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

Graphene Carbon Nanotube Carpets Grown Using Binary Catalysts for High-Performance Lithium-Ion Capacitors

Here we show that a versatile binary catalyst solution of Fe₃O₄/AlO_x nanoparticles enables homogeneous growth of single to few-walled carbon nanotube (CNT) carpets from three-dimensional carbon-based substrates, moving past existing two-dimensional limited growth methods. The binary catalyst is composed of amorphous AlO_x nanoclusters over Fe₃O₄ crystalline nanoparticles, facilitating the creation of seamless junctions between the CNTs and the underlying carbon platform. The resulting graphene-CNT (GCNT) structure is a high-density CNT carpet ohmically connected to the carbon substrate, an important feature for advanced carbon electronics. As a demonstration of the utility of this approach, we use GCNTs as anodes and cathodes in binder-free lithium-ion capacitors, producing stable devices with high-energy densities (∼120 Wh kg^-1), high-power density capabilities (∼20,500 W kg^-1 at 29 Wh kg^-1), and a large operating voltage window (4.3 to 0.01 V).

Chemical Bath Deposition of Aluminum Oxide Buffer on Curved Surfaces for Growing Aligned Carbon Nanotube Arrays

Direct growth of vertically aligned carbon nanotube (CNT) arrays on substrates requires the deposition of an aluminum oxide buffer (AOB) layer to prevent the diffusion and coalescence of catalyst nanoparticles. Although AOB layers can be readily created on flat substrates using a variety of physical and chemical methods, the preparation of AOB layers on substrates with highly curved surfaces remains challenging. Here, we report a new solution-based method for preparing uniform layers of AOB on highly curved surfaces by the chemical bath deposition of basic aluminum sulfate and annealing. We show that the thickness of AOB layer can be increased by extending the immersion time of a substrate in the chemical bath, following the classical Johnson-Mehl-Avrami-Kolmogorov crystallization kinetics. The increase of AOB thickness in turn leads to the increase of CNT length and the reduction of CNT curviness. Using this method, we have successfully synthesized dense aligned CNT arrays of micrometers in length on substrates with highly curved surfaces including glass fibers, stainless steel mesh, and porous ceramic foam.

The interaction of carboxylic acids with aluminium oxides: journeying from a basic understanding of alumina nanoparticles to water treatment for industrial and humanitarian applications

Carboxylic acids are found to react with aluminium oxides via a topotactic reaction such that the carboxylate acts as a bridging ligand. This reaction allows for carboxylate-functionalized alumina nanoparticles to be prepared directly from boehmite (AlOOH). Understanding the structural relationship between molecular and surface species allows for the rationalization/prediction of suitable alternative ligands as well as alternative oxide surfaces. The identity of the carboxylate substituent controls the pH stability of a nanoparticle as well as the porosity and processability of ceramics prepared by thermolysis. Through the choice of functional groups on the carboxylic acid the properties of the alumina surface or alumina nanoparticle can be tailored. For example, the solubility/miscibility of nanoparticles can be tuned to the solvent/matrix, and the wettability to be varied from hydrophobic to super hydrophilic. The choice Zwitter ionic substituents on alumina micro-/ultra-filtration membranes are found to enhance the flux and limit fouling while allowing for the facile separation of organic compounds from water. Examples are presented of purification of frac and flow-back water from oil well production as well as providing drinking water from contaminated sources in underdeveloped regions.

SWCNT networks on nanoporous silica catalyst support: morphological and connectivity control for nanoelectronic, gas-sensing, and biosensing devices

Effective control of morphology and electrical connectivity of networks of single-walled carbon nanotubes (SWCNTs) by using rough, nanoporous silica supports of Fe catalyst nanoparticles in catalytic chemical vapor deposition is demonstrated experimentally. The very high quality of the nanotubes is evidenced by the G-to-D Raman peak ratios (>50) within the range of the highest known ratios. Transitions from separated nanotubes on smooth SiO(2) surface to densely interconnected networks on the nanoporous SiO(2) are accompanied by an almost two-order of magnitude increase of the nanotube density. These transitions herald the hardly detectable onset of the nanoscale connectivity and are confirmed by the microanalysis and electrical measurements. The achieved effective nanotube interconnection leads to the dramatic, almost three-orders of magnitude decrease of the SWCNT network resistivity compared to networks of similar density produced by wet chemistry-based assembly of preformed nanotubes. The growth model, supported by multiscale, multiphase modeling of SWCNT nucleation reveals multiple constructive roles of the porous catalyst support in facilitating the catalyst saturation and SWCNT nucleation, consistent with the observed higher density of longer nanotubes. The associated mechanisms are related to the unique surface conditions (roughness, wettability, and reduced catalyst coalescence) on the porous SiO(2) and the increased carbon supply through the supporting porous structure. This approach is promising for the direct integration of SWCNT networks into Si-based nanodevice platforms and multiple applications ranging from nanoelectronics and energy conversion to bio- and environmental sensing.

Closed-edged graphene nanoribbons from large-diameter collapsed nanotubes

The diameter dependence of the collapse of single- and double-walled carbon nanotubes to two- and four-walled graphene nanoribbons with closed edges (CE(x)GNRs) has been experimentally determined and compared to theory. TEM and AFM were used to characterize nanotubes grown from preformed 4.0 nm diameter aluminum-iron oxide particles. Experimental data indicate that the energy equivalence point (the diameter at which the energy of a round and fully collapsed nanotube is the same) is 2.6 and 4.0 nm for single- and double-walled carbon nanotubes, respectively. Molecular dynamics simulations predict similar energy equivalence diameters with the use of ε = 54 meV/pair to calculate the carbon-carbon van der Waals interaction.

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.