(706e) CVD Growth of Continuous Carbon Nanotube Arrays in Segregated Reactant Flow

Scalable and low-cost production of ultra-long carbon nanotubes (CNTs) will enable rapid insertion of these materials in electronic and structural technologies. In chemical vapor deposition (CVD) systems, precise control over reactor flow and thermal characteristics as well as uniformity and composition of the catalyst is needed. Furthermore, premature CNT growth termination often occurs due to amorphous carbon deposition or structural aggregation. Mainstream Engineering is developing a method for continuous production of ultra-long CNTs via a structure-directed downward growth mechanism. A novel CNT growth reactor has been designed which is designed to segregate CVD gas flow and mitigate some causes of growth termination. Another focus of this work is to grow long, straight and continuous CNT arrays/fibers at low temperature. Low-temperature growth presents challenges associated with catalyst treatment, composition and growth conditions. The system is also designed to structure-direct catalyst sites of high curvature without regard to substrate/catalyst surface energy, enabling the seeded process. We will discuss the current development as well as the technological roadmap to low-cost and large-scale manufacturing of continuous CNTs.