Insight into BN Impurity Formation during Boron Nitride Nanotube Synthesis by High-Temperature Plasma.

The high-temperature plasma process has demonstrated great potential in growing high-quality boron nitride nanotubes (BNNTs) with small diameters (∼5 nm) and few walls (3-4 walls) and led to successful commercialization with a high production rate approaching 20 g/h. However, the process is still accompanied by the production of BN impurities (e.g., a-BN, BN shell, BN flakes) whose physicochemical properties are similar to those of BNNTs. This renders the post-purification process very challenging and thus hampers the development of their practical applications. In this study, we have employed both experimental and numerical approaches for a mechanistic understanding of BN impurity formation in the high-temperature plasma process. This study suggests that the flow structure of the plasma jet (e.g., laminar or turbulent) plays a key role in the formation of BN impurities by dictating the transport phenomena of BNNT seeds (e.g., B droplets), which play an important role in BNNT nucleation. We discussed that the turbulence enhances the radial diffusion of B droplets as well as their interparticle coagulation, which leads to a significant reduction in the population of effective BNNT seeds in the BNNT growth zone (T < 4000 K). This results in the generation of unreacted BN precursors (e.g., B-N-H species) in the BNNT growth zone that eventually self-assemble into BN impurities. Our numerical simulation also suggests that a higher thermal energy input makes the flow more turbulent in the BNNT growth zone due to the elevated velocity difference between the plasma jet and ambient cold gas. This finding provides critical insight into the process design that can suppress the BN impurity formation in the high-temperature plasma process.

Enriched Pyridinic Nitrogen Atoms at Nanoholes of Carbon Nanohorns for Efficient Oxygen Reduction.

Nitrogen (N)-doped nanostructured carbons have been actively examined as promising alternatives for precious-metal catalysts in various electrochemical energy generation systems. Herein, an effective approach for synthesizing N-doped single-walled carbon nanohorns (SWNHs) with highly electrocatalytic active sites via controlled oxidation followed by N2 plasma is presented. Nanosized holes were created on the conical tips and sidewalls of SWNHs under mild oxidation, and subsequently, the edges of the holes were easily decorated with N atoms. The N atoms were present preferentially in a pyridinic configuration along the edges of the nanosized holes without significant structural change of the SWNHs. The enriched edges decorated with the pyridinic-N atoms at the atomic scale increased the number of active sites for the oxygen reduction reaction, and the inherent spherical three-dimensional feature of the SWNHs provided good electrical conductivity and excellent mass transport. We demonstrated an effective method for promoting the electrocatalytic active sites within N-doped SWNHs by combining defect engineering with the preferential formation of N atoms having a specific configuration.

Direct spinning and densification method for high-performance carbon nanotube fibers.

Developing methods to assemble nanomaterials into macroscopic scaffolds is of critical significance at the current stage of nanotechnology. However, the complications of the fabrication methods impede the widespread usages of newly developed materials even with the superior properties in many cases. Here, we demonstrate the feasibility of a highly-efficient and potentially-continuous fiber-spinning method to produce high-performance carbon nanotube (CNT) fiber (CNTF). The processing time is <1 min from synthesis of CNTs to fabrication of highly densified and aligned CNTFs. CNTFs that are fabricated by the developed spinning method are ultra-lightweight, strong (specific tensile strength = 4.08 ± 0.25 Ntex-1), stiff (specific tensile modulus = 187.5 ± 7.4 Ntex-1), electrically conductive (2,270 S m2kg-1), and highly flexible (knot efficiency = 48 ± 15%), so they are suitable for various high-value fabric-based applications.

Electrically and Thermally Conductive Carbon Fibre Fabric Reinforced Polymer Composites Based on Nanocarbons and an In-situ Polymerizable Cyclic Oligoester.

There is growing interest in carbon fibre fabric reinforced polymer (CFRP) composites based on a thermoplastic matrix, which is easy to rapidly produce, repair or recycle. To expand the applications of thermoplastic CFRP composites, we propose a process for fabricating conductive CFRP composites with improved electrical and thermal conductivities using an in-situ polymerizable and thermoplastic cyclic butylene terephthalate oligomer matrix, which can induce good impregnation of carbon fibres and a high dispersion of nanocarbon fillers. Under optimal processing conditions, the surface resistivity below the order of 10+10 Ω/sq, which can enable electrostatic powder painting application for automotive outer panels, can be induced with a low nanofiller content of 1 wt%. Furthermore, CFRP composites containing 20 wt% graphene nanoplatelets (GNPs) were found to exhibit an excellent thermal conductivity of 13.7 W/m·K. Incorporating multi-walled carbon nanotubes into CFRP composites is more advantageous for improving electrical conductivity, whereas incorporating GNPs is more beneficial for enhancing thermal conductivity. It is possible to fabricate the developed thermoplastic CFRP composites within 2 min. The proposed composites have sufficient potential for use in automotive outer panels, engine blocks and other mechanical components that require conductive characteristics.