recent progress in chemical detection with single-walled carbon nanotube networks
TRANSCRIPT
www.rsc.org/analyst Volume 132 | Number 8 | August 2007 | Pages 709–824
Interdisciplinary detection science
ISSN 0003-2654
HIGHLIGHTMarcus D. Lay et al.Recent progress in chemical detection with single-walled carbon nanotube networks
PAPERJaromir Ruzicka et al.Automated capture and on-column detection of biotinylated DNA on a disposable solid support
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Recent progress in chemical detection withsingle-walled carbon nanotube networksPornnipa Vichchulada, Qinghui Zhang and Marcus D. Lay*
DOI: 10.1039/b618824a
Single-walled carbon nanotubes (SWNTs) have had significant impact on thedevelopment of gas sensors in the last decade. However, useful applications ofSWNTs are limited by the lack of manufacturable routes to device formation. ThisHighlight article chronicles recent progress in this area and demonstrates thegreat promise of a new room temperature deposition method for SWNT networksin gas sensing applications. This liquid deposition technique allows the depositionof pre-treated, highly aligned SWNT networks on a wide variety of substrates. Asignificant advantage of SWNT-network sensors is that fluctuations in theelectrical response of individual SWNTs become less important as the size of thenetwork increases. Therefore, device properties can be controlled by the overalldensity of the network rather than the physical properties of any individual SWNT.At densities where semiconducting pathways dominate, highly sensitive thin-filmchemoresistive sensors can be fabricated. Such devices also have higher signal-to-noise ratios and are easier to fabricate than devices based on a single SWNT.
Introduction
Single-walled carbon nanotubes
(SWNTs) have many enhanced mechani-
cal, structural, and electronic properties
that have made them the focus of intense
research. Though it has long been known
that carbon fibers, along with soot, can
be produced with a carbon arc,1,2 it was
not until 1991, when Iijima observed that
these fibers were hollow, that the current
effusion of interest began.3 That report
demonstrated that the carbon fibers
observed in soot from an arc discharge
experiment consisted of several con-
centric tubes nestled inside each other.
These nanometer-scale structures are
known today as multi-walled carbon
nanotubes (MWNTs). Subsequently, in
1993 separate reports from the Iijima and
Bethune research groups independently
confirmed the existence of SWNTs.4 The
past decade has seen an exponential
increase in publications related to both
types of nanotubes.5
There has been great recent interest
in investigating SWNTs, due to their
unique physical and chemical charac-
teristics. These one-dimensional wires
are the strongest known material.6,7
Further, they also exhibit enhanced
electronic properties, including near bal-
listic transport.8–11 Therefore, SWNTs
show great potential as the building
blocks of nano- and micro-electronic
devices of the near future.12–16 There
are many other possible applications of
SWNTs, including hydrogen storage,17
field emission materials,18 tips for scan-
ning probe microscopy,19 chromatogra-
phic stationary phases,20 and sensors.21,22
There is a direct correlation between
the physical rolling vector (chirality) of a
carbon nanotube and its electronic pro-
perties; SWNTs may be either semicon-
ductors or metallic. In a bulk sample of
SWNT material, roughly one-third will
be metallic and two-thirds semiconduct-
ing.23–26 Absolute control of SWNT
properties is necessary to fabricate a
device based on a single SWNT.
Therefore, there has been great research
into methods of separating the different
types of nanotubes. Thus far, these
investigations have met with limited
success for exceedingly small masses of
material.27–31
However, separation of metallic and
semiconducting SWNTs will not result
in total control over device response
as the properties of semiconducting
SWNTs vary greatly with chirality and
diameter.32–34 Particularly, the bandgap
of semiconducting SWNTs varies
inversely with diameter. Consequently,
smaller diameter nanotubes have larger
bandgaps. Therefore, reproducibility in
SWNT device performance is limited not
only by the presence of metallic SWNTs,
but also by the inability to control all
physical properties of the nanotubes
during the growth process.
Another route to incorporation of
SWNT material into functional electro-
nic devices is the use of networks of
SWNTs. In a SWNT network, a macro-
scopic material is formed by depositing
individual SWNTs on a surface at a
density such that there is significant
overlap. At densities between the perco-
lation threshold for semiconducting and
metallic SWNTs, this material behaves as
a thin-film semiconductor.35 This is due
to the fact that fully metallic conductive
pathways are highly unfavored below
their percolation threshold.
One application of SWNT networks is
in the field of sensing. There are two
common types of gas sensors: surface
acoustic wave (SAW) devices and che-
moresistors. The SAW device is com-
posed of a polymer-coated quartz crystal
micro balance chip which is oscillated
near its resonance frequency. The fre-
quency of oscillation changes during
Department of Chemistry, and NanoscaleScience and Engineering Center (NanoSEC),University of Georgia, Athens, GA 30602E-mail: [email protected]
i-SECTION: HIGHLIGHT www.rsc.org/analyst | The Analyst
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mass uptake as this polymer specifically
absorbs an analyte. This change in
frequency results in a detectable signal.
Another common sensor configuration
is the chemoresistor, in which signal
transduction occurs via a change in
resistance observed upon analyte adsorp-
tion/absorption. Carbon black sensors, a
type of chemoresistor, are composed of a
thin film of micron-sized conducting
carbon particles embedded in a non-
conducting polymer matrix. The loading
of carbon black is such that tunnel
junctions between particles exist over
macroscopic dimensions, resulting in a
material with defined conductance.
Swelling of the polymer matrix during
exposure results in a change in conduc-
tivity that can be easily detected.
SWNTs are expected to work very
well in chemoresistive-type sensors due
to their nanometer-scale diameter and
incredibly high aspect ratio; effective
response can be achieved with thinner
polymer matrices, increasing the kinetics
of response. Further, the surface area of
individual SWNTs is about 1600 m2 g21,
the highest value for any known mate-
rial.36 This presents a huge effective
sensing area for the adsorption of
vapors. As a result, SWNT sensors show
a fast response and a significantly higher
sensitivity than that of existing room
temperature solid-state sensors.11
Sensors based on one SWNT
Early reports indicated great promise for
SWNTs in high-performance macro-
scale sensors. Dai and co-workers were
the first to report the use of SWNTs to
detect NO2 and NH3, where the resis-
tance of a single semiconducting SWNT
was observed to increase or decrease by
2–3 orders of magnitude upon exposure
to NO2 or NH3, respectively.22 This
change in resistance was attributed to
shifts in the valence band with respect
to the Fermi level. In a p-type semi-
conductor, like a SWNT, the depletion of
charge carriers by NH3 (an electron-
donating adsorbate) results in a shift of
the valence band away from the Fermi
level, and a corresponding decrease in
conductivity. In contrast, NO2 (an elec-
tron-withdrawing adsorbate) resulted in
shifting the valence band toward the
Fermi level, resulting in an observable
increase in conductivity. Subsequent
work by numerous researchers has
demonstrated the efficacy of SWNT
sensors for a wide variety of gas phase
analytes.37–40
Sensors composed of bundlesof SWNTs
While highly effective for specialized use,
sensors based on a single SWNT are
impractical for mass production due to
great variability in SWNT properties;
variations in chirality and diameter result
in irregular device function. As a result,
many investigators have studied the
sensor applications of bundles or ‘ropes’
of SWNTs. In fact, a recent study by
Manohar’s group41 demonstrated that
SWNTs bundles deposited onto poly-
(ethylene terephthalate) (overhead trans-
parency film) displayed a change in
conductance that was four times as
sensitive to toluene vapors as a similar
sensor composed of carbon black.
Bundles of purified SWNTs were found
to exhibit even greater sensor response.
This enhancement was attributed to
chemically bound oxygen on the purified
SWNTs. Furthermore, four point probe
studies showed that sensors composed of
carbon nanotube bundles demonstrated
enhanced response to a variety of organic
vapors. The reproducibility of this
response was demonstrated to be roughly
four times greater than that obtained for
similar carbon black sensors.
Although sensors composed of carbon
nanotube bundles have demonstrated
interesting properties, two-dimensional
networks of SWNTs exhibit heightened
response due to the fact that the presence
of metallic SWNTs in a bundle will
mitigate the electrical response of the
semiconducting SWNTs. Therefore, two-
dimensional networks of unbundled
SWNTs may present the best com-
promise between ease of fabrication and
heightened signal-to-noise ratio.
High temperature formationof SWNT networks
Initial methods of SWNT-network
fabrication involved chemical vapor
deposition (CVD). This method involves
catalytic decomposition of hydrocarbon
precursors and subsequent formation of
SWNTs at metal nanoparticles. Owing to
the high temperatures involved, CVD
growth of SWNT networks typically
involves the use of silicon wafer frag-
ments as substrates. Growth conditions
vary widely (i.e. catalyst, carbon source,
and substrate),42–48 but remain variations
on the method reported by Lieber and
co-workers.49
Si wafer fragments are dipped in an Fe
salt/2-propanol solution and rinsed with
solvent. This is followed by placing the
substrate in a tube furnace under Ar flow
at 600–800 uC. Next, H2 is flowed into
the system to reduce surface-bound metal
catalyst nanoparticles to elemental metal.
Finally, a hydrocarbon source is intro-
duced and SWNTs grow from the metal
nanoclusters, which act as catalysts for
the decomposition of the hydrocarbon
gas. This process flow results in the
growth of a random network of
unbundled SWNTs. Owing to the high
aspect ratio of SWNTs, they overlap at
low densities (ca. 2 SWNTs mm22),
resulting in an electrically continuous
network.
CVD-grown SWNT-network-based
sensors were first reported by Dai and
co-workers.50 It was demonstrated that
SWNT networks in aqueous solution
were highly sensitive protein detectors.
These devices were composed of SWNT
networks bridging to metal electrodes on
a dielectric surface. Subsequent reports
confirmed the high sensitivity of SWNT
networks to a variety of gases.41,48,51–53
However, though highly effective, this
procedure requires a substrate that can
withstand the high temperatures neces-
sary for catalytic decomposition of
hydrocarbon sources. Additionally, a
by-product of this growth method is the
growth of amorphous carbon. Another
source of contamination is the remaining
catalyst used in the growth process. The
effect of these impurities on device
reproducibility and performance cannot
be neglected. Therefore, exploration of
liquid deposition techniques has recently
increased.
Room temperature depositionof two-dimensional networksof SWNTs
The major advantage of liquid deposition
of SWNT networks is that it occurs at
room temperature. This facilitates the
inclusion of heat-sensitive substrates, like
various polymers, plastics, and glass.54
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Another very important advantage is
that as the SWNT growth and deposition
processes occur in two separate steps,
purification protocols can be applied
prior to the formation of the SWNT
networks. This becomes extremely
important in cases where purified, or
otherwise modified SWNTs, are desired.
Further, liquid deposition methods
allow inexpensive and rapid development
of custom patterns that are fully compa-
tible with current optical lithography
techniques.
Networks of SWNT bundles have
been deposited at room temperature by
various techniques such as spin-casting,
spray-coating or filtering followed by a
contact printing step.55,56 It was recently
reported that networks of highly aligned
SWNTs could be formed using a facile
liquid deposition technique (Fig. 1).35
The alignment of SWNTs in the
deposition process was directed by the
laminar N2 flow used. This discovery
presented a new opportunity for the
creation of enhanced sensing materials
from SWNTs.
In a method similar to molecular
combing of DNA,57–63 unidirectional
air flow is applied to the air–liquid
interface in a manner which imparts
order to the SWNTs in aqueous suspen-
sion and then deposits them on a surface
(i.e. Si/SiOx coated with a silane, over-
head transparency film, polyimide, etc.).
This room temperature technique for the
formation of electrically continuous net-
works of highly aligned SWNTs is
compatible with a wide variety of sub-
strates (including polymer substrates)
and can be combined with existing
optical lithography methods. This pro-
vides a facile route to the formation of
chemical sensing devices.
The properties of this material can be
explained thus: although individual
SWNTs average 1–3 mm in length, at
sufficiently high density, many of the
tubes overlap at some point. This causes
electrical conductivity over macroscopic
lengths (wafer-scale and beyond) at low
SWNT coverage. The result is the crea-
tion of a transparent, flexible, thin-film
semiconductor that can be deposited on a
wide variety of substrates.
This liquid deposition technique allows
the formation of highly parallel SWNT
networks having arbitrary density and
orientation. The density of the SWNT
network is determined by the density of
the SWNTs in the suspension and the
number of deposition cycles. Fig. 2 is an
atomic force microscopy (AFM) micro-
graph obtained after one deposition cycle
from an aqueous suspension of approxi-
mately 0.1 mg mL21 SWNTs. This
large-scale micrograph demonstrates the
level of control in deposition that is
possible without any photolithographic
modification of the surface. AFM
indicated that this surface was covered
with a uniform layer of highly aligned
SWNTs over its entire area. This process
has been observed to occur with high
efficiency for shortened HNO3 treated
SWNTs, as well as with longer as-
produced nanotubes.
The number of SWNTs on a surface
increases linearly with the number of
deposition cycles, with macroscopic net-
work formation occurring between three
and five deposition cycles, depending on
the SWNT suspension concentration.
Fig. 3 shows a typical deposit formed
from three deposition cycles of the same
solution used in Fig. 2. This low-density
network of aligned SWNTs is trans-
parent in the visible range and electrically
conductive over macroscopic scales.
It has been previously determined that
this material has anisotropic electrical
properties.35 The on/off ratio of thin-film
transistors composed of highly aligned
carbon nanotube networks varies accord-
ing to the direction of the nanotube
network with respect to the electrical
contacts. This results in another layer
of control over the response to vapor
phase analytes. This group is further
investigating this effect and how this
may be used to obtain further enhanced
chemical sensors. Further, the molecular
combing method used to deposit
Fig. 1 Two-dimensional networks of highly aligned SWNTs are fabricated on Si/SiOx
wafers (or any flat substrate) using a molecular combing process. A suspension of SWNTs is
deposited on a prepared surface, and then unidirectional air flow is applied to the solid–
liquid interface in a manner to effect laminar flow of the suspension and deposition of highly
aligned SWNTs.
Fig. 2 AFM micrograph of a two-dimensional network of SWNTs deposited using a
laminar flow liquid deposition technique. The density of SWNTs deposited is easily
controlled by varying the solution concentration and number of deposition cycles.
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horizontally aligned SWNTs has been
demonstrated as a very capable method
for the formation of higher order con-
structs with the formation of SWNT
crossbar nanostructures.64
The count of impurities on the surface
increases with deposition cycles. This
necessitates the development of purifica-
tion steps. Therefore, this group is
investigating numerous purification pro-
tocols to remove amorphous carbon,
catalyst nanoparticles, and other impu-
rities. The removal of these impurities is
expected to increase the reproducibility
of sensor response. The harshness of a
purification method (and its effect on a
given substrate) is not a concern as
network formation occurs in a subse-
quent step.
In addition, this group is also investi-
gating the cause of 1/f noise (which is a
factor that affects the detection limit of a
sensor) in chemoresistors composed of
nano-scale molecular wires. As it has
been demonstrated that the level of 1/f
noise is strongly dependent on device
geometry and application of a gate bias,
studies into the effect of device dimen-
sions on the detection limit are expected
to result in even lower detection limits.65
Additionally, non-covalent modification
with metal nanoclusters and chemoselec-
tive polymers present routes to enhanced
SWNT sensors. Liquid deposition is
compatible with most SWNT modifica-
tion protocols.
Summary
Novel nano-scale electronic materials
will play a role of great significance in
sensing transducers of the near future. As
single-walled carbon nanotubes are com-
posed entirely of surface atoms, they are
exquisitely sensitive to gas phase phy-
sisorption events and have demonstrated
great promise in chemical sensing appli-
cations. Such sensors work for a wide
variety of volatile organics. Furthermore,
chemoresistors present a greatly simpli-
fied route to sensor fabrication without
sacrificing sensitivity. Recent advances
in the chemical modification of SWNTs
present an opportunity to obtain
enhanced selectivity and sensitivity in
chemoresistor sensors.
The optical transparency and flexibi-
lity of these networks will likely result in
numerous novel sensor applications.
Further, liquid room temperature routes
to fabrication present great advantages
over high temperature methods, includ-
ing ease of fabrication, pre-deposition
purification of SWNT material and
compatibility with heat-sensitive sub-
strates. These advantages facilitate
the development of numerous novel
applications.
A novel deposition technique for the
formation of unbundled networks of
highly aligned SWNTs is currently being
investigated as a tool for achieving
greater gas sensor reproducibility and
performance. This deposition process, in
combination with various purification
and functionalization techniques, is
expected to hasten the development of
functional device structures composed of
flexible, transparent SWNT thin films.
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