Search Results (23)

In recent years, significant efforts have been dedicated to understanding the growth mechanisms behind the synthesis of vertically aligned nanocarbon structures using plasma-enhanced chemical vapor deposition (PECVD). This study explores how varying synthesis conditions, specifically hydrocarbon flow rate, hydrocarbon type, and plasma power,—affect the microstructure, properties, and electrochemical performance of nitrogen-doped vertically aligned graphene (NVG) and nitrogen-doped vertically aligned carbon nanofibers (NVCNFs) hybrids. It was observed that adjustments in these synthesis parameters led to noticeable changes in the microstructure, with particularly significant alterations when changing the hydrocarbon precursor from acetylene to methane. The electrochemical investigation revealed that the sample synthesized at higher plasma power exhibited enhanced electron transfer kinetics, likely due to the higher density of open edges and nitrogen doping level. This study contributes to better understanding the PECVD process for fabricating nanocarbon materials, particularly for sensor applications. Full article

This research reports the development of 3D carbon nanostructures that can provide unique capabilities for manufacturing carbon nanotube (CNT) electronic components, electrochemical probes, biosensors, and tissue scaffolds. The shaped CNT arrays were grown on patterned catalytic substrate by chemical vapor deposition (CVD) method. The new fabrication process for catalyst patterning based on combination of nanoimprint lithography (NIL), magnetron sputtering, and reactive etching techniques was studied. The optimal process parameters for each technique were evaluated. The catalyst was made by deposition of Fe and Co nanoparticles over an alumina support layer on a Si/SiO₂ substrate. The metal particles were deposited using direct current (DC) magnetron sputtering technique, with a particle ranging from 6 nm to 12 nm and density from 70 to 1000 particles/micron. The Alumina layer was deposited by radio frequency (RF) and reactive pulsed DC sputtering, and the effect of sputtering parameters on surface roughness was studied. The pattern was developed by thermal NIL using Si master-molds with PMMA and NRX1025 polymers as thermal resists. Catalyst patterns of lines, dots, and holes ranging from 70 nm to 500 nm were produced and characterized by scanning electron microscopy (SEM) and atomic force microscopy (AFM). Vertically aligned CNTs were successfully grown on patterned catalyst and their quality was evaluated by SEM and micro-Raman. The results confirm that the new fabrication process has the ability to control the size and shape of CNT arrays with superior quality. Full article

Less defective, nitrogen-doped 3-dimensional graphene (N3DG) and defect-rich, nitrogen-doped 3-dimensional graphene (N3DG-D) were made by the thermal CVD (Chemical Vapor Deposition) process via varying the carbon precursors and synthesis temperature. These modified 3D graphene materials were compared with pristine 3-dimensional graphene (P3DG), which has fewer defects and no nitrogen in its structure. The different types of graphene obtained were characterized for morphological, structural, and compositional assessment through Scanning Electron Microscopy (SEM), Raman Spectroscopy, and X-ray Photoelectron Spectroscopy (XPS) techniques. Electrodes were fabricated, and electrochemical characterizations were conducted to evaluate the suitability of the three types of graphene for heavy metal sensing (lead) and Electric Double-Layer Capacitor (EDLC) applications. Initially, the various electrodes were treated with a mixture of 2.5 mM Ruhex (Ru (NH₃)₆Cl₃ and 25 mM KCl to confirm that all the electrodes underwent a reversible and diffusion-controlled electrochemical process. Defect-rich graphene (N3DG-D) revealed the highest current density, followed by pristine (P3DG) and less-defect graphene (N3DG). Further, the three types of graphene were subjected to a sensing test by square wave anodic stripping voltammetry (SWASV) for lead detection. The obtained preliminary results showed that the N3DG material provided a great lead-sensing capability, detecting as little as 1 µM of lead in a water solution. The suitability of the electrodes to be employed in an Electric Double-Layer Capacitor (EDLC) was also comparatively assessed. Electrochemical characterization using 1 M sodium sulfate electrolyte was conducted through cyclic voltammetry and galvanostatic charge-discharge studies. The voltammogram and the galvanostatic charge-discharge (GCD) curves of the three types of graphene confirmed their suitability to be used as EDLC. The N3DG electrode proved superior with a gravimetric capacitance of 6.1 mF/g, followed by P3DG and N3DG, exhibiting 1.74 mF/g and 0.32 mF/g, respectively, at a current density of 2 A/g. Full article

Carbon nanotube (CNT) hybrid composites were formed by combining a CNT and silicone elastomer solution with Kevlar yarn, Kevlar fabric, and Kevlar veil materials. The integration of a CNT-silicone matrix with Kevlar yarn and fabric materials produced a composite with moderate electrical and thermal conductivity due to CNT fabric combined with the strength of Kevlar fabric or yarn. In the material synthesis, a notable difficulty was that the CNT-silicone did not bond strongly to the Kevlar. The composites passed the Vertical Flame Test ASTM D6413 and the Forced Air Oven Test NFPA 1971. These hybrid composites can have multiple applications in areas requiring favorable conductivity, strength, and flame and heat resistance. The application areas include firefighter apparel, military equipment, conductive/smart structures, and flexible electronics. The synthesis process used to manufacture CNT-silicone/Kevlar composites yielded composite sheets with an area of 2250 cm². The process is scalable and customizable for the synthesis of CNT composites with tailored properties. Improvements in the bonding of CNT-silicone to Kevlar are being investigated. Full article

The substitution of traditional copper power transmission cables with lightweight copper–carbon nanotube (Cu–CNT) composite fibers is critical for reducing the weight, fuel consumption, and CO₂ emissions of automobiles and aircrafts. Such a replacement will also allow for lowering the transmission power loss in copper cables resulting in a decrease in coal and gas consumption, and ultimately diminishing the carbon footprint. In this work, we created a lightweight Cu–CNT composite fiber through a multistep scalable process, including spinning, densification, functionalization, and double-layer copper deposition. The characterization and testing of the fabricated fiber included surface morphology, electrical conductivity, mechanical strength, crystallinity, and ampacity (current density). The electrical conductivity of the resultant composite fiber was measured to be 0.5 × 10⁶ S/m with an ampacity of 0.18 × 10⁵ A/cm². The copper-coated CNT fibers were 16 times lighter and 2.7 times stronger than copper wire, as they revealed a gravimetric density of 0.4 g/cm³ and a mechanical strength of 0.68 GPa, suggesting a great potential in future applications as lightweight power transmission cables. Full article

Carbon nanotubes (CNTs) have extraordinary properties and are used for applications in various fields of engineering and research. Due to their unique combination of properties, such as good electrical and thermal conductivity and mechanical strength, there is an increasing demand to produce CNTs with enhanced and customized properties. CNTs are produced using different synthesis methods and have extraordinary properties individually at the nanotube scale. However, it is challenging to achieve these properties when CNTs are used to form macroscopic sheets, tapes, and yarns. To further improve the properties of macroscale forms of CNTs, various types of nanoparticles and microfibers can be integrated into the CNT materials. The nanoparticles and microfibers can be chosen to selectively enhance the properties of CNT materials at the macroscopic level. In this paper, we propose a technique to manufacture carbon hybrid materials (CHMs) by combining CNT non-woven fabric (in the form of sheets or tapes) with microfibers to form CNT-CF hybrid materials with new/improved properties. CHMs are formed by integrating or adding nanoparticles, microparticles, or fibers into the CNT sheet. The additive materials can be incorporated into the synthesis process from the inlet or the outlet of the reactor system. This paper focuses on CHMs produced using the gas phase pyrolysis method with microparticles/fibers integrated at the outlet of the reactor and continuous microfiber tapes integrated into the CNT sheet at the outlet using a tape feeding machine. After synthesis, characterizations such as microscopy and thermogravimetric analysis were used to study the morphology and composition of the CNTs, and examples for potential applications are discussed in this paper. Full article

Nitrogen-doped, 3-dimensional graphene (N3DG), synthesized as a one-step thermal CVD process, was further functionalized with atmospheric pressure oxygen plasma. Electrodes were fabricated and tested based on the functionalized N3DG. Their characterization included scanning electron microscopy (SEM), Raman spectroscopy, X-ray photoelectron spectroscopy (XPS), Brunauer–Emmet–Teller (BET), and electrochemical measurements. The tested electrodes revealed a 208% increase in the specific capacitance compared to pristine 3D graphene electrodes in a three-electrode configuration. The performed doping and plasma treatment enabled an increase in the electrode‘s surface area by 4 times compared to pristine samples. Furthermore, the XPS results revealed the presence of nitrogen and oxygen functional groups in the doped and functionalized material. Symmetric supercapacitors assembled from the functionalized 3D graphene using aqueous and organic electrolytes were compared for electrochemical performance. The device with ionic electrolyte EMIMB₄ electrolyte exhibited a superior energy density of 54 Wh/kg and power density of 1224 W/kg. It also demonstrated a high-cyclic stability of 15,000 cycles with a capacitance retention of 107%. Full article

High demand for electrochemical storage devices is increasing the need for high-performance batteries. A Zn-CO₂ battery offers a promising solution for CO₂ reduction as well as energy storage applications. For this study, a Zn-CO₂ battery was fabricated using a Carbon Nanotube (CNT) sheet as a cathode and a Zn plate as an anode. The electrochemical activation technique was used to increase the surface area of the CNT electrode by roughly 4.5 times. Copper (Cu) as a catalyst was then deposited onto the activated CNT electrode using electrodeposition method and different Cu loadings were investigated to optimize CO₂ reduction. The final assembled Zn-CO₂ battery has a 1.6 V output voltage at a current density of 0.063 mA/cm², which is higher than most devices reported in the literature. This study demonstrates the importance of activation process which enabled more catalyst loading on the cathode resulted in additional active sites for electroreduction process. This paper presents the activated CNT sheet as a promising cathode material for Zn-CO₂ batteries. Full article

As wearable electronic devices are becoming an integral part of modern life, there is a vast demand for safe and efficient energy storage devices to power them. While the research and development of microbatteries and supercapacitors (SCs) have significantly progressed, the latter has attracted much attention due to their excellent power density, longevity, and safety. Furthermore, SCs with a 1D fiber shape are preferred because of their ease of integration into today’s smart garments and other wearable devices. Fiber supercapacitors based on carbon nanotubes (CNT) are promising candidates with a unique 1D structure, high electrical and thermal conductivity, outstanding flexibility, excellent mechanical strength, and low gravimetric density. This review aims to serve as a comprehensive publication presenting the fundamentals and recent developments on CNT-fiber-based SCs. The first section gives a general overview of the supercapacitor types based on the charge storage mechanisms and electrode configuration, followed by the various fiber fabrication methods. The next section explores the different strategies used to enhance the electrochemical performance of these SCs, followed by a broad study on their stretchability and multifunctionality. Finally, the review presents the current performance and scalability challenges affecting the CNT-based SCs, highlighting their prospects. Full article

Fiber-shaped batteries have attracted much interest in the last few years. However, a major challenge for this type of battery is their relatively low energy density. Here, we present a freestanding, flexible CNT fiber with high electrical conductivity and applied oxygen plasma-functionalization, which was successfully employed to serve as an effective cathode for Li-S batteries. The electrochemical results obtained from the conducted battery tests showed a decent rate capability and cyclic stability. The cathode delivered a capacity of 1019 mAh g⁻¹ at 0.1 C. It accommodated a high sulfur loading of 73% and maintained 47% of the initial capacity after 300 cycles. The demonstrated performance of the fiber cathode provides new insights for the designing and fabrication of high energy density fiber-shaped batteries. Full article

This work studies synthesis of carbon nanotube (CNT) sheet using the high temperature (1400 °C) floating catalyst chemical vapor deposition (FC-CVD) method. Three metallocenes—ferrocene, nickelocene, cobaltocene—and their combinations are used as precursors for metal catalysts in the synthesis process. For the carbon source, an alcohol fuel, a combination of methanol and n-hexane (9:1), is used. First, the metallocenes were dissolved in the alcohol fuel. Then, the fuel mixture was injected into a tube furnace using an ultrasonic atomizer with Ar/H₂ carrier gas in a ratio of about 12/1. The synthesis of CNTs from a combination of two or three metallocenes reduces the percentage of metal catalyst impurity in the CNT sheet. However, there is an increase in structural defects in the CNTs when using mixtures of two or three metallocenes as catalysts. Furthermore, the specific electrical conductivity of the CNT sheet was highest when using a mixture of ferrocene and cobaltocene as the catalyst. Overall, the multi-catalyst method described enables tailoring certain properties of the CNT sheet. However, the standard ferrocene catalyst seems most appropriate for large-scale manufacturing at the lowest cost. Full article

The carbon nanotube (CNT) is celebrated for its electrothermal property, which indicates the capability of a material to transform electrical energy into heat due to the Joule effect. The CNT nanostructure itself, as a one-dimensional material, limits the electron conduction path, thereby creating a unique heating phenomenon. In this work, we explore the possible correlation between CNT alignment in sheets and heating performance. The alignment of carbon nanotubes is induced by immersion and stretching in chlorosulfonic acid (CSA) solution. The developed CSA-stretched CNT sheet demonstrated excellent heating performance with a fast response rate of 6.5 °C/s and reached 180 °C in less than 30 s under a low voltage of 2.5 V. The heating profile of the stretched CNT sheet remained stable after bending and twisting movements, making it a suitable heating material for wearable devices, heatable smart windows, and in de-icing or defogging applications. The specific strength and specific conductance of the CSA-stretched CNT sheet also increased five- and two-fold, respectively, in comparison to the pristine CNT sheet. Full article

The development of new flexible and lightweight electronics has increased the demand for compatible energy storage devices to power them. Carbon nanotube (CNT) fibers have long been known for their ability to be assembled into yarns, offering their integration into electronic devices. They are hindered, however, by their low intrinsic energy storage properties. Herein, we report a novel composite yarn, synthesized through solvothermal processes, that attained energy densities in the range between 0.17 µWh/cm² and 3.06 µWh/cm², and power densities between 0.26 mW/cm² and 0.97 mW/cm², when assembled in a supercapacitor with a PVDF-EMIMBF4 electrolyte. The created unique composition of iron oxalate + iron hydroxide + CNT as an anode worked well in synergy with the much-studied PANI + CNT cathode, resulting in a highly stable yarn energy storage device that maintained 96.76% of its energy density after 4000 cycles. This device showed no observable change in performance under stress/bend tests which makes it a viable candidate for powering wearable electronics. Full article

A comparative experimental study between advanced carbon nanostructured electrodes, in similar hydrogen uptake/desorption conditions, is investigated making use of the recent molecular beam-thermal desorption spectrometry. This technique is used for monitoring hydrogen uptake and release from different carbon electrocatalysts: 3D-graphene, single-walled carbon nanotube networks, multi-walled carbon nanotube networks, and carbon nanotube thread. It allows an accurate determination of the hydrogen mass absorbed in electrodes made from these materials, with significant enhancement in the signal-to-noise ratio for trace hydrogen avoiding recourse to ultra-high vacuum procedures. The hydrogen mass spectra account for the enhanced surface capability for hydrogen adsorption in the different types of electrode in similar uptake conditions, and confirm their enhanced hydrogen storage capacity, pointing to a great potential of carbon nanotube threads in replacing the heavier metals or metal alloys as hydrogen storage media. Full article

Decades of extensive research have matured the development of carbon nanotubes (CNTs). Still, the properties of macroscale assemblages, such as sheets of carbon nanotubes, are not good enough to satisfy many applications. This paper gives an overview of different approaches to synthesize CNTs and then focuses on the floating catalyst method to form CNT sheets. A method is also described in this paper to modify the properties of macroscale carbon nanotube sheets produced by the floating catalyst method. The CNT sheet is modified to form a carbon nanotube hybrid (CNTH) sheet by incorporating metal, ceramic, or other types of nanoparticles into the high-temperature synthesis process to improve and customize the properties of the traditional nanotube sheet. This paper also discusses manufacturing obstacles and the possible commercial applications of the CNT sheet and CNTH sheet. Manufacturing problems include the difficulty of injecting dry nanoparticles uniformly, increasing the output of the process to reduce cost, and safely handling the hydrogen gas generated in the process. Applications for CNT sheet include air and water filtering, energy storage applications, and compositing CNTH sheets to produce apparel with anti-microbial properties to protect the population from infectious diseases. The paper also provides an outlook towards large scale commercialization of CNT material. Full article