Aerosol based synthesis of highly conducting carbon nanotube macro assemblies by novel mist assisted precursor purging system

Taking hardware complexity into consideration of traditional continuous precursor purging systems for synthesis of few wall carbon nanotubes (CNTs) is a big challenge. Therefore, a novel precursor purging system for aerosol formation is designed to achieve uniform diameter distribution of CNTs, with the aerosol flow rate controlled either by number of ultrasonic mist makers or flow rate of carrier gas. Large droplets are turned into aerosol via an as-customized mist-producing system without the use of temperature or any chemical reaction. A built-in atomized gas valve is used to introduce the aerosol into a floating catalyst chemical vapour deposition (FCCVD) reactor. After an influential comparison of as-customized purging systems to the mostly used complex and big-budget systems for uniform diameter distribution, the quality of these CNT assemblies, synthesized using two different carrier gases (argon and hydrogen) is examined. Herein, CNT sheets with mostly fewer walls CNTs (diameter 2–10 nm) have been synthesized using this approach, with the controlled size of catalyst nanoparticles, under H2 atmosphere exhibiting low sulphur impurities, as evidenced by Raman, EDS, and XPS spectra, and have a fourteen-fold greater electrical conductivity (5.78 × 104S/m) than those synthesized under Ar atmosphere. Moreover, these sheets are also twisted and wrapped by insulating heat shrink tubes. The maximum current density of these conducting CNT wires having 250 µm diameter is 8.15 × 106A/m2. Further, one of the domestic applications of LED bulb (3–45 W) lightning is also demonstrated which shows the suitability of these conducting wires in numerous hi-profile applications.