein the inorganic catalyst further comprises iron.  
     
     
         22 . The system of  claim 18 , wherein the inorganic catalyst further comprises nickel.  
     
     
         23 . The system of  claim 21 , wherein the inorganic catalyst further comprises aluminum.  
     
     
         24 . The system of  claim 22 , wherein the inorganic catalyst further comprises yttrium.  
     
     
         25 . The system of  claim 15 , wherein the inorganic catalyst comprises cobalt and zinc.  
     
     
         26 . A method for making carbon fibrils wherein the method comprises reacting a carbon source and a catalyst system comprising an inorganic catalyst comprising nickel and one of the following substances selected from the group consisting of chromium; chromium and iron; chromium and molybdenum; chromium, molybdenum, and iron; aluminum; yttrium and iron; yttrium, iron and aluminum; zinc; copper; yttrium; yttrium and chromium; and yttrium, chromium and zinc.  
     
     
         27 . The method of  claim 26 , wherein the inorganic catalyst comprises nickel and chromium.  
     
     
         28 . The method of  claim 27 , wherein the inorganic catalyst further comprises iron.  
     
     
         29 . The method of  claim 28 , wherein the inorganic catalyst further comprises molybdenum.  
     
     
         30 . The method of  claim 29 , wherein the inorganic catalyst further comprises iron.  
     
     
         31 . The method of  claim 27 , wherein the inorganic catalyst further comprises yttrium.  
     
     
         32 . The method of  claim 31 , wherein the inorganic catalyst further comprises zinc.  
     
     
         33 . The method of  claim 26 , wherein the inorganic catalyst comprises nickel and aluminum.  
     
     
         34 . The method of  claim 26 , wherein the inorganic catalyst comprises nickel and yttrium.  
     
     
         35 . The method of  claim 34 , wherein the inorganic catalyst further comprises iron.  
     
     
         36 . The method of  claim 35 , wherein the inorganic catalyst further comprises aluminum.  
     
     
         37 . The method of  claim 26 , wherein the inorganic catalyst comprises nickel and zinc.  
     
     
         38 . The method of  claim 26 , wherein the inorganic catalyst comprises nickel and copper.  
     
     
         39 . The method of  claim 26 , wherein the inorganic catalyst is substantially free of iron.  
     
     
         40 . The method of  claim 26 , wherein the carbon source comprises acetylene, ethylene, methane, benzene, carbon monoxide or mixtures thereof.  
     
     
         41 . A method for making carbon fibrils wherein the method comprises reacting an carbon source and a catalyst system comprising an inorganic catalyst comprising cobalt and one of the following substances selected from the group consisting of chromium; aluminum; zinc; copper; copper and zinc; copper, zinc, and chromium; copper and iron; copper, iron, and aluminum; copper and nickel; and yttrium, nickel and copper.  
     
     
         42 . The method of  claim 41 , wherein the inorganic catalyst comprises cobalt and chromium.  
     
     
         43 . The method of  claim 41 , wherein the inorganic catalyst comprises cobalt and aluminum.  
     
     
         44 . The method of  claim 41 , wherein the inorganic catalyst comprises cobalt and copper.  
     
     
         45 . The method of  claim 44 , wherein the inorganic catalyst further comprises zinc.  
     
     
         46 . The method of  claim 45 , wherein the inorganic catalyst further comprises chromium.  
     
     
         47 . The method of  claim 44 , wherein the inorganic catalyst further comprises iron.  
     
     
         48 . The method of  claim 44 , wherein the inorganic catalyst further comprises nickel.  
     
     
         49 . The method of  claim 47 , wherein the inorganic catalyst further comprises aluminum.  
     
     
         50 . The method of  claim 48 , wherein the inorganic catalyst further comprises yttrium.  
     
     
         51 . The method of  claim 41 , wherein the inorganic catalyst comprises cobalt and zinc.  
     
     
         52 . The method of  claim 41 , wherein the carbon source comprises acetylene, ethylene, methane, benzene, carbon monoxide or mixtures thereof.  
     
     
         53 . A carbon fibril made from the catalyst system of  claim 1 .  
     
     
         54 . A carbon fibril made from. the catalyst system of  claim 15 .  
     
     
         55 . A carbon fibril made by the method of  claim 26 .  
     
     
         56 . A carbon fibril made by the method of  claim 41 .  
     
     
         57 . An organic resin which comprises carbon fibrils made from the catalyst system of  claim 1 .  
     
     
         58 . The organic resin of  claim 57  wherein the carbon fibrils are present in a range between about 0.01% by weight and about 20% by weight of the organic resin.  
     
     
         59 . The organic resin of  claim 58  wherein the carbon fibrils are present in a range between about 0.1% by weight and about 7% by weight of the organic resin.  
     
     
         60 . The organic resin of  claim 57  wherein the organic resin comprises polyphenylene ether or polycarbonate.  
     
     
         61 . An organic resin which comprises carbon fibrils made from the catalyst system of  claim 15 .  
     
     
         62 . The organic resin of  claim 61  wherein the carbon fibrils are present in a range between about 0.01% by weight and about 20% by weight of the organic resin.  
     
     
         63 . The organic resin of  claim 62  wherein the carbon fibrils are present in a range between about 0.1% by weight and about 7% by weight of the organic resin.  
     
     
         64 . The organic resin of  claim 61  wherein the organic resin comprises polyphenylene ether or polycarbonate.  
     
     
         65 . A organic resin which comprises carbon fibrils made by the method of  claim 26 .  
     
     
         66 . The organic resin of  claim 65  wherein the carbon fibrils are present in a range between about 0.01% by weight and about 20% by weight of the organic resin.  
     
     
         67 . The organic resin of  claim 66  wherein the carbon fibrils are present in a range between about 0.1% by weight and about 7% by weight of the organic resin.  
     
     
         68 . The organic resin of  claim 65  wherein the organic resin comprises polyphenylene ether or polycarbonate.  
     
     
         69 . A organic resin which comprises carbon fibrils made by the method of  claim 41 .  
     
     
         70 . The organic resin of  claim 69  wherein the carbon fibrils are present in a range between about 0.01% by weight and about 20% by weight of the organic resin.  
     
     
         71 . The organic resin of  claim 70  wherein the carbon fibrils are present in a range between about 0.1% by weight and about 7% by weight of the organic resin.  
     
     
         72 . The organic resin of  claim 69  wherein the organic resin comprises polyphenylene ether or polycarbonate.  
     
     
         73 . A organic resin comprising carbon fibrils in a range between about 0.01% by weight and about 20% by weight of the organic resin.  
     
     
         74 . The organic resin in accordance with  claim 73 , wherein the carbon fibrils are present in a range between about 0.1% by weight and about 7% by weight of the organic resin.  
     
     
         75 . A polyphenylene ether comprising carbon fibrils in a range between about 0.1% by weight and about 7% by weight of the polyphenylene ether.  
     
     
         76 . A polycarbonate comprising carbon fibrils in a range between about 0.1% by weight and about 7% by weight of the polycarbonate resin.

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