Methods of making carbon nanotube films, layers, fabrics, ribbons, elements and articles

Abstract

Methods of making carbon nanotube films, layers, fabrics, ribbons, elements and articles are disclosed. Carbon nanotube growth catalyst is applied on to a surface of a substrate. The substrate is subjected to a chemical vapor deposition of a carbon-containing gas to grow a non-woven fabric of carbon nanotubes. Portions of the non-woven fabric are selectively removed according to a defined pattern to create the article. A non-woven fabric of carbon nanotubes may be made by applying carbon nanotube growth catalyst on to a surface of a wafer substrate to create a dispersed monolayer of catalyst. The substrate is subjected to a chemical vapor deposition of a carbon-containing gas to grow a non-woven fabric of carbon nanotubes in contact and covering the surface of the wafer and in which the fabric is substantially uniform density.

1 . A nanotube article manufactured by the following steps:
 applying carbon nanotube growth catalyst on to a surface of a substrate;   subjecting the substrate to a chemical vapor deposition of a carbon-containing gas to grow a non-woven fabric of carbon nanotubes, wherein the nanotubes of the fabric are substantially parallel to said surface of the substrate;   selectively removing portions of the non-woven fabric according to a defined pattern; and   providing first and second electrodes in contact with respective first and second portions of the patterned non-woven fabric;   wherein the patterned non-woven fabric forms a conductive trace between the first and second electrodes to create the nanotube article.   
     
     
         2 . The nanotube article of  claim 1  wherein the carbon nanotube growth catalyst applied to a surface of a substrate includes metallic nanoparticles. 
     
     
         3 . The nanotube article of  claim 1  wherein the carbon nanotube growth catalyst applied to a surface of a substrate includes metal oxide nanoparticles. 
     
     
         4 . The nanotube article of  claim 1  further manufactured by a step of derivitizing the surface of the substrate. 
     
     
         5 . The nanotube article of  claim 4  wherein the step of derivitizing the surface of the substrate includes creating a more hydrophobic environment to promote adhesion of the carbon nanotube growth catalyst. 
     
     
         6 . The nanotube article of  claim 4  wherein the step of derivitizing the surface of the substrate includes creating a more hydrophilic environment to promote adhesion of the carbon nanotube growth catalyst. 
     
     
         7 . The nanotube article of  claim 1  wherein the step of applying carbon nanotube growth catalyst on to a surface of a substrate includes applying a ferritin solution. 
     
     
         8 . The nanotube article of  claim 1  wherein the carbon nanotube growth catalyst creates a substantial monolayer of nanoparticles on the surface of the substrate. 
     
     
         9 . The nanotube article of  claim 1  wherein the step of applying carbon nanotube growth catalyst on to a surface of a substrate includes applying a metal ligand-catalyst precursor. 
     
     
         10 . The nanotube article of  claim 9  wherein the surface is functionalized to promote binding of the ligand. 
     
     
         11 . The nanotube article of  claim 9  wherein the metal ligand-catalyst precursor has a formula ML, in which M is metal from a group including iron, cobalt, or nickel, and in which L is at least one organic ligand. 
     
     
         12 . The nanotube article of  claim 9  wherein the metal ligand-catalyst precursor is applied by a spin coating technique. 
     
     
         13 . The nanotube article of  claim 9  in which the metal ligand-catalyst precursor is oxidized to remove an organic shell therefrom. 
     
     
         14 . The nanotube article of  claim 1  wherein the step of applying carbon nanotube growth catalyst on to a surface of a substrate includes applying a solution of iron oxide nanoparticles on the surface of the substrate. 
     
     
         15 . The nanotube article of  claim 14  wherein a spin coating technique is used to apply the solution of iron oxide. 
     
     
         16 . The nanotube article of  claim 15  wherein the spin coating technique includes repetitive applications of the solution of iron oxide nanoparticles and repetitive distributing thereof by spinning the substrate at a defined rate. 
     
     
         17 . The nanotube article of  claim 1  wherein the step of applying carbon nanotube growth catalyst on to a surface of a substrate includes applying a suspension of liquid metal catalyst precursor on the surface of the substrate. 
     
     
         18 . The nanotube article of  claim 1  wherein the carbon-containing gas comprises methane. 
     
     
         19 . The nanotube article of  claim 1  wherein the carbon-containing gas comprises ethylene. 
     
     
         20 . The nanotube article of  claim 18  wherein chemical vapor deposition is at about 850° C. for about ten minutes and the methane is applied at about a 500 sccm flow. 
     
     
         21 . The nanotube article of  claim 19  wherein chemical vapor deposition is at about 800° C. for about forty minutes and the ethylene is applied at about a 10 sccm flow. 
     
     
         22 . The nanotube article of  claim 1  wherein the step of subjecting the substrate to chemical vapor deposition includes subjecting the substrate to inert gasses. 
     
     
         23 . The nanotube article of  claim 22  wherein the inert gasses comprise a controlled flow of Argon and Hydrogen. 
     
     
         24 . The nanotube article of  claim 23  wherein the controlled flow of Argon and Hydrogen comprises a flow ratio of 1:4. 
     
     
         25 . The nanotube article of  claim 1  further manufactured by a step of oxidizing the substrate prior to chemical vapor deposition. 
     
     
         26 . The nanotube article of  claim 1  wherein the nanotube growth catalysts comprise nanoparticles having selected diameters. 
     
     
         27 . The nanotube article of  claim 1  wherein the carbon nanotubes of the non-woven fabric include metallic nanotubes and semiconducting nanotubes and wherein the relative composition of metallic and semiconducting nanotubes in the fabric is controlled. 
     
     
         28 . The nanotube article of  claim 1  wherein the carbon nanotubes of the non-woven fabric include metallic nanotubes and semiconducting nanotubes and wherein the manufacturing steps further includes selectively removing metallic nanotubes. 
     
     
         29 . The nanotube article of  claim 1  wherein the carbon nanotubes of the non-woven fabric include metallic nanotubes and semiconducting nanotubes and wherein the manufacturing steps further includes selectively removing semiconducting nanotubes.