Method for patterning carbon nanotube coating and carbon nanotube wiring

• US 20040099438A1
• Filed: 05/21/2003
• Published: 05/27/2004
• Est. Priority Date: 05/21/2002
• Status: Active Grant

• Current Assignee: Eikos, Inc.
• Original Assignee: Eikos, Inc.
• Inventors: Arthur, David J., Glatkowski, Paul J.
• Granted Patent: US 6,988,925 B2
• Time in Patent Office: Days
• US Class Current: 174/257
• CPC Class Codes: B82Y 10/00 Nanotechnology for information processing, storage or transmission, e.g. quantum computing or single electron logic
• CPC Class Codes: H01J 1/304 Field-emissive cathodes
• CPC Class Codes: H01J 2201/30469 Carbon nanotubes (CNTs)
• CPC Class Codes: H05K 1/095 for polymer thick films, i.e. having a permanent organic polymeric binder
• CPC Class Codes: H05K 2201/026 Nanotubes or nanowires
• CPC Class Codes: H05K 2201/0323 Carbon
• CPC Class Codes: H05K 2203/0514 Photodevelopable thick film, e.g. conductive or insulating paste
• CPC Class Codes: H05K 2203/0522 Using an adhesive pattern
• CPC Class Codes: H05K 2203/1147 Sealing or impregnating, e.g. of pores
• CPC Class Codes: H05K 3/02 in which the conductive material is applied to the surface of the insulating support and is thereafter removed from such areas of the surface which are not intended for current conducting or shielding
• CPC Class Codes: H05K 3/046 by selective transfer or selective detachment of a conductive layer
• CPC Class Codes: H05K 3/12 using thick film techniques, e.g. printing techniques to apply the conductive material or similar techniques for applying conductive paste or ink patterns
• CPC Class Codes: H10K 71/233 by photolithographic etching
• CPC Class Codes: H10K 85/221 Carbon nanotubes
• CPC Class Codes: Y02E 10/549 Organic PV cells
• CPC Class Codes: Y10S 977/89 Deposition of materials, e.g. coating, cvd, or ald

Abstract

A method for making a nanocomposite electrode or circuit pattern includes forming a continuous carbon nanotube layer impregnated with a binder and patterning the binder resin using various printing or photo imaging techniques. An alternative method includes patterning the carbon nanotube layer using various printing or imaging techniques and subsequently applying a continuous coating of binder resin to the patterned carbon nanotube layer. Articles made from these patterned nanocomposite coatings include transparent electrodes and circuits for flat panel displays, photovoltaics, touch screens, electroluminescent lamps, and EMI shielding.

Claims

1. A carbon nanotube wiring comprising:

a substrate; and

a patterned wiring line or electrode disposed on the substrate and comprising carbon nanotubes.

2. The carbon nanotube wiring of claim 1, wherein the wiring line or the electrode further comprises a binder or a photoresist.

3. The carbon nanotube wiring of claim 1, wherein the carbon nanotubes have an outer diameter of 3.5 nm or smaller.

4. The carbon nanotube wiring of claim 1, wherein the wiring line or the electrode further comprises metal fillers.

5. The carbon nanotube wiring of claim 4, wherein the metal fillers comprises silver, gold, copper or combinations thereof.

6. The carbon nanotube wiring of claim 1, wherein the wiring line or the electrode has a surface resistance in a range between 10² and 10⁴ ohms/square.

7. The carbon nanotube wiring of claim 1, wherein the wiring line or the electrode has a volume resistance in a range between 10⁻

2 and 10⁰ ohms-cm.

8. The carbon nanotube wiring of claim 1, wherein the wiring line or the electrode has a light transmittance of 80% or higher.

9. The carbon nanotube wiring of claim 1, wherein the wiring line or the electrode has a carbon nanotube concentration between 5% and 50% by volume.

10. The carbon nanotube wiring of claim 1, further comprising an insulating layer disposed on the wiring line or the electrode.

11. The carbon nanotube wiring of claim 1, wherein the substrate is a glass substrate, a polymer substrate, a silicon wafer, a prepreg or combinations thereof.

12. A method for patterning a carbon nanotube coating, comprising:

providing a solution of carbon nanotubes;

applying the solution to a substrate to form a film of consolidated carbon nanotubes on the substrate;

impregnating the carbon nanotube film selectively with a binder; and

removing at least a part of the carbon nanotube film that is not impregnated with the binder from the substrate.

13. The method for patterning the carbon nanotube coating of claim 12, wherein providing the solution of carbon nanotubes comprises purifying the carbon nanotubes.

14. The method for patterning the carbon nanotube coating of claim 12, wherein the providing of the solution of carbon nanotubes comprises dispersing the carbon nanotubes in a solution of water and an alcohol.

15. The method for patterning the carbon nanotube coating of claim 12, wherein applying of the solution comprises spraying the solution with an atomizer.

16. The method for patterning the carbon nanotube coating of claim 12, wherein impregnating the carbon nanotube film comprises printing the binder on the carbon nanotube film with a predetermined pattern.

17. The method for patterning the carbon nanotube coating of claim 12, wherein removing the carbon nanotubes comprising spray washing the carbon nanotube film with a mixture of water and a surfactant.

40. The method for patterning the carbon nanotube coating of claim 12, wherein impregnating the carbon nanotube film comprises spraying the binder.

41. The method for patterning the carbon nanotube coating of claim 12, wherein removing the carbon nanotubes comprising transferring a part of the carbon nanotube film from the substrate to a sticky surface.

18. A method for patterning a carbon nanotube coating, comprising:

providing a solution of carbon nanotubes;

applying the solution to a substrate to form a film of consolidated carbon nanotubes on the substrate;

impregnating the carbon nanotube film with a photoresist;

projecting a predetermined pattern onto the carbon nanotube film impregnated with the photoresist to secure a part of the carbon nanotube film; and

removing at lest a part of the carbon nanotube film that is not secured by the projection from the substrate.

19. The method for patterning a carbon nanotube coating of claim 18, wherein providing the solution of carbon nanotubes comprises purifying the carbon nanotubes.

20. The method for patterning a carbon nanotube coating of claim 18, wherein providing the solution of carbon nanotubes comprises dispersing the carbon nanotubes in a solution of water and an alcohol.

21. The method for patterning a carbon nanotube coating of claim 18, wherein applying the solution comprises spraying the solution with an atomizer.

22. The method for patterning a carbon nanotube coating of claim 18, wherein impregnating the carbon nanotube film comprises rod coating the photoresist on the substrate or spin coating the photoresist on the substrate.

23. The method for patterning a carbon nanotube coating of claim 18, wherein removing the carbon nanotube film comprises removing the unsecured part of the carbon nanotube film with a developer solution of the photoresist.

24. A method for patterning a carbon nanotube coating, comprising:

providing a solution of carbon nanotubes;

applying the solution to a substrate to form a film of consolidated carbon nanotubes on the substrate;

exposing the carbon nanotube film to a light source through a mask; and

impregnating the exposed carbon nanotube film with a binder.

25. The method for patterning a carbon nanotube coating of claim 25, wherein providing the solution of carbon nanotubes comprises purifying.

26. The method for patterning a carbon nanotube coating of claim 25, wherein providing the solution of carbon nanotubes comprises dispersing the carbon nanotubes in a solution of water and an alcohol.

27. The method for patterning a carbon nanotube coating of claim 25, wherein applying the solution comprises spraying the solution with an atomizer.

28. The method for patterning a carbon nanotube coating of claim 25, wherein impregnating the carbon nanotube film comprises spraying the binder.

29. A method for patterning a carbon nanotube coating, comprising:

providing a coating mixture comprising carbon nanotubes and a solvent;

applying the coating mixture on a substrate to form a predetermined pattern;

removing the solvent from the coating mixture printed on the substrate to leave a film of consolidated carbon nanotubes on the substrate; and

impregnating the carbon nanotube film with a binder.

30. The method for patterning a carbon nanotube coating of claim 30, wherein providing the coating mixture comprises purifying.

31. The method for patterning a carbon nanotube coating of claim 30, wherein providing the coating mixture comprises dispersing the carbon nanotubes in a solution of water.

32. The method for patterning a carbon nanotube coating of claim 30, wherein applying the coating mixture comprises screen printing, jet printing or gravure roll printing.

33. The method for patterning a carbon nanotube coating of claim 30, wherein removing the solvent comprises heating the substrate.

34. The method for patterning a carbon nanotube coating of claim 30, wherein impregnating the carbon nanotube film comprises spraying the binder.

35. The method for patterning a carbon nanotube coating of claim 30, wherein providing the coating mixture comprises adding a viscosity modifying agent.

36. A method for patterning a carbon nanotube coating, comprising:

providing a solution of carbon nanotubes;

applying the solution to a substrate to form a film of consolidated carbon nanotubes on the substrate;

removing at least a part of the carbon nanotube film from the substrate.

impregnating the carbon nanotube film remaining on the substrate with a binder.

37. The method for patterning the carbon nanotube coating of claim 37, wherein providing the solution of carbon nanotubes comprises purifying the carbon nanotubes.

38. The method for patterning the carbon nanotube coating of claim 37, wherein the providing of the solution of carbon nanotubes comprises dispersing the carbon nanotubes in a solution of water and an alcohol.

39. The method for patterning the carbon nanotube coating of claim 37, wherein applying of the solution comprises spraying the solution with an atomizer.