Large Area Growth of Aligned CNT Arrays on Spheres: Towards Large Scale and Continuous Production

Atomic Layer Deposition of Inorganic Films for the Synthesis of Vertically Aligned Carbon Nanotube Arrays and Their Hybrids

Vertically aligned carbon nanotube arrays (VACNTs) have many excellent properties and show great potential for various applications. Recently, there has been a desire to grow VACNTs on nonplanar surfaces and synthesize core-sheath-structured VACNT–inorganic hybrids. To achieve this aim, atomic layer deposition (ALD) has been extensively applied, especially due to its atomic-scale thickness controllability and excellent conformality of films on three-dimensional (3D) structures with high aspect ratios. In this paper, the ALD of catalyst thin films for the growth of VACNTs, such as Co3O4, Al2O3, and Fe2O3, was first mentioned. After that, the ALD of thin films for the synthesis of VACNT–inorganic hybrids was also discussed. To highlight the importance of these hybrids, their potential applications in supercapacitors, solar cells, fuel cells, and sensors have also been reviewed.

Atomic Layer Deposition of Buffer Layers for the Growth of Vertically Aligned Carbon Nanotube Arrays

Vertically aligned carbon nanotube arrays (VACNTs) show a great potential for various applications, such as thermal interface materials (TIMs). Besides the thermally oxidized SiO₂, atomic layer deposition (ALD) was also used to synthesize oxide buffer layers before the deposition of the catalyst, such as Al₂O₃, TiO₂, and ZnO. The growth of VACNTs was found to be largely dependent on different oxide buffer layers, which generally prevented the diffusion of the catalyst into the substrate. Among them, the thickest and densest VACNTs could be achieved on Al₂O₃, and carbon nanotubes were mostly triple-walled. Besides, the deposition temperature was critical to the growth of VACNTs on Al₂O₃, and their growth rate obviously reduced above 650 °C, which might be related to the Ostwald ripening of the catalyst nanoparticles or subsurface diffusion of the catalyst. Furthermore, the VACNTs/graphene composite film was prepared as the thermal interface material. The VACNTs and graphene were proved to be the effective vertical and transverse heat transfer pathways in it, respectively.

Carbon Nanotubes and Related Nanomaterials: Critical Advances and Challenges for Synthesis toward Mainstream Commercial Applications

Advances in the synthesis and scalable manufacturing of single-walled carbon nanotubes (SWCNTs) remain critical to realizing many important commercial applications. Here we review recent breakthroughs in the synthesis of SWCNTs and highlight key ongoing research areas and challenges. A few key applications that capitalize on the properties of SWCNTs are also reviewed with respect to the recent synthesis breakthroughs and ways in which synthesis science can enable advances in these applications. While the primary focus of this review is on the science framework of SWCNT growth, we draw connections to mechanisms underlying the synthesis of other 1D and 2D materials such as boron nitride nanotubes and graphene.

Continuous flow chemical vapour deposition of carbon nanotube sea urchins

Hybrid structures consisting of functional materials enhanced by carbon nanotubes (CNTs) have potential for a variety of high impact applications, as shown by the impressive progress in sensing and mechanical applications enabled by CNT-enhanced materials. The hierarchical organisation of CNTs with other materials is key to the design of macroscale devices benefiting from the unique properties of individual CNTs, provided CNT density, morphology and binding with other materials are optimized. In this paper, we provide an analysis of a continuous aerosol process to create a hybrid hierarchical sea urchin structure with CNTs organized around a functional metal oxide core. We propose a new mechanism for the growth of these carbon nanotube sea urchins (CNTSU) and give new insight into their chemical composition. To corroborate the new mechanism, we examine the influence of CNT growth conditions on CNTSU morphology and demonstrate a new in-line characterisation technique to continuously monitor aerosol CNT growth during synthesis, which enables industrial-scale production optimization. Based upon the new formation mechanism we describe the first substrate-based chemical vapour deposition growth of CNTSUs which increases CNT length and improves G to D ratio, which also allows for the formation of CNTSU carpets with unique structures.

Assessment of exhaust emissions from carbon nanotube production and particle collection by sampling filters

This study performed a workplace evaluation of emission control using available air sampling filters and characterized the emitted particles captured in filters. Characterized particles were contained in the exhaust gas released from carbon nanotube (CNT) synthesis using chemical vapor deposition (CVD). Emitted nanoparticles were collected on grids to be analyzed using transmission electron microscopy (TEM). CNT clusters in the exhaust gas were collected on filters for investigation. Three types of filters, including Nalgene surfactant-free cellulose acetate (SFCA), Pall A/E glass fiber, and Whatman QMA quartz filters, were evaluated as emission control measures, and particles deposited in the filters were characterized using scanning transmission electron microscopy (STEM) to further understand the nature of particles emitted from this CNT production. STEM analysis for collected particles on filters found that particles deposited on filter fibers had a similar morphology on all three filters, that is, hydrophobic agglomerates forming circular beaded clusters on hydrophilic filter fibers on the collecting side of the filter. CNT agglomerates were found trapped underneath the filter surface. The particle agglomerates consisted mostly of elemental carbon regardless of the shapes. Most particles were trapped in filters and no particles were found in the exhaust downstream from A/E and quartz filters, while a few nanometer-sized and submicrometer-sized individual particles and filament agglomerates were found downstream from the SFCA filter. The number concentration of particles with diameters from 5 nm to 20 µm was measured while collecting particles on grids at the exhaust piping. Total number concentration was reduced from an average of 88,500 to 700 particle/cm(3) for the lowest found for all filters used. Overall, the quartz filter showed the most consistent and highest particle reduction control, and exhaust particles containing nanotubes were successfully collected and trapped inside this filter.

IMPLICATIONS

As concern for the toxicity of engineered nanoparticles grows, there is a need to characterize emission from carbon nanotube synthesis processes and to investigate methods to prevent their environmental release. At this time, the particles emitted from synthesis were not well characterized when collected on filters, and limited information was available about filter performance to such emission. This field study used readily available sampling filters to collect nanoparticles from the exhaust gas of a carbon nanotube furnace. New agglomerates were found on filters from such emitted particles, and the performance of using the filters studied was encouraging in terms of capturing emissions from carbon nanotube synthesis.

Rapid growth of vertically aligned multi-walled carbon nanotubes on a lamellar support

The important influence of Al on Fe and Co catalyzed growth of vertically aligned carbon nanotube forests between layers of a lamellar support is reported.

Bulk synthesis of crystalline and crystalline core/amorphous shell silicon nanowires and their application for energy storage

Silicon nanowires (NWs) have stimulated significant interest and found numerous applications; however, many applications will require a bulk quantity of nanowires to be synthesized in a reliable way. In this paper, we report the bulk synthesis of silicon nanowires on millimeter scale Al(2)O(3) spheres with a thermal chemical vapor deposition system (CVD) via the vapor-liquid-solid (VLS) growth mechanism. The spherical substrates enable the realization of Si nanowire synthesis on three-dimensional surfaces in comparison with the synthesis on a planar, two-dimensional wafer substrate. By modifying temperature in the recipe of synthesis, both single-crystalline and crystalline core/amorphous shell Si nanowires were obtained with this nanowire-on-spherical-support method. Conspicuous distinction in crystallinity of the nanowires was revealed by transmission electron microscopy characterization. The crystalline core/amorphous shell Si nanowires were utilized to form the anode of Li-ion battery half-cells with the traditional slurry method. Galvanostatic measurement demonstrated that the maximum power capacity achievable by the electrodes was 3500 mAh/g and capacity sustained at 1100 mAh/g after 60 cycles of charging and discharging.

Carbon nanotube mass production: principles and processes

Our society requires new materials for a sustainable future, and carbon nanotubes (CNTs) are among the most important advanced materials. This Review describes the state-of-the-art of CNT synthesis, with a focus on their mass-production in industry. At the nanoscale, the production of CNTs involves the self-assembly of carbon atoms into a one-dimensional tubular structure. We describe how this synthesis can be achieved on the macroscopic scale in processes akin to the continuous tonne-scale mass production of chemical products in the modern chemical industry. Our overview includes discussions on processing methods for high-purity CNTs, and the handling of heat and mass transfer problems. Manufacturing strategies for agglomerated and aligned single-/multiwalled CNTs are used as examples of the engineering science of CNT production, which includes an understanding of their growth mechanism, agglomeration mechanism, reactor design, and process intensification. We aim to provide guidelines for the production and commercialization of CNTs. Although CNTs can now be produced on the tonne scale, knowledge of the growth mechanism at the atomic scale, the relationship between CNT structure and application, and scale-up of the production of CNTs with specific chirality are still inadequate. A multidisciplinary approach is a prerequisite for the sustainable development of the CNT industry.

Synthesis of vertically aligned carbon nanotube arrays on polyhedral Fe/Al2O3 catalysts

Polyhedral Fe/Al(2)O(3) catalysts prepared by an impregnation method were used for the synthesis of vertically aligned carbon nanotube (CNT) arrays from the pyrolysis of ethylene at 800 °C.

Wet catalyst-support films for production of vertically aligned carbon nanotubes

A procedure for vertically aligned carbon nanotube (VA-CNT) production has been developed through liquid-phase deposition of alumoxanes (aluminum oxide hydroxides, boehmite) as a catalyst support. Through a simple spin-coating of alumoxane nanoparticles, uniform centimer-square thin film surfaces were coated and used as supports for subsequent deposition of metal catalyst. Uniform VA-CNTs are observed to grow from this film following deposition of both conventional evaporated Fe catalyst, as well as premade Fe nanoparticles drop-dried from the liquid phase. The quality and uniformity of the VA-CNTs are comparable to growth from conventional evaporated layers of Al(2)O(3). The combined use of alumoxane and Fe nanoparticles to coat surfaces represents an inexpensive and scalable approach to large-scale VA-CNT production that makes chemical vapor deposition significantly more competitive when compared to other CNT production techniques.

Characterization and evaluation of nanoparticle release during the synthesis of single-walled and multiwalled carbon nanotubes by chemical vapor deposition

Airborne nanoparticles released during the synthesis of single-walled and multi-walled carbon nanotubes were measured and characterized. This study reported the field measurements during the development of carbon nanotube production. Monitoring data were taken and the sampling methods to characterize aerosol release were developed along with the modification of carbon nanotube production in a time period from 2006 to 2009. Particle number concentrations for diameters from 5 nm to 20 microm were measured using the fast mobility particle sizer and the aerodynamic particle sizer; the particles released from the furnace were found to be less than 500 nm in diameter. The morphology and elemental composition of the released nanoparticles were characterized by scanning and transmission electron microscopy and energy dispersive spectroscopy. Different operating conditions of multi-walled carbon nanotubes (MWCNT) production were studied to evaluate their effects on the number and morphology of aerosol particles, and the number of particles released. Carbon nanotube filaments and carbon particles in clusters were found among the released aerosol particles during production of multiwalled carbon nanotubes.

Synthesis of high aspect-ratio carbon nanotube "flying carpets" from nanostructured flake substrates

We present a robust method for synthesis of aligned, single-walled carbon nanotube (CNT) "flying carpets" from nanostructured alumina flakes. Roll-to-roll e-beam deposition is utilized to produce the flakes, and hot filament chemical vapor deposition is utilized to grow dense, aligned carbon nanotubes from the flakes with remarkably high CNT yields. The flakes are captured inside a mesh cage and freely suspended in the gas flow during growth. Optical characterization indicates the presence of high quality, small diameter single-walled carbon nanotubes.