Key Points
Demand for Carbon Nanotubes: #CarbonNanotubes (CNTs) are one-dimensional nanomaterials with excellent thermal, mechanical, and electromagnetic properties, making them highly sought after in fields such as carbon-based integrated circuits, super-strong and tough fibers, transparent conductive films, and flexible wearable devices. High-end applications demand stringent requirements for CNTs in terms of length, orientation, defect levels, and purity.
Challenges in Growing Ultra-Long CNTs: Ultra-long CNTs, which follow a tip-growth mode, are essential for meeting these requirements and realizing the intrinsic superior properties of CNTs. However, the growth process involves the self-assembly of tens of billions of atoms under stringent conditions, leading to low yield and array density typically less than 50 tubes per mm, limiting application development.
3.
New Method with Floating Bimetallic Catalysts (FBCs): Building on their previous strategy of substrate interception guidance, Zhang’s team proposed an in-situ gas-phase synthesis method using FBCs (Figure 1). They introduced ferrocene and acetylacetonate salts (as iron and secondary metal precursors) into the reactor. The diverse and easily sublimable nature of acetylacetonate salts facilitates the formation of new binary alloy floating catalysts.
4.
Process Description: The precursors undergo sublimation, decomposition, and coalescence at the reactor inlet to form FBC nanoparticles, which are continuously introduced into the reactor with carrier gas. The carbon source decomposes on the FBC particles, growing CNTs floating in the gas phase. Substrate edges in the reactor intercept these floating CNTs, guiding their growth and significantly increasing the probability of “kite” mode growth. FeCu catalysts grown CNT horizontal arrays showed markedly improved yield, density, and uniformity compared to Fe catalysts.
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Professor at Indian Institute of Technology, Bombay
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