Methods of using pre-formed nanotubes to make carbon nanotube films, layers, fabrics, ribbons, elements and articles

• US 7,335,395 B2
• Filed: 01/13/2003
• Issued: 02/26/2008
• Est. Priority Date: 04/23/2002
• Status: Expired due to Term

• Current Assignee: ZEON Corporation
• Original Assignee: Nantero Incorporated
• Inventors: Ward, Jonathan W., Segal, Brent M., Rueckes, Thomas
• Primary Examiner(s): Parker; Fred J.
• Application Number:
  US10/341,054
• Publication Number:
  US 20070248758A1
• Time in Patent Office: 1,870 Days
• Field of Search: 427/198, 427/240, 427/264, 427/270, 427/271, 427/903, 977/842, 977/892, 423/447.1, 423/445.B, 118/320
• US Class Current: 427/198
• CPC Class Codes: B05D 1/002 the substrate being rotated
• CPC Class Codes: B05D 3/0254 After-treatment
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C23C 16/0281 of metallic sub-layers C23C16/029 takes precedence
• CPC Class Codes: C23C 16/26 Deposition of carbon only
• CPC Class Codes: D04H 1/4234 Metal fibres
• CPC Class Codes: D04H 1/4242 Carbon fibres
• CPC Class Codes: D04H 1/43838 Ultrafine fibres, e.g. microfibres
• CPC Class Codes: D04H 1/43914 hollow fibres

Abstract

Methods of Using Preformed Nanotubes to Make Carbon Nanotube Films, Layers, Fabrics, Ribbons, Elements and Articles are disclosed. To make various articles, certain embodiments provide a substrate. Preformed nanotubes are applied to a surface of the substrate to create a non-woven fabric of carbon nanotubes. Portions of the non-woven fabric are selectively removed according to a defined pattern to create the article. To make a nanofabric, a substrate is provided. Preformed nanotubes are applied to a surface of the substrate to create a non-woven fabric of carbon nanotubes wherein the non-woven fabric is substantially uniform density.

Claims

1. A method of making an article, comprising:

providing a substrate;

applying preformed nanotubes to a surface of the substrate to create a non-woven fabric of carbon nanotubes;

selectively removing portions of the non-woven fabric by etching the fabric according to a defined pattern to create the article.

2. The method of claim 1 including functionalizing the surface to promote adhesion of the preformed nanotubes to the surface of the substrate.

3. The method of claim 2 wherein the act of functionalizing the surface includes derivitizing the surface to chemically convert the surface state.

4. The method of claim 2 further including oxidizing the surface to remove carbon and other impurities.

5. The method of claim 1 wherein the surface is reacted with a silane.

6. The method of claim 1 wherein the surface is exposed to 3-aminopropyltriethoxysilane (APTS).

7. The method of claim 6 wherein the surface is exposed to an approximately 1-50 molar solution of APTS.

8. The method of claim 6 wherein the surface is exposed to an approximately 13-28 molar solution of APTS.

9. The method of claim 8 wherein the solution of APTS includes hexane.

10. The method of claim 7 wherein the substrate is immersed in the solution of APTS for a predetermined time.

11. The method of claim 5 wherein silane is deposited on the surface as substantially a monolayer.

12. The method of claim 9 wherein the substrate is stored in hexane prior to the application of pre-formed nanotubes.

13. The method of claim 1 wherein the application of nanotubes to the surface includes spinning the substrate to disperse the pre-formed nanotubes.

14. The method of claim 1 wherein the pre-formed nanotubes are laser-ablated nanotubes.

15. The method of claim 1 wherein the pre-formed nanotubes are high pressure carbon monoxide decomposition nanotubes.

16. The method of claim 1 wherein the pre-formed nanotubes are single-walled nanotubes.

17. The method of claim 1 wherein the pre-formed nanotubes are multi-walled nanotubes.

18. The method of claim 14 wherein the nanotubes are mixed with a solvent at a concentration of about 100-500 μ

g/mL.

19. The method of claim 18 wherein the solvent is 1,2 dichlorobenzene.

20. The method of claim 18 wherein the nanotubes in the solvent are caused to be dispersed.

21. The method of claim 20 wherein the solution of nanotubes and solvent are subjected to sonication.

22. The method of claim 15 wherein the nanotubes are mixed with a solvent at a concentration of about 10-200 μ

g/mL.

23. The method of claim 22 wherein the solvent is 1,2 dichlorobenzene.

24. The method of claim 22 wherein the nanotubes in the solvent are caused to be dispersed.

25. The method of claim 24 wherein the solution of nanotubes and solvent are subjected to sonication.

26. The method of claim 13 wherein the substrate is caused to spin at a predefined rate as a solution including nanotubes is deposited on the surface and wherein the surface continues to spin for a defined duration.

27. The method of claim 26 wherein the predefined rate is about 1000 rpm and the defined duration is about 30 seconds.

28. The method of claim 26 wherein the substrate is dried subsequent to the application of nanotubes.

29. The method of claim 28 wherein the substrate is dried by a subsequent spinning operation.

30. The method of claim 13 wherein the application of nanotubes is accomplished by multiple spin coating operations of a solution of pre-formed nanotubes.

31. The method of claim 30 wherein between spin coating operations the substrate is dried of solvent.

32. The method of claim 1 wherein the application of nanotubes causes a sufficient density of nanotubes to yield a non-woven fabric characterized by a resistance of about 1-1000 kΩ

/□

.

33. The method of claim 1 wherein the substrate with non-woven fabric is annealed.

34. The method of claim 1 wherein the carbon nanotubes of the non-woven fabric include metallic nanotubes and semiconducting nanotubes and wherein the relative composition of metallic and semiconducting nanotubes in the fabric is controlled.

35. The method of claim 1 wherein the carbon nanotubes of the non-woven fabric include metallic nanotubes and semiconducting nanotubes and wherein the method further includes selectively removing metallic nanotubes.

36. The method of claim 1 wherein the carbon nanotubes of the non-woven fabric include metallic nanotubes and semiconducting nanotubes and wherein the method further includes selectively removing semiconducting nanotubes.

37. The method of claim 35 wherein subsequent to selectively removing metallic nanotubes a subsequent application of preformed nanotubes is made.

38. The method of claim 36 wherein subsequent to selectively removing semiconducting nanotubes a subsequent application of preformed nanotubes is made.

39. The method of claim 1 wherein the non-woven fabric is made to cover the surface of the substrate and to be of substantially uniform density.

40. The method of claim 1 wherein the non-woven fabric is made to cover the surface of the substrate and to be about 2 nm or less in thickness.

41. The method of claim 1 wherein the preformed nanotubes applied to the substrate have a controlled composition of metallic nanotubes relative to semiconducting nanotubes.