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Whitepaper 1437
Whitepaper 1437
1437
Carbon nanotubes, which consist of rolled graphene sheets built from sp2 hybridized
carbon atoms, are now attracting scientists from various disciplines due to their
fascinating physico-chemical properties. In this account, we will review the recent
progress on the synthetic techniques for the large-scale production of carbon nano-
tubes, especially focusing on the floating-catalyst method used in the chemical vapour
deposition (CVD) process. We will also describe effective purification methods avoid-
ing structural damage, and discuss the electrochemical applications of these systems
including the fabrication of: (i) lithium-ion secondary batteries; (ii) lead-acid batter-
ies; (iii) electric double-layer capacitors; (iv) fuel cells; and (v) multifunctional fillers
in polymer composites. We foresee that carbon nanotubes will find numerous appli-
cations and take an important place in the development of emerging technologies in
the near future.
Keywords: carbon nanotubes; chemical vapour deposition; growth; size-effects
1. Introduction
We will define nanocarbons as materials built at a nanometre scale from sp2
hybridized carbon atoms. These include various forms ranging from fullerenes (Kroto
et al . 1985) and carbon nanotubes (Oberlin et al . 1976; Iijima 1991) to nanoporous
materials (Tanaka et al . 1999). Among them, one-dimensional carbon nanotubes have
attracted particular interest due to their unique morphology, nanosized scale, novel
physico-chemical properties and, furthermore, their versatile applications (Dressel-
haus et al . 1996; Saito et al . 1998; Harris 1999; Ajayan & Zhou 2001; Baughman et
al . 2002; Yasuda et al . 2003). Carbon nanotubes could be visualized as rolled sheets
of graphene (sp2 carbon arranged in a honeycomb lattice), which are sometimes
capped (by a fullerene-like hemisphere) at each end (see figure 1). They could be
either single walled with diameters as small as 0.4 nm, or multi-walled consisting of
1.5
1.0
band gap (eV)
0.5
nested tubes (e.g. 2–30 concentric tubes positioned one inside the other) with outer
diameters ranging from 5 to 100 nm. The constituent cylinders within multi-walled
carbon nanotubes (MWNTs) may possess different chiral structures. In particular, it
has been predicted that the electronic properties of single-walled carbon nanotubes
(SWNTs) may vary from semiconductors to metals, depending upon the chiral angle
(the way the hexagons are positioned with respect to the tube axis) (Dresselhaus et
al . 1996; Saito et al . 1998). Figure 2 shows the band gap, estimated by a tight-binding
approach, as a function of the nanotube radius. The plot indicates that as the nano-
tube’s diameter becomes larger (the curvature of a graphene cylinder becomes less
200 nm 5 nm 5 nm
Figure 3. (a) SEM image exhibiting web-like SWNT structures on the surface of zeolite template.
(b), (c) TEM images of CVD derived SWNTs in an isolated and a bundle state, respectively.
pronounced), the value of the band gap is closer to that of a planar graphene sheet
(Mintmire & White 1995). In particular, three typical chiral structures of SWNTs
have been proposed (armchair, zigzag and helical), and their structures have been
confirmed using scanning tunnelling microscopy (STM) and electron diffraction stud-
ies (Ge & Sattler 1993; Dresselhaus et al . 1996; Wilder et al . 1998). For example, if
the C60 molecule is bisected normally to the fivefold axis, the cap for an ‘armchair’
nanotube is formed, and if the C60 molecule is bisected normally to the threefold
axis, the cap for a ‘zigzag’ nanotube is generated. In addition to the armchair and
zigzag nanotubes, a large number of chiral or helical carbon nanotubes could be
obtained, exhibiting a screw-like hexagonal pattern along the nanotube axis, which
is terminated by a large variety of ‘hemispherical’ but asymmetric caps. It is impor-
tant to emphasize that three-dimensional stacking does not exist in MWNTs, even
though each individual shell consists of a perfect rolled hexagonal graphene sheet.
In MWNTs, the curvature of the graphene sheets is responsible for weaker van der
Waals interactions, thus resulting in a larger inter-layer spacing (0.34 nm) when com-
pared with three-dimensional crystalline graphite (0.335 nm). In this paper, we will
review large-scale synthetic methods for producing carbon nanotubes, their purifica-
tion technique, and finally we will discuss some applications of these nanomaterials
in electrochemical systems and as multifunctional fillers in the fabrication of polymer
composites.
unit: nanometre
1.222
intensity (arb. units)
1.389
arc-discharge
1.223
1.667 1.389 0.989 0.845
CVD
Figure 5. A graphical description of the tip-growth and root-growth nanotube models, in which
the catalytic particles are located at the tip and at the root, respectively. Carbon species are
illustrated as benzene molecules, and the base is the simplified model of the zeolite (Hayashi et
al . 2003).
(a) (b)
3 nm 2 nm
Figure 6. TEM images of the tubes with the catalytic particles (dark contrast) at (a) the root
of the tubes, and (b) the tip of the tube. This demonstrates that the tube growth in the zeolite
floating-substrate method occurs both at the root and at the tip of the tube (Hayashi et al .
2003).
1.667 nm) compared with those produced by the arc-discharge method. In addition,
the intensity of the D-band (ca. 1350 cm−1 ), in the case of CVD-derived SWNTs, is
higher than that of arc-discharge SWNTs (see Dresselhaus & Eklund (2000) and Saito
et al . (2000) for details on Raman spectroscopy). This result indicates a larger defect
concentration, including point defects due to a lower tube-formation temperature. It
is important to emphasize that each Raman spectrum exhibits different RBMs, thus
confirming the diversity of SWNTs produced, due to the different growth conditions
of the metal particles embedded in the zeolite template.
There are two major mechanisms for the catalytic growth of carbon nanotubes
depending on the position of the catalyst with respect to the substrate. Figure 5
shows both the tip-growth mechanism, whereby the catalyst particle is always located
at the tip of a growing tube, and the root-growth mechanism, in which the catalytic
particle is placed at the root (bottom) of the tube (Oberlin et al . 1976; Tibbetts
1984; Tibbetts et al . 1987; Baker 1989). For the SWNTs, catalytic particles can be
found at both: the roots and the tips of the tubes (figure 6). This indicates that
SWNTs are able to grow within these two frameworks. Moreover, we believe that
both growth mechanisms occur simultaneously and depend on the position of the
catalytic particle, which acts as a carbon ‘extruder’.
Regarding the bulk production of nanotubes (concentric graphene tubules) and
nanofibres (irregular carbon nanofilaments) for industrial applications, it is impor-
tant to mention that in the early 1990s, Hyperion Catalysis International, Inc. (Cam-
bridge, MA) started the large-scale production of MWNTs. This company has a wide
range of patents on synthesis and applications of nanotubes and nanofibres of carbon,
which expire in 2004. The Carbon Nanotech Research Institute (CNRI), a subsidiary
of Mitsui & Co., Ltd., plans to engage in developing technologies for the large-scale
production of 120 t of MWNTs annually. Others companies such as Applied Sci-
ences, Inc. (API) and Showa Denko (SDK) already have a large-scale production
capacity for MWNTs, which exhibit a wide distribution of diameters in the range
from 70 to 200 nm. The most interesting point is that all companies selected a cat-
alytic CVD method, and furthermore three companies (not Hyperion) adopted the
floating-reactant technique for the large-scale production of MWNTs. The devel-
opment of the floating-reactant/catalyst techniques allows a three-dimensional dis-
persion of the hydrocarbon together with the catalytic particles derived from the
pyrolysis of organometallic compounds. This results in a semi-continuous production
of MWNTs (Endo 1988; Tibbetts et al . 1994; Lake 2001; Collins et al . 2002).
Therefore, it is clear that a great deal of progress has been achieved related to
the bulk synthesis of carbon nanotubes. However, at present the most important
challenge is to tailor the chirality of SWNTs and MWNTs.
0.34 nm
10 nm 10 nm
Figure 7. (a) HR-TEM image of highly disordered carbon nanotubes. (b) HR-TEM image of an
annealed carbon nanotube at 2800 ◦ C showing linear, stiff graphene layers along the tube axis.
(c) Enlarged HR-TEM image of (b). Note that the distance between adjacent graphene layers
is 0.34 nm.
Chemical methods have been applied for purifying SWNTs. A generalized method
for SWNT purification developed by Smalley and co-workers (Liu et al . 1998) consists
of refluxing as-grown SWNTs in nitric acid solutions. Subsequently, more-effective
purification techniques have been developed with minor physical damage of the tubes
(Bandow et al . 1997; Rinzler et al . 1998; Dillon et al . 1999). Chattopadhyay et al .
(2002) reported the complete removal of metallic impurities through a sonication-
mediated treatment of as-grown SWNTs in a mixture of hydrofluoric and nitric acids.
Also, Martinez et al . (2002) reported a combined technique of high-temperature
air oxidation in conjunction with microwave acid treatments, thus removing a high
portion of metal particles in relatively short periods of time.
For MWNTs, high-temperature treatments in an inert atmosphere (graphitiza-
tion or annealing) are the most effective methods for removing structural defects
(heptagons and heptagon–pentagon pairs) or impurities such as metallic compounds
(Andrews et al . 2001; Grimes et al . 2001; Endo et al . 2001a).
In this context, figure 7 shows the structural transformation of a disordered
MWNT into a highly ordered multi-wall carbon nanotube. This crystallization is
a stepwise process:
(i) straightening and rearrangement of distorted graphene layers,
(ii) fusion between graphene layers, and
(iii) growth to larger graphene layers along the tube axis and removal of stacking
faults between graphene layers (Kim et al . 2003).
4. Electrochemical system
(a) Lithium-ion battery
The outstanding mechanical properties and the high surface-to-volume ratio (due
to their small diameter) make carbon nanotubes potentially useful as anode materi-
als (Endo et al . 1995; Tatsumi et al . 1999; Frackowiak et al . 1999; Wu et al . 1999;
Gao et al . 1999; Frackowiak & Beguin 2002) or as additives (Endo et al . 2001b) in
lithium-ion battery systems. An SEM image of an electrode containing 10 wt % of
(a) (b)
100
95
85
added weight percents of nanotube
0 1 5 10
3 µm
80
0 10 20 30 40 50 60 70
cycle number
Figure 8. (a) SEM micrographs of the anode sheet containing carbon nanotubes in a commercial
lithium-ion battery. (b) The cyclic efficiency of synthetic graphite, heat treated at 2900 ◦ C, as a
function of weight percent, in the range 0–1.5 V, with a current density of 0.2 mA cm−2 .
100
addition of CNTs
to negative plate
60
no addition
40
(vii) The cyclic efficiency of the lithium-ion battery was improved for a relatively
long cycle when compared with that of carbon black.
10 nm
(d ) Fuel cells
Fuel cells have been considered as the next generation of energy devices because
this type of system transforms the chemical reaction energy from hydrogen and oxy-
gen into electric energy (Williams 2001). Carbon nanotubes decorated with metal
nanoparticles as the electrode have doubled the performance of the fuel cell, owing
to the increased catalytic activity of nanotube-based electrodes (Britto et al . 1999;
Che et al . 1999; Yoshitake et al . 2002). In this context, we have reported the efficient
impregnation of Pt nanoparticles (outer diameter less than 3 nm) on cup-stacked-
type carbon nanotubes (Endo et al . 2003). The method involves dispersion of the
fibres in H2 PtCl6 , followed by low-temperature annealing. The Pt particle deposition
is always homogeneous, and can be controlled selectively on the outer or inner core
using the hydrophobic nature of the material (see figure 10). Since the Pt particle
activity on the fibres is high, this material could find application as an efficient cata-
lyst or biological device. It may be that carbon nanotube technology will contribute
to the development of fuel cells as a catalyst support and also as a main component
of bipolar systems. However, additional basic and applied research is necessary.
D = 1.37 nm
armchair (10,10)
tensile stress (GPa)
100
zigzag (17,0)
50 CNT
σ b = 11–63 GPa
ε b ~ 12%
E = 0.94 TPa
D = 1.35 nm
0 5 10 15 20
strain, ε (%)
Figure 11. Stress–strain response of a carbon nanotube under tensile loading.
human hair
nanogear
0.2 mm
0.1 mm
2 µm
Figure 12. SEM image of the smallest working gear (carbon nanotube/nylon composite);
the inset shows the fractured surface.
The best use of the intrinsic properties of these fibrous nanocarbons in polymers
can be achieved by optimizing the interface interaction of the nanotube surface and
the polymer. Therefore, surface treatments via oxidation could be used in order to
improve adhesion properties between the filler and the matrix. This results in a good
stress transfer from the polymer to the nanotube. There are various surface oxida-
tive processes, such as electrochemical, chemical and plasma techniques. From the
industrial point of view, ozone treatment is a very attractive technique. In addition,
the dispersion of the nanotubes/nanofibres in the polymer should be uniform within
the matrix.
The smallest working composite gear has been prepared by mixing nanotubes into
molten nylon and then injecting into the tiny mould. As shown in figure 12, this gear
is as small as the diameter of a human hair. This piece exhibits a high mechanical
strength, high abrasion resistance and also good electrical and thermal conductivity.
When cup-stacked-type carbon nanotubes are incorporated in polypropylene, the
improvement of the tensile strength is very noticeable (up to 40%). This remarkable
result can be explained by the particular morphology of cup-stacked-type carbon
nanotubes. In other words, a large portion of edge sites on the outer surface of the
nanotubes might act as nucleation sites, resulting in good adhesion between nano-
tubes and polymers (good stress transfer). Recently, various studies on the nucle-
ation effect of nanotubes on the crystallization of semi-crystalline polymers have
been reported (Valentini et al . 2003; Bhattacharyya et al . 2003; Cadek et al . 2003).
6. Conclusion
This account has mainly described the possible routes to large-scale synthesis of
carbon nanotubes (single and multi-walled), with emphasis on their applications in
electrochemical systems and polymer nanocomposites. The unique electronic prop-
erties of nanotubes also make them good candidates in the electronics industry for
replacing silicon-based technologies with those based on nanocarbons (Collins &
Avouris 2002). At present, researchers are working on the following areas in order to
apply carbon nanotubes in emerging technologies.
(i) Production of defect-free and high-purity carbon nanotubes.
(ii) Establishment of useful techniques for quantifying the number of defects (their
types, where they are, etc.) in the nanotube structure.
(iii) Development of effective purification techniques (below the parts per million
level) for the metal particles within carbon nanotubes, especially for biological
and electronic applications.
(iv) Achieving homogeneous carbon nanotube dispersions in polymer composites.
The possible applications of carbon nanotubes range from electronics to field-
emission displays, energy-storage devices and functional fillers in composites. These
have attracted both industrial and academic interest. Therefore, it is important that
some of the basic knowledge is transferred to industry very shortly so that real and
novel technologies appear commercially.
We are thankful for financial support from the CLUSTER of Ministry of Education, Culture,
Sports, Science and Technology. We also thank CONACYT-México, grants W-8001-Millennium
Initiative (H.T., M.T.), 37589-U (M.T.) and 41464-Inter American Collaboration (M.T.).
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