Deep-injection floating-catalyst chemical vapor deposition to continuously synthesize carbon nanotubes with high aspect ratio and high crystallinity

The deep-injection floating-catalyst chemical vapor deposition (DI-FCCVD) technique is introduced to continuously synthesize carbon nanotubes (CNTs) with high aspect ratio (AR>17000) and high crystal-linity (I-G/I-D > 60) at high production rate (>6 mg/min). In this technique all reactants are injected directly and rapidly into high-temperature reaction zone through thin alumina tube; this process leads to simultaneous thermal decomposition of well-mixed catalyst precursors (ferrocene and thiophene), and thus to formation of uniformly-sized catalyst particles. Carbon nanotube fiber (CNTF) fabricated from high-AR CNT has specific strength of 2.94 N/tex and specific modulus of 231 N/tex, which are comparable to those of the state-of-the-art carbon fiber. Both DI-FCCVD and wet spinning methods are easily scalable to mass production, so this study may enable widespread industrial application of CNTFs. (C) 2020 Elsevier Ltd. All rights reserved.

Automated summary

The DI-FCCVD technique enables continuous synthesis of carbon nanotubes with high aspect ratio and high crystallinity at a high production rate. The carbon nanotube fiber produced from this technique demonstrates comparable performance to state-of-the-art carbon fibers, making it suitable for widespread industrial applications.