Methods and device for generating energy with deuterium-carbon materials

Abstract

Disclosed are methods and apparatus for producing energy by introducing a deuterium¬ carbon material to the surface of a solid substrate capable of initiating the growth of three- dimensional crystalline nanostructured carbon on the substrate surface by chemical vapor deposition. The carbon in the deuterium-carbon material pyrolyzes and forms the three- dimensional crystalline shapes comprising carbon, such as carbon nanotubes. The deuterium reacts with the three-dimensional crystalline nanostructured carbon to produce energy, such as through a nuclear confinement fusion reaction. Also disclosed are devices for producing energy made by the method.

Description

METHODS AND DEVICE FOR GENERATING ENERGY WITH DEUTERIUM-CARBONMATERIALSTECHNICAL FIELD

[0001] The present disclosure relates generally to methods for producing energy using three-dimensional crystalline shapes comprising carbon, such as carbon nanotubes, and deuterium-containing carbon molecules. The present disclosure also relates to devices for producing energy made by the method.BACKGROUND

[0002] The environmental impact and cost of energy production has produced a long standing need for efficient, clean, and affordable energy. All energy production methods in current use have significant drawbacks.

[0003] The combustion of hydrocarbons such as natural gas or fuel oil and the combustion of coal form the basis of most energy production in the world. While these fuels produce relatively inexpensive energy, the cost to find, extract, refine, and distribute such fuels is significant. Their combustion also produces harmful byproducts and greenhouse gases without expensive combustion gas treatment. The extraction of such fuels can also have severe environmental impact and can require expensive site remediation after the extraction of the fuel is complete.

[0004] While solar energy has promise, it requires significant government subsidies to economically produce electricity and the cost of manufacturing, siting, and installing solar arrays is formidable. The siting requires predominantly clear skies to maximize energy production and such sites cannot produce significant energy at night. In addition, the solid- state panels have a definite useful life and means for environmentally disposal or recycling are still being developed.

[0005] Wind turbine technology also has restrictions on siting and capital costs that make this technology viable only in specific locations and only with significant government subsidies. The energy output of wind turbines, like solar panel technology is weather dependent.

[0006] Nuclear fission reactors currently play a significant role in providing inexpensive electrical power, but they have severe drawbacks. They emit dangerous levels of radiation that require massive shielding to make the reactor environmentally safe. The radiation makes the reactor components intrinsically radioactive and degrades their properties. Inaddition, the prospect of a steam explosion or fuel meltdown with radioactive contaminants requires significant security measures and expensive system controls. In addition, the spent nuclear fuel is dangerously radioactive for thousands of years and its disposal and storage is a problem yet to be resolved. These drawbacks significantly limit the future of fission power reactors as commercial energy sources.

[0007] Nuclear fusion reactors do not produce dangerous nuclear waste and show great potential. Current fusion reactors induce a fusion reaction by confining deuterium and / or tritium with either lasers or magnetic fields to produce extremely high temperature plasma that must be confined to produce extremely high pressures. Confining a plasma with magnetic fields or laser energy has proved to be extremely difficult. Several experimental fusion reactors exist, but they are complex, massive, expensive, and none have produced more energy than they consume to induce the fusion reaction.

[0008] There exists a need for an alternative source of energy that is economical and safe, without producing dangerous byproducts. This disclosure describes a method of meeting current and future energy needs, producing commercially valuable energy in an environmentally friendly way.SUMMARY

[0009] One embodiment of the present invention is a method for producing energy where the three-dimensional nanostructured carbon material is formed from deuterated hydrocarbons or deuterocarbon by chemical vapor deposition. The deuterated three- dimensional nanostructured carbon material induces a nuclear fusion reaction.

[0010] Another embodiment of the present invention is a method of producing energy that includes providing a solid substrate capable of initiating the growth of a plurality of carbon nanotubes from the surface of the solid substrate. A deuterated hydrocarbon or deuterocarbon is introduced onto the surface in a chemical vapor deposition process. The carbon in the deuterated hydrocarbon or deuterocarbon forms carbon nanotubes on the surface and the deuterium reacts in a fusion reaction to produce energy.

[0011] Still another embodiment of the invention is a device for forming an energy-producing sheet material by chemical vapor deposition. The device includes a source of at least one gaseous or vaporous deuterium carbon material and a system for supplying the deuterium material at controlled temperatures, flow rates, and pressures to a container for receiving the deuterium material. A solid substrate is located at a deposition location within thecontainer and the substrate has at least one carbon-deposition catalyst on a first surface. The substrate is capable of initiating the growth of at least one three-dimensional nanostructured carbon shape on the first surface. The device may further include a system for introducing deuterium carbon material to the container and the first surface of the substrate. The hydrocarbon forms at least one, and preferably a plurality of three- dimensional nanostructured carbon shapes on the first surface. The deuterium reacts with the three-dimensional nanostructured carbon shapes to produce energy.

[0012] Still another embodiment of the invention is a device that includes a continuous foil of metal as the substrate onto which the catalyst is deposited and introduced to the chemical vapor deposition system. In still another embodiment separate “coupons” of substrate having catalyst deposited thereon are transported into the system.

[0013] Still another embodiment of the device includes an apparatus for extracting the metal foil from the deposition location and an apparatus in flow communication the container for accumulating the metal foil and an apparatus for extracting a specific amount of the foil having energy-producing deuterium and three-dimensional nanostructured carbon shapes thereon from the device.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The accompanying figures are incorporated in and constitute a part of this specification.

[0015] Fig. 1 is a schematic representation of a single-walled carbon nanotube, a species of three-dimensional nanostructured carbon shapes. In Fig. 1 the spheres represent carbon atoms and the elements linking the spheres represent chemical bonds.

[0016] Fig. 2 is a schematic representation of the surface of a deposition substrate having a single deposition site and a single carbon nanotube growing therefrom.

[0017] Figs. 3(a), 3(b), 3(c), and 3(d) are a schematic representation of several deposition substrates depicting a pattern of active deposition sites catalyzed to produce an array of three-dimensional nanostructured carbon shapes only at those sites.

[0118] Fig. 4 is a schematic top plan view of a chemical vapor deposition apparatus including a system for extracting the post-deposition substrate from the interior of the deposition chamber.

[0019] Fig. 5 is a schematic side view of the chemical vapor deposition apparatus of Fig. 4 including substrate supply system and a system for extracting the post-deposition substrate from the interior of the deposition chamber.

[0020] Fig. 6 is a schematic representation of an apparatus generating electrical energy using an embodiment of the present invention.DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] Published U.S. Patent application 13 / 986,086 and European Patent 2656350 A1 both disclose a method of producing energy by combining three-dimensional nanostructured carbon such as carbon nanotubes with deuterium. It discloses that such a combination produces a nuclear confinement fusion reaction that creates energy, helium, and no harmful byproducts. In such a process, the three-dimensional graphene materials (such as carbon nanotubes) are exposed to a source of deuterium such as deuterium gas (D2) or heavy water (D2O). The electronic environment of the three-dimensional nanostructured carbon material provides shielding and allows the deuterium or deuterons (deuterium nuclei) atoms to overcome the natural Coulombic repulsion of adjacent deuterium atoms or deuterons and a nuclear fusion reaction occurs. It is believed the fusion reaction that occurs is 2D + 2D4He + 23.8 MeV, but it is possible that the reaction is another known fusion reaction or possible a previously unknown fusion reaction induced by the unique interaction of three-dimensional nanostructured carbon shapes with deuterium.

[0022] The preferred method of making three-dimensional nanostructured carbon materials is by chemical vapor deposition (CVD). In CVD processes hydrocarbons are chemically deposited onto a heated solid substrate where they are pyrolyzed and form three- dimensional nanostructured carbon material.

[0023] Chemical vapor deposition to produce three-dimensional nanostructured carbon is the preferred process for forming such materials. The disclosure of “An Overview on Methods for the Production of Carbon Nanotubes,” Journal of Industrial and Engineering Chemistry, 20 (2014) 1186-1197, Mubarak, et al. and “Production of Carbon Nanotubes using CVD - Study of the Operating Parameters,” Reviews on Advanced Mateiiais Science, 10(2005)314- 319, Mitri et al. are incorporated by reference herein.

[0024] When the form of the three-dimensional crystalline nanostructured carbon material is tubular, and has but a single layer, the resulting carbon structure is called a single-walled carbon nanotube (SWCNT). The carbon nanotube can also have more than one layer and such a material is called a multiwalled carbon nanotube. Non-tubular three- dimensional graphene materials can also be formed and those are commonly referred to as multilayer graphite, buckyballs, carbon onions, carbon nanohorns.

[0025] The four principal process parameters that determine the type of three-dimensional graphene material produced are the hydrocarbon source, the catalyst, the atmosphere within the CVD chamber, and the process temperature.

[0026] The hydrocarbon source in a conventional chemical vapor deposition process is normally gases or liquids, but solid hydrocarbons can be used if they undergo sublimation at low enough temperatures. If liquids are the hydrocarbon source, their vapors are mixed with carrier gases and introduced to the CVD apparatus. The carbon source is typically a hydrocarbon material, a gas such as methane, ethylene, and acetylene, or a liquid such as different types of alcohols. The carrier gases are used to input the carbon clouds into the reactor. Sometimes a mixture of an inert carrier gas and hydrogen are used as a reducing agent.

[0027] The catalyst is normally a metal particle. The catalyst is important to the process in two ways. First, the metal particles serve as nucleation sites for the growth of three- dimensional crystalline graphene structures and the size of the particles determine the size (diameter) of the structure if it is tubular. Second, and catalyst promotes the decomposition of the hydrocarbon at a low temperature. The metals iron, cobalt and nickel are commonly used as catalysts.

[0028] The function of the carrier gas is to transport the hydrocarbon into the system. Its flow rate into the chemical vapor deposition chamber directly influences the process of carbon nucleation and growth. When the flow rate of the carrier gas is low, few carbon nanotubes are formed because there are not enough precursor vapors passing through the reactor to be deposited onto the catalysts. If the flow rate is too low, polymerization of the precursor can result. If the flow rate is too high the carrier gas and most of the precursor are carried out of the reactor without sufficient decomposition of the hydrocarbon to provide the carbon source for the deposition on the catalyst. The optimum flow rate for the carrier gas is one that provides the time for complete decomposition of the carbon source, nucleation of the carbon and deposition on the nucleated sites while minimizing the throughput of unreacted hydrocarbon.

[0029] The concentration of reactants in the mixture is determined by flow meters.Generally, the operating temperature inside the chemical vapor deposition apparatus in in the range of 930 to 2,200°F (500°C to 1200°C).

[0030] Generally, lower process temperatures in the range of 1,100 to 1,650°F (600 to 900°C) yields multiwalled carbon nanotubes (MWCNTs), and higher temperatures of more than 1,650°F (900°C) produce mostly single-walled carbon nanotubes (SWCNTs).

[0031] The following terms or phrases used in the present disclosure have the meanings outlined below:

[0032] The term "graphene" is defined as a one-atom-thick sheet of sp2-bonded carbon atoms that are densely packed in a honeycomb crystal lattice.

[0033] The term "nanotube" refers to a tubular-shaped, molecular structure generally having an average diameter in the inclusive range of 1-60 nm and an average length in the inclusive range of 0.1pm to 250 mm.

[0034] The term "carbon nanotube" or any version thereof refers to a tubular-shaped, molecular structure composed primarily of carbon atoms arranged in a hexagonal lattice (a graphene sheet) which closes upon itself to form the walls of a seamless cylindrical tube. These tubular sheets can either occur alone (single-walled) or as many concentric tubular sheets (multi-walled).

[0035] The term "nuclear fusion" is the process in which two or more atomic nuclei join together, or "fuse", to form a single heavier nucleus. This is accompanied by the release of large quantities of energy.

[0036] The term “confinement fusion” is defined as a local nuclear fusion event that results from the confinement of deuterium within a crystalline material such that the Coulombic repulsion between deuterium atoms or deuterons is reduced or negated.

[0037] The terms “nanoconfinement fusion” and “nano confinement fusion” are both defined as a local nuclear fusion event that results from the confinement of deuterium within a three-dimensional nanostructured carbon crystalline material such that the Coulombic repulsion between deuterium atoms or deuterons is reduced or negated.

[0038] The term “crystalline material” is defined as a solid material having periodicity to the atomic structure.

[0039] The terms "nanostructured" and "nano-scaled" refers to a structure or a material which possesses components having at least one dimension that is 100nm or smaller.

[0040] The phrase "nanostructured material" refers to a material whose components have an arrangement that has at least one characteristic length scale that is 100 nanometers or less. The phrase "characteristic length scale" refers to a measure of the size of a pattern within the arrangement, such as but not limited to the characteristic diameter of the pores created within the structure, the interstitial distance between fibers or the distance between subsequent fiber crossings. This measurement may also be done through the methods of applied mathematics such as principal component or spectral analysis that give multi-scale information characterizing the length scales within the material.

[0041] The term "deuterocarbon" is defined as a molecule having the molecular structure of a hydrocarbon having a deuterium atom located at every site in the molecule that would be occupied by a hydrogen atom in the hydrocarbon molecule.

[0042] The term "deuterated hydrocarbon " is defined as hydrocarbon molecule where at least one hydrogen atom of the hydrocarbon molecule has been substituted by a deuterium atom.

[0043] The term “deuterium carbon material” is defined as a material that has the structure of a hydrocarbon molecule where at least one hydrogen atom of the hydrocarbon molecule has been substituted by a deuterium atom.

[0044] The phrases "chosen from" or "selected from" as used herein refers to selection of individual components or the combination of two (or more) components.

[0045] The present invention is a method and apparatus for producing energy by combining three-dimensional nanostructured carbon such as nanostructured carbon nanotubes with deuterium in a chemical vapor deposition process. The three-dimensional crystalline nanostructured carbon is preferably single-wall carbon nanotubes, multiwall carbon nanotubes, or mixtures thereof. The source of deuterium can be the deuterium in the three-dimensional graphene materials to produce the fusion reaction. Not to be bound by theory, it is believed the electrons from the deuterium must be stripped to form deuterons. In another embodiment D2gas may be introduced into the chemical vapor deposition chamber. Similarly, it believed that when deuterium gas is used the D2 must be disassociated to deuterium atoms and the electrons stripped to form deuterons.

[0046] There are other likely barriers to the introduction of deuterons to the electronic environment of the three-dimensional graphene materials. One is the attraction of three- dimensional graphene materials such as carbon nanotubes to hydrogen. If the processesused to pre-treat the three-dimensional graphene materials prior to the introduction of deuterium include any hydrogen the sites that would be reactive to deuterium may be occupied by hydrogen, inhibiting the fusion reaction.

[0047] While carbon nanotubes are known to by hydrophobic, the presence of water in or on the three-dimensional nanostructured carbon may also inhibit the introduction of deuterons to these materials. Recent reported research ("Quantum Tunneling of Water in Beryl: A New State of the Water Molecule,” 116, Physical Review Letters, 167802 (2016), Alexander I. Kolesnikov et al.) indicates that water can enter the interior of a carbon nanotube in spite of it being hydroscopic.

[0047] The conventional formation of three-dimensional nanostructured carbon materials by chemical vapor deposition of hydrocarbons produces water and hydrogen in the pyrolysis reaction. Both of these may occupy sites on the three-dimensional nanostructured carbon and thereby inhibit the fusion reaction.

[0048] While the presence of water, hydrogen or other materials that inhibit the fusion reaction, they do not prevent it. The fusion reaction occurs with either the introduction of deuterium gas (D2) or heavy water (D2O) but it is believed that the aforementioned “contaminants” may inhibit the participation rate of the deuterons with the three- dimensional nanostructured carbon materials and thus reduce the energy output from a given mass of reactive materials.

[0049] The present invention overcomes the issue of what is referred to above as contamination by synthesizing the three-dimensional graphene materials in a different way. Specifically, the present invention uses deuterated hydrocarbons or deuterocarbon in the synthesis so that the process produces neither hydrogen nor water.

[0050] One embodiment of the invention is a method for producing energy. In this embodiment a solid substrate capable of initiating the growth of a plurality of three- dimensional crystalline nanostructured carbon shapes on one surface is used in a chemical vapor deposition process where the carbon source is a deuterated source of carbon is pyrolyzed forming at least one three-dimensional nanostructured carbon shape on that surface. It is preferred that the source of the carbon be a deuterocarbon, entirely free of hydrogen.

[0051] In an embodiment, the substrate forms a plurality of three-dimensional nanostructured carbon shapes which may consist essentially of single-wall carbonnanotubes as shown in Fig. 1, multiwall carbon nanotubes which are configured similarly to the carbon nanotube of Fig. 1 only there are concentric tubular nanotubes in a multiwall carbon nanotube, or combinations thereof.

[0052] Fig. 2 shows a schematic representation of a substrate 10 with an upper surface 12 onto which is located a single catalyst 15 that has nucleated and grown a single carbon nanotube 14. Because the carbon nanotube 14 was formed without hydrogen or water, the deuterium is associated with the carbon nanotube in a way that increased the probability that the deuterium and deuterons they will react in a fusion reaction to produce energy.

[0053] Preferably the energy output is controlled by controlling the number of nucleation sites on the surface 12 of the substrate 10. As depicted in Figs. 3 (a)-(d) the surface 12 includes a pattern of active sites (produced by local catalyst sites 15) producing an array of three-dimensional nanostructured carbon shapes in that pattern. The density of the pattern will determine the number of active energy-emitting carbon nanotubes and thus the energy output of the device made from portions of the substrate 10.

[0054] The four principal process parameters that determine the type of three-dimensional graphene material produced are the carbon source, the catalyst, the atmosphere within the chemical vapor deposition chamber, and the process temperature.

[0055] In this embodiment the carbon source comprises the deuterium-containing carbon molecule. In non-limiting embodiments, the deuterium-containing carbon molecule consists essentially of a material selected from the group consisting of deuterated acetylene, deuterated ethylene, or a deuterated alcohol. In another embodiment, the deuterium- containing carbon molecule is essentially free of hydrogen and is referred to herein as deuterocarbon. A deuterocarbon has the same molecular structure as its hydrocarbon analog with deuterium at the sites on the molecule normally occupied by a hydrogen atom.

[0056] The first step in this embodiment is providing a solid substrate capable of initiating the growth of a plurality of three-dimensional crystalline nanostructured carbon structures from the surface of the solid substrate by chemical vapor deposition. The composition of the solid substrate is not known to be critical and any metal capable of withstanding the temperatures and gaseous environment of chemical vapor deposition without inhibiting the activity of the catalyst on its surface will be operable. Typical metals include iron and iron alloys which may be in the form of solid organometallic metallocene compound. For example, iron (from ferrocene), cobalt, and nickel as organometallic metallocenecompounds, are widely used as carbon nanotube catalysts because they can release metal nanoparticles, resulting in more effectively catalyzing the decomposition of hydrocarbons.

[0057] The catalyst influences the chemical vapor deposition process in several ways. The size of the catalyst determines the size of the three-dimensional nanostructured carbon. In addition, its composition affects temperature of the decomposition deuterium carbon material. The catalyst particles serve as nucleation sites for the three-dimensional nanostructured carbon structures. To carry out these functions the catalyst should have a high solubility of carbon at high temperatures. The catalyst should not prevent or reduce the diffusion rate of carbon on its surface, and it should have a high melting point and low equilibrium-vapor pressure at the operating temperatures of a chemical vapor deposition process. Iron, cobalt, and nickel are normally used.

[0058] Conventional chemical vapor deposition processes for producing carbon nanotubes can use as the hydrocarbon source methane, acetylene, benzene, or carbon monoxide, but the most popular precursor is ethanol. It is believed that the molecular structure of the hydrocarbon source has an effect on the structure of the carbon nanotubes. Linear hydrocarbons such as methane, ethylene, and acetylene thermally decompose to form atomic carbon or linear molecules of carbon. They generally directly produce hollow carbon nanotubes. The hydrocarbon sources with the higher number of carbon atoms, more than seven atoms, produce branched carbon nanotubes. Generally, process temperatures under 900 °C produce multiwalled carbon nanotubes, while those over 900 °C yield single walled carbon nanotubes.

[0059] Carrier gases are used to input the carbon containing material into the reactor. In conventional chemical vapor deposition the carrier gas is normally hydrogen or argon. In such conventional chemical vapor deposition processes hydrogen is normally the preferred carrier gas because it provides a reducing atmosphere and scavenges oxygen. Nitrogen and ammonia have also been used.

[0060] In a preferred embodiment of the invention the carrier gas is an inert gas that includes deuterium gas. Another preferred embodiment has a carrier gas that consists essentially of deuterium gas.

[0061] The flow rate of the carrier gas directly influences the process of nucleation and growth of the three-dimensional crystalline nanostructured carbon. When the flow rate ofthe carrier gas is too low, very few carbon nanotubes (“CNTs”) are formed, because not enough precursor vapors are deposited onto the catalyst. Low flow rates decrease the CNT production due for lack of carbon, and any further reactions may be the polymerization of the precursor. When the flow rate is too high the carrier gas and most of the precursor are carried out of the reactor with very slow or incomplete decomposition. The best flow rate provides the time needed for a complete decom- position of the hydrocarbon source.

[0062] Generally, the length of the three-dimensional nanostructured carbon decreases with the increasing flow rates of the carrier gas and a high vapor pressure within the range that causes growth of the three-dimensional nanostructured carbon three-dimensional nanostructured carbon.

[0063] The temperature of the reaction also affects the chemical vapor deposition process. Preferably the substrate temperature in the process of this embodiment is at least 1 ,100°F (600°C). Generally, lower process temperatures in the range of 1 ,100 to 1 ,650°F (600 to 900°C) yields multiwalled carbon nanotubes (MWCNTs), and higher temperatures of more than 1,650°F (900°C) produce mostly single-walled carbon nanotubes (SWCNTs).

[0064] The CVD process parameters associated with the present invention are not known to be different from the pressures, carrier gas flow rates, hydrocarbon concentrations and flow rates for conventional chemical vapor deposition processes and can be determined by practice of a conventional chemical vapor deposition process modified in light of the method embodiment of the invention.

[0065] In accordance with the invention there is a device for forming an energy-producing sheet material by chemical vapor deposition. As here embodied, and depicted schematically in Figs. 4 and 5, the device may include a deposition chamber 16 in which a chemical vapor deposition process is conducted. It is in flow communication with a source of gasses, depicted in Fig. 4 as gas source 18 that may provide a source 20 of at least one gaseous or vaporous deuterated hydrocarbon or deuterocarbon. As with conventional chemical vapor deposition apparatus, the device may include sources of oxygen, shown in Fig. 4 as source 22, and a carrier gas source 24. An embodiment may further include a control system for supplying deuterated hydrocarbon materials at controlled temperatures, flow rates, and pressures to the deposition chamber 16. As here embodied a master control system 26 is in communication with the source of each gas (the deuterium gassource 20, the oxygen source 22 and the carrier gas source 24) and controls the flow rated of these gases to the deposition chamber 16.

[0066] In accordance with the invention the system may include a solid substrate at a deposition location with the substrate having at least one carbon-deposition catalyst on a first surface within the deposition chamber. The catalysts on the substrate are capable of initiating the growth of at least one three-dimensional crystalline graphene shape on a surface thereof. As here embodied and depicted in Figs. 3(a)-(d), the solid substrate 10 includes on its upper surface 12 a plurality of catalyzed sites (as shown schematically in Figs. 3(a)-(d) as sites 15) on the surface 12 onto which the gasses from the gas sources 18 are imposed.

[0067] In accordance with the invention a plurality of three-dimensional crystalline graphene shapes is formed on the surface of the substrate at the nucleation sites.Because those three-dimensional graphene materials do not contain anything but deuterium and carbon, they react to produce energy. The resulting gaseous products and any carrier gas exit the deposition chamber at the outlet 30.

[0068] A preferred embodiment of a system to produce energy is depicted schematically in Fig. 5. Preferably this embodiment includes a substrate supply 32 containing a coiled metal substrate 28 that is preferred to be a metal foil. In this embodiment a seal 34 isolates the substrate supply 32 from the chemical vapor deposition process being carried out in the deposition chamber 16. In this embodiment an opposed pair of rolls 36 transport the foil 28 into the chemical vapor deposition process being carried out in the deposition chamber 16. In this embodiment the foil 28 is supported by a foil support 38 and then driven out of the deposition chamber 16 by the opposed rolls 40 and 40’. The upper roll 40’ may have a surface configuration such that it does not engage the surface of the foil at a location where the three-dimensional graphene materials are deposited. The deposition chamber 16 may further include a seal 42 that retains the gases in the deposition chamber 16 while the foil 28 exits the deposition chamber.

[0069] The embodiment of Fig. 5 may further include a device in flow communication with the deposition chamber for sizing the metal foil on which the three-dimensional graphene materials have been deposited by the chemical vapor deposition process. By sizing the metal foil it is meant to be the cutting of the metal foil into discrete portions having the number of active three-dimensional graphene materials thereon in an amount that willprovide the desired energy output for that portion. If the embodiment does not use a continuous metal foil as a substrate and uses discrete deposition substrates, then the area of those substrates will determine the desired energy output.

[0070] As here embodied and depicted in Figs. 4 and 5 the system includes a substrate receiving system 44. The substrate receiving system may include a set of opposed rolls 48 and 48’ on opposite sides of the substrate 28. In this embodiment the upper roll 48’ includes a projection 50 that severs the continuous substrate into discrete portions of the appropriate size. While the schematically depicted embodiment may be configured to simply cut the substrate at regular intervals to produce the appropriately sized energy- emitting coupons (depicted here as coupons 52), the upper roll 48’ may cooperate with the lower roll 48 and trim the substrate into any appropriate external shape.

[0071] The embodiment of Fig. 5 may further include a transport system for removing the coupons from the system. As here embodied, the system includes a conventional conveyor belt 54 passing over opposed rolls, at least one of which is driven.

[0072] While the embodiment of the invention depicted in Figs. 4 and 5 uses a coil-like configuration for the substrate 28 where, subsequent to the CNT formation, the substrate is severed into discrete portions (depicted here as coupons 52 in Fig. 5), the substrate could also be discrete coupons like those depicted in Figs. 3 (a)-(c). In such an embodiment the entry and exit of such coupons into and out of the deposition chamber 16 could be by standard apparatus like that used to introduce individual substrates into a deposition chamber where layered semiconductor devices are made.

[0073] In accordance with the invention the system may include at least one control system. As here embodied and depicted schematically in Fig. 4 the system includes master control system 26. In this embodiment master control system 26 is in communication with sensors (not shown) in the source of gases 18 (including each of the separate gas sources 20, 22, and 24) to supply the gases needed in the CVD process being carried out in the deposition chamber 16 at the appropriate flow rates, temperatures and pressures. One skilled in the art of CVD processes and process control can readily devise subsystems to create those conditions. In this embodiment the master control system 26 is also in communication with the deposition chamber 16, the outlet 30, and sensors associated therewith to monitor and control the conditions in the deposition chamber 16. In this embodiment the master control system 26 is also in communicationwith the substrate supply 32 such that the feed rate of the substrate into the deposition chamber is capable of being monitored and controlled. In this embodiment the master control system 26 is also in communication with the substrate receiving system 44 and any substrate transporting systems, like the rolls 36, 40 and 48.

[0074] In accordance with the invention the system may include an energy monitoring system. As here embodied, and depicted schematically in Fig. 4 and 5, the system includes energy monitoring system 56. The energy monitoring system 56 measures and transmits to the master control system 26 the amount of energy being emitted by the active coupons 52 at different locations in the system. As here embodied the energy monitoring system 56 includes an energy sensor 58 inside the deposition chamber 16. The energy monitoring system 56 may further include a sensor 60 where the active coupons 52 exit the rolls 48 and at the active coupon transport system, here depicted as a conveyor belt 54, with sensor 62.

[0075] The present invention also comprises a device for supplying useful energy using an energy-emitting coupon made in accordance with the method disclosed herein. Fig. 6 is a schematic depiction of such a device. As here embodied, active coupon 52 has deposited thereon at least one energy-emitting three-dimensional crystalline graphene shape. The device further includes a transducer 64 that converts the emitted energy to electricity. Element 66 is a device for measuring the electrical output of the energy emitting coupon.

[0076] Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the true scope of the invention being indicated by the following claims.

Claims

CLAIMS:

1. A method for producing energy, said method comprising the steps of: a) providing a solid substrate capable of initiating the growth of a plurality of three- dimensional crystalline shapes comprising carbon from the surface of said solid substrate by chemical vapor deposition; and b) introducing a deuterium-containing carbon molecule to said surface, the carbon in said deuterium-containing carbon molecule forming at least one three-dimensional nanostructured shape comprising carbon on said surface, the deuterium from the deuterium-containing carbon molecule reacting to produce energy.

2. The method of claim 1 , wherein said solid substrate forms a plurality of three- dimensional nanostructured shapes comprising carbon.

3. The method of claim 1 , wherein said three-dimensional nanostructured shapes consists essentially of single-wall carbon nanotubes.

4. The method of claim 1 , wherein said three-dimensional nanostructured shapes consists essentially of multiwall carbon nanotubes.

5. The method of claim 1 , wherein said surface includes a pattern of active sites of catalytic material producing an array of crystalline three-dimensional nanostructured shapes in said pattern.

6. The method of claim 1 , wherein said deuterium-containing carbon molecule consists essentially of a material selected from the group consisting of deuterated acetylene, deuterated ethylene, or a deuterated alcohol.

7. The method of claim 1 , wherein said deuterium-containing carbon molecule is essentially free of hydrogen.

8. The method of claim 1 , wherein said method includes the step of using a carrier gas to transport carbon-containing molecules to the surface of said solid substrate with said carrier gas being essentially free of hydrogen.

9. The method of claim 8, wherein said carrier gas comprises deuterium gas.

10. The method of claim 1 , wherein said energy is produced in a fusion reaction.

11. The method of claim 10, wherein said energy is produced in a confinement fusion reaction.

12. A method for producing energy comprising the steps of:a) providing a solid substrate capable of initiating the growth of at least one carbon nanotube from the surface of said solid substrate; and b) introducing at least one deuterocarbon to said surface, the carbon in said deuterocarbon forming at least a single carbon nanotube on said surface, the deuterium in said deutercarbon reacting with said at least one carbon nanotube to produce energy.

13. The method of claim 12, wherein said carbon nanotube consists essentially of a multiwall carbon nanotube.

14. The method of claim 12, further including the step of introduction of deuterium gas with said deuterocarbon.

15. The method of claim 12, wherein said deutercarbon consists essentially of a material selected from the group consisting of carbon-free molecules having the structure of acetylene, ethylene, or an alcohol.

16. The method of claim 12, wherein said carbon nanotube consists essentially of a single-wall carbon nanotube.

17. The method of claim 12, wherein said surface includes a pattern of active sites of catalytic material producing an array of carbon nanotubes in said pattern.

18. A device for forming an energy-producing sheet material by chemical vapor deposition, said device comprising: a) a source of at least one gaseous or vaporous material selected from the group of deuterated hydrocarbons and deuterocarbons; b) a system for supplying the deuterated hydrocarbon or deuterocarbon materials at controlled temperatures, flow rates, and pressures; c) a container for receiving said deuterated hydrocarbon or deuterocarbon materials; d) a deposition location within said container; e) a solid substrate at said deposition location having at least one carbon-deposition catalyst on a first surface within said container, said substrate including a catalyst capable of initiating the nucleation of at least one three-dimensional nanostructured carbon shape on the first surface thereof; f) a system for introducing said vaporous material to said first surface, said material reacting with said catalyst and forming a plurality of three-dimensional nanostructured carbon shapes on said first catalyst the deuterium in said vaporous material reacting with said plurality of three-dimensional nanostructured carbon shapes to produce energy;f) a device for extracting said substrate from said deposition location; g) a device in flow communication with said container for accumulating said substrate; and h) a device for extracting a specific amount of said substrate having energy- producing deuterium and three- three-dimensional nanostructured carbon shapes thereon from said device.

19. The device of claim 18, further including a source of deuterium gas in flow communication with said container.

20. The device of claim 19, including a carrier gas for supplying the deuterated hydrocarbon or deuterocarbon materials to said container, said deuterium gas comprising said carrier gas.

21. The device of claim 18, wherein said solid substrate comprises a continuous metal foil.

22. The device of claim 18, wherein said solid substrate comprises separate articles introduced to said container serially.

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