Controlled patterning and growth of single wall and multi-wall carbon nanotubes
First Claim
1. A method for producing at least one of a single wall nanotube, a multi-wall nanotube and a nanofiber containing primarily carbon, the method comprising:
- providing a substrate of a selected material in a heated chamber, a first layer of a first selected thickness of material that is produced primarily by sputtering a combination of Al and Ir onto the substrate, and a second layer of a second selected thickness of material, drawn from a second group of materials including at least one of Fe, Co and Ni, that is deposited on the first layer that is deposited on the substrate, where at least one of the first layer and the second layer is deposited with a selected non-uniform layer pattern;
providing a hydrocarbon-containing (“
HC-containing”
) gas containing at least one of CH4, C2H4 and C2H2, heated to a selected temperature in a mange between 400°
C. and 1000°
C. within the chamber, and passing the HC-containing gas over a selected portion of the coated substrate; and
allowing at least one layer deposited on the substrate to remove H atoms and molecules from the HC-containing gas and to deposit C particles as part of at least one of a single wall nanotube, a multi-wall nanotube and a nanofiber on the coated substrate, in an array defined in part by the selected pattern.
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Accused Products
Abstract
Method and system for producing a selected pattern or array of at least one of a single wall nanotube and/or a multi-wall nanotube containing primarily carbon. A substrate is coated with a first layer (optional) of a first selected metal (e.g., Al and/or Ir) and with a second layer of a catalyst (e.g., Fe, Co, Ni and/or Mo), having selected first and second layer thicknesses provided by ion sputtering, arc discharge, laser ablation, evaporation or CVD. The first layer and/or the second layer may be formed in a desired non-uniform pattern, using a mask with suitable aperture(s), to promote growth of carbon nanotubes in a corresponding pattern. A selected heated feed gas (primarily CH4 or C2Hn with n=2 and/or 4) is passed over the coated substrate and forms primarily single wall nanotubes or multiple wall nanotubes, depending upon the selected feed gas and its temperature. Nanofibers, as well as single wall and multi-wall nanotubes, are produced using plasma-aided growth from the second (catalyst) layer. An overcoating of a selected metal or alloy can be deposited, over the second layer, to provide a coating for the carbon nanotubes grown in this manner.
228 Citations
21 Claims
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1. A method for producing at least one of a single wall nanotube, a multi-wall nanotube and a nanofiber containing primarily carbon, the method comprising:
-
providing a substrate of a selected material in a heated chamber, a first layer of a first selected thickness of material that is produced primarily by sputtering a combination of Al and Ir onto the substrate, and a second layer of a second selected thickness of material, drawn from a second group of materials including at least one of Fe, Co and Ni, that is deposited on the first layer that is deposited on the substrate, where at least one of the first layer and the second layer is deposited with a selected non-uniform layer pattern;
providing a hydrocarbon-containing (“
HC-containing”
) gas containing at least one of CH4, C2H4 and C2H2, heated to a selected temperature in a mange between 400°
C. and 1000°
C. within the chamber, and passing the HC-containing gas over a selected portion of the coated substrate; and
allowing at least one layer deposited on the substrate to remove H atoms and molecules from the HC-containing gas and to deposit C particles as part of at least one of a single wall nanotube, a multi-wall nanotube and a nanofiber on the coated substrate, in an array defined in part by the selected pattern. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21)
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Specification