3d-scaffold

Patent metadata

Field	Value
Publication number	US-2021273230-A1
Application number	US-201917257944-A
Country	US
Kind code	A1
Filing date	Jul 10, 2019
Priority date	Jul 10, 2018
Publication date	Sep 2, 2021
Grant date	—

Abstract

A substrate comprises carbon nanotubes, oriented largely parallel in a direction away from the substrate. In a plane along a surface of said substrate carbon nanotubes are formed in first cells of a connected structure of carbon nanotubes. Said first cells formed within a second structure of second cells, the carbon nanotubes are thereby patterned in a structure of first cells, nested in a structure of second cells. The first cells comprise at least one opening, without carbon nano tubes, to provide access to the surface of the substrate. Second cells are separated from each other by a trench to prevent carbon nanotubes of a second cell from contacting carbon nanotubes of another second cell across a first gap formed by said trench. The trench provides access to the substrate.

First claim

1 . A scaffold structure on a substrate, the scaffold structure comprising carbon nanotubes, wherein said nanotubes are oriented largely parallel in a direction away from said substrate, and
wherein in a plane along a surface of said substrate, carbon nanotubes are formed in first cells formed by one or more connected structures of carbon nanotubes, wherein said first cells are nested in a structure of second cells, different from the first cells, wherein the connected structures comprise at least one opening, without carbon nanotubes, to provide access to the surface of the substrate, wherein second cells are separated from other ones of the second cells by a trench to prevent carbon nanotubes of ones of the second cells from contacting a carbon nanotube of other ones of the second cells across a first gap formed by said trench, and wherein the trench provides access to the substrate between connected structures of carbon nanotubes.

2 . A scaffold structure on a substrate, the scaffold structure comprising carbon nanotubes, wherein said nanotubes are oriented largely parallel in a direction away from said substrate, and
wherein in a plane along a surface of said substrate, carbon nanotubes are formed in one or more connected structures of carbon nanotubes, wherein the connected structures leave at least one area free of carbon nanotubes, to provide access to the surface of the substrate, and wherein ones of the connected structures are separated from other ones of the connected structures by one or more trenches to prevent carbon nanotubes of ones of the connected structures from contacting a carbon nanotube of another one of the connected structures across a first gap formed by said trench, and wherein the trench provides access to the substrate between connected structures of carbon nanotubes.

3 . The scaffold structure according to claim 1 , wherein said nanotubes have a length between 20 and 500 micrometer.

4 . The scaffold structure according to claim 1 , wherein said first gap formed by said trench separates nanotubes across said first gap by a distance between 500 nm and 20 micrometer.

5 . The scaffold structure according to claim 1 , wherein said connected structure of carbon nanotubes comprises a smallest lateral dimension (Dmin), in a direction along said substrate, in the range from 1.6 micrometer to 85 micrometer, more in particular, wherein said smallest lateral dimension ranges between 1.6 micrometer and 8.5 micrometer for covering ratios ranging between 80% and 20% and the connected structure having a height ranging between 20 micrometer and 50 micrometer; wherein said smallest lateral dimension ranges between 4.0 micrometer and 17 micrometer for covering ratios ranging between 80% and 20% and the connected structure having a height ranging between 50 micrometer and 100 micrometer; wherein said smallest lateral dimension ranges between 8.0 micrometer and 25.5 micrometer for covering ratios ranging between 80% and 20% and the connected structure having a height ranging between 100 micrometer and 150 micrometer; and wherein said smallest lateral dimension ranges between 12 micrometer and 85 micrometer for covering ratios ranging between 80% and 20% and the connected structure having a height ranging between 150 micrometer and 500 micrometer.

6 . The scaffold structure according to claim 1 , wherein the connected structure of carbon nanotubes comprises a largest dimension, in a direction along said substrate, of less than 500 micrometer.

7 . The scaffold structure according to claim 1 , wherein said one or more trenches separating said one or more connected structures are oriented along a single direction of movement of said substrate during processing to utilize a drag flow induced by said movement.

8 . The scaffold structure according to claim 1 , wherein said at least one opening may be defined by one or more structures taken from the group consisting of:
an inner surface of said connected structure, an outer surface of said connected structure, and an opening defined by outer surfaces of adjacent structures.

9 . The scaffold structure according to claim 1 , wherein said one or more openings have an orientation in a direction along the substrate.

10 . The scaffold structure according to claim 1 , wherein said substrate is a flexible substrate.

11 . The scaffold structure according to claim 1 , wherein a top layer is present covering the connected structures of carbon nanotubes to maintain a constant distance between terminal ends of said carbon nanotubes.

12 . A process for the production of scaffold structure comprising:
providing a substrate, patterning the substrate, growing largely parallel carbon nanotubes from the patterned substrate in a direction away from said substrate, wherein the pattern is arranged to define carbon nanotubes growth, in a plane along a surface of said substrate, in first cells of a connected structure of carbon nanotubes, said first cells are nested in a structure of second cells, different from the first cells, formed of second connected structures of carbon nanotubes, wherein the connected structure of carbon nanotubes comprises at least one opening, without carbon nanotubes, to provide access to the surface of the substrate, and wherein ones of the second cells are separated from other ones of the second cells by a trench to prevent carbon nanotubes of one of the second cells from contacting a carbon nanotube of another one of the second cells across a first gap formed by said trench, so that said trench provides access to the substrate.

13 . The process according to claim 12 , further comprising depositing a further material on said scaffold structure using a fluid processing step,
wherein the fluid processing step comprises one or more types of fluid processing taken from the group consisting of: sputtering and CVD, and ALD and wet deposition methods.

14 . A three-dimensional (3D) electrode comprising:
the scaffold structure according to claim 1 ; and a layer of further material deposited and/or impregnated onto the scaffold structure, wherein said further material comprises an electrode.

15 . The 3D electrode according to claim 14 , further comprising a top layer covering the connected structures of connected carbon nanotube structures, and an ingress structure formed by channels provided in the top layer, to allow access to a fluid.

16 . An energy storage structure comprising the scaffold according to claim 1 and at least a composite layer, provided, at least in part, on a surface of said carbon nanotubes, wherein said composite layer comprises a first electrode material.

17 . The energy storage structure according to claim 16 , wherein said composite material is further provided with an additional layer comprising an electrolyte material and a further additional layer comprising an second electrode material, wherein the electrolyte material comprises a solid state electrolyte material, and wherein the first and/or the second electrode layer comprises lithium or sodium.

18 . The energy storage structure according to claim 16 , wherein said composite layer is provided after a controlled collapse of the scaffold structure by a wet deposition method.

19 . The energy storage structure according to claim 16 , wherein said composite layer has a gradient in a direction away from the substrate or in a direction along the substrate.

20 . The scaffold structure according to claim 1 , wherein said substrate is a rigid substrate.

Assignees

• TNO

Inventors

• Van Den Ham Evert Jonathan
• Haverkate Lucas Augustinus
• Hermes Dorothee Christine
• Tulodziecki Michal
• Unnikrishnan Sandeep

Classifications

• C01B2202/08

  Aligned nanotubes · CPC title

• H01M10/052

  Li-accumulators · CPC title

• C01B32/168 Primary

  After-treatment · CPC title

• Y02E60/10

  Energy storage using batteries · CPC title

• B82Y40/00

  Manufacture or treatment of nanostructures · CPC title