Scaled-Up Production and Transport Applications of Graphitic Carbon Nanomaterials

Kimberly R Saviers, Purdue University

Abstract

Graphitic carbon nanomaterials enhance the performance of engineered systems for energy harvesting and storage. However, commercial availability remains largely cost-prohibitive due to technical barriers to mass production. This thesis examines both the scaled-up production and energy transport applications of graphitic materials. Cost driven-production of graphitic petals is developed, carbon nanotube array thermal interface materials enhance waste heat energy harvesting, and microsupercapacitors are visually examined using a new electroreflectance measurement method. Graphitic materials have previously been synthesized using batch-style processing methods with small sample sizes, limiting their commercial viability. In order to increase production throughput, a roll-to-roll radio-frequency plasma chemical vapor deposition method is employed to continuously deposit graphitic petals on carbon fiber tow. In consideration of a full production framework, efficient and informative characterization methods in the form of electrical resistance and electrochemical capacitance are highlighted. To co-optimize the functional characteristics of the material, the processing conditions are comprehensively varied using a data-driven predictive design of experiments method. Repeatable and reliable production of graphitic materials will enable a host of creative graphene-based devices to emerge into the marketplace. Two such applications are discussed in the remaining chapters. Waste heat is most efficiently harvested at high temperatures, such as vehicle exhaust systems near 600°C. However, the resistance to heat flux at the interfaces between the harvesting device and its surroundings is detrimental to the system-level performance. To study the performance of thermal interface materials up to 700°C, a reference bar measurement method was designed. Design considerations are discussed and compared to past implementations, particularly regarding radiation heat flux and thermal expansion at these elevated temperatures. The microscale roughness of the contacting measurement surface is fully characterized, as it fundamentally affects the resulting thermal interface resistance. This comprehensive method for determining thermal interface resistance at high temperatures includes the physical equipment, data acquisition system, and data analysis method. Thermomechanical evaluation of carbon nanotube arrays up to 700°C has shown that the arrays provide mechanical flexibility to accommodate thermal expansion in a thermomechanically mismatched interface. To demonstrate the application of the arrays for improving energy generation, they were evaluated in conjunction with a thermoelectric module. The system-level efficiency increases significantly when a carbon nanotube array is applied to the hot side of the thermoelectric module. Additional materials characterization suggests the presence of a strong thermal connection between the carbon nanotubes and their catalyst layers, due to covalent bonding between them. In another application of harvesting waste heat, the carbon nanotube arrays increase the performance of a thermo-magnetically actuated shuttle device for solar photovoltaic cells due to decreased thermal interface resistance. Vertically-oriented graphitic petals have previously enhanced supercapacitor power density. Here, a spatiotemporal characterization method is developed and utilized to study ageing phenomena in microsupercapacitor electrodes. The electroreflectance method captures images of charge accumulation in the electrodes at varying states during each charge-discharge cycle. The method was exploited by imaging each an ideal device and a device with defects over an extended period of over four million cycles. The charge accumulation patterns over the ageing period relate to the physical transport behavior. During a single discharge cycle, one may visually observe the electrons drifting out of the electrode. Overall, the investigations herein determine the following. Continuous production of graphitic petals is possible and is optimized by considering the effect of plasma conditions on the resulting functional performance of the material. Thermal interface resistance may be measured at high temperatures in order to understand the viability of interface materials for energy harvesting applications. Carbon nanotube array thermal interface materials lead to increased energy generation from thermoelectric modules. Spatial electroreflectance measurements of microsupercapacitors lead to observation of decreased physical wetting between the electrode and electrolyte, impacting device performance. Looking forward, creative application of graphitic carbon nanomaterials, coupled with cost-driven production capability, will launch them into the commercial marketplace.

Degree

Ph.D.

Advisors

Fisher, Purdue University.

Subject Area

Mechanical engineering|Nanotechnology|Materials science

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