Modifying the morphology and properties of aligned CNT foams through secondary CNT growth.

In this work, we report for the first time, growth of secondary carbon nanotubes (CNTs) throughout a three-dimensional assembly of CNTs. The assembly of nanotubes was in the form of aligned CNT/carbon (ACNT/C) foams. These low-density CNT foams were conformally coated with an alumina buffer layer using atomic layer deposition. Chemical vapor deposition was further used to grow new CNTs. The CNT foam's extremely high porosity allowed for growth of secondary CNTs inside the bulk of the foams. Due to the heavy growth of new nanotubes, density of the foams increased more than 2.5 times. Secondary nanotubes had the same graphitic quality as the primary CNTs. Microscopy and chemical analysis revealed that the thickness of the buffer layer affected the diameter, nucleation density as well as growth uniformity across the thickness of the foams. The effects of secondary nanotubes on the compressive mechanical properties of the foams was also investigated.

Ultralight Interconnected Metal Oxide Nanotube Networks.

Record-breaking ultralow density aluminum oxide structures are prepared using a novel templating technique. The alumina structures are unique in that they are comprised by highly aligned and interconnected nanotubes yielding anisotropic behavior. Large-scale network structures with complex form-factors can easily be made using this technique. The application of the low density networks as humidity sensing materials as well as thermal insulation is demonstrated.

Ultralight anisotropic foams from layered aligned carbon nanotube sheets.

In this work, we present large scale, ultralight aligned carbon nanotube (CNT) structures which have densities an order of magnitude lower than CNT arrays, have tunable properties and exhibit resiliency after compression. By stacking aligned sheets of carbon nanotubes and then infiltrating with a pyrolytic carbon (PyC), resilient foam-like materials were produced that exhibited complete recovery from 90% compressive strain. With density as low as 3.8 mg cm(-3), the foam structure is over 500 times less dense than bulk graphite. Microscopy revealed that PyC coated the junctions among CNTs, and also increased CNT surface roughness. These changes in the morphology explain the transition from inelastic behavior to foam-like recovery of the layered CNT sheet structure. Mechanical and thermal properties of the foams were tuned for different applications through variation of PyC deposition duration while dynamic mechanical analysis showed no change in mechanical properties over a large temperature range. Observation of a large and linear electrical resistance change during compression of the aligned CNT/carbon (ACNT/C) foams makes strain/pressure sensors a relevant application. The foams have high oil absorption capacities, up to 275 times their own weight, which suggests they may be useful in water treatment and oil spill cleanup. Finally, the ACNT/C foam's high porosity, surface area and stability allow for demonstration of the foams as catalyst support structures.

High performance carbon nanotube--polymer nanofiber hybrid fabrics.

Stable nanoscale hybrid fabrics containing both polymer nanofibers and separate and distinct carbon nanotubes (CNTs) are highly desirable but very challenging to produce. Here, we report the first instance of such a hybrid fabric, which can be easily tailored to contain 0-100% millimeter long CNTs. The novel CNT - polymer hybrid nonwoven fabrics were created by simultaneously electrospinning nanofibers onto aligned CNT sheets which were drawn and collected on a grounded, rotating mandrel. Due to the unique properties of the CNTs, the hybrids show very high tensile strength, very small pore size, high specific surface area and electrical conductivity. In order to further examine the hybrid fabric properties, they were consolidated under pressure, and also calendered at 70 °C. After calendering, the fabric's strength increased by an order of magnitude due to increased interactions and intermingling with the CNTs. The hybrids are highly efficient as aerosol filters; consolidated hybrid fabrics with a thickness of 20 microns and areal density of only 8 g m(-2) exhibited ultra low particulate (ULPA) filter performance. The flexibility of this nanofabrication method allows for the use of many different polymer systems which provides the opportunity for engineering a wide range of nanoscale hybrid materials with desired functionalities.