8d Controlling the Morphology of Carbon Nanotube Films by Varying the Areal Density of Catalyst Nanoclusters Using Block Copolymer Micellar Thin Films

Ryan D. Bennett, Anastasios J. Hart, and Robert E. Cohen. Massachusetts Institute of Technology, MIT 66-353, 77 Massachusetts Avenue, Cambridge, MA 02139

We demonstrate a general route that utilizes block copolymer micelles as a means to create tunable inorganic nanocluster arrays which serve as catalysts for carbon nanotube (CNT) growth. Our approach uses the amphiphilic block copolymer, poly(styrene-block-acrylic acid) (PS-b-PAA), which forms spherical micelles in solution that can be selectively loaded with metal ions and then spin-coated onto a substrate to create quasi-hexagonal arrays of metal-loaded PAA domains within a PS matrix. This catalyst system has significant value compared to commonly prepared thin metal film catalysts because it enables the creation of nanocluster arrays of a chosen metal species, with independent control of the nanocluster diameter and areal density. We use this block copolymer micellar system to create iron oxide nanoclusters, which are catalytically active in the thermal chemical vapor deposition (CVD) growth of CNTs. Through appropriate selection of the substrate, catalyst preparation procedure, and reaction conditions (combination of C2H4/H2/Ar gases), we achieve vertical CNT growth from our catalyst system. Because this catalyst system allows for precise quantification of the nanocluster areal density, we can also estimate the percentage of nanoclusters which nucleate the growth of a CNT. By uniformly varying the areal density of iron oxide nanoclusters on the substrate surface, we manipulate the morphology of the CNT film from a tangled and sparse arrangement of individual CNTs, through a transition region with locally bunched and self-aligned CNTs, to rapid growth of thick vertical CNT films. We also present a microcontact printing approach to create patterned inorganic nanocluster arrays that are utilized to synthesize patterned vertical growth of CNTs. The control afforded by this micellar catalyst system could be promising for both CNT applications as well as for improved understanding of the combination of chemical and mechanical conditions necessary for the growth of uniform CNT films.