Machining carbon nanotubes into uniform slices

Shearing the carbon nanotubes (CNTs) to desired size or trimming the CNT tips conveniently is usually necessary for many applications. CNTs are normally believed possessing very high strength and toughness. In this paper we present a simple and novel method to actualize this process. In this method, aligned CNT arrays were embedded in paraffin matrix, and then the materials were carefully sliced up along the direction normal to the CNTs with a microtome. These slices consisted of vertically aligned CNTs with desired and uniform length. The experiments proved that there were enough interaction forces between the CNTs and the paraffin matrix to prevent the CNTs from being pulled out during the machining process. These sheared CNTs have shown better performance for thermal interface materials and field emission applications. This process may redound to unlocking the great potential of CNT applications.     

Macroscopic Carbon Nanotube Structures for Lithium Batteries

Carbon nanotubes (CNTs) are regarded as one of the most promising materials to manufacture high‐performance lithium batteries. This prospect is closely related to the construction of macroscopic architectures of CNTs. The superaligned CNT (SACNT) array is a unique kind of vertically aligned CNT array. Its highly oriented feature and strong intertube force facilitate the fabrication of macroscopic SACNT structures with various forms, including unidirectional films, buckypapers, and aerogels, etc. The as‐produced SACNT macroscopic architectures are successfully introduced into lithium batteries due to their outstanding electrical and mechanical properties. Herein, an overview of the functions of macroscopic SACNTs in lithium batteries is proposed, including their applications in composite electrodes, current collectors, interlayers, and flexible full cells.     

Highly conductive carbon nanotube buckypapers with improved doping stability via conjugational cross-linking

Carbon nanotube (CNT) sheets or buckypapers have demonstrated promising electrical conductivity and mechanical performance. However, their electrical conductivity is still far below the requirements for engineering applications, such as using as a substitute for copper mesh, which is currently used in composite aircraft structures for lightning strike protection. In this study, different CNT buckypapers were stretched to increase their alignment, and then subjected to conjugational cross-linking via chemical functionalization. The conjugationally cross-linked buckypapers (CCL-BPs) demonstrated higher electrical conductivity of up to 6200?S?cm( - 1), which is more than one order increase compared to the pristine buckypapers. The CCL-BPs also showed excellent doping stability in over 300?h in atmosphere and were resistant to degradation at elevated temperatures. The tensile strength of the stretched CCL-BPs reached 220?MPa, which is about three times that of pristine buckypapers. We attribute these property improvements to the effective and stable conjugational cross-links of CNTs, which can simultaneously improve the electrical conductivity, doping stability and mechanical properties. Specifically, the electrical conductivity increase resulted from improving the CNT alignment and inter-tube electron transport capability. The conjugational cross-links provide effective 3D conductive paths to increase the mobility of electrons among individual nanotubes. The stable covalent bonding also enhances the thermal stability and load transfer. The significant electrical and mechanical property improvement renders buckypaper a multifunctional material for various applications, such as conducting composites, battery electrodes, capacitors, etc.     

Growth control of carbon nanotubes by plasma enhanced chemical vapor deposition

Plasma enhanced chemical vapor deposition (PECVD), which enables growth of vertically aligned carbon nanotubes (CNTs) directly onto a solid substrate, is considered to be a suitable method for preparing CNTs for nanoelectronics applications such as electron sources for field emission displays (FEDs). For these purposes, establishment of an efficient CNT growth process has been required. We have examined growth characteristics of CNTs using a radio frequency PECVD (RF-PECVD) method with the intention to develop a high efficiency process for CNT growth at a low enough temperature suitable for nanoelectronics applications. Here we report an effect of pretreatment of the catalyst thin film that plays an important role in CNT growth using RF-PECVD. Results of this study show that uniform formation of fine catalyst nanoparticles on the substrate is important for the efficient CNT growth.     

Multi-branching carbon nanotubes via self-seeded catalysts

A novel multi-branching carbon nanotube (CNT) structure is synthesized by direct current plasma enhanced chemical vapor deposition. The structure consists of aligned CNTs which have branches of smaller diameters growing aligned along a direction perpendicular to the original CNT. The mechanism of branching is explained in terms of a self-seeding of Ni catalyst which is transferred by sputtering from the original catalyst particles in the backbone CNTs to the walls of those CNTs. It is also shown that the branching induced a large increase in surface area and total nanotube length and can be beneficial in supporting very fine Pt nanoparticles for fuel cell and other catalytic applications. Such an array of Y-junction nanostructures could be useful for the fabrication of a high-density array of nanoelectronics switches and transistors.     

Controlled two-dimensional pattern of spontaneously aligned carbon nanotubes

We report a simple solution process to form controlled patterns of aligned single-walled carbon nanotubes on solid substrates. The essential step of the process is to deposit a dilute solution of DNA-wrapped carbon nanotubes (DNA-CNTs) on a SiO(2) surface covered with a thin hydrophobic layer. This leads to deposition of fully aligned CNTs. The alignment pattern can be controlled by metal electrodes in the deposition region and can be quantitatively modeled by the behavior of a quasi-two-dimensional DNA-CNT nematic phase near the solution/SiO(2) interface. These results point to the possibility of rational design and economical fabrication of CNT alignment patterns on solid substrates.     

Electrochemical properties and myocyte interaction of carbon nanotube microelectrodes

Arrays of carbon nanotube (CNT) microelectrodes (nominal geometric surface areas 20-200 μm(2)) were fabricated by photolithography with chemical vapor deposition of randomly oriented CNTs. Raman spectroscopy showed strong peak intensities in both G and D bands (G/D = 0.86), indicative of significant disorder in the graphitic layers of the randomly oriented CNTs. The impedance spectra of gold and CNT microelectrodes were compared using equivalent circuit models. Compared to planar gold surfaces, pristine nanotubes lowered the overall electrode impedance at 1 kHz by 75%, while nanotubes treated in O(2) plasma reduced the impedance by 95%. Cyclic voltammetry in potassium ferricyanide showed potential peak separations of 133 and 198 mV for gold and carbon nanotube electrodes, respectively. The interaction of cultured cardiac myocytes with randomly oriented and vertically aligned CNTs was investigated by the sectioning of myocytes using focused-ion-beam milling. Vertically aligned nanotubes deposited by plasma-enhanced chemical vapor deposition (PECVD) were observed to penetrate the membrane of neonatal-rat ventricular myocytes, while randomly oriented CNTs remained external to the cells. These results demonstrated that CNT electrodes can be leveraged to reduce impedance and enhance biological interfaces for microelectrodes of subcellular size.     

Neural stimulation with a carbon nanotube microelectrode array

We present a novel prototype neural interface using vertically aligned multiwalled carbon nanotube (CNT) pillars as microelectrodes. Functionalized hydrophilic CNT microelectrodes offer a high charge injection limit (1-1.6 mC/cm2) without faradic reactions. The first repeated in vitro stimulation of hippocampal neurons with CNT electrodes is demonstrated. These results suggest that CNTs are capable of providing far safer and more efficacious solutions for neural prostheses than previous metal electrode approaches.     

Macroscopic carbon nanotube assemblies: preparation, properties, and potential applications

As classical 1D nanoscale structures, carbon nanotubes (CNTs) possess remarkable mechanical, electrical, thermal, and optical properties. In the past several years, considerable attention has been paid to the use of CNTs as building blocks for novel high-performance materials. In this way, the production of macroscopic architectures based on assembled CNTs with controlled orientation and configurations is an important step towards their application. So far, various forms of macroscale CNT assemblies have been produced, such as 1D CNT fibers, 2D CNT films/sheets, and 3D aligned CNT arrays or foams. These macroarchitectures, depending on the manner in which they are assembled, display a variety of fascinating features that cannot be achieved using conventional materials. This review provides an overview of various macroscopic CNT assemblies, with a focus on their preparation and mechanical properties as well as their potential applications in practical fields.     

Binder-free activated carbon/carbon nanotube paper electrodes for use in supercapacitors

Novel inexpensive, light, flexible, and even rollup or wearable devices are required for multi-functional portable electronics and developing new versatile and flexible electrode materials as alternatives to the materials used in contemporary batteries and supercapacitors is a key challenge. Here, binder-free activated carbon (AC)/carbon nanotube (CNT) paper electrodes for use in advanced supercapacitors have been fabricated based on low-cost, industrial-grade aligned CNTs. By a two-step shearing strategy, aligned CNTs were dispersed into individual long CNTs, and then 90 wt%–99 wt% of AC powder was incorporated into the CNT pulp and the AC/CNT paper electrode was fabricated by deposition on a filter. The specific capacity, rate performance, and power density of the AC/CNT paper electrode were better than the corresponding values for an AC/acetylene black electrode. The capacity reached a maximum value of 267.6 F/g with a CNT loading of 5 wt%, and the energy density and power density were 22.5 W·h/kg and 7.3 kW/kg at a high current density of 20 A/g. The AC/CNT paper electrode also showed a good cycle performance, with 97.5% of the original capacity retained after 5000 cycles at a scan rate of 200 mV/s. This method affords not only a promising paper-like nanocomposite for use in low-cost and flexible supercapacitors, but also a general way of fabricating multi-functional paper-like CNT-based nanocomposites for use in devices such as flexible lithium ion batteries and solar cells.      

Mechanical property enhancement of aligned multi-walled carbon nanotube sheets and composites through press-drawing process

A solid-state drawing and winding process was done to create thin aligned carbon nanotube (CNT) sheets from CNT arrays. However, waviness and poor packing of CNTs in the sheets are two main weaknesses restricting their reinforcing efficiency in composites. This report proposes a simple press-drawing technique to reduce wavy CNTs and to enhance dense packing of CNTs in the sheets. Non-pressed and pressed CNT/epoxy composites were developed using prepreg processing with a vacuum-assisted system. Effects of pressing on the mechanical properties of the aligned CNT sheets and CNT/epoxy composites were examined. Pressing with distributed loads of 147, 221, and 294 N/m showed a substantial increase in the tensile strength and the elastic modulus of the aligned CNT sheets and their composites. The CNT sheets under a press load of 221 N/m exhibited the best mechanical properties found in this study. With a press load of 221 N/m, the pressed CNT sheet and its composite, respectively, enhanced the tensile strength by 139.1 and 141.9%, and the elastic modulus by 489 and 77.6% when compared with non-pressed ones. The pressed CNT/epoxy composites achieved high tensile strength (526.2 MPa) and elastic modulus (100.2 GPa). Results show that press-drawing is an important step to produce superior CNT sheets for development of high-performance CNT composites.     

Non-destructive characterization of structural hierarchy within aligned carbon nanotube assemblies

Understanding and controlling the hierarchical self-assembly of carbon nanotubes (CNTs) is vital for designing materials such as transparent conductors, chemical sensors, high-performance composites, and microelectronic interconnects. In particular, many applications require high-density CNT assemblies that cannot currently be made directly by low-density CNT growth, and therefore require post-processing by methods such as elastocapillary densification. We characterize the hierarchical structure of pristine and densified vertically aligned multi-wall CNT forests, by combining small-angle and ultra-small-angle x-ray scattering (USAXS) techniques. This enables the nondestructive measurement of both the individual CNT diameter and CNT bundle diameter within CNT forests, which are otherwise quantified only by delicate and often destructive microscopy techniques. Our measurements show that multi-wall CNT forests grown by chemical vapor deposition consist of isolated and bundled CNTs, with an average bundle diameter of 16 nm. After capillary densification of the CNT forest, USAXS reveals bundles with a diameter >4 μm, in addition to the small bundles observed in the as-grown forests. Combining these characterization methods with new CNT processing methods could enable the engineering of macro-scale CNT assemblies that exhibit significantly improved bulk properties.     

Enhanced field emission characteristics of nitrogen-doped carbon nanotube films grown by microwave plasma enhanced chemical vapor deposition process

Nitrogen-doped carbon nanotube (CNT) films have been synthesized by simple microwave plasma enhanced chemical vapor deposition technique. The morphology and structures were investigated by scanning electron microscopy and high resolution transmission electron microscopy. Morphology of the films was found to be greatly affected by the nature of the substrates. Vertically aligned CNTs were observed on mirror polished Si substrates. On the other hand, randomly oriented flower like morphology of CNTs was found on mechanically polished ones. All the CNTs were found to have bamboo structure with very sharp tips. These films showed very good field emission characteristics with threshold field in the range of 2.65-3.55 V/μm. CNT film with flower like morphology showed lower threshold field as compared to vertically aligned structures. Open graphite edges on the side surface of the bamboo-shaped CNT are suggested to enhance the field emission characteristics which may act as additional emission sites.     

Effect of density variation and non-covalent functionalization on the compressive behavior of carbon nanotube arrays

Arrays of aligned carbon nanotubes (CNTs) have been proposed for different applications, including electrochemical energy storage and shock-absorbing materials. Understanding their mechanical response, in relation to their structural characteristics, is important for tailoring the synthesis method to the different operational conditions of the material. In this paper, we grow vertically aligned CNT arrays using a thermal chemical vapor deposition system, and we study the effects of precursor flow on the structural and mechanical properties of the CNT arrays. We show that the CNT growth process is inhomogeneous along the direction of the precursor flow, resulting in varying bulk density at different points on the growth substrate. We also study the effects of non-covalent functionalization of the CNTs after growth, using surfactant and nanoparticles, to vary the effective bulk density and structural arrangement of the arrays. We find that the stiffness and peak stress of the materials increase approximately linearly with increasing bulk density.     

Formation and microstructural characterization of coaxial carbon cylinders consisting of aligned carbon nanotube stacks

The macroscopic coaxial carbon cylinders (dia. approximately 0.5 cm with varying lengths approximately 2-5 cm) consisting of aligned carbon nanotube (CNT) stacks have been prepared by spray pyrolysis of benzene-ferrocene solution in argon atmosphere at approximately 850 degrees C-900 degrees C temperature. The coaxial carbon cylinders of CNT stacks have been formed directly inside the quartz tube. We attempted to prepare superimposed multi carbon cylinder configurations, each consisting of ordered and aligned CNTs stacked over each other. For this, we have terminated the spray of precursor after run of about 25 minutes, for a short interval (approximately 5 min), and then the solution was sprayed again over the already deposited hot CNT stack. Gross structural characterization of CNTs was done through X-ray diffraction technique (XRD). Microstructural characterizations of as prepared coaxial carbon cylinders with CNT stacks were done by scanning electron microscopic (SEM) techniques. SEM studies show that the CNTs are well aligned along the periphery of the cross section of coaxial carbon cylinder, each consisting of CNTs of the type described in the above. Comparisons have been made between the present macroscopic coaxial carbon cylinders with CNT stacks studied earlier by several other workers. Plausible explanation for the synthesis of CNT stacks will be put forward.     

Versatile transfer of aligned carbon nanotubes with polydimethylsiloxane as the intermediate

A simple technique to transfer aligned multi-walled carbon nanotubes (MWCNTs) is demonstrated in this work. With polydimethylsiloxane (PDMS) as the transfer medium, as-grown or patterned MWCNT arrays are directly transferred onto a wide variety of Pt-coated substrates such as glossy paper, cloth, polymers, glass slides, and metal foils at low temperatures. The surface of the transferred CNTs is cleaner with better alignment, compared with the as-grown one. Furthermore, the transferred CNTs show strong adhesion and good electric contact with the target substrates. A maximal current density of ～10(4)?A?cm(-2) has been achieved from the CNT interconnects prepared with this technique. Because of the lower density and open-ended structures, improved field emission performance has been obtained from CNTs transferred on polymers, based on which flexible emitter devices can be fabricated. In addition, the surface of transferred CNTs becomes more hydrophilic, with an averaged contact angle of 93.4 ± 5.8°, in contrast to the super-hydrophobic as-grown CNT surface (contact angle 151.6 ± 5.5°). With versatile properties and flexible applications, the technique provides a simple and cost-effective way towards future nanodevices based on CNTs.     

Super-long aligned TiO2/carbon nanotube arrays

5?mm long aligned titanium oxide/carbon nanotube (TiO(2)/CNT) coaxial nanowire arrays have been prepared by electrochemically coating the constituent CNTs with a uniform layer of highly crystalline anatase TiO(2) nanoparticles. While the presence of the TiO(2) coating was confirmed by scanning electron microscopy, transmission electron microscopy, Raman spectroscopy and x-ray diffraction, the resultant TiO(2)/CNT coaxial arrays were demonstrated to exhibit minimized recombination of photoinduced electron-hole pairs and fast electron transfer from the long TiO(2)/CNT arrays to external circuits. This, in conjunction with the aligned macrostructure, facilitates the fabrication of TiO(2)/CNT arrays for various device applications, ranging from photodetectors to photocatalytic systems. Thus, the millimeter long TiO(2)/CNT arrays represent a significant advance in the development of new macroscopic photoelectronic nanomaterials attractive for a variety of device applications beyond those demonstrated in this study.     

Flow-dependent directional growth of carbon nanotube forests by chemical vapor deposition

We demonstrated that the structural formation of vertically aligned carbon nanotube (CNT) forests is primarily affected by the geometry-related gas flow, leading to the change of growth directions during the chemical vapor deposition (CVD) process. By varying the growing time, flow rate, and direction of the carrier gas, the structures and the formation mechanisms of the vertically aligned CNT forests were carefully investigated. The growth directions of CNTs are found to be highly dependent on the nonlinear local gas flows induced by microchannels. The angle of growth significantly changes with increasing gas flows perpendicular to the microchannel, while the parallel gas flow shows almost no effect. A computational fluid dynamics (CFD) model was employed to explain the flow-dependent growth of CNT forests, revealing that the variation of the local pressure induced by microchannels is an important parameter determining the directionality of the CNT growth. We expect that the present method and analyses would provide useful information to control the micro- and macrostructures of vertically aligned CNTs for various structural/electrical applications.     

Growth of horizontally aligned dense carbon nanotubes from trench sidewalls

Horizontally aligned, dense carbon nanotubes (HADCNTs) in the form of CNT cantilevers/bridges were grown from selected trench sidewalls in silicon substrate by chemical vapor deposition (CVD). The as-grown CNT cantilevers/bridges are packed with multiwalled carbon nanotubes (MWCNTs) with a linear density of about 10 CNTs μm(-1). The excellent horizontal alignment of these CNTs is mainly ascribed to the van der Waals interactions within the dense CNT bundles. What is more, the Raman intensity ratio I(G)/I(D) shows a gradual increase from the CNT roots to tips, indicating a defect gradient along CNTs generated during their growth. These results will inspire further efforts to explore the fundamentals and applications of HADCNTs.     

ZnO-based FBAR resonators with carbon nanotube electrodes

Film bulk acoustic resonator (FBAR) devices with carbon nanotube (CNT) electrodes directly grown on a ZnO film by thermal chemical vapor deposition have been fabricated. CNT electrodes possess a very low density and high acoustic impedance, which reduces the intrinsic mass loading effect resulting from the electrodes? weight and better confines the longitudinal acoustic standing waves inside the resonator, in turn providing a resonator with a higher quality factor. The influence of the CNTs on the frequency response of the FBAR devices was studied by comparing two identical sets of devices; one set comprised FBARs fabricated with chromium/ gold bilayer electrodes, and the second set comprised FBARs fabricated with CNT electrodes. It was found that the CNTs had a significant effect on attenuating traveling waves at the surface of the FBARs' membranes because of their high elastic stiffness. Three-dimensional finite element analysis of the devices fabricated was carried out, and the numerical simulations were consistent with the experimental results obtained.