The present disclosure relates to methods for depositing vertically oriented carbon nanowalls (CNWs) using non-equilibrium gases such as gaseous plasma. Methods are disclosed for rapid deposition of uniformly distributed nanowalls on large surfaces of substrates using ablation of bulk carbon materials by reactive gaseous species, formation of oxidized carbon-containing gaseous molecules, ionization of said molecules and interacting said molecules, neutral or positively charged, with a substrate. The CNWs prepared are useful in different applications such as fuel cells, lithium ion batteries, photovoltaic devices and sensors of specific gaseous molecules.

Methods and systems include supplying pulsed microwave radiation through a waveguide, where the microwave radiation propagates in a direction along the waveguide. A pressure within the waveguide is at least 0.1 atmosphere. A supply gas is provided at a first location along a length of the waveguide, a majority of the supply gas flowing in the direction of the microwave radiation propagation. A plasma is generated in the supply gas, and a process gas is added into the waveguide at a second location downstream from the first location. A majority of the process gas flows in the direction of the microwave propagation at a rate greater than 5 slm. An average energy of the plasma is controlled to convert the process gas into separated components, by controlling at least one of a pulsing frequency of the pulsed microwave radiation, and a duty cycle of the pulsed microwave radiation.

A method is employed to separate a carbon structure, which is disposed on a seed structure, from the seed structure. In the method, a carbon structure is deposited on the seed structure in a process chamber of a CND reactor. The substrate comprising the seed structure (2) and the carbon structure (1) is heated to a process temperature. At least one etching gas is injected into the process chamber, the etching gas having the chemical formula AO.sub.mX.sub.n, AO.sub.mX.sub.nY.sub.p or A.sub.mX.sub.n, wherein A is selected from a group of elements that includes S, C and N, wherein O is oxygen, wherein X and Y are different halogens, and wherein m, n and p are natural numbers greater than zero. Through a chemical reaction with the etching gas, the seed structure is converted into a gaseous reaction product. A carrier gas flow is used to remove the gaseous reaction product from the process chamber.

A method is employed to separate a carbon structure, which is disposed on a seed structure, from the seed structure. In the method, a carbon structure is deposited on the seed structure in a process chamber of a CND reactor. The substrate comprising the seed structure (2) and the carbon structure (1) is heated to a process temperature. At least one etching gas is injected into the process chamber, the etching gas having the chemical formula AO.sub.mX.sub.n, AO.sub.mX.sub.nY.sub.p or A.sub.mX.sub.n, wherein A is selected from a group of elements that includes S, C and N, wherein O is oxygen, wherein X and Y are different halogens, and wherein m, n and p are natural numbers greater than zero. Through a chemical reaction with the etching gas, the seed structure is converted into a gaseous reaction product. A carrier gas flow is used to remove the gaseous reaction product from the process chamber.

(Problem) In conventional method for producing artificial graphite, in order to obtain a product having excellent crystallinity, it was necessary to mold a filler and a binder and then repeat impregnation, carbonization and graphitization, and since carbonization and graphitization proceeded by a solid phase reaction, a period of time of as long as 2 to 3 months was required for the production and cost was high and further, a large size structure in the shape of column and cylinder could not be produced. In addition, nanocarbon materials such as carbon nanotube, carbon nanofiber and carbon nanohorn could not be produced. (Means to solve) A properly pre-baked filler is sealed in a graphite vessel and is subsequently subjected to hot isostatic pressing (HIP) treatment, thereby allowing gases such as hydrocarbon and hydrogen to be generated from the filler and precipitating vapor-phase-grown graphite around and inside the filler using the generated gases as a source material, and thereby, an integrated structure of carbide of the filler and the vapor-phase-grown graphite is produced. In addition, nanocarbon materials are produced selectively and efficiently by adding a catalyst or adjusting the HIP treating temperature.

A method includes the following steps: a first step: the material containing heteroatom and graphite powder are mixed for a preset time by grinding, and the molar ratio of heteroatom to carbon atom is 1%-10%, then the heteroatom precursors are obtained; a second contact step: the heteroatom precursor is filled into a graphite rod with holes and compacted, then the graphite rod is dried for a preset time to obtain a plasma anode and using a DC arc plasma device to prepare the graphite anode into heteroatom-doped CNHs; a third contact step: the heteroatom-doped CNHs are dispersed in a reducing solution, a platinum salt is added to stir evenly, the reduction reaction is carried out by heating and stirring, and after centrifugation, washing and drying, a catalyst with platinum loading is obtained.

A method includes the following steps: a first step: the material containing heteroatom and graphite powder are mixed for a preset time by grinding, and the molar ratio of heteroatom to carbon atom is 1%-10%, then the heteroatom precursors are obtained; a second contact step: the heteroatom precursor is filled into a graphite rod with holes and compacted, then the graphite rod is dried for a preset time to obtain a plasma anode and using a DC arc plasma device to prepare the graphite anode into heteroatom-doped CNHs; a third contact step: the heteroatom-doped CNHs are dispersed in a reducing solution, a platinum salt is added to stir evenly, the reduction reaction is carried out by heating and stirring, and after centrifugation, washing and drying, a catalyst with platinum loading is obtained.

There is disclosed a material comprising an assembly of at least one spun yarn, comprising: synthetic inorganic fibers, such as carbon, metal, oxides, carbides or alloys or combinations thereof, wherein a majority of the fibers: (a) are longer than 300 μm, (b) have a diameter ranging from 0.25 nm and 700 nm, and (c) are substantially crystalline, wherein the yarn has substantial flexibility and uniformity in diameter. A method of making the material is also disclosed. In one embodiment, the method comprises spinning yarn by pulling fibers from a bulk material with at least one spinner that has real time feedback controls.

The present disclosure relates to a green method for producing and exploiting multiple nano-carbon polymorphs from coal commonly known as anthracite, meta-anthracite, and semi-graphite. The method disrupts the prevalent environmentally unfriendly practices of burning coal with poor profitability and sustainability because the method yields an unexpectedly rich mixture of high-performance nano-materials, comprising carbon nano-fibers, carbon nano-tubes, carbon nano-onions, nano-graphite-plates, and nano-graphene-disks, by simply mechanically-comminuting coal to nano-size, with minimal sorting efforts. The resulting total-yield of nano-carbon polymorphs is over 50% by weight from properly selected coal. Innovative means are added to the prevalent comminution and sorting practices to further reduce energy and chemical consumption. More importantly, the method also refines the comminution and sorting details for producing the best custom-made formulations. This holistic engineering approach eliminates unnecessary separation and sorting steps because a custom-made formulation typically requires blending the sorted components. Formulations with mixed nano-carbon polymorphs are engineered as new and high-valued-added composite ingredients to critically raise the performance of cement-based, polymer-based, and metal-based composites.

The present disclosure relates to a green method for producing and exploiting multiple nano-carbon polymorphs from coal commonly known as anthracite, meta-anthracite, and semi-graphite. The method disrupts the prevalent environmentally unfriendly practices of burning coal with poor profitability and sustainability because the method yields an unexpectedly rich mixture of high-performance nano-materials, comprising carbon nano-fibers, carbon nano-tubes, carbon nano-onions, nano-graphite-plates, and nano-graphene-disks, by simply mechanically-comminuting coal to nano-size, with minimal sorting efforts. The resulting total-yield of nano-carbon polymorphs is over 50% by weight from properly selected coal. Innovative means are added to the prevalent comminution and sorting practices to further reduce energy and chemical consumption. More importantly, the method also refines the comminution and sorting details for producing the best custom-made formulations. This holistic engineering approach eliminates unnecessary separation and sorting steps because a custom-made formulation typically requires blending the sorted components. Formulations with mixed nano-carbon polymorphs are engineered as new and high-valued-added composite ingredients to critically raise the performance of cement-based, polymer-based, and metal-based composites.