Nanowire structures comprising carbon

• US 7,939,218 B2
• Filed: 11/20/2006
• Issued: 05/10/2011
• Est. Priority Date: 12/09/2004
• Status: Active Grant

• Current Assignee: ONED Material Incorporated
• Original Assignee: Nanosys Incorporated (Shoei Electronic Materials, Inc.)
• Inventors: Niu, Chunming
• Primary Examiner(s): Kalafut; Stephen J.
• Application Number:
  US11/601,842
• Publication Number:
  US 20070212538A1
• Time in Patent Office: 1,632 Days
• Field of Search: 429/44, 429/231.8, 429/532, 502/101, 427/115, 427/122, 427/215, 423/447.3, 423/445.R
• US Class Current: 429/532
• CPC Class Codes: H01B 1/04 mainly consisting of carbon-silicon compounds, carbon or silicon
• CPC Class Codes: H01M 4/133 Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/625 Carbon or graphite
• CPC Class Codes: H01M 4/8605 Porous electrodes
• CPC Class Codes: H01M 4/8657 layered
• CPC Class Codes: H01M 8/1004 characterised by membrane-electrode assemblies [MEA] H01M8/12 takes precedence
• CPC Class Codes: H01M 8/1097 Fuel cells applied on a support, e.g. miniature fuel cells deposited on silica supports
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 428/2918 including free carbon or carbide or therewith [not as steel]

Abstract

The present invention is directed to nanowire structures and interconnected nanowire networks comprising such structures, as well as methods for their production. The nanowire structures comprise a nanowire core, a carbon-based layer, and in additional embodiments, carbon-based structures such as nanographitic plates consisting of graphenes formed on the nanowire cores, interconnecting the nanowire structures in the networks. The networks are porous structures that can be formed into membranes or particles. The nanowire structures and the networks formed using them are useful in catalyst and electrode applications, including fuel cells, as well as field emission devices, support substrates and chromatographic applications.

Claims

1. A nanowire comprising a carbon-based layer, wherein the carbon-based layer is substantially devoid of basal plane carbon.

2. The nanowire of claim 1, wherein the carbon-based layer contains less than about 0.5% basal plane carbon.

3. The nanowire of claim 1, further comprising a core.

4. The nanowire of claim 3, wherein the core comprises a semiconductor material.

5. The nanowire of claim 4, wherein the semiconductor material is selected from the group consisting of Si, B, SiC and GaN.

6. The nanowire of claim 4, wherein the semiconductor material is doped.

7. The nanowire of claim 3, wherein the core and/or the carbon-based layer comprise carbon.

8. The nanowire of claim 3, wherein the core and/or the carbon-based layer consist essentially of carbon.

9. The nanowire of claim 3, wherein the core and/or the carbon-based layer consist of carbon.

10. The nanowire of claim 3, wherein the core comprises carbide.

11. The nanowire of claim 10, wherein the core comprises SiC.

12. The nanowire of claim 3, wherein the core is Si and the carbon-based layer is SiC.

13. The nanowire of claim 3, wherein the core is SiC and the carbon-based layer is carbon.

14. The nanowire of claim 1, wherein the carbon-based layer is between about 1 nm to about 500 nm in thickness.

15. A method of manufacturing a nanowire, comprising:

(a) heating a nanowire core; and

(b) contacting the nanowire core with one or more carbon-comprising gases to form a carbon-based layer on the nanowire core, wherein the carbon-based layer is substantially devoid of basal plane carbon.

16. The method of claim 15, wherein said heating is to a temperature of greater than about 600°

C.

17. The method of claim 15, wherein said contacting step comprises contacting with a gas comprising carbon monoxide, methane, ethane, propane, butane, ethylene or propylene and optionally further comprises contacting with a gas comprising He, Ne, Ar, Kr, Xe, or H₂.

18. A method of manufacturing a nanowire, comprising:

(a) heating a nanowire core;

(b) contacting the nanowire core with one or more carbon-comprising gases to faun a carbon-based layer on the nanowire core; and

(c) forming a precursor coating selected from the group consisting of TiO₂, ZrO₂, HfO₂, Nb₂O₃, Ta₂O₅, MoO₃ and WO₃ on the nanowire core prior to the heating step.

19. A method for preparing a fuel cell electrode comprising:

providing a semiconductor wafer having a first surface and a second surface;

forming one or more channels on the first surface and the second surface;

disposing one or more nanowires in the channels in the first and second surfaces;

contacting the nanowires and the first and second surfaces with one or more carbon-comprising gases to form a carbon-based layer on the nanowires and the first and second surfaces; and

disposing one or more metal catalysts on the nanowires.

20. The method of claim 19, wherein said forming of one or more channels comprises etching.

21. The method of claim 20, wherein said etching comprises etching with NaOH.

22. The method of claim 19, wherein said disposing of one or more nanowires comprises growing nanowires in the channels.

23. The method of claim 19, wherein the disposing of one or more metal catalysts on the nanowires comprises depositing one or more Pt nanoparticles on nanowires on the first surface and PtRu nanoparticles on nanowires on the second surface.

24. A fuel cell electrode prepared by the method of claim 19.