Oriented Carbon Nanotube Wire Assembly for Long Conductive Bundles

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Solution Overview

Problem

Current methods for producing carbon nanotubes result in short lengths and lack of orientation, limiting their use as high-strength electric wires, as they are not effectively elongated or assembled in a longitudinal direction.

Innovation Solution

A carbon nanotube assembled wire is created by orienting and assembling carbon nanotubes with a degree of orientation between 0.9 and 1, using catalyst particles with diameters between 0.6 nm and 30 nm, and incorporating metal elements like iron and sulfur to maintain electrical conductivity and mechanical properties, while a bundle of these wires is formed with an oriented region and an amorphous region for added flexibility and strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If carbon nanotubes are produced through conventional vapor deposition methods, then carbon nanotubes can be obtained with excellent material properties, but the carbon nanotubes are short and lack orientation

Engineering Contradiction:

Improvemechanical strengthVSAvoidcarbon nanotube length

Core Design Contradiction:

StrengthVSLength of moving object

Solution Approach 1:

The patent applies preliminary action by first growing carbon nanotubes on catalyst particles to a controlled length, then assembling these pre-formed nanotubes into bundles before final elongation. This preliminary assembly and orientation process enables the production of long, oriented carbon nanotube wires while maintaining the excellent mechanical properties of individually grown nanotubes.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent segments the carbon nanotube production process into distinct stages: (1) growth of nanotubes on catalyst particles, (2) assembly of nanotubes into bundles, and (3) elongation and orientation of the bundles. This segmentation allows each stage to be optimized independently, achieving both long length and high orientation.

Inventive Principle:

Principle #1Segmentation

2Strength

If carbon nanotubes are produced through conventional methods, then carbon nanotubes can be obtained, but they lack orientation in the longitudinal direction

Engineering Contradiction:

Improvemechanical strengthVSAvoidorientation

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The patent employs dynamic processes to achieve orientation, including mechanical elongation of the carbon nanotube bundles and application of external fields (such as electric or magnetic fields) during assembly. These dynamic actions align the nanotubes in the longitudinal direction while preserving their mechanical strength through controlled processing.

Inventive Principle:

Principle #15Dynamics

3Length of moving object

If carbon nanotubes are elongated and assembled, then length and orientation are improved, but manufacturing complexity increases

Engineering Contradiction:

Improvecarbon nanotube lengthVSAvoidmanufacturing process complexity

Core Design Contradiction:

Length of moving objectVSDevice complexity

Solution Approach 1:

The patent uses a nested structure where individual carbon nanotubes are assembled into bundles, which are then elongated and oriented. This nested assembly approach simplifies manufacturing by building complex structures from simpler components, reducing overall process complexity while achieving long, oriented wires.

Inventive Principle:

Principle #7Nested doll (Nesting)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution enables the production of elongated carbon nanotube wires with enhanced mechanical strength and electrical conductivity, allowing for the creation of high-strength, flexible, and durable carbon nanotube assemblies suitable for various applications.

Implementation Method 1

The carbon nanotube is obtained, for example, through vapor deposition by supplying a carbon-containing source gas while heating a fine catalyst such as iron to grow the carbon nanotube from the catalyst

Methodology Applied

Scientific EffectVapor deposition: Physical Vapour Deposition