Process and apparatus for producing composite material that includes carbon nanotubes

A process for producing a composite material having carbon nanotubes present on a surface of a base material, the base material having a catalyst on a surface, the process comprising:

• providing an apparatus that includes a hollow body defining an elongated chamber configured to have a gas flow therethrough and being heatable, the hollow body being mounted for rotation about a major axis and being inclined, the apparatus including an introduction site configured for inputting the base material into the chamber and a supply site configured for inputting a carbon source vapor into the chamber, the introduction site and the supply site being arranged so that contact between the base material and the carbon source vapor occurs in a reaction zone, and the apparatus having a plurality of ribs disposed on at least one inner peripheral wall of the hollow body at least within a portion of the elongated chamber adjacent to the reaction zone,
• inputting the base material into the chamber of the hollow body via the introduction site;
• supplying the carbon source vapor via the supply site, and
• rotating the hollow body about the major axis to move the base material along the inclined hollow body, to lift the base material on the ribs and to drop the base material from the ribs such that the base material and the carbon source vapor make contact in the reaction zone.

An apparatus capable of producing a composite material having carbon nanotubes present on a surface of a base material, comprising:

• a hollow body rotatable about a major axis and disposed such that the major axis is inclined with an upstream side of the hollow body on one end of the major axis being higher than a downstream side of the hollow body on the other end,
• an elongated chamber comprising a reaction zone defined within the hollow body over at least one longitudinal section of the elongated chamber along the major axis,
• a plurality of ribs disposed on at least one inner peripheral wall of the hollow body in at least a portion of the elongated chamber that is adjacent to the reaction zone,
• an input device configured to input the base material into the chamber via a base material introduction port,
• a carbon source vapor supply device configured to supply a carbon source vapor into the chamber via a carbon source supply port, and
• a heater configured to heat at least the reaction zone to a temperature at which carbon nanotubes form from the carbon source vapor,
• wherein the ribs are configured to catch base material disposed on the inner peripheral wall of the hollow body when the hollow body rotates and then drop the base material through the reaction zone so that the base material contacts the carbon source vapor.