One millimeter per minute growth rates for single wall carbon nanotube forests enabled by porous metal substrates

Matsumoto, Naoyuki; Oshima, Azusa; Ishizawa, Sachiko; Chen, Guohai; Hata, Kenji; Futaba, Don N.

doi:10.1039/c7ra13093g

Cited by 12 publications

(6 citation statements)

References 33 publications

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“…CNT growth rates measured without sulfur addition have diffusion-limited values of 0.2-17 µm s −1[219,220,221,222]. Growth rates of CNTs in direct-spinning systems are not diffusion-limited and a recent paper has shown that S increases the growth rate[223].…”

mentioning

confidence: 99%

Mapping the parameter space for direct-spun carbon nanotube aerogels

Weller

Smail

Elliott

et al. 2019

Carbon

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confidence: 99%

Mapping the parameter space for direct-spun carbon nanotube aerogels

Weller

Smail

Elliott

et al. 2019

Carbon

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“…It has been previously shown that by using metal mesh substrates, uniform gas delivery could be achieved resulting in the exceptionally high speed synthesis as high as 1 mm/min of SWCNTs and the catalyst-substrate system could be grown for arbitrarily long periods, independent of a fluidization requirement [12]. While this report did demonstrate that a mesh substrate could increase SWCNT yield by ∼8-fold, a single layer would be insufficient for mass production purposes.…”

Section: Introductionmentioning

confidence: 63%

“…In place of silicon substrates, stainless steel (SUS) mesh substrates with aperture size (0.35 mm), wire diameter (0.21 mm) and open porosity of 29.9% and sputtered on both sides were used. This variety was chosen as it was found to be the optimum structure for achieving high efficiency SWCNT growth [12]. It should be noted that the catalyst thickness was chosen because it is well-known to grow SWCNT forests in high efficiency from silicon substrates.…”

Section: Methodsmentioning

confidence: 99%

“…Each substrate served two roles: One, they acted as high surface growth substrates (2.8-times that of a flat nonporous substrate). We previously demonstrated the high efficiency synthesis of SWCNT forests (height: > 3.47 mm, average growth rate: 301 m/min, and yield: 12.7 mg/cm 2 in 10 min growth time) in vertical furnace [12]. We also showed that the initial growth rates could exceed 1 millimeter per minute (1000 m/min) in this reference.…”

Section: Introductionmentioning

confidence: 99%

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High Yield Single-Walled Carbon Nanotube Synthesis Through Multilayer Porous Mesh Substrates

Matsumoto

Ishizawa

Hata

et al. 2018

e-J. Surf. Sci. Nanotech.

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We demonstrate the high yield synthesis of single-walled carbon nanotubes (SWCNTs) using a multi-layer, threedimensional (3-D) metal mesh porous substrate consisting of eight parallel and evenly spaced mesh substrates. SWCNT yield in this synthesis improved 78-times compared to that of a single flat nonporous substrate. In addition, the total SWCNT yield was greater than eight-fold (mesh layered number). This yield improvement caused from the two reasons. First, mesh substrate could play a role as higher surface substrates than that of a flat nonporous substrate. Second, it also could achieve gas heating elements to allow the uniform delivery of heated source gases. In addition, CNTs grown were sustained the single-walled structure from the first layer to the final (8th) layer. This architecture leads to achieve the total carbon conversion efficiency of above 80% with single-walled structure (average: 1.2 number of walls). We can demonstrate this process as an interesting alternative approach for the efficient synthesis of high yield SWCNT synthesis for mass production through simply a change to the layered porous substrates (metal meshes).

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“…Finally, we explored how experimental and simulation data may be combined to understand a typical graphene growth process using the above-mentioned example of the synthesis of adlayer-free and single-crystalline SLG on Cu(111) foils. While there have been previous attempts to simulate reactor conditions for the CVD growth of nanomaterials, ,, to the best of our knowledge, this is the first systematic exploration for 2D materials synthesis. Based on this study, we have identified the different external parameters that typically control the reaction environment and designed a recommended protocol for experimentalists to use to report a process in the literature in a way that will facilitate its reproduction in a different reactor by an interested researcher (Figure ).…”

Section: Introductionmentioning

confidence: 99%

Repeatability and Reproducibility in the Chemical Vapor Deposition of 2D Films: A Physics-Driven Exploration of the Reactor Black Box

Chatterjee,

Abadie,

Wang

et al. 2024

Chem. Mater.

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Although chemical vapor deposition (CVD) remains the method of choice for synthesizing defect-free and high-quality 2D films (such as graphene and h-BN), the method has serious issues with process repeatability and reproducibility. This makes it difficult to build up from the literature, test a hypothesis quickly, or scale up a process. The primary reason for this is that the CVD reactor, to this day, remains a black box with a reaction environment that is poorly understood and cannot be measured or monitored directly. Consequently, it is also difficult to study process kinetics and growth mechanisms and correlate experimental results to atomic-level simulations. A possible way to overcome this problem is to use Computational Fluid Dynamics (CFD), both to identify the measurable external (process and reactor) parameters that control the reaction environment and to simulate this reaction environment and understand how it changes when these controllable external parameters are varied. This paper describes how this may be done in practice using the growth of single-layer graphene in a hot-wall tube reactor as the representative case and the CFD toolbox OpenFOAM. Based on our findings, we have shown why it is critical (1) to understand the flow properties inside the reactor and combine it with experimental results to study the growth process for graphene and other 2D films and (2) to measure, monitor, and report all relevant external parameters to ensure process repeatability and reproducibility.

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One millimeter per minute growth rates for single wall carbon nanotube forests enabled by porous metal substrates

Abstract: We report an exceptionally high-efficiency synthesis of long single-wall carbon nanotube (SWCNT) forests using a porous substrate (metal meshes) in place of nonporous flat substrates.

Cited by 12 publications

References 33 publications

Mapping the parameter space for direct-spun carbon nanotube aerogels

Mapping the parameter space for direct-spun carbon nanotube aerogels

High Yield Single-Walled Carbon Nanotube Synthesis Through Multilayer Porous Mesh Substrates

Repeatability and Reproducibility in the Chemical Vapor Deposition of 2D Films: A Physics-Driven Exploration of the Reactor Black Box

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