This Small Business Innovation Research Phase I project will demonstrate plasma enhanced vapor-liquid-solid (PE-VLS) growth of carbon nanotubes. The resulting low cost, low temperature process will enable commercial applications of high quality carbon nanotubes grown on large area substrates. Since the discovery of nanotubes in 1991, breakthrough applications have been anticipated in structural, electronic, electrochemical, catalytic, and sensing materials technology. Unfortunately, existing laboratory synthesis and processing techniques are inappropriate for nanotube commercialization. However, the understanding gained from these laboratory techniques does indicate a new path to commercially attractive synthesis. This novel, PE-VLS process combines and develops two cost-effective materials processing technologies: VLS growth, and non-equilibrium, volume, plasma processing. This Phase I project will first demonstrate uniform substrate coverage of nanometer catalyst dispersions. Second, high temperature VLS growth will demonstrate catalyst effectiveness for nanotube synthesis. Third, nanotube adherence to the substrate will be evaluated. Finally, plasma enhancement will demonstrate the quality increase and bulk temperature decrease obtainable with PE-VLS. Potential commercial applications for the PE-VLS process include electrochemical electrodes, flat panel displays, surface modification, composite structures, catalysis, sensors and ultrafiltration. With our industrial partner, we will examine applications in low energy separation, fuel cells, and internal combustion engines.
