Carbon Nanotubes and Related Nanomaterials: Critical Advances and Challenges for Synthesis toward Mainstream Commercial Applications.

Advances in the synthesis and scalable manufacturing of single-walled carbon nanotubes (SWCNTs) remain critical to realizing many important commercial applications. Here we review recent breakthroughs in the synthesis of SWCNTs and highlight key ongoing research areas and challenges. A few key applications that capitalize on the properties of SWCNTs are also reviewed with respect to the recent synthesis breakthroughs and ways in which synthesis science can enable advances in these applications. While the primary focus of this review is on the science framework of SWCNT growth, we draw connections to mechanisms underlying the synthesis of other 1D and 2D materials such as boron nitride nanotubes and graphene.

Overcoming Catalyst Residue Inhibition of the Functionalization of Single-Walled Carbon Nanotubes via the Billups-Birch Reduction.

The Billups-Birch Reduction chemistry has been shown to functionalize single-walled carbon nanotubes (SWCNTs) without damaging the sidewalls, but has challenges in scalability. Currently published work uses a large mole ratio of Li to carbon atoms in the SWCNT (Li:C) to account for lithium amide formation, however this increases the cost and hazard of the reaction. We report here the systematic understanding of the effect of various parameters on the extent of functionalization using resonant Raman spectroscopy. Addition of 1-iodododecane yielded alkyl-functionalized SWCNTs, which were isolated by solvent extraction and evaporation, and purified by a hydrocarbon wash. The presence of SWCNT growth catalyst residue (Fe) was shown to have a strong adverse effect on SWCNT functionalization. Chlorination-based SWCNT purification reduced the amount of residual Fe, and achieve a maximum ID/IG ratio using a Li:C ratio of 6:1 in a reaction time of 30 min. This result is consistent with published literature requiring 20-fold mole equivalents of Li per mole SWCNT with a reaction time of over 12 h. This new understanding of the factors influencing the functionalization chemistry will help cut down material and process costs, and also increase the selectivity of the reaction toward the desired product.

Wafer-scale monodomain films of spontaneously aligned single-walled carbon nanotubes.

The one-dimensional character of electrons, phonons and excitons in individual single-walled carbon nanotubes leads to extremely anisotropic electronic, thermal and optical properties. However, despite significant efforts to develop ways to produce large-scale architectures of aligned nanotubes, macroscopic manifestations of such properties remain limited. Here, we show that large (>cm(2)) monodomain films of aligned single-walled carbon nanotubes can be prepared using slow vacuum filtration. The produced films are globally aligned within ±1.5° (a nematic order parameter of ∼1) and are highly packed, containing 1 × 10(6) nanotubes in a cross-sectional area of 1 µm(2). The method works for nanotubes synthesized by various methods, and film thickness is controllable from a few nanometres to ∼100 nm. We use the approach to create ideal polarizers in the terahertz frequency range and, by combining the method with recently developed sorting techniques, highly aligned and chirality-enriched nanotube thin-film devices. Semiconductor-enriched devices exhibit polarized light emission and polarization-dependent photocurrent, as well as anisotropic conductivities and transistor action with high on/off ratios.

True solutions of single-walled carbon nanotubes for assembly into macroscopic materials.

Translating the unique characteristics of individual single-walled carbon nanotubes into macroscopic materials such as fibres and sheets has been hindered by ineffective assembly. Fluid-phase assembly is particularly attractive, but the ability to dissolve nanotubes in solvents has eluded researchers for over a decade. Here, we show that single-walled nanotubes form true thermodynamic solutions in superacids, and report the full phase diagram, allowing the rational design of fluid-phase assembly processes. Single-walled nanotubes dissolve spontaneously in chlorosulphonic acid at weight concentrations of up to 0.5 wt%, 1,000 times higher than previously reported in other acids. At higher concentrations, they form liquid-crystal phases that can be readily processed into fibres and sheets of controlled morphology. These results lay the foundation for bottom-up assembly of nanotubes and nanorods into functional materials.

Macroscopic, neat, single-walled carbon nanotube fibers.

Well-aligned macroscopic fibers composed solely of single-walled carbon nanotubes (SWNTs) were produced by conventional spinning. Fuming sulfuric acid charges SWNTs and promotes their ordering into an aligned phase of individual mobile SWNTs surrounded by acid anions. This ordered dispersion was extruded via solution spinning into continuous lengths of macroscopic neat SWNT fibers. Such fibers possess interesting structural composition and physical properties.