Strongly bound carbon nanotube arrays directly grown on substrates and methods for production thereof

• US 8,709,373 B2
• Filed: 12/11/2009
• Issued: 04/29/2014
• Est. Priority Date: 12/11/2008
• Status: Active Grant

• Current Assignee: Rice University
• Original Assignee: Rice University
• Inventors: Hauge, Robert, Pint, Cary, Alvarez, Noe, Kittrell, W. Carter
• Primary Examiner(s): MCCRACKEN, DANIEL
• Application Number:
  US13/139,418
• Publication Number:
  US 20110311427A1
• Time in Patent Office: 1,600 Days
• Field of Search: 4234471-4473, 423/445.B, 977742-754, 977842-848
• US Class Current: 423/447.1
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: B82Y 40/00 Manufacture or treatment of nanostructures
• CPC Class Codes: C01B 2202/08 Aligned nanotubes
• CPC Class Codes: C01B 32/15 Nano-sized carbon materials
• CPC Class Codes: C01B 32/162 characterised by catalysts
• CPC Class Codes: H01J 2201/30469 Carbon nanotubes (CNTs)
• CPC Class Codes: H01J 9/025 of field emission cathodes

Abstract

The present disclosure describes carbon nanotube arrays having carbon nanotubes grown directly on a substrate and methods for making such carbon nanotube arrays. In various embodiments, the carbon nanotubes may be covalently bonded to the substrate by nanotube carbon-substrate covalent bonds. The present carbon nanotube arrays may be grown on substrates that are not typically conducive to carbon nanotube growth by conventional carbon nanotube growth methods. For example, the carbon nanotube arrays of the present disclosure may be grown on carbon substrates including carbon foil, carbon fibers and diamond. Methods for growing carbon nanotubes include a) providing a substrate, b) depositing a catalyst layer on the substrate, c) depositing an insulating layer on the catalyst layer, and d) growing carbon nanotubes on the substrate. Various uses for the carbon nanotube arrays are contemplated herein including, for example, electronic device and polymer composite applications.

Claims

1. A carbon nanotube array, comprising:

a substrate, wherein there is no catalyst immobilized on the substrate; and

carbon nanotubes directly grown on the substrate without an intervening oxide layer between the substrate and a catalyst;

wherein the carbon nanotubes are arranged as a vertically aligned carbon nanotube array on the substrate, and

wherein the carbon nanotubes are covalently bonded to the substrate by a plurality of direct nanotube carbon-substrate covalent bonds.

2. The carbon nanotube array of claim 1, wherein the substrate is an electrical conductor.

3. The carbon nanotube array of claim 1, wherein the substrate is a carbon substrate.

4. The carbon nanotube array of claim 3, wherein the carbon substrate comprises a carbon foil.

5. The carbon nanotube array of claim 3, wherein the carbon substrate comprises carbon fibers.

6. The carbon nanotube array of claim 3, wherein the carbon substrate comprises diamond.

7. The carbon nanotube array of claim 1, wherein the substrate is selected from the group consisting of carbon, carbon fibers, carbon foil, graphite, diamond, nano-diamond, diamond-like carbon, glassy carbon, silicon, quartz, silicon carbide, non-metal carbides, metal carbides, binary carbides and metals.

8. The carbon nanotube array of claim 1, wherein the carbon nanotubes comprise single-wall carbon nanotubes.

9. A carbon nanotube array, comprising:

a carbon substrate, wherein there is no catalyst immobilized on the carbon substrate; and

carbon nanotubes directly grown on the carbon substrate without an intervening oxide layer between the carbon substrate and a catalyst;

wherein the carbon nanotubes are arranged as a vertically aligned carbon nanotube array on the carbon substrate,

wherein the carbon nanotubes are covalently bonded to the carbon substrate by a plurality of direct nanotube carbon-carbon substrate covalent bonds, and

wherein the carbon substrate is selected from the group consisting of carbon foil, carbon fibers and diamond.