Graphene-carbon nanotube hybrid materials and use as electrodes

Patent metadata

Field	Value
Publication number	US-9455094-B2
Application number	US-201214358864-A
Country	US
Kind code	B2
Filing date	Nov 19, 2012
Priority date	Nov 18, 2011
Publication date	Sep 27, 2016
Grant date	Sep 27, 2016

Abstract

Provided are methods of making graphene-carbon nanotube hybrid materials. Such methods generally include: (1) associating a graphene film with a substrate; (2) applying a catalyst and a carbon source to the graphene film; and (3) growing carbon nanotubes on the graphene film. The grown carbon nanotubes become covalently linked to the graphene film through carbon-carbon bonds that are located at one or more junctions between the carbon nanotubes and the graphene film. In addition, the grown carbon nanotubes are in ohmic contact with the graphene film through the carbon-carbon bonds at the one or more junctions. The one or more junctions may include seven-membered carbon rings. Also provided are the formed graphene-carbon nanotube hybrid materials.

First claim

What is claimed is:

1. A method of making a graphene-carbon nanotube hybrid material, comprising:
associating a graphene film with a substrate;
applying a catalyst and a carbon source to the graphene film; and
growing carbon nanotubes on the graphene film,
wherein the grown carbon nanotubes are covalently linked to the graphene film through carbon-carbon bonds,
wherein the grown carbon-carbon bonds are at one or more junctions between the carbon nanotubes and the graphene film, and
wherein the grown carbon nanotubes are in ohmic contact with the graphene film through the carbon-carbon bonds at the one or more junctions.

2. The method of claim 1 , wherein the substrate comprises one or more atoms selected from the group consisting of Ni, Co, Fe, Pt, Au, Al, Cr, Cu, Mg, Mn, Mo, Rh, Si, Ta, Ti, W, U, V, Zr, SiO 2 , Al 2 O 3 , BN, diamond, alloys thereof, and combinations thereof.

3. The method of claim 1 , wherein the substrate is a copper foil.

4. The method of claim 1 , wherein the substrate is a porous substrate.

5. The method of claim 4 , wherein the porous substrate comprises porous nickel.

6. The method of claim 1 , wherein the associating comprises forming the graphene film on the substrate.

7. The method of claim 6 , wherein the forming comprises chemical vapor deposition.

8. The method of claim 1 , wherein the associating comprises transferring a pre-grown graphene film onto the substrate.

9. The method of claim 1 , wherein the graphene film is selected from the group consisting of monolayer graphene, few-layer graphene, double-layer graphene, triple-layer graphene, multi-layer graphene, and combinations thereof.

10. The method of claim 1 , wherein the graphene film excludes reduced graphene oxide.

11. The method of claim 1 , wherein the graphene film excludes graphite.

12. The method of claim 1 , wherein the catalyst comprises a metal, wherein the metal is selected from the group consisting of iron, nickel, cobalt, palladium, platinum, gold, ruthenium, rhodium, iridium, alloys thereof, and combinations thereof.

13. The method of claim 1 , wherein the catalyst comprises a metal and a buffer.

14. The method of claim 13 , wherein the metal comprises iron.

15. The method of claim 13 , wherein the buffer is selected from the group consisting of aluminum, magnesium, silicon, alloys thereof, derivatives thereof, and combinations thereof.

16. The method of claim 13 , wherein the buffer comprises aluminum oxide.

17. The method of claim 13 , wherein the buffer has a thickness between about 1 nm to about 10 nm.

18. The method of claim 13 , wherein the metal has a thickness of about 1 nm.

19. The method of claim 13 , wherein the applying comprises:
depositing the metal onto a surface of the graphene film; and
depositing the buffer onto a surface of the metal.

20. The method of claim 1 , wherein the applying occurs by electron beam deposition.

21. The method of claim 1 , wherein the carbon source is selected from the group consisting of alkanes, alkenes, alkylenes, alkynes, polymers, carbon oxides, and combinations thereof.

22. The method of claim 1 , wherein the growing of carbon nanotubes comprises heating.

23. The method of claim 22 , wherein the heating occurs at temperatures between about 500° C. and about 1,100° C.

24. The method of claim 1 , wherein the catalyst is lifted off from the graphene film by the carbon nanotubes.

25. The method of claim 1 , wherein the grown carbon nanotubes are selected from the group consisting of single-walled carbon nanotubes, double-walled carbon nanotubes, triple-walled carbon nanotubes, multi-walled carbon nanotubes, ultra-short carbon nanotubes, small diameter carbon nanotubes, and combinations thereof.

26. The method of claim 1 , wherein the grown carbon nanotubes comprise vertically aligned carbon nanotubes that are substantially perpendicular to the graphene film.

27. The method of claim 1 , further comprising a step of controlling the length of the grown carbon nanotubes.

28. The method of claim 27 , wherein the controlling comprises adjusting carbon nanotube growth time.

29. The method of claim 28 , wherein the growth time is adjusted from about 1 minute to about 20 minutes.

30. The method of claim 1 , further comprising a step of removing the substrate from the graphene-carbon nanotube hybrid material, wherein the removing forms free-standing graphene-carbon nanotube hybrid materials.

31. The method of claim 30 , wherein the removing comprises etching the substrate from the graphene-carbon nanotube hybrid material.

32. The method of claim 1 , wherein the graphene-carbon nanotube hybrid material spans one side of the substrate.

33. The method of claim 1 , wherein the graphene-carbon nanotube hybrid material spans both sides of the substrate.

34. The method of claim 1 , wherein the one or more junctions comprise seven-membered carbon rings.

35. The method of claim 1 , wherein the one or more junctions are seamless.

36. A graphene-carbon nanotube hybrid material, comprising:
a graphene film; and
carbon nanotubes,
wherein the carbon nanotubes are covalently linked to the graphene film through carbon-carbon bonds,
wherein the carbon-carbon bonds are at one or more junctions between the carbon nanotubes and the graphene film, and
wherein the grown carbon nanotubes are in ohmic contact with the graphene film through the carbon-carbon bonds at the one or more junctions.

37. The graphene-carbon nanotube hybrid material of claim 36 , wherein the graphene film is selected from the group consisting of monolayer graphene, few-layer graphene, double-layer graphene, triple-layer graphene, multi-layer graphene, and combinations thereof.

38. The graphene-carbon nanotube hybrid material of claim 36 , wherein the graphene film excludes reduced graphene oxide.

39. The graphene-carbon nanotube hybrid material of claim 36 , wherein the graphene film excludes graphite.

40. The graphene-carbon nanotube hybrid material of claim 36 , wherein the carbon nanotubes are selected from the group consisting of single-walled carbon nanotubes, double-walled carbon nanotubes, triple-walled carbon nanotubes, multi-walled carbon nanotubes, ultra-short carbon nanotubes, small diameter carbon nanotubes, and combinations thereof.

41. The graphene-carbon nanotube hybrid material of claim 36 , wherein the carbon nanotubes comprise vertically aligned carbon nanotubes that are substantially perpendicular to the graphene film.

42. The graphene-carbon nanotube hybrid material of claim 41 , wherein the carbon nanotubes comprise vertically aligned single-walled carbon nanotubes.

43. The graphene-carbon nanotube hybrid material of claim 36 , wherein the one or more junctions comprise seven-membered carbon rings.

44. The graphene-carbon nanotube hybrid material of claim 36 , wherein the one or more junctions are seamless.

45. The graphene-carbon nanotube hybrid material of claim 36 , further comprising a substrate associated with the graphene film.

46. The graphene-carbon nanotube hybrid

Assignees

• Tour James M
• Zhu Yu
• Li Lei
• Yan Zheng
• Lin Jian
• Univ Rice William M

Inventors

• Tour James M
• Zhu Yu
• Li Lei
• Yan Zheng
• Lin Jian

Classifications

• C01B32/159

  single-walled · CPC title

• H01G11/72

  specially adapted for integration in multiple or stacked hybrid or EDL capacitors · CPC title

• C01B32/194

  After-treatment · CPC title

• C01B32/18

  Nanoonions; Nanoscrolls; Nanohorns; Nanocones; Nanowalls · CPC title

• C01B32/16 Primary

  Preparation · CPC title