Suspended heated silicon platform for rapid thermal control of surface reactions with application to carbon nanotube synthesis.

Rapid continuous thermal control of chemical reactions such as those for chemical vapor deposition (CVD) growth of nanotubes and nanowires cannot be studied using traditional reactors such as tube furnaces, which have large thermal masses. We present the design, modeling, and verification of a simple, low-cost reactor based on resistive heating of a suspended silicon platform. This system achieves slew rates exceeding 100 degrees C/s, enabling studies of rapid heating and thermal cycling. Moreover, the reaction surface is available for optical monitoring. A first-generation CVD apparatus encapsulates the heated silicon platform inside a sealed quartz tube, and initial experiments demonstrate growth of films of tangled single-wall and aligned multiwall carbon nanotubes using this system. The reactor can be straightforwardly scaled to larger or smaller substrate sizes and may be extended for a wide variety of reactions, for performing in situ reaction diagnostics, for chip-scale growth of nanostructures, and for rapid thermal processing of microelectronic and micromechanical devices.

Rapid growth and flow-mediated nucleation of millimeter-scale aligned carbon nanotube structures from a thin-film catalyst.

We discuss the rapid growth of films and lithographically templated microstructures of vertically aligned small-diameter multiwalled carbon nanotubes (VA-MWNTs), by atmospheric-pressure thermal chemical vapor deposition (CVD) of C2H4/H2/Ar on a Fe/Al2O3 catalyst film deposited by electron beam evaporation. The structures grow to 1 mm height in 15 min and reach close to 2 mm in 60 min. The growth rate and final height of CNT microstructures grown from catalyst patterns depend strongly on the local areal density of catalyst, representing a reverse analogue of loading effects which occur in plasma etching processes. Abrupt transitions between areas of micrometer-thick tangled CNT films and millimeter-scale aligned CNT structures are manipulated by changing the duration of pretreatment by H2/Ar prior to introduction of C2H4 and by changing the configuration of the substrate sample in the furnace tube. This demonstrates that the flow profile over the sample mediates the supply of reactants to the catalyst and that pretreatment using H2 significantly affects the initial activity of the catalyst.

Extremely Elastic Wearable Carbon Nanotube Fiber Strain Sensor for Monitoring of Human Motion.

The increasing demand for wearable electronic devices has made the development of highly elastic strain sensors that can monitor various physical parameters an essential factor for realizing next generation electronics. Here, we report an ultrahigh stretchable and wearable device fabricated from dry-spun carbon nanotube (CNT) fibers. Stretching the highly oriented CNT fibers grown on a flexible substrate (Ecoflex) induces a constant decrease in the conductive pathways and contact areas between nanotubes depending on the stretching distance; this enables CNT fibers to behave as highly sensitive strain sensors. Owing to its unique structure and mechanism, this device can be stretched by over 900% while retaining high sensitivity, responsiveness, and durability. Furthermore, the device with biaxially oriented CNT fiber arrays shows independent cross-sensitivity, which facilitates simultaneous measurement of strains along multiple axes. We demonstrated potential applications of the proposed device, such as strain gauge, single and multiaxial detecting motion sensors. These devices can be incorporated into various motion detecting systems where their applications are limited to their strain.

Force output, control of film structure, and microscale shape transfer by carbon nanotube growth under mechanical pressure.

We demonstrate that a film of vertically aligned multiwall carbon nanotubes (CNTs) can exert mechanical energy as it grows, and in our experiments the average force output is approximately 0.16 nN per CNT, for CNTs having an outer diameter of 9 nm and five walls. The film thickness after a fixed growth time and the alignment of CNTs within the film decrease concomitantly with increasing pressure which is applied by placing a weight on the catalyst substrate prior to growth, and CNTs grown under applied pressure exhibit significant structural faults. The measured mechanical energy density of CNT growth is significantly less than the energies of primary steps in the CNT formation process yet, based on the film volume, is comparable to the energy density of muscle and based on the volume of CNTs is comparable to hydraulic actuators. We utilize this principle to fabricate three-dimensional structures of CNTs which conform to the shape of a microfabricated template. This technique is a catalytic analogue to micromolding of polymer and metal microstructures; it enables growth of nanostructures in arbitrarily shaped forms having sloped surfaces and nonorthogonal corners and does not require patterning of the catalyst before growth.