Method of and Printable Compositions for Manufacturing a Multilayer Carbon Nanotube Capacitor

Abstract

Multilayer carbon nanotube capacitors, and methods and printable compositions for manufacturing multilayer carbon nanotubes (CNTs) are disclosed. A first capacitor embodiment comprises: a first conductor; a plurality of fixed CNTs in an ionic liquid, each fixed CNT comprising a magnetic catalyst nanoparticle coupled to a carbon nanotube and further coupled to the first conductor; and a first plurality of free CNTs dispersed and moveable in the ionic liquid. Another capacitor embodiment comprises: a first conductor; a conductive nanomesh coupled to the first conductor; a first plurality of fixed CNTs in an ionic liquid and further coupled to the conductive nanomesh; and a plurality of free CNTs dispersed and moveable in the ionic liquid. Various methods of printing the CNTs and other structures, and methods of aligning and moving the CNTs using applied electric and magnetic fields, are also disclosed.

1 . A method of fabricating a capacitor, the method comprising:
 depositing a plurality of carbon nanotube-magnetic catalyst nanoparticle structures dispersed in an ionic liquid over a first conductor, each carbon nanotube-magnetic catalyst nanoparticle structure comprising a carbon nanotube coupled to a magnetic catalyst nanoparticle;   using an applied magnetic field, aligning and moving the plurality of CNT-magnetic catalyst nanoparticle structures toward the first conductor;   coupling the magnetic catalyst nanoparticles to the first conductor to form a first plurality of fixed carbon nanotubes; and   depositing a first plurality of carbon nanotubes dispersed and moveable in an ionic liquid over the first plurality of fixed carbon nanotubes to form a first plurality of free carbon nanotubes.   
     
     
         2 . The method of  claim 1 , wherein prior to the step of depositing a plurality of carbon nanotube-magnetic catalyst nanoparticle structures, the method further comprises:
 providing a support structure coupled to the first conductor.   
     
     
         3 . The method of  claim 2 , wherein the step of providing a support structure further comprises:
 electrospinning a polymer over the first conductor to form the support structure.   
     
     
         4 . The method of  claim 3 , wherein the polymer is at least one polymer selected from the group consisting of: polypyrolle; polianiline; polythiophene;
 polyterthiophene; derivatives of polythiophene and polyterthiophene; poly(3,4-ethylenedioxythiophene) (PEDOT); poly(3-(4-fluorophenyl)thiophene) (MPFT); poly(3-(3,4-difluorophenyl)thiophene) (MPFT); poly(3-(4-trifluoromethylphenyl)-thiophene) (PTFMPT); poly(1-cyano-2-(2-(3,4-ethylenedioxylthienyl))-1-(2-thienyl)vinylene (ThCNVEDT); poly(3-methyl thiophene)(PMeT); and mixtures thereof.   
     
     
         5 . The method of  claim 2 , wherein the step of providing a support structure further comprises:
 attaching a screen or a mesh structure over and spaced apart from the first conductor.   
     
     
         6 . The method of  claim 2 , wherein the step of aligning and moving the plurality of CNT-magnetic catalyst nanoparticle structures toward the first conductor further comprises:
 using the applied magnetic field, aligning and moving the plurality of CNT-magnetic catalyst nanoparticle structures through the support structure and toward the first conductor.   
     
     
         7 . The method of  claim 1 , further comprising:
 applying solder over the first conductor.   
     
     
         8 . The method of  claim 7 , wherein the step of coupling the magnetic catalyst nanoparticles to the first conductor to form a first plurality of fixed carbon nanotubes further comprises:
 heating the magnetic catalyst nanoparticles, the solder and the first conductor to bond the magnetic catalyst nanoparticles to the first conductor.   
     
     
         9 . The method of  claim 1 , wherein the step of aligning and moving the plurality of CNT-magnetic catalyst nanoparticle structures toward the first conductor further comprises:
 rotating and translating the plurality of CNT-magnetic catalyst nanoparticle structures toward the first conductor.   
     
     
         10 . The method of  claim 1 , further comprising:
 etching the first conductor.   
     
     
         11 . The method of  claim 1 , further comprising:
 coupling a semipermeable membrane over the first plurality of free carbon nanotubes.   
     
     
         12 . The method of  claim 11 , further comprising:
 depositing a second plurality of carbon nanotubes dispersed and moveable in an ionic liquid over the semipermeable membrane to form a second plurality of free carbon nanotubes.   
     
     
         13 . The method of  claim 12 , wherein the first plurality of fixed carbon nanotubes coupled to the first conductor comprises a first electrode, and wherein the method further comprises:
 attaching a second electrode over the second plurality of free carbon nanotubes, the second electrode comprising a second plurality of fixed carbon nanotubes coupled to a second conductor.   
     
     
         14 . The method of  claim 1 , wherein the step of depositing the plurality of carbon nanotube-magnetic catalyst nanoparticle structures further comprises:
 printing the plurality of carbon nanotube-magnetic catalyst nanoparticle structures dispersed in an ionic liquid over the first conductor.   
     
     
         15 . The method of  claim 1 , wherein the step of depositing the plurality of carbon nanotube-magnetic catalyst nanoparticle structures further comprises:
 printing the first plurality of carbon nanotubes dispersed and moveable in an ionic liquid over the first plurality of fixed carbon nanotubes.   
     
     
         16 . The method of  claim 1 , wherein the ionic liquid is at least one ionic liquid selected from the group consisting of: butyltrimethylammonium bis(trifluoromethylsulfonyl)imide, 1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide, 1-methyl-3-propylimidazolium bis(trifluoromethylsulfonyl)imide, 1-hexyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide, 1-methyl-3-propylimidazolium iodide, 1-ethyl-3-methylimidazolium thiocyanate, 1-methyl-1-propylpiperidinium bis(trifluoromethylsulfonyl)imide, 1-butyl-2-methylpyridinium bis(trifluoromethylsulfonyl)imide, 1-butyl-4-methylpyridinium bis(trifluoromethylsulfonyl)imide, 1-butyl-1-methylpyrrolidinium bis(trifluoromethylsulfonyl)imide, diethylmethylsulfonium bis(trifluoromethylsulfonyl)imide, lithium bis(trifluoromethylsulfonyl)imide, and mixtures thereof. 
     
     
         17 . The method of  claim 1 , wherein the magnetic catalyst nanoparticle is at least one catalyst selected from the group consisting of: cobalt, molybdenum, nickel, iron, ruthenium, mixtures thereof; alloys thereof; and their compounds. 
     
     
         18 . The method of  claim 1 , wherein for each fixed carbon nanotube of the first plurality of fixed carbon nanotubes, the magnetic catalyst nanoparticle is coupled to the carbon nanotube at a first end of the carbon nanotube and the carbon nanotube is open or uncapped at a second end opposite the first end coupled to the magnetic catalyst nanoparticle, and wherein each carbon nanotube of the first plurality of free carbon nanotubes is open or uncapped at least at one end. 
     
     
         19 . The method of  claim 1 , wherein each fixed carbon nanotube of the first plurality of fixed carbon nanotubes is single-walled, and wherein each carbon nanotube of the first plurality of free carbon nanotubes is multi-walled or single-walled. 
     
     
         20 . The method of  claim 1 , wherein each carbon nanotube of the first plurality of fixed carbon nanotubes and each carbon nanotube of the first plurality of free carbon nanotubes has an interior diameter between about 0.5 m and 1.5 m. 
     
     
         21 . A printable carbon nanotube composition comprising:
 an ionic liquid; and   a plurality of carbon nanotube-magnetic catalyst nanoparticle structures dispersed in the ionic liquid, each carbon nanotube-magnetic catalyst nanoparticle structure comprising a carbon nanotube coupled to a magnetic catalyst nanoparticle.   
     
     
         22 . The composition of  claim 21 , wherein the magnetic catalyst nanoparticle is at least one catalyst selected from the group consisting of: cobalt, molybdenum, nickel, iron, ruthenium, mixtures thereof; alloys thereof; and their compounds. 
     
     
         23 . The composition of  claim 21 , wherein the ionic liquid is at least one ionic liquid selected from the group consisting of: butyltrimethylammonium bis(trifluoromethylsulfonyl)imide, 1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide, 1-methyl-3-propylimidazolium bis(trifluoromethylsulfonyl)imide, 1-hexyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide, 1-methyl-3-propylimidazolium iodide, 1-ethyl-3-methylimidazolium thiocyanate, 1-methyl-1-propylpiperidinium bis(trifluoromethylsulfonyl)imide, 1-butyl-2-methylpyridinium bis(trifluoromethylsulfonyl)imide, 1-butyl-4-methylpyridinium bis(trifluoromethylsulfonyl)imide, 1-butyl-1-methylpyrrolidinium bis(trifluoromethylsulfonyl)imide, diethylmethylsulfonium bis(trifluoromethylsulfonyl)imide, lithium bis(trifluoromethylsulfonyl)imide, and mixtures thereof. 
     
     
         24 . A method of fabricating a capacitor, the method comprising:
 depositing a plurality of conductive nanorods over a first conductor to form a first conductive nanomesh;   depositing a first plurality of carbon nanotubes dispersed in an ionic liquid over the first conductive nanomesh and the first conductor;   using an applied electric field and an applied magnetic field, aligning and moving at least some of the carbon nanotubes of the first plurality of carbon nanotubes into the first conductive nanomesh and toward the first conductor;   coupling at least some of the carbon nanotubes to the first conductive nanomesh or to the first conductor to form a first plurality of fixed carbon nanotubes; and   depositing a second plurality of carbon nanotubes dispersed and moveable in an ionic liquid over the first plurality of fixed carbon nanotubes to form a first plurality of free carbon nanotubes.   
     
     
         25 . The method of  claim 24 , wherein the first conductive nanomesh is metallic. 
     
     
         26 . The method of  claim 25 , wherein the first conductive nanomesh comprises gold or palladium nanorods. 
     
     
         27 . The method of  claim 24 , wherein the first conductive nanomesh comprises metallic nanorods having a diameter of less than about 100 nm and a length between about 200 nm and about 1.0 microns. 
     
     
         28 . The method of  claim 24 , wherein the first conductor is coupled to a substrate or wherein the first conductor is a conductive substrate. 
     
     
         29 . The method of  claim 24 , wherein the coupling step further comprises:
 applying heat to at least some of the carbon nanotubes, to the conductive nanomesh, and to the first conductor to form the first plurality of fixed carbon nanotubes.   
     
     
         30 . The method of  claim 24 , wherein the coupling step further comprises:
 sintering at least some of the carbon nanotubes to the conductive nanomesh or to the first conductor to form the first plurality of fixed carbon nanotubes.   
     
     
         31 . The method of  claim 24 , wherein the step of aligning and moving further comprises:
 rotating and translating at least some of the carbon nanotubes of the first plurality of carbon nanotubes into the nanomesh and toward the first conductor.   
     
     
         32 . The method of  claim 24 , further comprising:
 etching the first conductor.   
     
     
         33 . The method of  claim 24 , further comprising:
 coupling a semipermeable membrane over the first plurality of free carbon nanotubes.   
     
     
         34 . The method of  claim 33 , further comprising:
 depositing a third plurality of carbon nanotubes dispersed and moveable in an ionic liquid over the semipermeable membrane to form a second plurality of free carbon nanotubes.   
     
     
         35 . The method of  claim 34 , wherein the first plurality of fixed carbon nanotubes coupled to the conductive nanomesh or the first conductor comprises a first electrode, and wherein the method further comprises:
 attaching a second electrode over the second plurality of free carbon nanotubes, the second electrode comprising a second plurality of fixed carbon nanotubes coupled to a second conductive nanomesh or to a second conductor.   
     
     
         36 . The method of  claim 24 , wherein the step of depositing the first plurality of carbon nanotubes further comprises:
 printing the plurality of carbon nanotubes dispersed in an ionic liquid over the first conductive nanomesh and the first conductor.   
     
     
         37 . The method of  claim 24 , wherein the step of depositing the second plurality of carbon nanotubes further comprises:
 printing the first plurality of carbon nanotubes dispersed and moveable in an ionic liquid over the first plurality of fixed carbon nanotubes.   
     
     
         38 . The method of  claim 24 , wherein the ionic liquid is at least one ionic liquid selected from the group consisting of: butyltrimethylammonium bis(trifluoromethylsulfonyl)imide, 1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide, 1-methyl-3-propylimidazolium bis(trifluoromethylsulfonyl)imide, 1-hexyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide, 1-methyl-3-propylimidazolium iodide, 1-ethyl-3-methylimidazolium thiocyanate, 1-methyl-1-propylpiperidinium bis(trifluoromethylsulfonyl)imide, 1-butyl-2-methylpyridinium bis(trifluoromethylsulfonyl)imide, 1-butyl-4-methylpyridinium bis(trifluoromethylsulfonyl)imide, 1-butyl-1-methylpyrrolidinium bis(trifluoromethylsulfonyl)imide, diethylmethylsulfonium bis(trifluoromethylsulfonyl)imide, lithium bis(trifluoromethylsulfonyl)imide, and mixtures thereof. 
     
     
         39 . The method of  claim 24 , wherein each fixed carbon nanotube of the first plurality of fixed carbon nanotubes is open or uncapped at least at one end and wherein each carbon nanotube of the first plurality of free carbon nanotubes is open or uncapped at least at one end. 
     
     
         40 . The method of  claim 24 , wherein each fixed carbon nanotube of the first plurality of fixed carbon nanotubes is single-walled, and wherein each carbon nanotube of the first plurality of free carbon nanotubes is multi-walled or single-walled. 
     
     
         41 . The method of  claim 24 , wherein each carbon nanotube of the first plurality of fixed carbon nanotubes and each carbon nanotube of the first plurality of free carbon nanotubes has an interior diameter between about 0.5 m and 1.5 m. 
     
     
         42 . A method of fabricating a capacitor, the method comprising:
 depositing a plurality of metallic nanorods over a first conductor to form a metallic nanomesh comprising gold or palladium nanorods having a diameter of less than about 100 nm and a length between about 200 nm and about 1.0 microns;   depositing a first plurality of carbon nanotubes dispersed in an ionic liquid over the metallic nanomesh and the first conductor;   using an applied electric field and an applied magnetic field, aligning and moving at least some of the carbon nanotubes of the first plurality of carbon nanotubes into the metallic nanomesh and toward the first conductor;   sintering at least some of the carbon nanotubes to the metallic nanomesh or to the first conductor to form a first plurality of fixed carbon nanotubes; and   depositing a second plurality of carbon nanotubes dispersed and moveable in an ionic liquid over the first plurality of fixed carbon nanotubes to form a first plurality of free carbon nanotubes.   
     
     
         43 . A method of fabricating a capacitor, the method comprising:
 electrospinning a polymer over a first conductor to form a support structure;   depositing a plurality of carbon nanotube-magnetic catalyst nanoparticle structures dispersed in an ionic liquid over the first conductor and the support structure, each carbon nanotube-magnetic catalyst nanoparticle structure comprising a carbon nanotube coupled to a magnetic catalyst nanoparticle;   using an applied magnetic field, aligning and moving the plurality of CNT-magnetic catalyst nanoparticle structures toward the first conductor;   coupling the magnetic catalyst nanoparticles to the first conductor to form a first plurality of fixed carbon nanotubes; and   depositing a first plurality of carbon nanotubes dispersed and moveable in an ionic liquid over the first plurality of fixed carbon nanotubes to form a first plurality of free carbon nanotubes.